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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation of U.S. patent application Ser. No. 11/623,417, filed on Jan. 16, 2007 which is a continuation-in-part of Ser. No. 10/915,933, filed on Aug. 10, 2004, and claims priority thereto under 35 U.S.C. §120.
FIELD OF THE INVENTION
[0002] This invention relates to compounds which are useful as therapeutic agents. Among other potential uses, these compounds are believed to have properties which are characteristic of prostaglandins.
BACKGROUND OF THE INVENTION
Description of Related Art
[0003] Ocular hypotensive agents are useful in the treatment of a number of various ocular hypertensive conditions, such as post-surgical and post-laser trabeculectomy ocular hypertensive episodes, glaucoma, and as presurgical adjuncts.
[0004] Glaucoma is a disease of the eye characterized by increased intraocular pressure. On the basis of its etiology, glaucoma has been classified as primary or secondary. For example, primary glaucoma in adults (congenital glaucoma) may be either open-angle or acute or chronic angle-closure. Secondary glaucoma results from pre-existing ocular diseases such as uveitis, intraocular tumor or an enlarged cataract.
[0005] The underlying causes of primary glaucoma are not yet known. The increased intraocular tension is due to the obstruction of aqueous humor outflow. In chronic open-angle glaucoma, the anterior chamber and its anatomic structures appear normal, but drainage of the aqueous humor is impeded. In acute or chronic angle-closure glaucoma, the anterior chamber is shallow, the filtration angle is narrowed, and the iris may obstruct the trabecular meshwork at the entrance of the canal of Schlemm. Dilation of the pupil may push the root of the iris forward against the angle, and may produce pupilary block and thus precipitate an acute attack. Eyes with narrow anterior chamber angles are predisposed to acute angle-closure glaucoma attacks of various degrees of severity.
[0006] Secondary glaucoma is caused by any interference with the flow of aqueous humor from the posterior chamber into the anterior chamber and subsequently, into the canal of Schlemm. Inflammatory disease of the anterior segment may prevent aqueous escape by causing complete posterior synechia in iris bombe, and may plug the drainage channel with exudates. Other common causes are intraocular tumors, enlarged cataracts, central retinal vein occlusion, trauma to the eye, operative procedures and intraocular hemorrhage.
[0007] Considering all types together, glaucoma occurs in about 2% of all persons over the age of 40 and may be asymptotic for years before progressing to rapid loss of vision. In cases where surgery is not indicated, topical β-adrenoreceptor antagonists have traditionally been the drugs of choice for treating glaucoma.
[0008] Certain eicosanoids and their derivatives have been reported to possess ocular hypotensive activity, and have been recommended for use in glaucoma management. Eicosanoids and derivatives include numerous biologically important compounds such as prostaglandins and their derivatives. Prostaglandins can be described as derivatives of prostanoic acid which have the following structural formula:
[0000]
[0009] Various types of prostaglandins are known, depending on the structure and substituents carried on the alicyclic ring of the prostanoic acid skeleton. Further classification is based on the number of unsaturated bonds in the side chain indicated by numerical subscripts after the generic type of prostaglandin [e.g. prostaglandin E 1 (PGE 1 ), prostaglandin E 2 (PGE 2 )], and on the configuration of the substituents on the alicyclic ring indicated by α or β [e.g. prostaglandin F 2α (PGF 2β )].
[0010] Prostaglandins were earlier regarded as potent ocular hypertensives, however, evidence accumulated in the last decade shows that some prostaglandins are highly effective ocular hypotensive agents, and are ideally suited for the long-term medical management of glaucoma (see, for example, Bito, L. Z. Biological Protection with Prostaglandins , Cohen, M. M., ed., Boca Raton, Fla., CRC Press Inc., 1985, pp. 231-252; and Bito, L. Z., Applied Pharmacology in the Medical Treatment of Glaucomas Drance, S. M. and Neufeld, A. H. eds., New York, Grune & Stratton, 1984, pp. 477-505. Such prostaglandins include PGF 2α , PGF 1α , PGE 2 , and certain lipid-soluble esters, such as C 1 to C 2 alkyl esters, e.g. 1-isopropyl ester, of such compounds.
[0011] Although the precise mechanism is not yet known experimental results indicate that the prostaglandin-induced reduction in intraocular pressure results from increased uveoscleral outflow [Nilsson et. al., Invest. Ophthalmol. Vis. Sci . (suppl), 284 (1987)].
[0012] The isopropyl ester of PGF 2α has been shown to have significantly greater hypotensive potency than the parent compound, presumably as a result of its more effective penetration through the cornea. In 1987, this compound was described as “the most potent ocular hypotensive agent ever reported” [see, for example, Bito, L. Z., Arch. Ophthalmol. 105, 1036 (1987), and Siebold et al., Ocular Surgery News 1989 Feb. 1; 7(3):3,31].
[0013] Whereas prostaglandins appear to be devoid of significant intraocular side effects, ocular surface (conjunctival) hyperemia and foreign-body sensation have been consistently associated with the topical ocular use of such compounds, in particular PGF 2α and its prodrugs, e.g., its 1-isopropyl ester, in humans. The clinical potentials of prostaglandins in the management of conditions associated with increased ocular pressure, e.g. glaucoma are greatly limited by these side effects.
[0014] In a series of United States patents assigned to Allergan, Inc. prostaglandin esters with increased ocular hypotensive activity accompanied with no or substantially reduced side-effects are disclosed. Some representative examples are U.S. Pat. No. 5,446,041, U.S. Pat. No. 4,994,274, U.S. Pat. No. 5,028,624 and U.S. Pat. No. 5,034,413 all of which are hereby expressly incorporated by reference.
[0015] GB 1,601,994 discloses compounds having the formula shown below
[0000]
[0000] in which A represents a CH═CH group;
B represents a-CH2-CH2-, trans-CH═CH— or —C≡C— group,
W represents a free, esterified or etherified hydroxymethylene group, wherein the hydroxy or esterified or etherified hydroxy group is in the- or A-configuration, . . . or W represents a free or ketalised carbonyl group,
D and E together represent a direct bond, or D represents an alkylene group having from 1 to 5 carbon atoms or a —C≡C— group, and
E represents an oxygen or sulphur atom or a direct bond,
R 3 represents an aliphatic hydrocarbon radical, preferably an alkyl group, which may be unsubstituted or substituted by a cycloalkyl, alkyl substituted cycloalkyl, unsubstituted or substituted aryl or heterocyclic group, a cycloalkyl or alkyl-substituted cycloalkyl group, or an unsubstituted or substituted aryl or heterocyclic group, e.g. a benzodioxol-2-yl group, and
Z represents a free or ketalised carbonyl group or a free esterified or etherified hydroxymethylene group in which the free, esterified or etherified hydroxy group may be in the α- or β-configuration.
[0016] JP 53135955 discloses several compounds such as the one shown below.
[0000]
[0017] DE 2719244 discloses several compounds such as the ones shown below.
[0000]
[0018] For the top compound (I), R=H, C 1-4 alkyl, or H 2 HC(CH 2 OH) 3 ; R 1 , R 2 =H or Me; and R 3 =a heterocycle (often substituted).
[0019] U.S. Pat. No. 4,055,602 discloses several compounds such as the one shown below,
[0000]
[0000] wherein n=2-4; R═H or OH; R 1 , R 2 ═H, F, Me; and Ar=aryl. The '602 patent also discloses the compound shown below, and others like it.
[0000]
[0020] DE 2626888 discloses several compounds such as the one shown below.
[0000]
[0021] Other references, such as U.S. Pat. No. 4,119,727, disclose similar compounds.
BRIEF DESCRIPTION OF THE INVENTION
[0022] A compound comprising
[0000]
[0000] or a pharmaceutically acceptable salt, or a prodrug thereof;
wherein the dashed line indicates the presence or absence of a bond;
A is —(CH 2 ) 6 —, or cis —CH 2 —CH═CH—(CH 2 ) 3 —, wherein 1 or 2 carbons may be substituted with S or O;
J is —OH or ═O;
[0023] or a pharmaceutically acceptable salt or a prodrug thereof, is disclosed herein.
[0024] Also disclosed herein are compounds having an α and an ω chain comprising
[0000]
[0000] or a derivative thereof,
wherein said derivative has a structure as shown above except that 1 or 2 alterations are made to the α chain and/or the ω chain, and
wherein an alteration consists of:
a. adding, removed, or substituting a non-hydrogen atom, or b. changing the bond order of an existing covalent bond without adding or deleting said bond;
or a pharmaceutically acceptable salt, a tetrazole, or a prodrug thereof.
[0027] Also disclosed herein are methods of treating diseases or conditions, including glaucoma and elevated intraocular pressure. Compositions and methods of manufacturing medicaments related thereto are also disclosed.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0028] FIGS. 1 and 2 illustrate one method of preparing the compounds disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0029] A person of ordinary skill in the art understands the meaning of the stereochemistry associated with the hatched wedge/solid wedge structural features. For example, an introductory organic chemistry textbook (Francis A. Carey, Organic Chemistry, New York: McGraw-Hill Book Company 1987, p. 63) states “a wedge indicates a bond coming from the plane of the paper toward the viewer” and the hatched wedge, indicated as a “dashed line”, “represents a bond receding from the viewer.”
[0030] In relation to the identity of A disclosed in the chemical structures presented herein, in the broadest sense, A is —(CH 2 ) 6 —, or cis —CH 2 CH═CH—(CH 2 ) 3 —, wherein 1 or 2 carbons may be substituted with S or O. In other words, A may be —(CH 2 ) 6 —, cis —CH 2 CH═CH—(CH 2 ) 3 —, or A may be a group which is related to one of these two moieties in that any carbon is substituted with S or O. For example, while not intending to limit the scope of the invention in any way, A may be an S substituted moiety such as one of the following or the like.
[0000]
[0000] Alternatively, while not intending to limit the scope of the invention in any way, A may be an O substituted moiety such as one of the following or the like.
[0000]
[0000] In other embodiments, A is —(CH 2 ) 6 — or cis-CH 2 CH═CH—(CH 2 ) 3 — having no heteroatom substitution.
[0031] Since J can be —OH or ═O, compounds of the structures shown below are possible, or pharmaceutically acceptable salts or prodrugs thereof
[0000]
[0032] A “pharmaceutically acceptable salt” is any salt that retains the activity of the parent compound and does not impart any additional deleterious or untoward effects on the subject to which it is administered and in the context in which it is administered compared to the parent compound. A pharmaceutically acceptable salt also refers to any salt which may form in vivo as a result of administration of an acid, another salt, or a prodrug which is converted into an acid or salt.
[0033] Pharmaceutically acceptable salts of acidic functional groups may be derived from organic or inorganic bases. The salt may comprise a mono or polyvalent ion. Of particular interest are the inorganic ions, lithium, sodium, potassium, calcium, and magnesium. Organic salts may be made with amines, particularly ammonium salts such as mono-, di- and trialkyl amines or ethanol amines. Salts may also be formed with caffeine, tromethamine and similar molecules. Hydrochloric acid or some other pharmaceutically acceptable acid may form a salt with a compound that includes a basic group, such as an amine or a pyridine ring.
[0034] A “prodrug” is a compound which is converted to a therapeutically active compound after administration, and the term should be interpreted as broadly herein as is generally understood in the art. While not intending to limit the scope of the invention, conversion may occur by hydrolysis of an ester group or some other biologically labile group. Ester prodrugs of the compounds disclosed herein are specifically contemplated. While not intending to be limiting, an ester may be an alkyl ester, an aryl ester, or a heteroaryl ester. The term alkyl has the meaning generally understood by those skilled in the art and refers to linear, branched, or cyclic alkyl moieties. C 1-6 alkyl esters are particularly useful, where alkyl part of the ester has from 1 to 6 carbon atoms and includes, but is not limited to, methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, iso-butyl, t-butyl, pentyl isomers, hexyl isomers, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and combinations thereof having from 1-6 carbon atoms, etc.
[0035] A “tetrazole” as disclosed herein is meant to be a compound wherein a carboxylic acid is substituted with a tetrazole functional group. Thus, a tetrazole of a compound of the structure
[0000]
[0000] would have the structure shown below.
[0000]
[0036] Tetrazoles are known in the art to be interchangeable with carboxylic acids in biological systems. In other words, if a compound comprising a carboxylic acid is substituted with a tetrazole, it is expected that the compound would have similar biological activity. A pharmaceutically acceptable salt or a prodrug of a tetrazole is also considered to be a tetrazole for the purposes of this disclosure.
[0037] Another embodiment comprises
[0000]
[0000] or a pharmaceutically acceptable salt, a tetrazole, or a prodrug thereof. In other embodiments, the compound is the acid or a pharmaceutically acceptable salt, and not a tetrazole or a prodrug.
[0038] Another embodiment comprises
[0000]
[0000] or a pharmaceutically acceptable salt, a tetrazole, or a prodrug thereof. In other embodiments, the compound is the acid or a pharmaceutically acceptable salt, and not a tetrazole or a prodrug.
[0039] One embodiment comprises derivatives of
[0000]
[0000] wherein said derivative has a structure as shown above except that 1 or 2 alterations are made to the α chain and/or the ω chain, wherein an alteration consists of 1) adding, removed, or substituting a non-hydrogen atom, or 2) changing the bond order of an existing covalent bond without adding or deleting said bond. Salts, tetrazoles, and prodrugs of the depicted compound or derivatives thereof are also contemplated.
[0040] Thus, a compound having the structure above is contemplated, as well as a pharmaceutically acceptable salt a prodrug, or a tetrazole thereof.
[0041] In making reference to a derivative and alterations to a structure as shown above, it should be emphasized that making alterations and forming derivatives is strictly a mental exercise used to define a set of chemical compounds, and has nothing to do with whether said alteration can actually be carried out in the laboratory, or whether a derivative can be prepared by an alteration described. However, whether the derivative can be prepared via any designated alteration or not, the differences between the derivatives and the aforementioned structure are such that a person of ordinary skill in the art could prepare the derivatives disclosed herein using routine methods known in the art without undue experimentation.
[0000]
[0042] The α chain is the group in the solid circle in the labeled structure above. The ω chain is the group in the dashed circle in the labeled structure above. Thus, in these embodiments said derivative may be different from the formula above at the α chain, while no alteration is made to the ω chain, as for example, in the structures shown below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0043] The derivatives may also be different from the formula above in the ω chain, while no alteration is made to the α chain, as shown in the examples below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0044] Alternatively, the derivatives may be different in both the α and ω chains, as shown in the examples below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0045] Changes to the structure can take several forms, if a non-hydrogen atom is added, the structure is changed by adding the atom, and any required hydrogens, but leaving the remaining non-hydrogen atoms unchanged, such as in the two examples shown below, with the added atoms in bold type.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0046] If a non-hydrogen atom is removed, the structure is changed by removing the atom, and any required hydrogens, but leaving the remaining non-hydrogen atoms unchanged, such as in the two examples shown below, with the previous location of the missing atoms indicated by arrows.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0047] If a non-hydrogen atom is substituted, the non-hydrogen atom is replaced by a different non-hydrogen atom, with any necessary adjustment made to the number of hydrogen atoms, such as in the two examples shown below, with the substituted atoms in bold type.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0048] Changing the bond order of an existing covalent bond without adding or deleting said bond refers to the changing of a single bond to a double or triple bond, changing a double bond to a single bond or a triple bond, or changing a triple bond to a double or a single bond. Adding or deleting a bond, such as occurs when an atom is added, deleted, or substituted, is not an additional alteration for the purposes disclosed herein, but the addition, deletion, or substitution of the non-hydrogen atom, and the accompanying changes in bonding are considered to be one alteration. Three examples of this type of alteration are shown below, with the top two examples showing alteration in the double bond of the α chain, and the bottom example showing alteration in the C—O single bond of the ω chain.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0049] If a derivative could reasonably be construed to consist of a different number of alterations, the derivative is considered to have the lowest reasonable number of alterations. For example, the compound shown below, having the modified portion of the molecule in bold, could be reasonably construed to have 1 or 2 alterations relative to the defined structure.
[0000]
[0050] By one line of reasoning, the first alteration would be to remove the hydroxyl group from the carboxylic acid functional group, yielding an aldehyde. The second alteration would be to change the C═O double bond to a single bond, yielding the alcohol derivative shown above. By a second line of reasoning, the derivative would be obtained by simply removing the carbonyl oxygen of the carboxylic acid to yield the alcohol. In accordance with the rule established above, the compound above is defined as having 1 alteration. Thus, an additional alteration could be made to the structure to obtain the compounds such as the examples shown below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0051] In one embodiment, O or S is substituted for CH 2 , as seen in several of the examples disclosed previously herein, as well as in the examples below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0052] Certain compounds comprise C═O, i.e. the bond order of the C—O bond is increased from a single to double bond as in the compounds shown below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0053] Other embodiments comprise no Br, i.e. it is removed or another atom is substituted for it, as in the examples shown below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0054] Other embodiments comprise no CH 3 , i.e. it is removed or another atom is substituted for it, as in the examples shown below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0055] In many embodiments, the compound comprises a thienyl or substituted thienyl moiety. A number of examples of these compounds are given above. However, certain embodiments may have a substituted furyl, phenyl, or other aromatic moiety, such as the examples shown below.
[0000]
[0000] Pharmaceutically acceptable salts, tetrazoles, and prodrugs of these compounds are also contemplated.
[0056] Another embodiment comprises (Z)-7-{(1R,2R)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-hydroxy-pent-1-enyl]-5-hydroxy-cyclopentyl}-hept-5-enoic acid.
[0057] The compounds of disclosed herein are useful for the prevention or treatment of glaucoma or ocular hypertension in mammals, or for the manufacture of a medicament for the treatment of glaucoma or ocular hypertension.
[0058] Those skilled in the art will readily understand that for administration or the manufacture of medicaments the compounds disclosed herein can be admixed with pharmaceutically acceptable excipients which per se are well known in the art. Specifically, a drug to be administered systemically, it may be confected as a powder, pill, tablet or the like, or as a solution, emulsion, suspension, aerosol, syrup or elixir suitable for oral or parenteral administration or inhalation.
[0059] For solid dosage forms or medicaments, non-toxic solid carriers include, but are not limited to, pharmaceutical grades of mannitol, lactose, starch, magnesium stearate, sodium saccharin, the polyalkylene glycols, talcum, cellulose, glucose, sucrose and magnesium carbonate. The solid dosage forms 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. They may also be coated by the technique described in the U.S. Pat. Nos. 4,256,108; 4,166,452; and 4,265,874 to form osmotic therapeutic tablets for control release. Liquid pharmaceutically administrable dosage forms can, for example, comprise a solution or suspension of one or more of the presently useful compounds and optional pharmaceutical adjutants in a carrier, such as for example, water, saline, aqueous dextrose, glycerol, ethanol and the like, to thereby form a solution or suspension. If desired, the pharmaceutical composition to be administered may also contain minor amounts of nontoxic auxiliary substances such as wetting or emulsifying agents, pH buffering agents and the like. Typical examples of such auxiliary agents are sodium acetate, sorbitan monolaurate, triethanolamine, sodium acetate, triethanolamine oleate, etc. Actual methods of preparing such dosage forms are known, or will be apparent, to those skilled in this art; for example, see Remington's Pharmaceutical Sciences, Mack Publishing Company, Easton, Pa., 16th Edition, 1980. The composition of the formulation to be administered, in any event, contains a quantity of one or more of the presently useful compounds in an amount effective to provide the desired therapeutic effect.
[0060] Parenteral administration is generally characterized by injection, either subcutaneously, intramuscularly or intravenously. Injectables can be prepared in conventional forms, either as liquid solutions or suspensions, solid forms suitable for solution or suspension in liquid prior to injection, or as emulsions. Suitable excipients are, for example, water, saline, dextrose, glycerol, ethanol and the like. In addition, if desired, the injectable pharmaceutical compositions to be administered may also contain minor amounts of non-toxic auxiliary substances such as wetting or emulsifying agents, pH buffering agents and the like.
[0061] The amount of the presently useful compound or compounds administered is, of course, dependent on the therapeutic effect or effects desired, on the specific mammal being treated, on the severity and nature of the mammal's condition, on the manner of administration, on the potency and pharmacodynamics of the particular compound or compounds employed, and on the judgment of the prescribing physician. The therapeutically effective dosage of the presently useful compound or compounds is preferably in the range of about 0.5 or about 1 to about 100 mg/kg/day.
[0062] A liquid which is ophthalmically acceptable is formulated such that it can be administered topically to the eye. The comfort should be maximized as much as possible, although sometimes formulation considerations (e.g. drug stability) may necessitate less than optimal comfort. In the case that comfort cannot be maximized, the liquid should be formulated such that the liquid is tolerable to the patient for topical ophthalmic use. Additionally, an ophthalmically acceptable liquid should either be packaged for single use, or contain a preservative to prevent contamination over multiple uses.
[0063] For ophthalmic application, solutions or medicaments are often prepared using a physiological saline solution as a major vehicle. Ophthalmic solutions should preferably be maintained at a comfortable pH with an appropriate buffer system. The formulations may also contain conventional, pharmaceutically acceptable preservatives, stabilizers and surfactants.
[0064] Preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric, acetate and phenylmercuric nitrate. A useful surfactant is, for example, Tween 80. Likewise, various useful vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose and purified water.
[0065] Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
[0066] Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
[0067] In a similar vein, an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
[0068] Other excipient components which may be included in the ophthalmic preparations are chelating agents. A useful chelating agent is edetate disodium, although other chelating agents may also be used in place or in conjunction with it.
[0069] The ingredients are usually used in the following amounts:
[0000]
Ingredient
Amount (% w/v)
active ingredient
about 0.001-5
preservative
0-0.10
vehicle
0-40
tonicity adjustor
1-10
buffer
0.01-10
pH adjustor
q.s. pH 4.5-7.5
antioxidant
as needed
surfactant
as needed
purified water
as needed to make 100%
[0070] For topical use, creams, ointments, gels, solutions or suspensions, etc., containing the compound disclosed herein are employed. Topical formulations may generally be comprised of a pharmaceutical carrier, cosolvent, emulsifier, penetration enhancer, preservative system, and emollient.
[0071] The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
Example 1
[0072] Compounds of Table 1 were prepared according to the following procedures. Compound 1 was prepared by methods disclosed in U.S. Pat. No. 6,124,344, incorporated by reference herein.
[0073] (Z)-7-[(1R,2R,3R,5S)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-(tetrahydro-pyran-2-yloxy)-pent-1-enyl]-3,5-bis-(tetrahydro-pyran-2-yloxy)-cyclopentyl]-hept-5-enoic acid methyl ester (2). An acetone (24 mL) solution of acid 1 was treated with DBU (1.4 mL, 9.36 mmol) and methyl iodide (0.6 mL, 9.63 mmol). The reaction was stirred for 21 h and then 50 mL 1 M HCl was added and the mixture extracted with ethyl acetate (3×50 mL). The combined ethyl acetate solution was dried (Na 2 SO 4 ), filtered and evaporated to leave a brown oil that was used directly in the next step.
[0074] (Z)-7-{(1R,2R,3R,5S)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-hydroxy-pent-1-enyl]-3,5-dihydroxy-cyclopentyl}-hept-5-enoic acid methyl ester (3). A mixture of the crude ester (2) in methanol (16 mL) was treated with pyridinium p-toluenesulfonate (2.625 g, 10.4 mmol). After 21 h, the solvent was evaporated in vacuo and the residue purified by flash chromatography on silica gel (90% ethyl acetate/hexanes→95%) to give 3 (3.453 g, 6.9 mmol, 86% for the two steps).
[0075] (Z)-7-[(1R,2R,3R,5S)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-(tert-butyl-dimethyl-silanyloxy)-pent-1-enyl]-3-(tert-butyl-dimethyl-silanyloxy)-5-hydroxy-cyclopentyl]-hept-5-enoic acid methyl ester (4). A dichloromethane (14 mL) solution of 3 (3.452 g, 6.9 mmol) was treated with triethylamine (2.9 mL, 20.8 mmol), DMAP (211 mg, 1.73 mmol) and TBSCl (2.130 g, 14.1 mmol). The reaction was allowed to stir for 22 h and then was quenched by addition of 100 mL saturated NaHCO 3 solution. The mixture was extracted with CH 2 Cl 2 (3×75 mL) and the combined CH 2 Cl 2 solution was dried (Na 2 SO 4 ), filtered and evaporated. Purification by flash chromatography (10% ethyl acetate/hexane→20%) gave 4 (3.591 g, 4.9 mmol, 71%).
[0076] (Z)-7-[(1R,2R,3R)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-(tert-butyl-dimethyl-silanyloxy)-pent-1-enyl]-3-(tert-butyl-dimethyl-silanyloxy)-5-oxo-cyclopentyl]-hept-5-enoic acid methyl ester (5). A mixture of alcohol 4 (3.591 g, 4.9 mmol), 4 A molecular sieves (2.5 g), and NMO (867 mg, 7.4 mmol) in dichloromethane (10 mL) was treated with TPAP (117 mg, 0.33 mmol). After 1 h, the mixture was filtered through celite and the filtrate evaporated in vacuo. Purification by flash chromatography (5% ethyl acetate/hexanes→7.5%) gave 5 (2.984 g, 4.1 mmol, 84%).
[0077] (Z)-7-{(1R,2S)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-hydroxy-pent-1-enyl]-5-oxo-cyclopent-3-enyl}-hept-5-enoic acid methyl ester (6). A mixture of 5 (1.486 g, 2.03 mmol), HOAc (20 mL), H 2 O (10 mL) and THF (10 mL) was stirred at 70° C. for 17 h. The reaction was then poured into 750 mL saturated NaHCO 3 solution and the resulting mixture was extracted with ethyl acetate (4×200 mL). The combined ethyl acetate solution was dried (Na 2 SO 4 ), filtered and evaporated. Flash chromatography (50% ethyl acetate/hexanes) gave 6 (497 mg, 1.03 mmol, 51%).
[0078] (Z)-7-{(1R,2S)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-(tert-butyl-dimethyl-silanyloxy)-pent-1-enyl]-5-oxo-cyclopent-3-enyl}-hept-5-enoic acid methyl ester (7). A dichloromethane (6 mL) solution of 6 (497 mg, 1.03 mmol) was treated with 2,6-lutidine (143 μL, 1.22 mmol) and TBSOTf (0.26 mL, 1.13 mmol). After 1.5 h, 50 mL saturated NaHCO 3 was added and the resulting mixture was extracted with 25 mL CH 2 Cl 2 . The CH 2 Cl 2 layer was washed with 50 mL 1 M HCl and 50 mL brine. The CH 2 Cl 2 solution was then dried (Na 2 SO 4 ), filtered and evaporated. Purification by flash chromatography (8% ethyl acetate/hexanes→10%) gave 7 (553 mg, 0.93 mmol, 90%).
[0079] (Z)-7-{(1R,2R)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-(tert-butyl-dimethyl-silanyloxy)-pent-1-enyl]-5-oxo-cyclopentyl}-hept-5-enoic acid methyl ester (8). A solution of 7 (170 mg, 0.28 mmol) in 4 mL toluene was added, by cannula, to a −40° C. mixture of hydrido(triphenylphosphine)copper(I) hexamer (300 mg, 0.15 mmol) in 4 mL toluene, rinsing with 0.5 mL toluene. The temperature was allowed to warm to 0° C. over 1 h and then was allowed to warm to room temperature. After a further 1 h, the reaction was quenched by addition of 15 mL saturated NH 4 Cl solution. The mixture was extracted with ethyl acetate (3×15 mL) and the combined ethyl acetate solution was dried (Na 2 SO 4 ), filtered and evaporated. Purification by flash chromatography (8% ethyl acetate/hexanes→10%) gave the title ketone (150 mg, 0.25 mmol, 89%).
[0080] (Z)-7-{(1R,2R)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-(tert-butyl-dimethyl-silanyloxy)-pent-1-enyl]-5-hydroxy-cyclopentyl}-hept-5-enoic acid methyl ester (9H,L). A methanol (0.8 mL) solution of ketone 8 (150 mg, 0.25 mmol) was treated with NaBH 4 (15 mg, 0.40 mmol). After 1 h, the reaction was quenched with 15 mL 1 M HCl and the resulting mixture was extracted with dichloromethane (3×15 mL). The combined dichloromethane solution was dried (Na 2 SO 4 ), filtered and evaporated to give the alcohols 9H,L which were used directly in the next step.
[0081] (Z)-7-{(1R,2R)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-hydroxy-pent-1-enyl]-5-hydroxy-cyclopentyl}-hept-5-enoic acid methyl ester (10H,L). A solution of the crude alcohols 9 in HOAc (2 mL)/H 2 O (1 mL)/THF (1 mL) was heated at 70° C. for 2 h and then was quenched by addition of 100 mL saturated NaHCO 3 solution. The resulting mixture was extracted with ethyl acetate (4×100 mL) and the combined ethyl acetate solution was dried (Na 2 SO 4 ), filtered and evaporated. Flash chromatography (45% ethyl acetate/hexanes) followed by preparative TLC (42% ethyl acetate/hexanes) gave the two C9 diastereomers: high R f 29 mg (0.06 mmol, 24% for 2 steps) and low R f 53 mg (0.11 mmol, 43%).
[0082] (Z)-7-{(1R,2R)-2-[(E)-(S)-5-(4-Bromo-5-methyl-thiophen-2-yl)-3-hydroxy-pent-1-enyl]-5-hydroxy-cyclopentyl}-hept-5-enoic acid (11H). A THF (1.3 mL) solution of 10H (27 mg, 0.055 mmol) was treated with 0.5 M LiOH (0.33 mL, 0.17 mmol). The reaction was allowed to stir for 18 h and then 10 mL 1 M HCl was added. The resulting mixture was extracted with dichloromethane (3×15 mL) and the combined dichloromethane solution was dried (Na 2 SO 4 ), filtered and evaporated. Purification by flash chromatography (5% methanol/dichloromethane) gave 11H (20 mg, 0.042 mmol, 77%). 300 MHz NMR (CDCl 3 , ppm) δ 6.58 (1H, s) 5.6-5.3 (4H, overlapping m) 4.3-4.1 (2H, overlapping m) 2.8-2.7 (2H, m) 2.32 (3H, s) 2.4-1.3 (16H, overlapping m).
[0000]
TABLE 1
FUNCTIONAL DATA (EC50 nm)
Rf
STRUCTURE
HFP
HEP1
HEP2
HEP3A
HEP4
HTP
HIP
HDP
High
2069
NA
NA
>10 5
NA
1868
NA
NA
Low
NA
NA
NA
NA
NA
NA
NA
NA
High
>10 5
NA
793
>10 5
96
NA
NA
Low
>10 5
NA
NA
>10 5
832
>10 5
NA
NA
Example 2
[0083] The biological activity of the compounds of Table 1 was tested using the following procedures.
Methods for FLIPR™ Studies
(a) Cell Culture
[0084] HEK-293(EBNA) cells, stably expressing one type or subtype of recombinant human prostaglandin receptors (prostaglandin receptors expressed: hDP/Gqs5; hEP 1 ; hEP 2 /Gqs5; hEP 3A /Gqi5; hEP 4 /Gqs5; hFP; hIP; hTP), were cultured in 100 mm culture dishes in high-glucose DMEM medium containing 10% fetal bovine serum, 2 mM 1-glutamine, 250 μg/ml geneticin (G418) and 200 μg/ml hygromycin B as selection markers, and 100 units/ml penicillin G, 100 μg/ml streptomycin and 0.25 μg/ml amphotericin B.
(b) Calcium Signal Studies on the FLIPR™
[0085] Cells were seeded at a density of 5×10 4 cells per well in Biocoat® Poly-D-lysine-coated black-wall, clear-bottom 96-well plates (Becton-Dickinson) and allowed to attach overnight in an incubator at 37° C. Cells were then washed two times with HBSS-HEPES buffer (Hanks Balanced Salt Solution without bicarbonate and phenol red, 20 mM HEPES, pH 7.4) using a Denley Cellwash plate washer (Labsystems). After 45 minutes of dye-loading in the dark, using the calcium-sensitive dye Fluo-4 AM at a final concentration of 2 μM, plates were washed four times with HBSS-HEPES buffer to remove excess dye leaving 100 μl in each well. Plates were re-equilibrated to 37° C. for a few minutes. Cells were excited with an Argon laser at 488 nm, and emission was measured through a 510-570 nm bandwidth emission filter (FLIPR™, Molecular Devices, Sunnyvale, Calif.). Drug solution was added in a 50 μl volume to each well to give the desired final concentration. The peak increase in fluorescence intensity was recorded for each well. On each plate, four wells each served as negative (HBSS-HEPES buffer) and positive controls (standard agonists: BW245C (hDP); PGE 2 (hEP 1 ; hEP 2 /Gqs5; hEP 3A /Gqi5; hEP 4 /Gqs5); PGF 2α (hFP); carbacyclin (hIP); U-46619 (hTP), depending on receptor). The peak fluorescence change in each drug-containing well was then expressed relative to the controls.
[0086] Compounds were tested in a high-throughput (HTS) or concentration-response (CoRe) format. In the HTS format, forty-four compounds per plate were examined in duplicates at a concentration of 10 −5 M. To generate concentration-response curves, four compounds per plate were tested in duplicates in a concentration range between 10 −5 and 10 −11 M. The duplicate values were averaged. In either, HTS or CoRe format each compound was tested on at least 3 separate plates using cells from different passages to give an n≧3.
[0087] The results of the activity studies presented in the table demonstrate that the compounds disclosed herein are prostaglandin receptor agonists, and are thus useful for the treatment of glaucoma, ocular hypertension, the other diseases or conditions related to the activity of the prostaglandin receptors.
[0088] The foregoing description details specific methods and compositions that can be employed to practice the present invention, and represents the best mode contemplated. However, it is apparent for one of ordinary skill in the art that further compounds with the desired pharmacological properties can be prepared in an analogous manner, and that the disclosed compounds can also be obtained from different starting compounds via different chemical reactions. Similarly, different pharmaceutical compositions may be prepared and used with substantially the same result. Thus, however detailed the foregoing may appear in text, it should not be construed as limiting the overall scope hereof; rather, the ambit of the present invention is to be governed only by the lawful construction of the appended claims.
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A compound comprising
or a pharmaceutically acceptable salt or a prodrug thereof,
having the groups described in detail herein is disclosed.
Also disclosed herein are compounds comprising
or derivatives thereof, or pharmaceutically acceptable salts, tetrazoles, or prodrugs of compounds of the structure or derivatives thereof, said derivatives being described in detail herein.
Also disclosed herein are methods of treating diseases or conditions, including glaucoma and elevated intraocular pressure. Compositions and methods of manufacturing medicaments related thereto are also disclosed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application seeks priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application 61/056,681, filed May 28, 2008, the entirety of which is incorporated by reference.
FIELD OF THE INVENTION
Aspects of the invention relate to deicing, anti-icing, de-contamination, or contamination prevention for structures where such capability would be beneficial. The technique invented here could also be utilized in non-destructive testing and structural health monitoring applications.
BACKGROUND INFORMATION
Ice formation on structures and components can cause decreases in component performance and, in some cases, component failure. Ice formation on helicopter rotor blades or on the wing leading edges of fixed-wing aircraft, for example, alter the aerodynamic characteristics of the aircraft and can result in reduced handling. Icing conditions, for the case of aircraft, often result in flight cancellations or delays. In the event that icing conditions are encountered during flight, ice build-up, which reduces aircraft handling and maneuverability, can cause the aircraft to crash.
Thermal deicing and pneumatic boot systems are used predominantly for structural deicing. These systems require significant power levels for operation. For the case of rotorcraft, the high power levels required by the thermal systems result in compromised rotorcraft functionality. Further, the thermal deicing systems often melt ice which then refreezes on other parts of the blade, wing, or component. Therefore, a need exists to replace thermal deicing systems with new technologies that require less power.
In addition to rotor blades and wing leading edges of fixed-wing aircraft, many other structures would benefit from a low-power deicing or anti-icing system, including, but not limited to, windshields in aircraft, automobiles, and other vehicles, ship hulls or other ship components, heat exchangers and other tubing where frost or ice could form, air-conditioning components, head lamp and other light coverings, and bridge structures and components.
The build up of dirt, mud, frozen soil, or other debris on structures can cause reduced functionality and increased weight. For example, excavation equipment can be difficult to start and operate if debris accumulates on the undercarriage of the equipment of vehicle. For excavation equipment, debris formation is sometimes mitigated by debris-phobic coatings which do not always work well and can wear overtime. Debris removal is often achieved using an object to strike the undercarriage to shake the debris loose. Using this time-consuming approach, project delays are often caused.
For excavation equipment, it would be beneficial to have debris prevention or removal technology that could be used during or after equipment use to prevent debris formation or quickly remove debris build-up.
Another example where debris build-up causes unwanted downtimes and increased cleaning costs is in the food industry where bacteria or other films can accrete to the inner diameter surface of tubing or pipes used to transport product. These tubes or pipes are routinely shut down and flushed with cleaning chemicals to remove unwanted build-up. There is a need to provide a technology to prevent build-up formation or assist the cleaning process in removing these films.
SUMMARY
It is an objective of an aspect of the invention to provide a method and arrangement for removing or preventing the formation of ice, mud, or other debris or contaminants, from structures where such capability would be beneficial.
It is also an objective of an aspect of the invention to reduce the amount of power required for ice, mud, debris or contamination removal or prevention via appropriate ultrasonic actuator design to excite specific ultrasonic modes in the structure.
It is a further objective of an aspect of the invention to improve the overall area of coverage for prevention of contamination and decontamination activities by using frequency tuning, over some frequency range and at some frequency increment, to change the structural areas where maximum ultrasonic stresses occur when considering the ultrasonic stresses produced in the structure from one or more actuators.
It is also an objective of an aspect of the invention to use frequency tuning to occasionally drive the actuator off-resonance to avoid over-heating or degradation of the actuator.
It is also an objective of an aspect of the invention to improve overall area of coverage by using multiple actuators combined with phased array focusing, using tone-burst pulse excitation, or time delay phasing, using continuous wave excitation, in the wave guide structure being considered to move the ultrasonic stress focal points around the structure.
It is also an objective of the present invention to use a tone burst or chirp input to the actuator, or actuators, to improve performance. The objectives are achieved as illustrated and described. In one embodiment, a method is provided including the steps of encompassing placing at least one ultrasonic actuator on the host structure and determining a special loading function to create a shear stress, normal stress, or other wave mechanics parameter in the host structure. The method further provides for activating the at least one ultrasonic actuator on the host structure to produce the shear stress via ultrasonic continuous wave activation, wherein at least one of ultrasonic initial transient wave propagation, reflection factor superposition, and time modal vibrations are used to at least one of delaminate and weaken an adhesion strength of the contamination to the host structure.
It is also an objective of the present invention to use a novel ultrasonic vibration technique for nondestructive testing or structural health monitoring purposes whereas a modal analysis approach is used for detection but transient wave analysis is used to select a particular guided wave mode, with a specific wave structure, to achieve improved detection sensitivity.
In another example embodiment, a method for at least one of removing and preventing ice from attaching to a host structure is provided. In this example embodiment, the method provides for the steps of one of permanently installing and periodically placing at least one ultrasonic actuator on the host structure, and activating the at least one ultrasonic actuator on the host structure to one of remove the ice from the host structure, decrease an adhesion strength of ice layers from the host structure and prevent ice from forming on the host structure
In another example embodiment, a method for at least one of removing and preventing contaminants from attaching to a host structure is provided. In this example embodiment, a method step of one of permanently installing and periodically placing at least one ultrasonic actuator on the host structure is provided. Additionally, the method provides for activating the at least one ultrasonic actuator on the host structure to provide ultrasonic stresses in the host adhesion strength of the contaminants from the host structure and prevent contaminates from forming on the host structure are provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a sample phase velocity dispersion curve showing activation lines for different loading scenarios.
FIG. 2 illustrates a comb or annular array actuator arrangement, wherein the finger spacing dictates the mode that will be excited.
FIG. 3 is an annular array actuator design.
FIG. 4 is a shear polarized actuator, wherein the actuator is poled through the length and an electric field is applied across the width to operate in a d 15 configuration.
FIGS. 5A and 5B are examples of shear horizontal phase velocity dispersion curves for an aluminum skin with adhered ice layers.
FIG. 6 illustrates a wave structure for a guided wave mode exhibiting large interface shear stresses.
FIG. 7 illustrates a wave structure for a guided wave mode exhibiting small interface shear stresses.
FIG. 8 shows an arrangement for a sample finite element method model used to predict the shear stresses produced at the interface of a steel plate with ice layers present.
FIG. 9 illustrates a sample finite element method modeling result predicting the shear stresses produced at the plate/ice layer interface.
FIGS. 10A , 10 B and 10 C illustrate the removal of ice layers from a steel plate using the ultrasonic frequency tuning approach.
DETAILED DESCRIPTION
In one non-limiting method of the invention, a phase velocity dispersion curve space is developed for a structure, in this example called a host structure. The host structure can be an airplane wing, a boat, a structural steel skeleton of a building, or other. The phase velocity dispersion curve space is then evaluated with respect to either a longitudinal wave (“Lamb type wave”) or shear horizontal wave case for the structure such that activation produces a Lamb type wave or shear horizontal wave in the structure by using a specific actuator design. The appropriate point chosen on the velocity dispersion curve space is based on the wave structure across the thickness of the substrate/ice or substrate/contaminant structure. Maximum or reasonable shear stress or normal stress is generated at that point chosen on the velocity dispersion curve space in order to fracture, delaminate, or weaken the interface between ice or materials adhering to the host structure substrate. An angle beam, comb type, normal beam longitudinal, vertical shear, or horizontal shear actuator may be used to create the maximum or reasonable shear stress for the fracture or delamination. In one example embodiment, an ultrasonic vibration method may be used whereby continuous wave excitation is produced.
In the methods and apparatus provided, actuator positioning on the host structure is important as the transient wave generated by the transducers starts traveling through the host structure with a suitable wave structure. As the wave encounters boundaries, the wave is reflected at various angles. The initial wave patterns are complex but eventually, after many reflections and as the wave travels from one boundary to another, a modal pattern is established at a resonant frequency. There are many resonant frequencies fairly close together because of the ultrasonic excitation. Deicing or decontamination can often occur at a resonant or a non-resonant situation.
With appropriate test points from the dispersion curves for the structures, the wave structure is preserved, with respect to suitable stress at the ice/substrate or ice/contaminate interface, after the many reflections leading to the vibration state. The ice or contaminant is removed as a result of ultrasonic transient waves, reflection factors, and eventual vibrations that, via continuous interference of the wave pattern, produce sufficient shear stress at the ice/substrate or ice/contaminant interface to cause fracture and delamination. The vibration pattern depends on the initial specifically designed ultrasonic loading functions.
In one embodiment, the ultrasonic guided wave is launched using an ultrasonic actuator with minimal input energy to achieve deicing or decontamination of a surface. This method and configuration solves the long felt need of decontamination without need for large input energies into the host structure.
Deicing or decontamination is achieved by providing sufficient shear or normal stresses, or combination thereof, at the ice, mud, and/or debris—substrate interface at the ultrasonic guided wave launching point and possibly over the entire structure being considered.
One or more actuators with proper physical positioning may be considered in order to alter wave interference phenomenon to create a number of maximum constructive interference zones or focal points that could be moved around the structure as frequency and/or wave mode is changed, resulting in the creation of natural focal spots. These focal points may be moved, through user selection, allowing deicing/decontamination at specific points of the structure.
In an alternative configuration and method, phased array focusing, using tone-burst pulse excitation, or time delay phasing, using continuous wave excitation, in the wave guide structure being considered may be used to move the focal points around the structure, thus allowing a user to select where material removal occurs.
Ice, mud, and/or debris delamination from the structure and/or cracking occur as a result of sufficient shear stress, normal stress, or other wave mechanics parameter being provided to the ice, mud, and/or debris-substrate interface in combination with frequency tuning, tone burst excitation phased array focusing, continues wave excitation time phasing, wave reflection factor superposition with waves emitted from the actuator, and/or vibration modes generated as a result of numerous reflections from the boundaries of the structure.
Aspects of specific ultrasonic mode and frequency excitation over a finite frequency range from 1 Hz-500 MHz are provided wherein frequency tuning over a selected specific frequency range, phased array, time phasing, or natural focusing achieved via optimal sensor positioning, reflection factor point constructive interferences and special modal vibration combination releases, and possible use of ice or mud phobic coatings in combination with all of the above.
Either one or a combination of some or all of these concepts may be used for ice, mud, and/or debris prevention or removal, depending on the situation. For example, ice or debris type or thickness, structural geometry, environmental conditions, etc. will affect which concepts are applicable.
The apparatus and methods provided can be applied to isotropic media as well as anisotropic composite media. Further, various combinations of these concepts can be selected so as to not cause structural damage.
Optimal actuator design and actuator frequency for providing large shear stresses, normal stresses, or other wave mechanics parameter to the ice, mud, and/or debris interface can be achieved using analytical dispersion curve and wave structure analysis in combination with finite element method modeling. Actuator designs that can be considered non-limiting embodiments include, normal incidence loading using either shear polarized piezoelectric elements or conventional disks or bars poled through the thickness, angle beam loading to excite specific points on the guided wave phase velocity dispersion curve, or annular array or comb actuators, again, to provide specific mode control. For the case of normal loading, mode control is limited and the actuator will excite some component of all guided wave modes present at the actuator driving frequency. Angle beam loading can be used to excite specific guided wave modes according to Snell's Law. Annular array or comb actuators can also be used to excite specific points in the dispersion curve space by designing the finger spacing of the probe to be equal to the wavelength of the mode you wish to excite. As an example, FIG. 1 shows the activation lines on the phase velocity dispersion curve for each type of loading. FIG. 2 demonstrates the concept of a comb actuator and FIG. 3 shows an annular array actuator. FIG. 4 demonstrates the concept of a shear polarized actuator for operating in the d 15 configuration.
As an embodiment, basic curves associated with this phenomenon for ice layers of thicknesses 1 mm and 2 mm on an aluminum skin in FIG. 1 are provided.
Referring to FIG. 1 , a sample phase velocity dispersion curve is shown with the activation lines for normal, angle beam, and comb loading. For a case of normal incidence, mode control is limited and the actuator will excite components of all modes present at the driving frequency. For a case of angle beam incidence, the angle of incidence can be determined using Snell's Law and the phase velocity of the desired wave mode. Once the incident angle is set, a horizontal activation line can be drawn on the dispersion curve and all modes intersecting the line can be excited by changing excitation frequency. For the case of comb activation, the activation line is drawn as shown with a slope equal to the wavelength or comb finger spacing. Again, all modes intersecting the activation line can be excited with the actuator by changing excitation frequency. The use of angle beam or comb activation is advantageous in that a single mode on the dispersion curve with a desired wave structure can be selected and the actuator can then be designed to excite the desired mode, and no other modes.
Referring to FIG. 2 , a comb probe 200 is shown. The fingers in the probe 200 are designed to be one wavelength apart, depending on the mode and corresponding wavelength one chooses to excite.
FIG. 3 shows a drawing of an annular array actuator 300 in one non-limiting embodiment. The annular array 300 is equivalent to a comb actuator and finger spacing is chosen in the same manner. In this embodiment, an electrode pattern is placed on top of a piezoelectric disk to create the desired wave mode as selected by a user.
FIG. 4 shows a conceptual drawing of a shear polarized actuator 400 . The actuator 400 is poled through the length and an electric field is applied across the width to operate in the d 15 configuration. Each of the shear polarized actuator 400 , the annular array actuator 300 and the comb probe 200 may be attached in a permanent manner to a host structure or temporarily attached to a host structure for actuation of host structure. The actuation may be used, in example embodiments, to limit/remove contamination, such as ice, mud and materials from a surface that is desired to be clean.
FIGS. 5A and 5B are examples of the ultrasonic guided wave phase velocity dispersion curves for an aluminum skin host structure with an ice layer frozen to the surface of the aluminum skin. Two ice layer thicknesses are represented in the curves. The curves have shifts as ice thickness varies. The dispersion curves represent possible transient wave guided wave modes that can be generated in this structure as a function of excitation frequency. Each point on the curve can be excited via special actuator design. Each point on the curve also has a different wave structure associated with it. Wave structure here refers to different displacement characteristics through the thickness of the part or aluminum skin. In addition to shear horizontal dispersion curves, Lamb wave dispersion curves can also be generated and analyzed similarly. Both types of dispersion curves can be generated for any substrate structure exposed to any ice layer or contaminant type or thickness.
FIG. 6 illustrates a shear stress distribution across the thickness of the aluminum skin host structure with ice layer for several selected points on the dispersion curve. In this example, mode 4 has a wave structure with relatively high shear stress at the aluminum plate/ice interface while mode 2 provides relatively low shear stress to the aluminum/ice interface.
FIG. 7 shows a shear stress distribution across the thickness of the aluminum skin with ice layer for several selected points on the dispersion curve. In this case, all of the modes provide low shear stress values to the interface.
FIG. 8 shows a finite element method (FEM) model arrangement to predict the stress produced in a steel plate with an ice patch as shown for a given actuator loading condition. There are two circular actuators embedded on the plate as shown. Three different ice thickness layers are provided in the model, wherein the actuators transfer ultrasonic energy into the different ice substrate.
FIG. 9 shows the shear stresses occurring at the interface of the ice patches for the arrangement in FIG. 8 . In this embodiment, the thicker ice patch has larger stresses at its interface than the two thinner patches.
Referring to FIGS. 10A , 10 B and 10 C, the removal of ice layers from a steel plate using the ultrasonic frequency sweeping deicing approach is illustrated. In this example embodiment, two actuators were bonded to a 22 gauge steel plate with dimensions of 1 ft.×2 ft. Six ice patches were then frozen to various positions on the plate. Ice patch thickness varied between 0.5-3 mm. The actuators were turned on and automated frequency sweeping software was used to continuously move the focal spots throughout the entire plate. Experimentation and modeling were used to determine the frequency sweeping range, increment, and duty cycle. A combination of frequency change and distance to the ice patches determined when deicing would occur, which in this example takes 15 s for complete deicing. As demonstrated in FIGS. 10A , 10 B and 10 C, some of the ice patches were completely delaminated within 4 s of turning the actuators on. Complete de-icing of the plate occurred after 15 s of continuous mode-tuning. The plate was positioned at the bottom of the freezer for the entire experiment and the ice patches were formed over a period of 15 hours.
The ultrasonic vibration approach can also be used for nondestructive testing or structural health monitoring. The purpose here is to develop a new ultrasonic vibration technique to bridge the gap between ultrasonic wave propagation and lower frequency modal analysis vibration methods in nondestructive evaluation and structural health monitoring in order to find defects with intermediate size compared to the more standard ultrasonic non deconstructive testing and structural health monitoring testing techniques.
As an example, in ultrasonic practices it may be possible to detect a 0.010″ long defect; in a vibration or modal vibration approach it might be possible to detects on the order of 5″ in length. It is anticipated that with this new ultrasonic vibration technique that it will be possible to detect defects on the order or 0.5″ long.
It is also proposed to inspect odd shaped parts with different attachment considerations or boundary conditions and even hidden, coated, or insulated parts as long as a small section is accessible.
The basic concept is as follows: the hypothesis is that the ultrasonic modal analysis result will depend on the initial ultrasonic loading function. The loading function would be associated with an ultrasonic sensor design based on dispersion curve analysis and corresponding wave structure to achieve special sensitivity to certain kinds of defects. In plane and out of plane displacements could be selected at any point across the structure to optimize defect detection sensitivity. The sensor could be a normal beam sensor of a certain diameter or it could be a comb type or annular array with specific segment spacing that would be able to get on to phase velocity dispersion curve at a specific point of interest. The idea behind this specific loading function is to be able to create a wave structure across the thickness of the test object that would achieve a certain stress distribution or other wave parameter distribution to be able to have high sensitivity for finding a certain kind of defect after hundreds of reflections from the edges of the structures in somewhat preserving the wave structure until the long time solution occurs in which a modal vibration pattern is reached, either on or off resonance. Multiple loading functions, in a series of tests, may also be used to find and describe different kinds of situations.
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An ultrasonic method for removing and/or avoiding unwanted build-up on structures is provided, wherein the term build-up refers to, but is not limited to, ice, dirt, mud, or other wanted debris or contamination. Deicing or anti-icing structures of interest can include, but are not limited to, helicopter rotor blades, other helicopter blade components, fixed wing aircraft components, windshields in aircraft, automobiles, and other vehicles, ship hulls or other ship components, heat exchangers and other tubing where frost or ice could form, air-conditioning components, head lamp and other light coverings, bridge structures and components, and any structure where anti-icing or deicing would be beneficial. One or more ultrasonic actuators permanently embedded or coupled to the structure may be used accomplish the removal. The technique presented herein could also be utilized for non-destructive evaluation and structural health monitoring applications.
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PRIORITY
This application claims the benefit of U.S. Provisional Application No. 60/357,138 filed on Feb. 19, 2002.
FIELD OF THE INVENTION
The present invention relates generally to sensing devices. More particularly, the present invention relates to self-powered sensing devices used for the detection of dangerous environments that can cause an explosion or a fire around appliances such as water heaters, stoves, gas fireplaces, etc.
BACKGROUND OF THE INVENTION
Currently there are studies warning consumers of the dangers of storing flammable materials in close proximity to water heaters. In particular, there is a concern with the presence of liquids that give off flammable vapors such as gasoline. Approximately 50 million homes have gas water heaters with an additional 3.5 million new heaters sold each year. Gas-fired water heaters igniting flammable vapors are associated with nearly 2,000 fires a year, resulting in an estimated 316 injuries, 17 deaths, and $26 million in property damage for a total societal cost, which may be as high as $395 million. Typically, injuries occur when the victim is using a flammable liquid (usually gasoline) for cleaning purposes or when the liquid leaks or is accidentally spilled near a water heater. Water heaters are often installed in locations where people might normally place other things for storage including flammable liquids (e.g. garages, basements, utility areas).
Water heater manufacturers have tried to educate consumers on measures that can be taken to reduce risk of fires related to water heaters and flammable vapors including:
Making sure gas fired water heaters are installed according to code requirements.
Elevating heaters (gas vapors are heavier than air) where possible.
Avoiding the use gasoline to clean equipment or tools.
Using gasoline only as a motor fuel.
Storing gasoline only in tightly sealed red containers intended for gasoline.
Keeping all flammable materials and liquids away from gas fired heaters.
There are two types of water heaters sold in the US. The vast majority of water heaters are naturally vented appliances that typically utilize a pilot light to light the heater and to provide a continuous natural draft for the exhaust flue of the heater. These types of water heaters typically do not require external power. About 10% of gas heaters sold are power vented where a fan is activated to induce a draft in a flue to exhaust combustion fumes. Both types of units draw combustion air from the area below the water heater. The risk occurs when the open flame or igniter of the water heater is exposed to flammable vapors from liquids stored nearby.
One possible solution is to utilize a sensor that could sense the presence of combustible vapors and which would turn off the pilot light or prevent a fan powered water heater. A specification for such a device should have the following characteristics:
Ability to sense hydrocarbon fumes like gasoline vapors very quickly and efficiently.
Ability to send a control signal to interact with water heater operation.
Long lifetime.
Ability to operate in high and low humidity environments.
The sensor must not require calibration or if calibration is required the sensor must be able to send a signal to the control that it is non functional.
In addition, for the vast majority of non-vented water heaters, a source of power for a sensor may not be available.
Traditional approaches to hydrocarbon sensing including electrochemical cell, metal oxide sensors and catalytic bead are problematic for this application because of the detection speed, lifetime, calibration and humidity requirements.
Infrared sensing has some inherent advantages as a sensor, but the conventional technology does need innovation to be applied to this application which also demands low product cost.
Accordingly, a system which is easily calibrated and can operate in high and low humidity environments is desired.
In addition, a system that is self-powered and can detect multiple vapors is also desired.
SUMMARY OF THE INVENTION
It is therefore a feature and advantage of the present invention to provide a sensor that is easily calibrated and operates in high and low humidity environments. In one embodiment of the invention the sensor does not require external calibration. In another embodiment the sensor requires calibration and sends a signal indicating that the sensor is non-functional.
It is another feature and advantage of the present invention to provide a sensor that is self powered and that can detect multiple vapors.
It is also another feature and advantage of the present invention to provide a sensor that has the ability to sense hydrocarbon fumes like gasoline vapors very quickly and efficiently.
It is also another feature and advantage of the present invention to provide a sensor that has the ability to send a signal to interact with water heater operation.
It is also another feature and advantage of the present invention to provide a sensor that has a long lifetime and that is self-powering.
The above and other features and advantages are achieved through the use of a novel device for sensing a dangerous environment as herein disclosed. In accordance with one embodiment of the present invention, a device for sensing a dangerous condition includes a sensor that provides a signal when a dangerous condition is sensed by the sensor. A power source in communication with the sensor is provided. The power source supplies the sensor with power. A trigger is provided which is in communication with the sensor. The trigger is activated by the signal to prevent the dangerous condition from producing a harmful effect.
In accordance with another embodiment of the present invention, a system for sensing a dangerous condition includes a sensing means for detecting a dangerous condition and providing a signal indicating that the dangerous condition has been detected. A power source means is provided for supplying the sensing means with power. The power source means is in communication with the sensor. A trigger means is provided for preventing the dangerous condition from producing a harmful effect when activated. The trigger means is in communication with the sensor means and is activated by the signal.
In accordance with another embodiment of the present invention, a method of preventing a harmful effect of a dangerous condition includes the steps of providing a sensor with power from a power source and using the sensor to determine if there is a dangerous condition when the sensor detects a dangerous condition, the dangerous condition is prevented from producing a harmful effect.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract included below, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a gas sensor utilizing a thermoelectric generator in a water heater.
FIG. 2 is an illustration of a gas sensor utilizing a thermoelectric generator in a water heater using a power blower vent.
FIG. 3 is an illustration of a sensor having a thermoelectric generator and a trigger for communicating with a water heater.
FIG. 4 is an illustration of the method steps of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
This invention includes a number of enhancements to the design of an infrared hydrocarbon sensor to make it more suitable and adaptable to this application for hydrocarbon measurement. Many of these innovations could also be applied to other gas fired appliances such as furnaces, cooking ranges radiant heaters and fireplaces or to the control mechanisms associated with regulating combustion such as gas valves and associated controls.
FIG. 1 is an illustration of a gas sensor (GS) utilizing a thermoelectric generator (TEG) in a water heater 100 . The multiple placements of the gas sensor (GS) and the thermoelectric generator (TEG) illustrate some of the locations the GS and TEG can be effectively placed.
Water heater 100 has a temperature sensor 102 connected to a gas valve/temperature control mechanism 104 . A gas line 106 is connected to the gas valve/temperature control mechanism 104 at one end and to a burner 108 at another end. A igniter or pilot light 110 is located next to the burner 108 . An exhaust 112 is located above burner 108 as an outlet for hot air and combustion fumes. A flue 114 is located above the exhaust 112 and is vented to the roof.
The water heater 100 has a storage compartment 116 for the storage of a liquid such as water. Storage compartment 116 has a cold water inlet 118 and a hot water outlet 120 . Support legs 122 are provided at the bottom of water heater 100 for stability.
The operation of water heater 100 is as follows. The gas valve/temperature control mechanism 104 can be set to control the temperature of the water stored in storage compartment 116 . When temperature sensor 102 senses that the water temperature is not at the appropriate level, gas is transmitted to burner 108 through gas line 106 . The gas is ignited by igniter or pilot light 110 and the water stored in storage compartment 102 is heated. Hot air and combustion fumes emitted from burner 108 are transmitted through exhaust 112 and through flue 114 .
When the water in storage compartment 116 reaches an appropriate level, sensor 102 will send a signal to gas valve/temperature control mechanism 104 to appropriately regulate the flow of gas to burner 108 .
In one embodiment of the invention, a gas sensor (GS) is placed in an area where a dangerous environment can be easily detected. As shown in FIG. 1 this can be in a multitude of locations around water heater 100 . In one embodiment of the invention, the gas sensor (GS) can be located along gas line 106 or around burner 108 .
The thermoelectric generator (TEG) can be located preferably in locations where there is a differential in temperature. For example as shown in FIG. 1, the TEG can be located around the flue 114 , the exhaust 112 , the burner 110 or the storage compartment 116 .
The gas sensor (GS) can be an infrared sensor. The sensor design can be calibrated and configured so that it is capable of detecting both the gas type used as a fuel source (e.g. natural gas or propane) to indicate malfunctioning equipment and to detect common flammable vapors that can cause accidental combustion (e.g. gasoline). Such a sensor can be placed in the ambient air below the water heater or at a location close to the floor to detect vapors that are heavier than air. An alternative location would be in the exhaust flue of the appliance. To ensure long term stability and low cost, a single beam sensor could be utilized which uses a self calibration algorithm similar that incorporated in Telaire's CO2 sensors where the sensor electronics periodically checks background levels over a number of different time periods and then calibrates itself to consider these background concentrations close to zero. For CO2, background levels are generally achieved when a space goes unoccupied during the evening hours (and inside levels drop to background levels). In this case the sensor remembers the lowest concentration over a 24 hour period as it relates to the occupied/unoccupied cycles of building occupancy.
For hydrocarbon or gasoline vapor. There should be no presence of gasoline vapors in normal conditions. Also when gasoline vapors do occur, it can be expected that concentration increase will take place over a relatively rapid period of time involving minutes, hours or in some cases days. This is in contrast to the natural drift of a well designed and manufactured sensor that should exhibit a very gradual increase or decrease in calibration over a number of months that is quantifiable by the manufacturer. Programming in the signal analysis of the sensor would be designed to consider the following parameters:
The sensor would be initially calibrated to ambient conditions when the sensor or water heater was installed in final location. This calibration could be activated manually by the installer activating the calibration (e.g. press a button) or automatically by programming the sensor to calibrate itself when first firing of the water heater occurs or when the sensor is first powered up (if line power is provided). While it is unlikely to be necessary this calibration could also be activated at any time during the sensor life during regular service or when the sensor indicates a need for calibration as a result of self diagnostics.
The sensor would activate a control signal if the concentration of explosive vapors exceed a predetermined Low Flame Limit (LFL) concentration (well below the point of 100% LFL). This control signal could be used to prevent ignition of the combustion source and/or to provide an alarm indication.
For self calibration the sensor would periodically check and remember the lowest background levels measured over an extended period of time of two to three months by remembering the lowest point measured on a periodic basis (e.g. weekly) and integrating these levels over the two to three month period. Based on the long term change of the background level the zero calibration of the sensor could be adjusted.
If the sensor detects an increase in short term concentrations, but not over the required threshold limit, the sensor logic would distinguish this type of increase as an actual exposure to hydrocarbons and sound an alarm or provide a control signal that could require the environment to be checked and if necessary the sensor to be checked or recalibrated.
For water heaters and other combustion devices that rely on line power to operate, the sensor can draw from this line power. However many gas appliances do not require line power to operate. For example, approximately 90 percent of the water heaters in North America are sold to operate without a source of power. Typically a continuously burning pilot light provides a source of combustion when there is demand for hot water. In some cases a sparking device of some sort may also provide a source of ignition. In these applications the sensor design must have provisions for operating where there is no line power. Even if line power is readily available, in the case of a power outage, many combustion devices will continue to operate including water heaters, ranges, fireplaces and cooking ranges. Also gas appliance used in portable and mobile applications (boats, RV's, camping equipment) will typically not require line power to operate.
Current infrared sensor designs consume so much power that it is probably unfeasible to make a battery operated sensor that could operate continuously under a battery operation only. Most installations would require that no maintenance is required over the life of the combustion device. Manufacturers of fire detectors that require periodic battery replacement have been the subject of numerous lawsuits when homeowners fail to replace batteries and the fire detector becomes non functional, manufacturers and users would prefer a no maintenance option. A number of strategies can be employed to conserve power and perhaps rely on parasitic form of power to ensure sensor operation when line power is unavailable.
In one embodiment of the invention in order to conserve power, the sensor would only be operated when there is a call for combustion and the burner is operating. In the case of a water heater the sensor would activate/power up upon a call for combustion and make a measurement for explosive vapors before combustion actually occurred. If no explosive vapors are detected above the target threshold range the combustion cycle would proceed. When the burner shuts off, the sensor would deactivate/power down until the next call for combustion. For devices where there is also a need to sense if combustion occurs (e.g. ranges of fireplaces) the sensor could continue operating for a preset period of time to confirm there is no build up of flammable vapors.
Such a sensor could be designed to operate off a battery that could be recharged using a thermoelectric (TE) generator which can convert heat to an electrical signal. There are already several commercially available TE generators available that are relatively inexpensive and would be well suited to the temperature and power requirement of this type of application. The TE generator can be located separate from the sensor so that it can take full advantage of the heat generated from the combustion device. A TE generator is typically a small wafer like device (e.g. 40×40×5 mm) generates electricity based on a difference in temperature experienced between the two sides of the device. Such generators are currently being used in wearable medical devices where the body heat from the patent is used to recharge a battery used to operate the device. A TE generator may can be selected with the performance characteristics to generate enough electricity to recharge the battery during the typical temperature rise of the gas fired appliance temperature. Location of the sensor is very important. In some locations a significant temperature rise may only occur as long as there is a temperature difference between the two surfaces, but once a steady-state was is achieved, no more generation would take place until the combustion system is turned off and cooled down. However, in some cases a location may be found for the TE generator that could create a more sustained temperature differential that could generate power throughout the combustion cycle (i.e. in the wall of a exhaust flue where one side is exposed to the heated combustion exhaust and the other side of the cooler is exposed to ambient air temperatures. (This use of a TE cooler to power a sensor may deserve to be a separate patent application). It also is applicable to a wide variety of combustion devices.
Another approach to sensor design could involve the design of an infrared sensor that could measure both hydrocarbons and CO 2 . Hydrocarbons could detect explosive gases or lack of combustion and CO 2 could be used to indicate in-flue combustion efficiency or a situation of a improperly vented combustion appliance when measured in ambient air (see Method for Detecting Venting of a Combustion Appliance within an Improper Space, U.S. Pat. No. 6,250,133, which is incorporated by reference). Infrared technology has the advantage that additional gas sensing channels can be added at a small incremental cost because the optical assembly and signal processing electronics can be shared by a multiple channel detector with multiple optical filters tuned to different gas wavelengths. Such a device could also be designed to also detect carbon monoxide (incomplete combustion, lack of combustion air, safety concern) and water vapor (also potentially used for detecting presence of combustion and the efficiency of combustion).
FIG. 2 is an illustration of a power vented water heater. Power vented water heater 200 has a temperature sensor 202 connected to a gas valve/temperature control mechanism 204 . A gas line 206 is connected to the gas valve/temperature control mechanism 204 at one end and to a burner 208 at another end. A igniter or pilot light 210 is located next to burner 208 . An exhaust 212 is located above burner 208 as an outlet for hot air and combustion fumes. A blower/power vent 214 is located above the exhaust 212 and is vented to the roof or side wall.
The water heater 200 has a storage compartment 216 for the storage of a liquid such as water. Storage compartment 216 has a cold water inlet 218 and a hot water outlet 220 . Support legs 222 are provided at the bottom of water heater 200 for stability.
Power vented water heaters comprise about 10% of the current water heater market. With a power vent system an additional feature may be added to the sensor. If elevated LFL concentration were detected in the space another control response could be to turn on the blower/power vent 214 to reduce the concentration of explosive gases in the space while preventing ignition of the combustion source.
In this embodiment of the invention, the sensor can be placed in an appropriate location to utilize the suction created by the blower/power vent 214 . This will draw a gas sample through the sensor, thereby, speeding up response time. When blower/power vent 214 is not operating the sensor will operate on a diffusion basis. These types of sensor could also be integrated into the control mechanism for gas valves to detect leaks or malfunctioning of the valve, which has been a periodic problem in the gas valve industry.
FIG. 3 is an illustration of a sensor having a thermoelectric generator (TEG) and a trigger for transmitting signals. The gas sensor 300 is connected to and powered by a thermoelectric generator 302 . When the gas sensor 300 detects a dangerous condition, trigger 304 is activated. Trigger 304 is connected to the water heater to prevent a dangerous situation such as an explosion or a fire. In one embodiment of the invention, trigger 304 is connected to a gas line to prevent gas from being fed to the burner. In another embodiment of the invention, trigger 304 is connected to the igniter or pilot light ( 110 , 210 ) to prevent the igniter or pilot light ( 110 , 210 ) from being activated. Yet in another embodiment of the invention, trigger 304 is connected to blower/power vent 214 . When trigger 304 is activated, blower/power vent 214 is activated in order to reduce the concentration of explosive gas in the exhaust 212 .
FIG. 4 is an illustration of the method steps of the present invention. In step 410 the gas sensor (GS) is supplied with power. In one embodiment of the invention, the gas sensor (GS) is supplied with power from a thermoelectric generator (TEG). In step 420 the environment surrounding the sensor is evaluated to determine if dangerous gasses or vapors are present. In step 430 if there are no dangerous conditions detected, the surrounding environment is again checked for dangerous conditions. This process will be repeated. In step 430 , if a dangerous condition is detected, the gas sensor (GS) will activate a triggering mechanism in step 440 . The triggering mechanism in one embodiment of the invention can appropriately regulate or shut down the flow of gas to a burner in the water heater. In another embodiment of the invention the triggering mechanism can activate a blower/power vent 214 to reduce the concentration of explosive gases in the space while preventing ignition of the combustion source. In another embodiment of the invention, the triggering mechanism can prevent the igniter or pilot light ( 110 , 210 ) from being activated.
The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirits and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A device for sensing a dangerous condition includes a sensor that provides a signal when a dangerous condition is sensed by the sensor. A power source is provided which is in communication with the sensor. The power source supplies the sensor with power. A trigger is provided which is in communication with the sensor. The trigger is activated by the signal to prevent the dangerous condition from producing a harmful effect. In one embodiment of the invention the power source is a thermoelectric power supply and the sensor is a self calibrating sensor.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a vehicular lamp with a lens attached to a lamp body by laser welding and a method of manufacturing same.
[0003] 2. Background Art
[0004] A vehicular lamp, such as a headlamp for a motor vehicle, is configured to dispose a bulb as a light source and a reflector in a lamp chamber, which is formed by attaching a lens to a front opening of a lamp body. For a configuration in which the lens is attached to the front opening of the lamp body, the prior art has used a laser welding method or the like. Patent Document 1 discloses a laser beam receiving surface is configured in a flange-like shape to protrude outwardly so that the receiving surface can receive a laser beam coming from an oblique direction with respect to a direction where the lens is mounted on the lampbody, which passes through the flange-like shaped portion of the lens.
[0005] Specifically, as shown in FIG. 10 , the laser welding is applied to the area where an abutment surface 231 A at an end of a seal leg 23 A of a lens 2 abuts on an abutment surface 121 A of a peripheral wall 12 A of a lamp body 1 A. A laser beam receiving surface 25 A that protrudes outward is formed on a top edge of the seal leg 23 A to receive the laser beam L projected onto the laser beam receiving surface 25 A from an outside of the lens 2 A to the abutment surface 121 A of the lamp body 1 A such that the abutment surfaces 121 A and 231 A of the lens 2 A and the lamp body 1 A are laser welded. By way of this configuration, as described in Patent Document 1, compared with the conventional manner that the laser welding process is performed by projecting the laser beam onto the abutment surface while transmitting it through the seal leg along the abutment surface, the disclosed art allows an optical path length that the laser beam transmits through the lens to be shortened. Accordingly, it may be possible to preferably perform laser-welding and avoid loss of the laser beam energy on the abutment surfaces.
[0006] [PUBLICATION 1] JP-A-2001-243811
[0007] In Patent Document 1, the laser beam receiving surface is configured to protrude beyond the outer surface of the seal leg of the lens. When the lens is seen from the front, the laser beam receiving surface appears to protrude from the periphery of the lens. Accordingly, an outside dimension of the lens, i.e., the outside dimension of the lamp, becomes large. Further, when the welded surface between the lens and the lamp body is seen from the front through the lens, it appears dark. Because width dimensions of the laser welded surface (i.e., dimensions in a direction of the thickness of the seal leg) enlarges due to forming the laser beam receiving surface, the dark portion with larger width come out from the outer edge of the lens, and thereby the appearance of the lamp deteriorates. Further, a metal molding structure employed for forming the lens having the laser beam receiving surface configured to protrude beyond the outer surface of the seal leg may be complicated. Thus, this creates rising cost.
[0008] An object of the present invention is to provide a lamp with an improved appearance by reducing the dimensions of a laser-welded surface in a direction of its width and a method for manufacturing the lamp.
SUMMARY OF INVENTION
[0009] According to an embodiment of the present invention, in a vehicular lamp in which a lamp body and a lens are brought into abutment, and each abutment surface of the lamp body and the lens is laser welded, the abutment surface of the lens is structured so as not to protrude outward at least from an outer surface of the lens, and to inclines with respect to a direction where the lamp body and the lens are brought into abutment.
[0010] According to an embodiment of the present invention, a method of manufacturing a vehicular lamp includes the steps of forming an inclined abutment surface that does not protrude beyond an outer surface of a lens along its peripheral portion, forming an inclined abutment surface along a peripheral portion of a front opening of a lamp body, and projecting a laser beam from an outside of the outer surface of the lens while holding the abutment surfaces of the lens and the lamp body in an abutment state such that the abutment surfaces are welded. In the method, the laser beam is projected at a predetermined angle in consideration with a refractive index of the laser beam on the outer surface of the lens such that the laser beam is projected in a direction perpendicular to the abutment surfaces.
[0011] According to an embodiment of the present invention, the laser welded surface is formed so as not to protrude beyond the outer surface of the lens. This may reduce the dimensions of the dark portion around the periphery of the lens when seen from the front. Thus the outer appearance of the lamp may be improved. Further, as the laser welded surface is inclined with respect to the direction where the lens is mounted on the lamp body, the laser-welded area may be expanded. Accordingly, welding performance may be enhanced.
[0012] According to an embodiment of the present invention, the angle of the projected laser beam with respect to the outer surface of the lens is adjusted such that the laser beam is projected in the direction perpendicular to the inclined abutment surface. Thus, the laser beam can be efficiently projected to the abutment surface without the laser beam receiving surface protruded outward. Accordingly, this makes it possible to make desirable laser welding.
[0013] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a partially exploded schematic view of a lamp according to an embodiment of the present invention.
[0015] FIG. 2 is a sectional view taken along line A-A of FIG. 1 .
[0016] FIG. 3 is an enlarged sectional view of a portion B shown in FIG. 2 .
[0017] FIGS. 4 ( a ) through 4 ( c ) are a view showing a welding process applied to the lamp according to an embodiment of the present invention.
[0018] FIG. 5 is a view showing a laser welding performed in an embodiment of the present invention.
[0019] FIGS. 6 ( a ) and 6 ( b ) is a sectional view of an essential portion of a modified exmaple of an embodiment of the present invention.
[0020] FIG. 7 is a sectional view showing an essential portion of an embodiment of the present invention.
[0021] FIG. 8 is a sectional view showing an essential portion of an embodiment of the present invention.
[0022] FIGS. 9 ( a ) and 9 ( b ) are a view showing a function of a flange portion in an embodiment of the present invention.
[0023] FIG. 10 is a sectional view showing a technology disclosed in Patent Document 1.
DETAILED DESCRIPTION
[0024] In the preferred embodiment of the present invention, the lens includes a seal leg portion with a substantially uniform thickness which extends in a direction where the lamp body and the lens are brought into abutment along an edge portion of the lens, and an end surface of the seal leg portion serves as the abutment surface. The abutment surface may be formed within a range of the thickness of the seal leg portion. Thus, the aesthetic appearance of the lamp improves. Further, the lamp body includes a tapered flange portion, which protrudes outward along the outer surface thereof, configured to gradually reduce its thickness as it goes outward, and a top surface of the flange portion serves as the abutment surface. Advantageously, the flange portion allows abutting performance between both to be enhanced upon deformation of the flange portion causing by abutment of the lens on the lamp body, and accordingly, the welding performance improves.
[0025] An embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a partially exploded schematic view of this embodiment applied the present invention to a tail lamp for a vehicle, in particular, a rear combination lamp RCL, which is integrated with a tail/stop lamp TSL and a back-up lamp. FIG. 2 is a sectional view along A-A line of the rear combination lamp RCL in assembling. A lamp body 1 is formed in a housing-like shape with a back surface 11 and a peripheral wall portion 12 that extends along the peripheral edge thereof, and made from ASA (acrylonitrile styrene acrylic rubber) containing a laser beam absorbing material such as a carbon black by a resin molding. A wall-like shade 13 is formed on an inner surface of the back surface 11 of the lamp body 1 , by which the tail/stop lamp TSL and the back-up lamp BUL are partitioned. Each of the inner surfaces of the back surface 11 and the peripheral wall portion 12 is treated with an aluminum evaporation. A predetermined portion of the peripheral wall portion 12 , i.e., the portion where the lens is welded is not treated with the aluminmu evaporation. The back surface 11 of the lamp body 1 has holes 14 and 15 corresponding to the lamps TSL and BUL, respectively. A tail/stop bulb 3 and a back-up bulb 4 are attached each other with bulb sockets 5 and 6 .
[0026] A lens 2 is integrally attached to the lamp body 1 so as to cover a front opening of the lamp body by welding. The lens 2 is composed of a red-colored tail/stop lens 21 and a white-colored back-up lens 22 formed on a predetermined area of the tail/stop lens 21 , which are integrally molded by a co-injection molding method upon resin material such as PC. The lens 2 has a wall-like seal leg 23 that extends along its peripheral edge. An end portion of the seal leg 23 is laser welded to an end portion of the peripheral wall portion 12 of the lamp body 1 such that the lens 2 is integrated with the lamp body 1 , configured to hermetically seal the gap therebetween.
[0027] FIG. 3 is an enlarged sectional view representing a portion B at which the lens 2 is welded to the lamp body 1 in FIG. 2 . The peripheral wall portion 12 of the lamp body 1 extends in parallel with an optical axis with a uniform thickness. A top surface of the peripheral wall portion 12 serves as an abutment surface 121 inclined outward at about 45° with respect to the optical axis. Similarly, the seal leg 23 of the lens 2 extends in parallel with the optical axis with a uniform thickness, and a top surface of the seal leg 23 serves as an abutment surface 231 inclined inward at about 45° with respect to the optical axis. The lens 2 is brought into abutment on the lamp body 1 in a direction of the optical axis such that the abutment surface 121 of the peripheral wall portion 12 abuts on the abutment surface 231 of the seal leg 23 . Then, they are contacted tightly with each other. A laser beam in a condensed state is projected to the tightly contacted abutment surfaces from an outer surface of the lens 2 . The abutment surfaces 121 and 231 of the lamp body 1 and the lens 2 are brought into molten states, and accordingly welded (the welded surface is shown by a reference code X). The lens 2 is, thus, integrated with the lamp body 1 . In this embodiment, the thickness of the top end of the peripheral wall portion 12 is slightly larger than that of the seal portion 23 for the purpose of positioning the seal leg 23 . Protrusions 122 and 123 are formed on the inner surface and the outer surface of the seal leg 23 , respectively, if so desired.
[0028] Referring to FIG. 4 ( a ), in welding the lamp body 1 and the lens 2 together at the abutment surfaces 121 and 231 , the lamp body 1 , which has been resin molded and aluminum evaporated on its predetermined surface, is seated on a lower mold DK such that the abutment surface 121 of the peripheral wall portion 12 faces upward. Meanwhile, the lens 2 is placed above the lamp body 1 with a positioning jig (not shown) such that the abutment surface 231 of the seal leg 23 abuts on the abutment surface 121 of the peripheral wall portion 12 . Referring to FIG. 4 ( b ), the upper mold UK is moved down to apply a downward pressure force to the lens 2 so that the lens 2 is pressed at a predetemrined pressure against the lamp body 1 . In this state, as shown in FIG. 4 ( c ), the laser beam L is projected from the outer surface of the lens 2 , more specifically, from the outer surface of the seal leg 23 toward the abutment surfaces 121 and 231 , which are in tight contact with each other, in a direction perpendicular thereto. Energy of the projected laser beam L is absorbed by the laser absorbing material contained in the lamp body 1 to cause the abutment surface 121 to be heated and brought into a molten state. Such heat is transferred to the abutment surface 231 of the lens 2 in tight contact with the abutment surface 121 , and then the abutment surface 231 of the lens 2 is brought into the molten state. By doing so, both the abutment surfaces 121 and 231 of the lamp body 1 and the lens 2 are melted and, accordingly, they will be bonded together after being cooled and solidified.
[0029] As shown in FIG. 5 , the laser beam L projected to the lens 2 is refracted upon incedence into the lens 2 from the outer side surface of the seal leg 23 , and it is further projected to the abutment surfaces 121 and 231 . Accordingly, the laser beam L is projected so as to reach the lens 2 at an angle θ that is slightly larger than 45° with respect to the plane perpendicular to the outer surface of the seal leg 23 in consideration of the refractive index of light rays on the lens 2 . The laser beam L that reaches the lens 2 is refracted and further projected in a direction perpendicular to the abutment surfaces 121 and 231 . This may allow the laser beam energy to be more efficiently used for the welding compared with the case that the laser beam is projected in the oblique direction with respect to the abutment surfaces 121 and 231 . Accordingly, the welding performance can be enhanced.
[0030] When the above-structured lamp RCL is seen from the front, the abutment surface 231 of the seal leg 23 of the lens 2 may appear to be dark through the lens 2 around its periphery due to the welding of the lens 2 to the lamp body 1 . However, in the seal leg 23 of the lens 2 , there is no protrusion that protrudes outward from the outer surface of the lens, which forms an outside dimension of the lens 2 , as shown in Patent Document 1. Thus, the abutment surface 231 of the lens 2 , i.e., the welded surface X, is formed so as not to exceed over the thickness of the seal leg 23 . The width of the dark portion is less than, or comparable to, the thickness of the seal leg 23 . Thus, the aesthetic appearance of the lamp improves. Further, as each of the abutment surfaces 121 and 231 inclines with respect to the optical axis of the lamp body 1 and the lens 2 , i.e., the direction where the peripheral wall portion 12 and the seal leg 23 extend, the area of the welded surface X may be expanded compared with each thickness of those portions. Accordingly, this allows the welding performance to be enhanced.
[0031] Preferably, the inclined angle at the abutment surfaces 121 and 231 of the lamp body 1 and the lens 2 is between 15° and 75°. If the inclined angle is smaller than 15°, it is difficult to project the laser beam in the direction perpendicular to the abutment surfaces. Thus, more laser energy is reflected on the incident surface of the lens, and a certain amount of energy cannot be absorbed. As a result, this may bring about insufficient welding. On the other hand, if the inclined angle is larger than 75°, the inclined angle at the abutment surface becomes so sharp that it is difficult to be resin molded. In this case, when the aforementioned abutment surfaces are pressed in the abutment state, the resultant force to displace each position of the lens and the lamp body further increases based on wedge effect. It may be difficult to weld while accurately positioning the lens and the lamp body.
[0032] In this embodiment, the abutment surfaces are completely inclined. Meanwhile, the lamp body and the lens may have portions 124 and 125 , and 232 and 233 , respectively, which are configured to be perpendicular to the direction where the lens mounts on the lamp body, in the area at the inner and outer sides of the abutment surfaces as shown in FIG. 6 ( a ). Alternatively, the lamp body and the lens may have portions 126 and 234 respectively, which are configured to be perpendicular to the direction where the lens mounts on the lamp body, in the outer side of the abutment surfaces as shown in FIG. 6 ( b ). These portions can effectively prevent a displacement between the lamp body 1 and the lens 2 causing by slipping upon the abutment surfaces.
[0033] FIG. 7 is an enlarged sectional view representing another embodiment, which corresponds to FIG. 3 of the aforementioned embodiment. In this embodiment, the seal leg is not formed on a part of the lens 2 in the peripheral direction but a protrusion 24 having a triangular shape in cross section is formed at the inner side of the lens 2 . A tapered surface 241 of the protrusion 24 serves as the abutment surface. The abutment surface 121 of the lamp body 1 is inclined outward at about 45° with respect to the optical axis as with the aforementioned embodiment. The abutment surface 241 of the protrusion 24 of the lens 2 is inclined inward at about 45° with respect to the optical axis so as to correspond to the abutment surface 121 . The lamp body 1 and the lens 2 are contacted in the direction of the optical axis such that the abutment surface 121 of the peripheral wall portion 12 and the abutment surface 241 of the protrusion 24 are brought into abutment in the direction of the optical axis and tightly contacted with each other. The condensing laser beam is projected from the outside of the outer surface of the lens toward the abutment surfaces 121 and 241 . By doing so, those abutment surfaces 121 and 241 are brought into molten states and are welded. Accordingly, the lens 2 is integrated with the lamp body 1 .
[0034] In this embodiment, the thickness of the lens 2 can be reduced at the portion of the protrusion 24 . This allows the laser beam to be projected from the front side of the lens 2 . In this case, however, the laser beam can be projected from the outer surface of the protrusion 24 toward the abutment surfaces 121 and 241 in the perpendicular direction by using the refraction of the laser beam by the outer surface. The energy efficiency of the laser beam can be improved, resulting in quality welding performance. Also, this embodiment allows the lens without the seal leg to be appropriately welded to the lamp body. Accordingly, the design freedom of the lens may be increased, improving design itself.
[0035] Further, in this embodiment, the abutment surface 241 of the protrusion 24 fomred on the peripheral edge of the lens 2 and welded to the lamp body 1 appears to be dark through the lens 2 when the lamp is seen from the front as with in the aforementioned embodiment. However, as the lens 2 has no protrusion that protrudes outward, the width of the dark portion may be reduced to the dimension as small as possible. Thus, the aesthetic appearance of the lamp improves.
[0036] FIG. 8 is an enlarged sectional view representing another embodiment, which corresponds to FIG. 3 representing the aforementioned embodiment. In this embodiment, the lens 2 has a seal leg 23 as with the aforementioned embodiment. The seal leg 23 has an abutment surface 231 with an inclined end surface. Meanwhile, the lamp body 1 includes a tapered flange 12 a , which protrudes outward along an end of the peripheral wall portion 12 , configured to gradually reduce its thickness as it goes outward. The surface of the flange 12 a serves as an abutment surface 121 . The abutment surface 121 of the flange 12 a is brought into abutment on the abutment surface 231 of the lens 2 , where laser welding process is performed.
[0037] In this embodiment, the laser beam is projected from the outside of the seal leg 23 of the lens 2 at a predetermined angle in the same manner as the aforementioned embodiments. Thus, the laser beam is projected to the abutment surfaces 121 and 231 in the direction perpendicular thereto based on the refraction by the outer surface of the lens 2 . Accordingly, the abutment surfaces 121 and 231 can be appropriately welded. Further, the seal leg 23 of the lens 2 has no protrusion that protrudes outward from the outer surface of the lens 2 . That is, the abutment surface 231 of the lens 2 is formed so as not to protrude over the width of the seal leg 23 . The width of the dark portion is less than or comparable to the thickness of the seal leg 23 . Accordingly, the aesthetic appearance of the lamp body is improved.
[0038] Furthermore, it is assumed that, as shown in FIG. 9 ( a ), each angle of the abutment surface 231 of the lens 2 and the abutment surface 121 of the flange 12 a upon abutment is not equal due to an error in the process of molding the lamp body 1 and the lens 2 , and that a gap is formed between the abutment surfaces 121 and 231 in the abutment state. In this case, when the lens 2 abuts on the lamp body 1 under pressure for performing the welding, the tapered flange 12 a is deformed by the force caused by the pressure applied to the lens 2 as shown by arrow in FIG. 9 ( b ). This may enhance the contact between the abutment surfaces 121 and 231 , and accordingly improve the laser welding quality.
[0039] The present invention is not limited to the rear combination lamp in the respective embodiments as described above. It is understood that the present invention may be applied to various forms of the lamp so long as it is formed by integrally welding the lens to the lamp body.
[0040] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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A vehicular lamp includes a lamp source, a lamp body accommodating the lamp source, and a lens attached to the lamp body. The lamp body has an abutment surface on the top portion of a peripheral wall, which is configured to rise in a direction of an optical axis of the light source along a peripheral edge of the lamp body. The abutment surface of the lamp body is configured to incline to the optical axis. Similary, the lens has an abutment surface corresponding to the abutment surface of the lamp body along a peripheral portion of the lens. In this case, the abutment surface of the lens is configured within the dimention of an outer surface of the lens so as not to protrude over the outer surface. The abutment surfaces of the lamp body and the lens are integrally jointed together by laser walding.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 10/494,396 filed May 3, 2004 which is a filing under 35 U.S.C. § 371 based on International Application No. PCT/US02/36443 filed Nov. 12, 2002 which claims the benefit under 35 USC § 119(e) of U.S. Provisional Application No. 60/347,818 filed Nov. 9, 2001, the applications being incorporated herein by reference, in their entirety.
BACKGROUND OF THE INVENTION
[0002] In the manufacture of paper from wood, the wood is first reduced to an intermediate stage in which the wood fibers are separated from their natural environment and transformed into a viscous liquid suspension known as a pulp. There are several classes of techniques which are known, and in general commercial use, for the production of pulp from various types of wood. The simplest in concept of these techniques is the so-called refiner mechanical pulping (RMP) method, in which the input wood is simply ground or abraded in water through a mechanical milling operation until the fibers are of a defined or desired state of freeness from each other. Other pulping methodologies include thermo-mechanical pulping (TMP), chemical treatment with thermo-mechanical pulping (CTMP), chemi-mechanical pulping (CMP), and the so-called kraft or sulfate process for pulping wood. In all of these processes for creating pulps from wood, the concept is to separate the wood fibers to a desired level of freeness from the complex matrix in which they are embedded in the native wood.
[0003] Of the constituents of wood as it exists in its native state, cellulose polymers are the predominate molecule. Cellulose is desired for retention in the pulp for paper production. The second most abundant polymer in the native wood is lignin. Lignin, the least desirable component in the pulp, is a complex macromolecule of aromatic units with several different types of interunit linkages. In the native wood, lignin physically protects cellulose polysaccharides in complexes known as lignocellulosics that must be disrupted for there to be accessibility to the polysaccharides, (e.g., by enzymes) or to separate lignin from the matrix of the wood fibers.
[0004] Mechanical pulping accounts for about 25% of the wood pulp production in the world today. This volume is expected to increase in the future as raw materials become more difficult to obtain. Mechanical pulping, with its high yield, is viewed as a way to extend these resources. However, mechanical pulping is electrical energy-intensive and yields paper with lower strength than chemical pulps. Kraft pulp is often added to mechanical pulp to impart strength, but it is much more expensive than mechanical pulp. These disadvantages limit the use of mechanical pulp in many grades of paper.
[0005] In the industry, chemical pulps are preferred for a variety of paper grades, generally for better strength as a result of superior pulp quality (e.g., higher freeness, higher fiber length, and lower lignin content). However, chemical pulps are expensive to produce and fiber yields are generally very low (about 50%). On the other hand, mechanical pulps have fiber yields in excess of 90%, but pulp quality is degraded because fiberization is sometimes not complete and fibers can be severely damaged. Each process has its own inherent advantages and disadvantages, and papermakers must weigh these factors when developing a furnish for a particular paper grade. However, faced with the reality of more restrictive environmental regulations, increased energy costs, competitive pricing, and a more diverse raw wood resource, papermakers are being forced to be more creative in selecting furnish components. Therefore, efforts must be made to develop new technologies that improve the quality of mechanical pulps, making them more attractive as a component in higher quality paper grades.
[0006] In the RMP process, wood chips are refined atmospherically to make paper. This process requires approximately 100-135 Horse Power Days (HPD) (about 1800-2400 kWh) energy/ton of wood and produces pulp with lower strength.
[0007] In thermo-mechanical processes (e.g., TMP and CTMP), high temperatures are used to separate the fibers during refining. These processes generally require the refining to be carried out in one or more steps. The first step is usually a pressurized step with refining being performed at temperatures above 100° C. and immediately below or at the softening temperature of lignin. During this step, the pulp is typically mechanically processed using the RMP method. In subsequent steps, the pressure and temperature is usually modulated to achieve the desired state of freeness between the fibers.
[0008] In the TMP process, a steam pressure of 30 lb or less (gauge pressure) is applied to the chips for 2-5 minutes prior to refining. This pressure is critical to separate the cell wall fibers in such a way that the resulting paper has much longer fibers (increased tear index) than the straight RMP process. If one exceeds the pressure above 30 lbs during presteaming, then the lignin will be melted and deposited on the surface of fibers and the fiber flexibility will be lost resulting in poor quality fibers that resemble the fibers produced during medium density fiber board production. Therefore, it is critical to maintain the right gauge pressure during refining. The drawback of the TMP process is that it takes significantly higher amounts of energy compared to the RMP process. For example, the energy requirement during the TMP process is in the range of 140-220 HPD (about 2500-4000 kWh)/ton of wood. The steam pressure also results in the darkening of pulp. Thus, more bleach chemicals are needed to obtain paper of a desired brightness.
[0009] Relatively large total electric energy amounts or large quantities of input wood are required to produce pulps using the above mentioned pulping techniques. In particular, high energy inputs are generally required to obtain fiber separation in woods rich in lignin as such woods typically call for extended refining periods and high temperatures and/or pressures. Studies have also suggested that even thermal or chemical softening treatments of such woods does not guarantee a lower total energy consumption in the production of pulp. This is because unprocessed fibers that are only mildly separated by the thermal or chemical treatments are difficult to fibrillate during the refining mechanical process. Fibrillation is the separation of larger fibers into small, thread-like structures called fibrils. Fibrillation is necessary to increase the flexibility of the fibers and to bring about the fine material characteristics of quality processed pulp. It has been suggested that a decrease in energy consumption from an established level in various TMP and CTMP processes has been associated with the deterioration of certain pulp properties, including a reduction in the long fiber content of the pulp, a lower tear strength and tensile strength, and a higher shive content. As a result, high energy consumption in TMP and CTMP processes has been generally necessary in current pulping practices.
[0010] Biopulping techniques have been developed to supplement traditional pulping methods and have been shown to reduce energy requirements and improve paper properties. Biopulping is defined as the treatment of wood chips with a “natural” wood decay fungus prior to mechanical pulping. In this technology, wood chips are steamed, cooled, inoculated with a fungus, and incubated for two weeks under forced aeration to remove metabolic heat generated by the fungus. The process saves a substantial amount of electrical energy (about 30%), improves paper quality, reduces the environmental impact of pulping, and enhances economic competitiveness. However, the economics of the process is highly dependent on the treatment time and processing costs such as those associated with ventilation of the pile for two weeks to remove metabolic heat generated by the fungus.
[0011] The direct application of enzymes has been proposed as a means to reduce costs associated with energy expenditures and processing required in traditional pulping methodologies. For example, lignin-degrading fungi such as Ceriporiopsis subvermispora, Hyphodontia setulos, Phlebia subserialis, Phlebia brevispora, Phlebia tremellosa and Phanerochaete chrysosporium . used in biopulping techniques secrete enzymes inside the wood cell walls which are responsible for breakdown or modification of lignin. However, it is known that direct application of isolated enzymes on wood chips does not yield results similar to those obtained with fungal pretreatment because these enzymes cannot penetrate the wood due to their larger size compared to the pore size in the wood. Live fungus is required to penetrate the wood and transport enzymes inside the wood cell walls. Because of the low accessibility of wood chips for enzymatic modification, incorporation of an enzymatic treatment step into a mechanical pulping process can be expected to be successful only after the primary stage of refining, during subsequent process steps. In pilot-scale experiments, an energy savings of 10-15% with CBH I (modified cellulase) has been reported with some improvement in tensile index, a strength property. However, technical difficulties have been reported in applying enzymes after primary stage refining because pulp after primary stage refining enters into secondary stage refining within seconds. Based on this difficulty, efforts directed to enzyme treatment are now mainly on reject pulp samples. Because most of the energy during TMP refining is consumed during primary and secondary stage refining and not during reject refining, direct enzyme application is useful only as a downstream process. Thus, to date, energy savings due to enzymes have been insignificant.
[0012] Similarly, in certain markets, lumbers are treated with chemicals to protect them from the environment and provide stability to the product. Currently, it is not possible for high molecular weight compounds to penetrate the logs or the lumber for certain applications, such as wood hardening. A technique that enhances permeability of wood to larger molecules would therefore be widely applicable, even outside the pulp and paper industry.
[0013] Another promising technology used in the pulp and paper industry for improving paper brightness, opacity, and bonding strength, as well as reducing energy consumption during drying, is a technique termed “fiber loading.” In fiber loading, calcium carbonate is deposited as a filler within, on the surface of, and outside the fibers. The process consists of at least two steps. First, calcium hydroxide is mixed into a pulp fiber slurry. Next, the pulp and calcium hydroxide mixture is reacted using a high consistency pressurized reactor (refiner or disk disperser) under carbon dioxide pressure to precipitate calcium carbonate. Calcium carbonate formed is termed fiber-loaded precipitated calcium carbonate (FLPCC). However, most applications of fiber loading have focused on fiber loading chemical pulps.
[0014] In addition to the above-described efforts to increase pulp yield, decrease energy consumption and enhance paper quality, another issue concerning the pulp and paper industry is pitch content. Pitch is a mixture of hydrophobic resinous materials and constitutes about 2-8% of the total wood weight depending upon the species and the time of the year. It causes a number of problems in wood processing, including at least deposits on tile and metal surfaces, plugging of drains, discoloration of felt, tears and other defects in paper and downtime for cleaning. Traditional methods of controlling pitch include natural seasoning of wood before pulping and/or adsorption and dispersion of the pitch particles with chemicals. During the pulping and papermaking processes, pitch reduction methods can also include adding fine talc, dispersants and other kinds of chemicals.
[0015] Biotechnological and enzymatic methods have also been developed and used industrially to reduce pitch. It has been reported that lipases reduce pitch by hydrolyzing triglycerides to glycerol and free fatty acids in mechanical pulps. A commercial lipase enzyme product, RESINASE™, has been developed (Novo Nordisk Biochem of North America, Franklinton, N.C.) to reduce pitch deposits from groundwood pine pulp. Another commercial product, CARTAPIP™ (Agra Sol Inc., Raleigh, N.C., U.S.A.) is a fungal inoculum of the ascomycete Ophiostoma piliferum . A water slurry of the fungal spores is sprayed onto wood chips as they are piled prior to pulping. The fungus invades the wood cells, degrading the pitch.
[0016] However, both traditional and biotechnological methods of pitch control fail to remove all traces of pitch from most wood species and thus only alleviate, but do not eliminate the problems associated with pitch in wood processing. A method that would provide enhanced pitch reduction would therefore be desirable.
[0017] Yet another dilemma faced by the pulp and paper industry is blue staining of wood. This problem occurs when freshly cut logs are stored for a long period of time in wood yards prior to debarking and chipping. These logs are normally colonized by the blue stain fungi present in the wood yard. The colonization results in wood staining and consequently, pulps with lower brightness. More bleach chemicals are therefore needed to overcome the loss of brightness which, in turn, results in increased costs for effluent treatment. This is a serious problem in the southern parts of the U.S. where the logs are exposed to high temperature and humidity, which tend to exacerbate the problem. Biotechnological methods of reducing blue staining include the use of CARTAPIP™ (Agra Sol Inc., Raleigh, N.C., U.S.A.), which, as discussed, is also used in reducing pitch. It has been shown that treatment with CARTAPIP™ also controls unwanted colored blue stain microorganisms that lead to increased costs in the purchase of bleach chemicals. However, as with pitch reduction methods, efforts to reduce blue staining have not been completely successful.
[0018] What is needed is an alternative method for producing pulp in an energy efficient manner that also improves paper strength properties while decreasing pollution. Also desirable is a method that enhances permeability and porosity of the internal structure of wood, thereby providing increased access for fungi, enzymes and other large molecules and chemicals.
SUMMARY OF THE INVENTION
[0019] Described is a method of pulping wood, including the step of treating, pretreating or exposing a source of pulp to microwave radiation to reduce substantially the power requirements, chemical requirements, or process time to convert the source of pulp to pulp.
[0020] Also described is a method of producing pulp for use in making paper products. In a preferred practice, the method includes steps of treating wood logs with or exposing logs to microwave radiation, chipping the logs and pulping the wood chips with a mechanical pulping process. Suitable mechanical pulping processes include RMP, TMP and CTMP. Optionally, the method can include fiber loading the pulp.
[0021] Chips obtained from microwaved logs could also be treated with microorganisms and enzymes to save energy, improve paper strength, reduce pitch content, and increase chemical penetration to benefit the pulp and paper and lumber processing industries.
[0022] The method can be used with hard- or softwood species as pulp sources. Suitable hardwood species include aspen, eucalyptus and oak. Suitable softwood species include spruce and pine.
[0023] The invention also encompasses a paper produced according to the methods described. Suitably, the paper demonstrates improved strength characteristics over methods not including a microwave step. Most suitably, the paper demonstrates at least a 10% increase in measurements of tensile index, tear and burst.
[0024] Another facet of the invention is a method of producing wood pulp that includes steps of treating the wood source, e.g., logs, with microwave radiation, chipping the logs to provide wood chips, inoculating the wood chips with a fungus and mechanically processing the inoculated wood chips to provide pulp. Suitable fungal species include the “white rot” species commonly used in biopulping. Included among the suitable species are Ceriporiopsis subvermispora, Hyphodontia setulos, Phlebia subserialis, Phlebia brevispora, Phlebia tremellosa or Phanerochaete chrysosporium. An additional species which can be used in a method of the invention is a white or colorless species of Ophistoma piliferum , which can be used to reduce pitch and/or blue staining.
[0025] The invention is also directed to a method of producing pulp that includes the steps of microwaving wood, chipping the wood, applying enzymes to the wood chips and mechanically processing the enzyme-treated wood chips to provide pulp. Suitable enzymes include lignin-degrading enzymes, xylanases, pectinases, lipases and cellulases.
[0026] The invention provides for energy savings during wood pulping and includes a method of reducing energy input requirements. The method includes steps of treating wood with microwave radiation, chipping the wood and mechanically pulping the wood chips, wherein the energy input requirement is reduced at least about 8% over a method not including the step of treating logs with microwave radiation. Suitably, the energy requirement is reduced at least about 8% to about 15%.
[0027] A method of reducing pitch is described wherein a pulp source is treated with microwave radiation prior to subsequent process steps.
BRIEF DESCRIPTION OF THE FIGURES
[0028] FIG. 1 is a photograph of a waveguide and chamber for a 60-kW industrial microwave oven that can be used in the methods of the invention.
[0029] FIG. 2 is a graph showing radial temperature as a function of microwave power level for 20- and 50-kW treated logs.
[0030] FIG. 3 is a photograph showing steam jet issuing from end of a log after microwave treatment at 50 kW for 5 minutes.
[0031] FIG. 4 is a photograph showing extensive radial checking after microwave treatment at 50 kW for 5 minutes.
[0032] FIG. 5 is a scanning electron micrograph of a tangential fracture surface after microwave treatment at 50 kW for 5 minutes.
[0033] FIG. 6 is a scanning electron micrograph of a tangential fracture surface after microwave treatment at 50 kW for 5 minutes.
[0034] FIG. 7 is a graph showing freeness as function of refiner energy consumption for several microwave pretreatments.
[0035] FIG. 8 is a graph showing refiner energy savings as a function of microwave power level for several microwave pretreatments.
[0036] FIG. 9 is a graph showing tensile index as a function of microwave power level for microwave-pretreated black spruce TMP.
[0037] FIG. 10 is a graph showing estimated annual pulp cost savings for 800 ton/day for a mill based on substitution of microwave-pretreated TMP for kraft pulp.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] It has now been discovered that a pulping process that includes a pre-treatment or exposure of the pulp source to microwave radiation allows for increased porosity and permeability of the pulp source. Generally speaking, this improved pulping process is most applicable to wood, generally in the form of logs. The increase in permeability after microwaving pretreatment is due, in part, to breakage of pit membranes and vessel cell ends caused by steam pressure generated inside the wood. Breakage of pit membranes and vessel cell walls by microwave exposure substantially increases access of process chemicals to wood. During the microwaving process, some of the water in the wood is converted to steam. Major advantages of microwave over other conventional methods are increased pulp yield, high speed, low or no chemical use, low wood inventories, low waste production, and low process cost during papermaking.
[0039] Not to be bound by theory, it is believed that the microwave process leads to steam pressure build-up inside the logs. This separates cell walls, increasing porosity and permeability so that less energy is required during subsequent refining and also results in a stronger paper product.
[0040] As used herein, “mechanical processing” and “mechanically processing” refer to processing methods in which mechanical, electrical or thermal energy is used to break down intact wood into constituent fibers to produce wood pulp with a desired level of freeeness. Suitable methods include TMP, RMP and CTMP. TMP is a preferred method.
[0041] As used herein, “biopulping” refers to a method used in the production of pulp that includes the use of a biological system to perform, or to assist in performing, the pulping of wood. Preferably, biopulping is carried out by inoculating steamed wood chips with a species of fungi known to degrade or modify lignin. Preferred fungal species include the so-called “white rot” fungi. Preferred among the white rot species are species of Ceriporiopsis subvermispora, Hyphodontia setulos, Phlebia subserialis, Phlebia brevispora, Phlebia tremellosa or Phanerochaete chrysosporium.
[0042] As used herein, the terms “reduced energy input requirements,” “improved strength properties,” and “enhanced permeability” are relative terms that indicate a reduction, improvement or enhancement, respectively, over a pulping method that does not include a microwave treatment (including modifications of a method to accommodate a microwave step), but otherwise including the same steps as the described methods. Suitably, the method of the invention reduces the energy input requirement at least about 8%. Most suitably, the method of the invention reduces the energy input requirement at least about 8% to about 15%. Paper produced according to the method of the invention suitably demonstrates at least about a 10% increase in strength properties. The permeability of wood to chemicals also is enhanced by exposure of the wood to microwave radiation according to one aspect of a method of this invention.
[0043] The benefits of microwave pre-treatment can be realized in many aspects of paper manufacturing. Microwave pretreatment of wood can reduce electrical power requirements, improve paper quality, reduce pitch and reject contents, improve paper machine operation and save energy during drying of pulp, etc. The technology also has potential for improving existing biopulping processes, by preventing blue staining of wood, enhancing the penetration of enzymes and other large molecules into wood, improving fiber loading processes, and improving chemical penetration during lumber processing.
[0044] In a method of the invention, the steps of treating logs with microwave radiation, chipping the logs and pulping the wood chips with a mechanical pulping process are carried out.
[0045] Microdry, Inc. (Crestwood, Ky.) is a manufacturer of custom industrial microwave ovens suitable for use in the present invention. Individual logs can be manually placed in the microwave chamber until appropriate treatment time, frequency and power are determined. Treatment parameters are dependent upon a number of factors, including type of wood, diameter of the log and moisture content. After optimization of treatment parameters, however, a continuous belt transport system capable of accommodating logs can be used. Microwaving can be done prior to or after debarking.
[0046] Chipping of logs is within those of skill in the art and be can be accomplished with any known suitable techniques. One suitable technique is to use a Sprout-Waldron Model D2202 single rotating 300 mm diameter disk refiner. After chipping, a mechanical pulping process is carried out. Mechanical pulping processes include RMP, TMP and CTMP. In thermomechanical pulping, high power refiners are used to mechanically reduce wood chips to fiber. To aid in this process, elevated temperatures are used to soften the wood. Several refining “passes” are generally required to obtain a target freeness. The first pass is usually defibration at temperatures above 100° C. and immediately below or at the glass transition temperature of lignin (T g <124° C.). During this pass, chips are typically fiberized under pressure using an aggressive plate pattern to produce a high freeness pulp. This pulp is then further reduced in multiple passes through an atmospheric refiner until the desired pulp freeness is obtained. The inventors have surprisingly found that microwave treatments alter the structure of wood such that fiberization occurs more easily during mechanical pulping, thereby reducing refiner energy requirements and improving the pulp.
[0047] Optionally, the method can include fiber loading the pulp. Fiber loading is described in U.S. Pat. No. 5,223,090, issued Jun. 29, 1993, and is incorporated herein by reference.
[0048] Further methods of the invention include producing pulp by treating logs with microwave radiation, chipping the logs to provide wood chips, inoculating the wood chips with a fungus and mechanically processing the inoculated wood chips. Microwave treatment, chipping and mechanical processing is carried out as described above. Included among the suitable species for inoculation of the wood chips are Ceriporiopsis subvermispora, Hyphodontia setulos, Phlebia subserialis, Phlebia brevispora, Phlebia tremellosa or Phanerochaete chrysosporium. When microwaved logs are debarked, chipped and inoculated with biopulping fungus, the treatment time is substantially reduced as compared to conventional biopulping without the use of microwave pretreatment. As discussed, it is believed that the enhanced porosity of the microwaved chips provides faster colonization of these chips by the fungus. Further, microwaved logs or chips from these logs can be inoculated with CARTAPIP™ or other fungal species to remove blue stain microorganisms or pitch. As described above, the enhanced porosity facilitates colonization, thereby reducing treatment and incubation times.
[0049] A method of the invention for reducing pitch and/or blue staining can be carried out using a colorless species of Ophistoma piliferum , which can be used to reduce pitch and/or blue staining. One species of Ophistoma piliferum is sold under the trade mark CARTAPIP™ by Agra Sol Inc. of Raleigh, N.C., U.S.A. In the method of the invention, this fungus is suitably applied to wood chips subsequent to microwaving as described. U.S. Pat. No. 5,607,855, issued Mar. 4, 1997, describes a suitable method of reducing pitch with fungi and is incorporated herein by reference. Even without the use of CARTAPIP™, microwaving of logs can be used to reduce or remove resinous material. Not to be bound by theory, it is believed that some of the components of this resinous material that are sticky, such as triglycerides, are converted into a less sticky material after microwaving.
[0050] The invention is also directed to a method of producing pulp that includes the steps of microwaving wood, chipping the wood and applying enzymes to the wood chips. Suitable enzymes include lignin-degrading enzymes, xylanases, pectinases, lipases and cellulases.
[0051] The invention provides for energy savings during wood pulping and includes a method of reducing energy input requirements. The method includes steps of treating wood with microwave radiation, chipping the wood and mechanically pulping the wood chips, wherein the energy input requirement is reduced at least about 8% over a method not including the step of treating logs with microwave radiation. Suitably, the energy requirement is reduced at least about 8% to about 15%. The inventors have discovered that higher energy savings correlate with higher power levels used during the microwave pretreatment step. Energy savings are also observed during debarking and chipping compared to logs that were not microwaved.
EXAMPLES
[0052] Details of the invention will become more apparent by reference to the following non-limiting examples, which, in some cases, illustrate laboratory-scale embodiments and results achieved thereby.
Example 1
Microwaving Logs and Structural Effects
[0053] Microdry, Inc. (Crestwood, Ky.) is a manufacturer of custom industrial microwave ovens suitable for use in the present invention. A high capacity microwave oven was used for initial tests ( FIG. 1 ). This oven is connected to a variable-power (up to 60 kW) 915-MHz frequency generator. Individual logs can be manually placed in the microwave chamber until appropriate treatment time, frequency and power are determined. Treatment parameters are dependent upon a number of factors, including type of wood, diameter of the log and moisture content. After optimization of treatment parameters, however, a continuous belt transport system capable of accommodating logs can be used.
[0054] Microwaved logs or chips obtained from these logs demonstrate increased porosity as has been observed in treated logs. In general, as shown in FIG. 2 , it has been determined that higher power levels result in higher log temperatures, with steeper temperature gradients from bark to pith. Of particular interest are results obtained using spruce logs microwaved for 5 min at 50 kW. Within a couple of minutes, splitting became intense and steam jets shot out the ends of the logs ( FIG. 3 ) In just 5 minutes, the logs had lost about 25% of their weight or nearly all of their moisture. A visual examination of the ends of the logs revealed extensive radial checking ( FIG. 4 ). Several fracture surfaces from logs treated at 5 min/50 kW were sampled to identify possible morphological changes in the fiber structure. A scanning electron microscope was used to obtain images of both tangential and radial surfaces ( FIGS. 5 and 6 ).
[0055] Based on the results of exploratory mechanical pulping trials, it was evident that microwave pretreatment can substantially lower refiner energy requirements while improving pulp quality. To verify this, a more extensive evaluation was undertaken using the logs that were microwave pretreated at several different power levels. The logs were debarked and chipped, then refined by the established TMP protocol. FIG. 7 shows pulp freeness as a function of total refining energy for the last three atmospheric refining passes, indicating total energy savings for all microwave pretreatments. Of particular interest is the relationship of increased energy savings to increased microwave power levels, as can be seen in FIG. 8 . Handsheets made from these pulps also exhibited an increase in mechanical properties, with only moderate reductions in brightness. As with total energy reduction, an increase in mechanical properties seems to correlate with an increase in microwave power level, as can be seen in FIG. 9 . Because pulp quality is improved, kraft components can be reduced, with a resultant savings in total pulp cost, as demonstrated in FIG. 10 . An estimate of capital costs for 20-kW and 50-kW systems could range from $7.5 to $12.5 million.
Example 2
Microwave Pretreatment of Spruce Logs
[0056] Spruce logs were divided into two lots. One lot was frozen and used as a control. The other lot was treated for 5 minutes with a high power microwave generator (50 kW at 915 MHz). During microwaving, significant moisture loss was observed and a temperature of 130° C. inside the log was recorded. Prior to refining atmospherically, both the control and the microwaved logs were completely submerged in water overnight to maintain the same moisture content in both the logs. Logs were then debarked, chipped, and refined through the RMP process. Following results were obtained (Table 1):
TABLE 1 Energy requirements and paper strength properties during RMP process Parameters Control Treatment (Microwaved) Energy during refining (Wh/kg) 2411 2051 Burst index (kN/g) 0.98 1.33 Tear index (mNm 2 /g) 3.31 3.91 Tensile index (Nm/g) 23.6 28.6 Breaking length (m) 2408 2912
[0057] The data in Table 1 indicates that the microwave treatment improved all major strength properties significantly with reduced energy input requirements. The observed enhancement of strength properties was surprising because microwaving resulted in a drying of logs which is typically associated with a decrease in paper strength properties.
[0058] Other highly unexpected results were obtained during bleaching. Although the initial pulp brightness of the treated samples was approximately 4 points lower than the control, as reported in Table 2, the microwave-treated samples demonstrated increased susceptibility to bleaching chemicals. As can be seen from the data, control samples required 2% hydrogen peroxide to reach the target brightness of 73% ISO, whereas treated samples required only 1.5% hydrogen peroxide to reach to the same level of brightness.
[0059] Thus, an additional advantage of the invention is a reduction in amounts of bleaching chemicals required during bleaching. This, in turn, increases the opacity of the resulting paper and reduces the effluent treatment costs associated with paper production.
TABLE 2 Brightness response Brightness Treatments (% ISO) Control 1 Initial Brightness 59.6 1.5% Hydrogen Peroxide + 1.5% Sodium Hydroxide 71.4 2% Hydrogen Peroxide + 2% Sodium Hydroxide 73.6 Treatment 2 Initial Brightness 55.5 1.5% Hydrogen Peroxide + 1.5% Sodium Hydroxide 73.4 1 Control produced using the conventional TMP process. Fifty five percent of this pulp was mixed with 45% of the Ground Wood Pulp (GWP a ). The initial brightness of this mixed pulp before bleaching was 59.6% ISO. Fifty percent of this mixture was bleached with 1.5% and 2% of hydrogen peroxide. 2 Treatment produced from microwaved logs using the conventional RMP process. Fifty five percent of this pulp was mixed with 45% of GWP. The initial brightness of this mixed pulp before bleaching was 55.5% ISO. Fifty percent of this mixture was bleached with only 1.5% hydrogen peroxide. a GWP was obtained from a mill producing lightweight coated (magazine) paper.
Example 3
Microwave Pretreatment of Pine Logs
[0060] Objective: To achieve electrical energy savings and improvements in paper strength by microwaving pine logs prior to mechanical pulping.
[0061] Materials: Pine logs were received from a mill specializing in the production of light weight coated paper. Logs were microwaved at Microdry in Louisville, Ky. Logs were debarked and chipped to a nominal size of 6-14 mm. Chips were placed in plastic freezer bags and frozen to prevent the growth of contaminating microorganisms. Log discs were cut before debarking and chipping that was approximately 3 centimeters thick. Moisture content varies from approximately 50%-56% depending on the microwave treatment time.
[0062] Microwave Treatments: Logs were subject to three microwaving conditions. Logs were microwaved at 50 kW for 5 minutes (50/5), 20 kW for 6 minutes (20/6), and 20 kW for 8 minutes (20/8).
[0063] Chip fiberization, pulp refining and handsheet production: Microwaved wood chips were fiberized in a Sprout-Waldron Model D2202 single rotating 300 mm diameter disk refiner. Energy consumption was measured using an Ohio Semitronic Model WH 30-11195 integrating Wattmeter attached to the power supply side of the 44.8 kW electric motor. Feed rate through the refiner was between 10 kW and 15 kW. Energy reported in WH/kg. Refiner plate settings were 0.025 inch, 0.014 inch, 0.010 inch, and 0.008 inch. Pulp was collected at each pass as hot water slurry. Between the passes the pulp slurry was dewatered to approximately 25% solids in a porous bag by vacuum. Dilution water at 85 degrees Celsius was then added each time as the pulp was fed into the refiner. Samples of the pulp were taken and tested for the Canadian Standard Freeness (CSF). Samples refined to 100 CSF. Handsheets were prepared and tested using TAPPI standard testing methods.
[0064] Results: See Table 3.
TABLE 3 Pine Treatments Sample Identification Burst Tear Energy Savings Including Log Size (kN/g) (mN−m{circumflex over ( )}2/g) (%) Control 0.47 1.99 — 50/5 0.56 2.43 11.7 20/6 0.53 2.20 6.9 20/8 0.52 2.14 9.1
Example 4
Microwave Pretreatment of Aspen Logs
[0065] Objective: To achieve electrical energy savings and improvements in paper strength by microwaving aspen logs prior to mechanical pulping.
[0066] Materials: Aspen logs were received from a mill specializing in the production of light weight coated paper. Logs were microwaved at Microdry in Louisville, Ky. Logs were debarked and chipped at FPL to a nominal size of 6-14 mm. Chips were placed in plastic freezer bags and frozen to prevent the growth of contaminating microorganisms. Log discs were cut before debarking and chipping that was approximately 3 centimeters thick. Moisture content varies from approximately 50%-56% depending on the microwave treatment time.
[0067] Microwave Treatments: Logs were subject to three microwaving conditions. Logs were microwaved at 50 kW for 5 minutes (50/5), 20 kW for 6 minutes (20/6), and 20 kW for 8 minutes (20/8).
[0068] Chip fiberization, pulp refining and handsheet production: Microwaved wood chips were fiberized in a Sprout-Waldron Model D2202 single rotating 300 mm diameter disk refiner. Energy consumption was measured using an Ohio Semitronic Model WH 30-11195 integrating Wattmeter attached to the power supply side of the 44.8 kW electric motor. Feed rate through the refiner was between 10 kW and 15 kW. Energy reported in WH/kg. Refiner plate settings were 0.025 inch, 0.014 inch, 0.010 inch, and 0.008 inch. Pulp was collected at each pass as hot water slurry. Between the passes the pulp slurry was dewatered to approximately 25% solids in a porous bag by vacuum. Dilution water at 85 degrees Celsius was then added each time as the pulp was fed into the refiner. Samples of the pulp were taken and tested for the Canadian Standard Freeness (CSF). Samples refined to 100 CSF. Handsheets were prepared and tested using TAPPI standard testing methods. Table 4 describes the results.
TABLE 4 Aspen Treatments Sample Identification Burst Tear Energy Savings Including Log Size (kN/g) (mN−m{circumflex over ( )}2/g) (%) Control 0.46 1.85 — 50/5 0.47 1.85 3.4 20/6 0.49 1.86 1.9 20/8 0.50 1.98 1.8
Example 5
Pitch Reduction
[0069] Logs were microwaved as described in Example 1. The control consisted of logs that did not undergo microwave treatment. All logs were then chipped and the chips were extracted with dichloromethane (DCM). A significant decrease in pitch was observed in the microwave pre-treated samples. Results are shown in Table 5.
TABLE 5 Dichloromethane extraction Treated Treated Microwaved Microwaved Pitch/Resin Acids Control 20 kw/6 min 50 kw/5 min DCM Extractives 1.81 1.70 1.55 (% dry weight basis) % reduction over control — 6 14 Resin Acids b Pimaric acid 98.5 77.1 83.0 Sandaracopimaric acid 134 95.9 93.0 Isopimaric acid 359 278 341 Levopimaric acid 246 145 258 Dehydroabietic acid 1310 839 892 Abietic acid 147 151 191 Neoabietic acid <25 <25 <25 Chlorodehydraoabietic acid <25 <25 <25 Dichlorodehydrobioetic acid <25 <25 <25 Total identified resin acids 2290 1590 1860 (μg/dry weight basis) % reduction over control — 31 19
Example 6
Enzyme Application
[0070] Logs are microwaved as described in Example 1. Logs are then chipped and sprayed with compositions containing a mixture of lipases, xylanases, pectinases, cellulases and lignin-degrading enzymes. Upon mechanical processing to provide pulp, a decrease in energy input requirements and an increase in paper strength and desirable optical characteristics are noted.
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A method of producing pulp for use in making paper products using microwave radiation to pretreat the source of pulp prior to further processing. Practicing the method of the invention results in substantial energy savings while decreasing environmental impact and improving paper qualities.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to screens for separating undesirable material from desirable material. More particularly, the present invention relates to screens for screening material used in the production of paper, board, and the like. Such screens are known in various designs and used world-wide in the paper industry.
[0002] Screens are known where blades mounted on a rotor have a cross-section shaped, in direction of rotation, similar to the wing of an aircraft and which begins with a bulb-like curve in the direction of rotation, then converges towards the rear and ends in the shape of a narrow droplet. These blades extend in the form of bars and are the same length as the rotor or screen basket. Normally a cylindrical rotor is provided. In the screens known, the surface of the blade facing the screen basket provided for the pulp particle suspension to pass through is curved such that the radial clearance between the function-bearing blade surface and the screen basket surface facing it is reduced first of all to a minimum in the leading sector of the blade. After a brief stretch where the minimum clearance to the facing screen basket surface remains approximately the same, the radial clearance then rises again towards the rear end or rear edge of the blade. The purpose of this is to squeeze the screening material suspension through the openings in the screen basket, assisted by dynamic pressure, in the leading front area of the blade with diminishing clearance to the screen basket. In the rear trailing sector of the blade, whose clearance to the screen basket surface facing it gradually increases, a kind of suction effect is generated on the suspension material already pushed through to the other side of the screen basket in order to achieve a backwashing and rinsing off action of the impurities on the screen basket. This suction effect is known and experts shared the opinion hitherto that blades with a cross-section similar to a narrow, curved droplet have the optimum shape for effectiveness of the rotor and the blades to achieve a substantial backwashing effect and obtain the lowest possible flow resistance as the blade moves through the fibre pulp.
[0003] In the present description of the state of the art, it should be added that there are two basic types of screen: There are screens with a screen basket which is fed suspension to be screened from the inside and which have blades inside the screen basket, known as “centrifugal screens”, and there are screens with blades rotating outside the screen basket and brushing over it on the outside with low clearance, where these so-called “centripetal screens” feed the material to be screened to the screen basket from the outside and the cleaned pulp suspension is carried off the inside of the screen basket.
[0004] In centripetal screens with screen basket on the inside and blades rotating on the outside of it, the rotating shank of the rotor has a star or disc-shaped support in the inlet or top section of the screen basket, overlapping outwards over this screen basket, and with extensions protruding downwards to which the blades rotating round the screen basket are secured.
SUMMARY OF THE INVENTION
[0005] The present invention is now based on the observation that the hitherto conventional airfoil shape of the blade surface closer to the screen basket, particularly the planned reduction in clearance between blade and screen basket in the leading sector of the blade is not the optimum design, neither in terms of fluid mechanics and energy efficiency, nor with regard to efficiency of the separation process, flow rates and separation performance.
[0006] It was discovered unexpectedly that a substantial improvement can be achieved in the operating results and quality of the cleaned material by modifying the clearance between the surface of the individual blades facing the screen basket and the screen basket surface facing each blade, and by selecting a special shape of blade cross-section.
[0007] Thus, the subject of the invention is a screen as described above, where the radial clearance between the leading sector of the blade, viewed in the direction of rotation, particularly the front end or the front edge of the surface of the blade facing the screen basket, and the surface of the screen basket is a minimum clearance and rises to a maximum clearance towards the rearmost sector, or the rear edge, of the blade.
[0008] The arrangement of the individual blades according to the invention and the continuous widening in clearance between the screen basket and the surface of the blades succeed in avoiding any pressure build-up. It has been demonstrated that the pressure exerted on the suspension to be screened in order to transport it through the screen is more than adequate to push sufficiently large quantities of pulp suspension through the openings in the screen basket and that no additional increase in pressure by special shaping of the rotor blade leading sector with diminishing clearance to the screen basket surface is required to implement this procedure effectively.
[0009] On the contrary, the increased suction effect now applied by the entire blade as a result of the widening clearance to the suction basket surface further back on the blade creates much more effective backwashing and, as a result, better removal of the particles and impurities separated from the screening material from the walls of the screen basket. The blades arranged and shaped according to the invention exert lower pressure or “underpressure” in the pulp suspension over their entire length and span in the direction of rotation, i.e. over the entire surface, compared to the pressure they otherwise apply in the screen casing. As a result, the inverse suction effect on a portion of the pulp suspension that has already passed through the openings in the screen basket is increased and backwashing occurs through the openings in the screen basket. Due to improved removal of the impurities retained, the separation behavior and performance of the screen according to the invention is enhanced. Due to the offset arrangement of the blades there is practically always vorticity at every point of the screen basket, which has the effect of cleaning the screen surface. The liquid flow from the feed may also be influenced favorably with a rotor shaped as a paraboloid of revolution.
[0010] The principal advantages of the screen and blades according to the invention are as follows:
[0011] Lower energy consumption as a result of the lower pressure build-up in the leading sector of the blade and thus, less flow resistance.
[0012] Lower pulsation generated by positioning the narrowest flow cross-section between blade and screw basket walls directly at or in the vicinity of the blade front edge.
[0013] Higher turbulence generated at the edges of the individual blades and thus, improved screen exposure for higher throughput and separation performance.
[0014] Low pressure shocks towards the screen surface and the area behind it, thus significant improvement in screening quality.
[0015] Lower rotor speed at constant throughput and thus, lower energy requirement.
[0016] The front or leading sector of the blade forms virtually no or only a small angle with the screen basket surface with minimum clearance to the blade. In those areas where the invention dictates a small angle, this configuration allows a high backwashing rate and the stronger suction effect ensures more effective removal of particle material from the screen basket surface.
[0017] The curvature of the blade surface facing the screen basket is important for the desired backwashing and for the suction effect. It has been shown that improved backwashing can be obtained with different curvature at the front and rear sectors, viewed in the direction of rotation, of the individual blades. That is, when the surface of the blades facing the screen basket are more curved in the leading sector than in the trailing sector. Preferably the curvature of the surface of the blade is greater at the front sector by some 5 to 20%, especially by 10 to 15%, than the curvature of the surface of the screen basket and the curvature of the surface of the blade is greater in its trailing sector by some 0 to 9%, preferably by 0 to 4%, than the curvature of the surface of the screen basket, and where preferably the transition zone from the preferably circular cylindrical curvature of the leading sector of the blade to the preferably circular cylindrical curvature of the trailing sector extends over the middle third of the length of the blade, where the transition from the strongly curved, leading sector to the less curved trailing sector takes place steadily. Such design boosts the effectiveness when separating the pulp suspension from the impurity particles.
[0018] The choice of different curvatures for the various sectors of the blade surface facing the screen basket allows the blade surface to be adapted effectively to cope with different operating conditions and material compositions. Maintaining a ratio of 0.05 to 0.5, preferably 0.1 to 0.3, between the minimum clearance and the maximum clearance between the surface of a blade and the screen basket also provides an advantage in this connection.
[0019] In detailed investigations aimed at optimizing the cross-sectional shape of the rotor blade it was established that the conventional configuration used hitherto with airfoil-shaped cross-section, which is both expensive and relatively complicated to implement technically, is not only unnecessary, but can even hamper effectiveness. Blades of a plate-type design, preferably with the same material thickness from the front edge or tip to the rear edge, provide a simpler and effective blade design which can be manufactured at reasonable cost. The lower centrifugal forces resulting from the plate-type blade cross-section—avoiding an airfoil shape—permit a cost-saving, light-weight design, virtually for the first time, and these can also be used with lighter-weight blade holding devices. Advantageously, the blades will have a thickness of 2 to 8 mm, particularly 5 to 6 mm, where preferably the blades are made of curved sheet metal, particularly, with their inner and outer surfaces parallel to one another.
[0020] In addition it was found that certain design details are capable of further enhancing the advantageous effects of the present invention. This is true, for example, of the shaping of the front edge of the rotor blade, viewed in direction of rotation, as a narrow rectangle, where the two front, corner edges can be rounded off it necessary.
[0021] Various different contours have proved favorable for the shape or form of the blade. For example, the contour of the blades may be narrower in a horizontal projection in their leading front sector than in their rear trailing sector or at the rear edge. The blades may have largely, triangular, deltoid, trapezoidal or dovetailed contours in a horizontal projection. The side edges of the blade may extend in a straight line from a front tip or narrow front edge and diverging at an angle towards the rear, forming an angle of 40 to 120°, preferably between 60 and 90°. If the contour is shaped in steps, these steps or indentations need not be located in a straight line by any means, but may describe a concave or convex curve. For the purposes of the invention, the blade contour widening from the front end towards the rear can have edges converging at an angle again in its rearmost third. The blade contour shapes described also contribute towards reducing the flow resistance when the blades move through the pulp suspension.
[0022] Furthermore it was established that the suction effect can be further increased if measures are implemented to ensure that the blade surfaces contain strip-like elevations extending at right angles to the direction of rotation of the rotor and on the far side of which an increased suction effect is generated locally in each case in contrast to the conventional suction effect of the blade surface.
[0023] The rotor itself can be formed in one piece. It can be expedient to use a design where several individual rotor modules are put together to form a rotor with any desired axial span. The rotor may have several blade supports, for example web plates, extending outwards from its shaft or the rotor body, mounted with uniform clearance to one another. Such features permit a highly robust construction in operation and also mechanical stability.
[0024] Additionally the invention includes a blade shaped as a bent or curved plate, preferably with the same material thickness from the front edge or tip to the rear edge. With conventional blades it was considered a disadvantage that these components were solid and heavy structures, particularly because these blades had an airfoil-shaped cross-section. With a blade design of the inventive type it is possible to manufacture a lightweight blade and lend the blades the desired shape by simple means, as well as to adapt the blades to suit different applications.
[0025] To facilitate changing the blade, particularly in order to insert blades that have been adapted to suit different rotor speeds or pulp suspensions, the blade may have a base section attached to its inner surface, on which fastening devices are provided. Alternatively, the blade may have screw holes for screwing it to a support.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings in which:
[0027] [0027]FIG. 1 is a schematic sectional view of a first type of conventional screen;
[0028] [0028]FIG. 2 is a cross-sectional view of the screen of FIG. 1;
[0029] [0029]FIG. 3 is a cross-sectional view of a second type of conventional screen;
[0030] [0030]FIG. 4 is an enlarged view of the blade and basket of FIG. 1;
[0031] [0031]FIG. 5 is a schematic sectional view of a blade, web plate, and basket in accordance with a first embodiment of the invention;
[0032] [0032]FIG. 6 is a schematic sectional view of a blade and basket in accordance with a second embodiment of the invention;
[0033] [0033]FIG. 7 is schematic view of a first blade arrangement in accordance with the invention;
[0034] [0034]FIG. 8 is schematic view of a second blade arrangement in accordance with the invention;
[0035] [0035]FIG. 9 is schematic view of a third blade arrangement in accordance with the invention;
[0036] [0036]FIG. 10 is a horizontal projection of a first blade in accordance with the invention;
[0037] [0037]FIG. 11 is a horizontal projection of a first blade in accordance with the invention;
[0038] [0038]FIG. 12 is a horizontal projection of a second blade in accordance with the invention;
[0039] [0039]FIG. 13 is a horizontal projection of a third blade in accordance with the invention;
[0040] [0040]FIG. 14 is a horizontal projection of a fourth blade in accordance with the invention;
[0041] [0041]FIG. 15 is a horizontal projection of a fifth blade in accordance with the invention;
[0042] [0042]FIG. 16 is a horizontal projection of a sixth blade in accordance with the invention;
[0043] [0043]FIG. 17 is an enlarged schematic sectional view of a blade and web plate in accordance with the invention illustrating a first apparatus for fastening the blade to the web plate;
[0044] [0044]FIG. 18 is an enlarged schematic sectional view of a blade and web plate in accordance with the invention illustrating a second apparatus for fastening the blade to the web plate; and
[0045] [0045]FIG. 19 is an enlarged schematic sectional view of a blade and web plate in accordance with the invention illustrating a third apparatus for fastening the blade to the web plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0046] The screen 100 shown schematically in a horizontal and a vertical sectional view in FIGS. 1 and 2 has a casing 5 with an inlet 51 for a screening material suspension, with an outlet 52 for accept pulp that has been freed of impurities. At the base of the casing 5 there is an outlet 53 or similar for discharging the impurities separated from the screening material. In the inner chamber 500 of the roughly barrel-shaped or cylindrical casing 5 there is a concentrically mounted, cylindrical screen basket 2 with round or slot-type screening openings 204 for the clean pulp suspension to pass through. In the inner chamber 200 of the screen basket 2 there is a rotor 300 and mounted on a pivoting bearing on a shaft 381 driven by a motor 6 through a vertical axis of rotation a3. Web plates 382 extend from the rotor 300 , particularly in radial direction, and each carry a blade 3 which can be moved past the inner surface 20 of the screen basket 2 at the end of the web plate 382 closest to the screen basket 2 . The screening material that is fed in through the inlet 51 under pressure, enters the screen basket's 2 inner chamber 200 , whose cross-section in this case becomes more and more constricted concentrically in the downward direction because of the paraboloid shape of the rotor 300 . The accept pulp, comprising fibrillated material free of impurities, is pushed by the action of the pressure introduced into the pulp suspension through the openings 204 in the screen basket 2 outwards into the inner chamber 500 of the casing 5 that surrounds the screen basket 2 and from where the suspension is discharged through the outlet 52 . The openings 204 in the screen basket 2 are dimensioned such that the impurity particles in the screening material suspension, such as glass splinters, coarser sand grains, small stones, metal particles, and similar, are retained in the screen basket 2 , particularly that they adhere to its inner surface 20 at the screening openings 204 . Without appropriate counter-measures the openings 204 would clog up and fibrillated accept suspension free of impurities would be prevented from passing through them. To prevent this from happening, the cross section of the known blades 3 is shaped like an aircraft wing and the trailing sector 33 —viewed in the direction of rotation dr—of their outer surface 30 exerts suction on the suspension as a result of its increasing clearance from the inner surface 20 of the screen basket 2 . This results in a small part of the accept suspension filtered immediately beforehand through the screen basket or pushed out of the screen basket, respectively, being washed back into the screen basket 2 . Due to this backwashing effect the impurities clogging the openings 204 are detached from the inner surface 20 of the screen basket 2 , fall to the floor of the screen basket 2 and eventually reach the outlet 53 .
[0047] The screen 100 shown in FIG. 3 works according to an operating principle that is inverse to that of the screen 100 shown in FIGS. 1 and 2. The casing 5 has an inlet 51 at the bottom for the pulp suspension to be screened, an outlet 52 at the top for the pulp suspension after it has been freed from impurities, and also a relatively high outlet 53 for impurities. In the casing 5 a rotor 300 with a conical cross-section is mounted that can be rotated round the axis a3 with a motor 6 . The top end of the rotor 300 supports a support disc or arms/web plates 382 extending radially in a star shape. Extending from the support disc or arms 382 there are blade supports 380 pointing downwards which hold the inwardly projecting blades 3 ′. The inner surfaces 30 ′ of the blades 3 ′ rotate round the screen basket 2 or rather round its outer surface 20 ′ with relatively little clearance. The separation of accept and impurities takes place in the same way as described in connection with FIGS. 1 and 2. The screen 100 illustrated in FIG. 3 and with the design known also has blades 3 ′ which are largely airfoil-shaped and display the disadvantages discussed above of higher energy consumption and lack of optimum backwashing effect, leading to less effective cleaning of the screen basket 2 and unplugging of the openings 204 .
[0048] The schematic drawing in FIG. 4 shows part of the screen basket 2 with its screening openings 204 for the accept suspension. The radial clearance ar between the surface 30 of the blade 3 facing the screen basket and the inner surface 20 of the screen basket 2 varies along the length of the blade 3 . The blade 3 with airfoil-shaped cross-section has relatively large radial clearance arv at its leading edge 310 and/or in the foremost, initial sector 31 . Between this initial sector 31 of the blade 3 and a relatively narrow middle zone 32 the radial clearance ar decreases to a minimum arm. From this zone 32 the radial clearance ar increases towards the rear sector 33 and trailing edge 330 up to a maximum value arh. At the front edge 310 and along the front sector 31 there is a pressure build-up extending to the middle zone 32 when the blade 3 is moved in the direction of rotation dr. Only in the trailing section 33 where the clearance between surface 30 and surface 20 of the screen basket 2 increases is an important suction effect generated for backwashing of the impurities. The blade 3 has a flat inner surface 3001 .
[0049] Detailed investigations have shown that an airfoil is not the optimum shape for the blade 3 in terms of the energy required to rotate the rotor 300 , the effectiveness of backwashing, and clearing of any impurities from the screening openings 204 . Since it is state of the art for the blade 3 with airfoil-shaped cross-section to have a front section 31 —viewed in the direction of rotation dr—where the clearance ar diminishes approximately as far as the sector where the web plate 382 is attached (FIG. 1), there is a dynamic pressure counter-effect in the pulp suspension which hampers rotation, thus increasing the energy consumption for rotation. Furthermore, only part of the entire blade surface 30 , to be precise the trailing sector 33 , is available for backwashing to clean the screen basket openings 204 .
[0050] The blade 3 shown in the sectional view in FIG. 5, mounted and designed according to the invention, has a convex outer surface 30 facing the cylinder jacket-shaped surface 20 of the screen basket 2 . The blade 3 is of plate-type design, e.g. made from sheet metal or synthetic material of even thickness ms. It is an advantage if the inner surface 3001 runs parallel to the outer surface 30 , that is to say these two surfaces 30 and 3001 have the same curvature.
[0051] In practice the blade 3 is some 5 to 6 mm thick, the screen basket 2 is usually 400 to 3000 mm in diameter and some 500 to 1500 mm high.
[0052] The small auxiliary sketches pertaining to FIG. 5 provide three examples of the preferred shape of front edge 310 of the blade 3 , where the face end has a rectangular cross-section in a), a similar cross-section section shape with rounded edges in b) 3101 , and is rounded off 3102 in sketch c).
[0053] The blade 3 according to the invention, which differs substantially from state-of-the-art blades, is mounted in relation to the facing surface 20 of the screen basket 2 such that the clearance between the surface 30 of the blade 3 and the surface 20 gradually increases from the blade's leading edge 310 towards its trailing edge 330 and the radial clearance ar increases from the front to the rear. The smallest radial clearance arv is found at the leading edge 310 , and the largest clearance arh is at the trailing edge 330 .
[0054] According to FIG. 5, the curvature radius rsk of the surface 20 of the screen basket 2 is greater than each of the two curvature radii rf1 and rf2 of the leading sector 31 and the trailing sector 33 of the surface 30 of the blade 3 . It is an advantage that the surface 30 runs virtually parallel to surface 20 in the vicinity of the front edge 310 . A tangent plane etf drawn at the front sector 31 in the direct vicinity of the front edge 310 forms an acute angle ∝ of a few degrees with the corresponding radial tangential plane ets drawn at the surface 20 . This acute angle is determined by the radius rf1 of the curvature at the front edge 310 .
[0055] The radial clearance ar of the surface 30 rises from the minimum clearance arv continuously to a maximum clearance arh and, due to this “pitch” of the blade 3 in relation to the direction of rotation dr and compared with the screen basket 2 , the suction effect that comes to bear during backwashing when the blade 3 moves in relation to the screen basket 2 is guaranteed over the entire span of the blade in the direction of rotation dr.
[0056] According to a special design shape, the radius rf1 of the curvature of the front sector 31 of the surface 30 can be smaller than the radius rf2 of the curvature in the trailing sector 33 , with a transition area being provided in the intermediate zone 32 between the two different curvatures. It is not desirable to have an edge approximately following the path of a generator of the surface 30 between the strongly curved leading sector 31 and the less curved trailing sector 33 of the surface 30 .
[0057] The modification described to the degree of curvature over the span of the blade 3 yields advantageous changes to the flow conditions and leads to favorable changes in pressure in the suspension. The curvatures should preferably have a circular cylindrical shape, but can also be oval or elliptical.
[0058] It is a particular advantage if the tangential plane etf drawn at the leading sector 31 of the surface 30 , 30 ′ facing the screen basket or at the area around the tip of the front edge 310 of the blade 3 , 3 ′ forms an angle ∝ of 0 to 15°, preferably between 0 and 8°, particularly between 0 and 2°, with the tangential plane ets drawn at a corresponding radial generator ezs of the surface 20 , 20 ′ of the screen basket 2 facing the blade 3 , 3 ′. As a result, the surface 30 obtained has more favorable fluid mechanics properties and the suction effect is improved. This sizing applies for blades 3 , 3 ′ rotating both inside and/or outside the screen basket 2 .
[0059] It can be an advantage if the curvature at the front or leading sector 31 of the surface 30 of the blade 3 adjacent to the screen basket is 5 to 20%, preferably 10 to 15%, larger than the curvature of the facing surface 20 of the screen basket 2 and if the curvature at the rear or trailing sector 33 of the surface 30 of the blade 3 is between 0 and 9%, preferably between 0 and 4%, larger than the curvature of the surface 30 of the screen basket 2 .
[0060] [0060]FIG. 6 shows a schematic view of the screen basket 2 of a centripetal screen with blades 3 ′ rotating around the outside of the screen basket 2 , with surfaces 30 ′ which have less curvature than the outer surface 20 of the screen basket 2 and whose convex surface 30 ′ faces the outer surface 20 ′ of the screen basket 2 . The broken line indicates that the curvature of the blade 3 ′ can possibly also be “infinite” in the front sector 31 ′, i.e. that the angle ∝ at the front edge 310 could be equal to the limiting value 0°.
[0061] [0061]FIG. 7 shows a rotor 300 with blades 3 offset in relation to each other in height, in a zigzag arrangement, and designed according to the invention. By contrast, FIG. 8 shows a rotor 300 with blades 3 offset in relation to each other round the circumference. FIG. 9 shows a rotor 300 fitted according to the invention with blades 3 arranged along an ascending spiral line.
[0062] FIGS. 10 to 16 show blades 3 , 3 ′ according to the invention with trapezoidal, triangular and basically trapezoidal overall contours, shown in the order of listing. On its surface 30 the blade 3 according to FIG. 12 has turbulence bumps 308 in strip form, arranged at angle γ to the blade generator ezf, where γ is preferably between 10 and 45°, particularly between 15 and 30°, in this case approximately parallel to the lower side edge 35 , to form a corrugated surface. Groove-shaped indentations can also be formed in the blade 3 instead of these bumps 308 .
[0063] The angle ω formed by the diverging side edges 35 against the direction of rotation dr measures between 20 and 60°, preferably 25 to 50°. The approximately strip-shaped bumps 308 or the indentations on the surface 30 of a blade 3 cause local underpressure turbulence when the blade 3 moves and this assists in detaching the impurity particles adhering to the screen basket 2 .
[0064] At the blade 3 in FIG. 13 the side edges 35 are convex with an obtuse angle and the sections 351 directly adjoining the short, front edge 310 together form the angle ω. The side edges 35 of the blade 3 in FIG. 14 are designed with even steps 352 . The graduated side edge 35 substantially increases its overall length and thus enhances the turbulence in the pulp suspension when the blade 3 rotates.
[0065] The contour shape of the blade 3 in FIG. 15 has diverging side edges 35 in its front sector which then begin to deflect inwards approximately in the rearmost third of the surface 30 , then run towards each other in two short branches to the rear at an angle and terminate at the rear edge 330 . The blade 3 shown in FIG. 16 has a dovetailed contour with a short front edge 310 .
[0066] [0066]FIGS. 17, 18, and 19 show diagrams of blades 3 , 3 ′ which can be connected in various ways by means of arms, web plates 382 or supports 384 extending out from the rotor 300 . The blades 3 , 3 ′ are made of curved sheet metal, particularly with a parallel outer surface 30 and inner surface 3001 . According to FIGS. 17 and 18, a base section 383 is shaped onto the blades 3 , 3 ′. The base section 383 in FIG. 17 has an internal, sleeve-shaped recess 385 , into which the prolongation 386 of the support 382 is inserted. Lateral projections 387 enclose the side limitations 388 of the recess 385 . The projection 386 and the recess 385 are connected by a screw—as intimated.
[0067] In the blade 3 , 3 ′ design shown in FIG. 18, the final sector of the base section 383 has a projection 389 which interacts with a projection 390 in the web plate 382 . The projections 389 and 390 are screwed together—as intimated at 384 .
[0068] According to FIG. 19, the blade 3 , 3 ′ can be screwed to a supporting member 391 secured to the support or web plate 382 using the screws intimated at 384 .
[0069] The designs illustrated allow easy replacement of the blades 3 , 3 ′ so that a screen fitted with this type of blade can be adapted quickly to handle different operating conditions.
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A screen, for screening material used in the production of paper, board and the like, having a screen basket and a rotor supporting several blades which can be moved along the wall of the screen basket when the rotor rotates. The blades having a convex curvature on the side facing the screen basket. The radial clearance between the surface of the blade facing the screen and the screen being lowest between the front sector, viewed in the direction of rotation, and increasing towards the rear edge of the blade.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/652,648, filed Aug. 31, 2000 now U.S. Pat. No. 7,197,853, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is in the field of building and facility walls and ceiling systems and associated architectural elements. More particularly, the present invention is in the field of wall and ceiling partitions having architectural elements which are demountable and reusable, and that have a seamless surface between the architectural elements when the wall and ceiling partitions are in place.
2. Description of the Related Art
A variety of removable and reusable wall systems are available for use in partitioning a building's interior space. The prior known wall systems each attempt to embody a subset of the overall objects and advantages that the industry seeks in such assemblies, often for a specific building application. The structure of such assemblies range from floor-to-ceiling full height wall partitions to modular-office-cubical-type panel assemblies having partial height walls.
Removable, full height wall partition assemblies are often referred to as “demountable” wall systems. Examples of such systems include the demountable wall systems of Allison (U.S. Pat. No. 5,060,434) and Moreno et al. (U.S. Pat. No. 5,216,859). Current demountable wall systems are designed separately from the buildings they are used in, and are incorporated separately into the interior space of the building as an accessory, after the building is completed.
Many limitations may be found in prior art demountable wall systems. The component parts of which are inherently sophisticated, complex, and intricate. They require custom prefabrication of processed-raw-material-stock. They require elaborate warehousing, stocking, inventorying of numerous parts many of which become obsolete over time. Each manufacturer must train and then maintain specialty crews in every major city in order to site assemble, disassemble, and reassemble their particular and unique demountable wall and system. Prior art demountable walls must create specialized custom doors, windows, door and window hardware, electrical, voice and data, plumbing, and the like which together dictate a complex problem prone system. All of the prior art systems have dimensional limitations of height and restricted flexibility in length due to prefabrication. Once a height is selected to fit a certain building it is often not usable in another building because of seemingly minor differences in height or most often in the degree of slope of the floors which the naked eye perceives as level but the demountable wall panels can not tolerate. Prior art wall system manufacturers attempt to overcome this limitation by adding more variety of product sizes which actually magnifies the above limitations because it magnifies the problems associated with complexity, inventorying, obsolesce, assembly crew training, and ever increasing costs associated with these limitations. The cost of prior art demountable wall systems is very high ($80 to $200 per lineal foot plus accessories compared to standard fixed wall cost of about $22 per lineal foot) and therefore the use of prior art demountable walls is not wide spread. If there were a wide spread use of demountable walls the impact on our environment and non-renewal resources would be very positive because the standard fixed walls do not accommodate reconfiguration. Therefore the standard fixed walls must be demolished and sent to special toxic waste landfills (decomposing gypsum releases a toxic gas) and new walls must be constructed using more of our non-renewal natural resources.
Another limitation of prior art demountable wall and ceiling systems is the resulting seams and gaps that occur between the component panels that make up the walls and ceiling. Architects and designers object strongly to these aesthetically unacceptable and often imbalanced sectioning of the architecture. Prior art demountable walls are limited to interior use, few, if any, are fire rated nor are they load bearing.
Since commercial buildings, particularly office buildings are often remodeled to accommodate changing space requirements, tenancy, and design tastes, it would be advantageous to have an interior and exterior space partitioning system which allows disassembly and ready reassembly and thus permits the general reuse of the elements of the system. This permits savings in material and downtime. It would be beneficial to have a demountable wall system that allowed the removal, reuse, and relocation of wall system elements, including not only wall panels and studs but also electrical and plumbing elements and door and window elements. The availability of a wall system embodying such recyclable elements would reduce waste and the cost of altering a building's space.
SUMMARY OF THE INVENTION
It is a feature of the present invention that it provides a wall and ceiling system which permits the general reuse of the elements of the system, thereby reducing material wastes and the cost of altering a building's space. The present invention overcomes most if not all of the aforementioned limitations to the prior art. Additional features and advantages of the invention will be set forth in part in the description which follows, and in part will become apparent from the description, or may be learned by practice of the invention. The features and advantages of the invention may be realized by practicing the combinations and steps described herein and particularly pointed out in the appended claims.
To achieve the foregoing features and advantages and in accordance with the purpose of the present invention as embodied and broadly described herein, the present invention is a non-load bearing wall partition system, the elements of which are demountable and reusable, and which may be assembled or reassembled using recyclable elements to provide a fastener-free surface, and may be finished to further provide a seamless as well as fastener-free surface.
More specifically, the present invention is a demountable wall assembly for partitioning room space between an overhead and a floor comprising wall surfaces that are fastener-free and which may be smooth and seamless when erected, and the structural elements of which are reusable after demounting. The wall assembly has two walls arranged in planar congruence and separated by spacers, which defines an inner wall space enclosed between the interior surfaces of the walls. This configuration also provides at least one exterior wall surface, which is a fastener-free wall surface, and may provide a second exterior wall surface which may or may not be fastener free. The surfaces are vertically positioned between and interface with the overhead (ceiling) and floor of the space to be partitioned. The fastener-free wall surface wall is made up of at least one removable wall panel. A wall panel may be sheet rock or some other type of panel suitable for use as a wall. The interior space formed between the two exterior walls may provide a space for the drop of modularized electrical, phone, and data lines at appropriate places throughout the interior space serviced by the demountable wall system.
A top spacer (variously called a header track, top plate, top sill, etc.) at the top of the wall assembly provides an interface between the overhead and other wall elements, e.g., internal spacers and wall panels. Similarly, a bottom spacer at the bottom of the wall assembly (variously called a bottom plate, bottom sill, etc.) provides an interface between the floor and other wall elements. The top spacer and bottom spacer are removably fixed to the overhead and floor respectively using any of a number of removable fasteners and releasable adhesives known to the ordinarily skilled artisan. Therefore, in the practice of the present invention, after being fixed in place, the top bottom spacers are removable and reusable. Similarly, top spacers and bottom spacers are removably fixed to the other wall elements using any of a number of removable fasteners and releasable adhesives known to the ordinarily skilled artisan. In those applications where removable fasteners are not to be used to long-term mount the other wall elements to the top or bottom spacer, or to each other, releasable adhesives may be substituted. As may be readily apparent, the mounting and demounting of the wall's various elements, (including top and bottom spacers, internal spacers, wall panels, trim, junction boxes, wiring, etc.) does not substantially impact their suitability for reuse.
A feature of the wall assembly of the present invention is an interior spacer which interfaces with the interior surfaces of the two walls and provides rigidity and support to the expanse of the wall, or an attachment interface at the perimeter edge of adjacent wall elements (panels). Interior wall spacers may run vertically, horizontally, or in any orientation required to accomplish their purpose. Internal spacers suitable for use in the wall assembly of the present invention includes any of the variety of wall studs typical of the building trades, and typically having a width of about 2.5 inches, and including a wooden 27W, or a removable head track and similar lumber and hardware.
A further feature of the present wall assembly is that the exterior surface of at least one of the walls is a fastener-free wall surface. A fastener-free wall surface is an exterior wall surface that has no fasteners in the exposed (i.e., not covered by trim or molding) surface of the wall. The second wall of the present invention may be a wall with a fastener-free exterior surface, an unfinished structural (bearing) wall or the like. In the typical practice of the present invention a wall having a fastener-free surface comprises a plurality of removable wall panels juxtapositioned at a perimeter edge to form a planar surface. An aspect of the fastener-free wall surface feature of the present invention is that the joint between the juxtapositioned panel edges may be treated as described herein to render the fastener-free surface also substantially smooth and seamless. Specifically, the joints may be filled with a releasable caulk or covered with a removable tape to provide a fastener-free surface that is substantially smooth when finished, and the caulk or tape being removable without substantial damage to the integrity of the wall panel. This permits the wall panels to be reused.
Unused wall panels may be inventoried and stored between redesigned wall systems providing further sound-deadening between the partitions and further structural support to the top and bottom spacers and the wall system generally. Alternatively, previously used wall panels may be moved to other sites for reinstallation.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and constitute a part of the instant specification, illustrate various preferred embodiments of the invention and together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. P illustrates a prior art wall assembly.
FIG. PA is a plan view cross section of the seam illustrating the prior art methodology in concealing and securing the seam between the panels in a conventional wall.
FIG. PB is a flow chart describing a prior art wall as illustrated in FIG. P and FIG. PA.
FIG. PC is a flow chart describing a prior art wall as illustrated in FIG. P.
FIG. 1 is an illustration of a preferred embodiment of the wall system of the present invention with the supports or studs at the panel edge including an invisible seam and bottom track.
FIG. 1A is a plan view cross section of the seam in FIG. 1 illustrating a methodology of the present invention in concealing and securing the seams between panels in the wall system.
FIG. 1B is a flow chart describing the wall of the present invention as illustrated in FIG. 1 .
FIG. 1C is an illustration of a preferred embodiment of the wall system of the present invention using releasable adhesive with the supports or studs at the panel edge including an invisible seam and bottom track.
FIG. 1D is an illustration of a preferred embodiment of the wall system of the present invention with the supports or studs at the panel edge including an invisible seam.
FIG. 2 is another embodiment of the wall system of the present invention where the releasable adhesive is used at the intermediate supports or studs.
FIG. 2A is a plan view cross section of the seam illustrated in FIG. 2 showing the methodology of securing the seams between panels in a wall system.
FIG. 2B is a flow chart describing the wall of the present invention as illustrated in FIG. 2 .
FIG. 2C is an illustration of a preferred embodiment of the wall system of the present invention using releasable adhesive with the supports or studs at the panel edge including an invisible seam and bottom track.
FIG. 2D is an illustration of a preferred embodiment of the wall system of the present invention with the supports or studs at the panel edge including an invisible seam.
FIG. 3 illustrates yet another preferred embodiment of the wall system of the present invention where zip tape is used at intermediate supports or studs.
FIG. 3A is a plan view cross section of the seam illustrated in FIG. 3 showing the methodology of securing the seams between panels in a wall system.
FIG. 3B is a flow chart describing the wall system illustrated in FIG. 3 where the support or stud is not at the panel edges and the panel is secured at the extremities by long term fasteners.
FIG. 3C is an illustration of a preferred embodiment of the wall system of the present invention using releasable adhesive with the supports or studs at the panel edge including an invisible seam and bottom track.
FIG. 4 is an illustration of yet another preferred wall system of the present invention where a removable substance is at the panel edge supports or studs to form an invisible seam.
FIG. 4A is a plan view cross-section illustration of the seam between two panels as illustrated in FIG. 4 .
FIG. 4B is a flow chart of the wall system of the present invention as illustrated in FIG. 4 where the support or stud is at the panel edges and the seam is made invisible by the removable substance.
FIG. 4C is a flow chart of the wall system of the present invention as illustrated in FIG. 4 where the support or stud is not at the panel edges.
FIG. 4D is an illustration of a preferred embodiment of the wall system of the present invention using releasable adhesive with the supports or studs at the panel edge including an invisible seam and a bottom track.
FIG. 5 is yet another preferred embodiment of a wall system of the present invention where releasable adhesive is used at the panel edge supports or studs.
FIG. 5A is a perspective, cross section of the seam associated with the two abutting panels as illustrated in FIG. 5 .
FIG. 5B is a flow chart of the wall system of the present invention as illustrated in FIG. 5 where the support or stud is at the panel edges and the seam is visible.
FIG. 5C is a flow chart of the wall system of the present invention as illustrated in FIG. 5 where the support or stud is not at the panel edges.
FIG. 5D is an illustration of a preferred embodiment of the wall system of the present invention using releasable adhesive with the supports or studs at the panel edge including an invisible seam and bottom track.
FIG. 6 illustrates a cross section of a wall system of the present invention with a wall panel removably engaged with a removable floor or bottom track and a removable head track.
FIG. 7 is an illustration of a portion of a ceiling or overhead using the system of the present invention; and similarly, FIG. 7 illustrates a tall wall system having a number of stacked panels.
FIG. 8 is a partial cutaway of an upper proportion of the wall system of the present invention illustrating a head track in association with the wall panels.
FIG. 9 illustrates a partial section of a lower portion of the wall system of the present invention with a removable bottom track in association with the wall panels.
FIG. 10 illustrates yet another embodiment of a wall system of the present invention showing a partial cross-section of a wall panel in association with a removable bottom track.
FIG. 11 is an illustration of a tri-channel head track for use in association with the wall system of the present invention.
FIG. 11A is an illustration of the tri-channel head track for use in association with the wall system of the present invention as illustrated in FIG. 11 having an unfeathered extension and releasable adhesive.
FIG. 11B is an illustration of the tri-channel head track for use in association with the wall system of the present invention as illustrated in FIG. 11 having a feathered extension and releasable adhesive.
FIG. 12 is a sectional illustration of a tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel.
FIG. 12A is a sectional illustration of a tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel and using removable adhesive.
FIG. 13 is sectional view of a quad-channel bottom track used with the wall system of the present invention having a slotted data channel.
FIG. 13A is a sectional illustration of a tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel and using removable adhesive.
FIG. 14 is yet another embodiment of the tri-channel bottom track for use with the wall system of the present invention having a slotted data channel for receiving the studs.
FIG. 14A is a sectional illustration of a tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel and using removable adhesive.
FIG. 15 is a sectional illustration of another tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel.
FIG. 15A is a sectional illustration of another tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel as illustrated in FIG. 15 and having an unfeathered extension and releasable adhesive.
FIG. 15B is a sectional illustration of another tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel as illustrated in FIG. 15 and having a feathered extension and releasable adhesive.
FIG. 16 is yet another embodiment of the tri-channel bottom track for use with the wall system of the present invention having a slotted data channel for receiving the studs.
FIG. 16A is a sectional illustration of another tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel as illustrated in FIG. 16 and having an unfeathered extension and releasable adhesive.
FIG. 17 illustrates a cross section of a wall system of the present invention with a wall panel removably engaged with removable electrical and plumbing fixtures.
FIG. 18 is a sectional illustration of a tri-channel bottom track used in association with the wall system of the present invention having elements that are bendable metal.
FIG. 19 is a sectional illustration of another embodiment of a tri-channel bottom track used in association with the wall system of the present invention having elements that are bendable metal.
FIG. 20 is a sectional illustration of yet another embodiment of a tri-channel bottom track used in association with the wall system of the present invention having elements that are bendable metal.
FIG. 21A is a sectional illustration of a channeled bottom track used in association with the wall system of the present invention having a data channel.
FIG. 21 AA is a sectional illustration of another channeled bottom track used in association with the wall system of the present invention having a data channel.
FIG. 21 AAA is a sectional illustration of yet another channeled bottom track used in association with the wall system of the present invention having a data channel.
FIG. 21B is a sectional illustration of another channeled bottom track used in association with a load-bearing wall system of the present invention having a data channel.
FIG. 22A is a sectional illustration of another channeled bottom track used in association with a wall system of the present invention having a data channel.
FIG. 22 AA is a sectional illustration of an alternate embodiment of the one piece base track with a raised channel-seat for the stud.
FIG. 22B is a sectional illustration of another channeled bottom track used in association with a wall system of the present invention having a data channel.
FIG. 22C is a sectional illustration of another channeled bottom track used in association with a load-bearing wall system of the present invention having a data channel.
FIG. 23 illustrates a one-piece head track for use with one embodiment of the present invention.
The above general description and the following detailed description are merely illustrative of the generic invention, and system of the present invention having elements that are bendable metal.
DETAILED DESCRIPTION
Reference will now be made in detail to the present preferred embodiments of the invention as described in the accompanying drawings.
PRIOR ART: FIG. P illustrates a prior art wall assembly P 00 . The prior art wall assembly P 00 comprises both sides of one or more panels P 02 , one or more studs P 20 , a top track P 23 , a bottom track P 22 , a mud compound P 05 , a porous paper P 10 , “floating” mud compound P 12 , a smooth surface P 14 which has been sanded and a plurality of non-removable fasteners P 04 . Typically, the prior art wall assembly P 00 has a base board P 30 , a top track P 23 , and a bottom track P 22 . Typically, the studs P 20 are aligned vertically using the top track P 23 and the bottom track P 22 . The panels P 02 are affixed to the studs P 20 using the non-removable fasteners P 04 . Typically, the panels are fixed to the top track P 23 and the bottom track P 22 using the non-removable fasteners P 04 . The non-removable fasteners P 04 can be screws, nails, staples, and the like. It is appreciated by those skilled in the art that many different non-removable fasteners P 04 can be used in the manufacture of the prior art wall assembly P 00 . The fasteners P 04 are non-removable because of how they are used. For example, typically, the fasteners P 04 are used so that they are covered with a mud compound P 05 , P 13 . Covering the fastener P 04 with the mud compound P 05 , P 13 makes accessing, finding, and removing the fasteners P 04 not practical. Adjacent panels P 02 form a joint or seam P 03 at, for example, a first stud P 20 A. The non-removable fasteners P 04 are used to fixably secure the panels P 02 to the first stud P 20 A. Similarly, a second stud P 20 C is used to securably affix the panel P 02 at its edge using the non-removable fasteners P 04 . Typically, there is at least one intermediate stud P 20 B between the first stud P 20 A and the third stud P 20 C. The intermediate stud P 20 B is needed, for example, to prevent the panel P 02 from vibrating with normal building use, such as for example, to control panel shape distortion where panels P 02 are wide and the opening and closing of doors, heating and air conditioning blowers turning on and off, etc. To prevent the panel P 02 from vibrating, a plurality of non-removable fasteners P 04 affix the panel P 02 to the intermediate stud P 20 B.
Once the panels P 02 are affixed to the stud P 20 A, the non-removable fasteners P 04 A and the seam P 03 A must be concealed to form a continuous smooth wall P 14 A. The non-removable fasteners P 04 B affixed to the intermediate stud P 20 B are covered with the mud compound P 13 B or “floated” over. Thereafter, the float mud compound P 13 is sanded smooth so that it provides a continuous smooth surface P 14 .
With respect to the studs P 20 A, P 20 C at the panel seams P 03 , a more lengthy process is required. The joint or seam P 03 A is filled with a mud compound P 05 A. The mud compound P 05 A fills and hides the fastener P 04 A heads. When the fastener P 04 A heads are filled with the mud compound P 05 A removal is impractical, if not impossible. Also, the mud compound P 05 A sticks to the panel P 02 making reuse of the panel P 02 impractical, if not impossible. Thereafter, a porous paper tape P 10 A is placed over the mud compound P 05 A which also covers the non-removable fasteners P 04 A. A mud compound P 12 A is applied over or “floated” over the porous paper tape P 10 A. The porous paper tape P 10 A helps to hold the panels P 02 together. The porous paper tape P 10 A and the mud compound P 05 A, P 12 A adheres to or bonds with the panels P 02 . The porous paper tape P 10 A provides structural integrity to the mud compound P 05 A, P 12 . After the mud compound P 05 A, P 12 is sufficiently cured, a unitary bond with the porous paper tape P 10 A, the panel P 02 of sheet rock, the fasteners P 04 A and the mud compound P 05 A, P 12 A is formed. The mud compound P 05 A, P 12 A has a purpose of adhering to or bonding with the panels P 02 and the porous paper tape P 10 A. Thereafter, the mud P 05 A, P 12 A is sanded to a smooth surface P 14 A. The smooth surface P 14 A provides that the seam P 03 A is invisible. The mud compound P 05 A, P 12 A has another purpose which is to provide a surface that can be sanded to a floated smooth surface to make the seam P 03 A invisible. Thereafter, a baseboard P 30 is typically placed over the extremity of the panels P 02 .
With respect to the intermediate stud P 20 B, the panel P 02 is also secured by the non-removable fasteners P 04 B. Similarly, the non-removable fasteners P 04 can be nails, staples, or the like. It is understood by those skilled in the art that the non-removable fasteners P 04 can not be easily accessed, found, or removed without damage to the panel P 02 . The non-removable fasteners P 04 are hidden under the covering of the mud compound P 13 and are impracticable, if not impossible, to remove.
In the prior art wall assembly P 00 , the long-term, non-removable fasteners P 04 create holes in the panels P 02 . The holes created by the fasteners P 04 are filled with or “floated” over with the mud compound P 05 , P 12 , P 13 . The mud compound P 05 , P 12 , P 13 hides the fastener P 04 screws and fills the holes and screw heads and adheres to the panel P 02 . The non-removable fasteners P 04 are not easily accessed, found and removed without damage to the panel P 02 . The mud compound P 05 , P 12 , P 13 cures to form a unitary bond with the porous paper tape P 10 , the panel P 02 of sheet rock, the fasteners P 04 , and the mud compound P 05 , P 12 , P 13 , thereby inhibiting reuse of any of the components.
FIG. PA is a plan view cross section of the seam P 03 A illustrating the prior art methodology in concealing and securing the seam P 03 between the panels P 02 in a conventional wall P 00 . The panels P 02 are abutted at the seam P 03 A as illustrated in FIG. PA. A base layer of mud compound P 05 A is applied to the seam P 03 A. Thereafter, a porous tape P 10 A is applied over the base layer of mud compound P 05 A. Thereafter, finish mud P 12 A is applied over the porous tape P 10 A. Thus, anything under the porous tape P 10 A is inaccessible and cannot be removed. The panels P 02 are joined so that the joint or seam P 03 A between the panels P 02 is turned into a smooth surface P 14 A, and the abutting panels P 02 form a single, continuous unitary panel P 02 .
FIG. PB is a flow chart describing a prior art wall P 00 as illustrated in FIG. P and FIG. PA. FIG. PA defines the treatment of the seam P 03 A. FIG. PB illustrates the prior art wall P 00 where the supports or studs P 20 A, P 20 C are at the panel P 02 edges. The seam P 03 A is treated to form a continuous, unitary panel P 02 having a smooth surface P 14 A. FIG. PB illustrates a prior art wall P 00 where a stud P 20 is at the panel P 02 , edge P 03 , and the seam P 03 A is rendered invisible.
FIG. PC is a flow chart describing a prior art wall P 00 as illustrated in FIG. P. FIG. PC defines the treatment of the supports or studs P 20 B not located at the edges of the panel P 02 . FIG. PB illustrates the prior art wall P 00 where the supports or studs P 20 B are located between the panel P 02 , edges P 03 , and is treated to form a smooth surface P 14 .
FIG. 1 : supports or studs 120 at the panel 102 edge and “zip” tape 110 A assists to form an invisible seam 114 A. FIG. 1 is an illustration of a preferred embodiment of the wall system 100 of the present invention with the supports or studs 120 at the panel 102 edge and the zip tape 110 A assists to form an invisible seam 114 A. The wall system 100 provides an innovative wall 100 having a support or stud 120 A at the edge of a panel 102 so as to form a seam 103 A. The wall system 100 of the present invention is different from the prior art wall assemblies in that the wall system 100 can be readily disassembled, relocated, and reassembled. The wall system 100 illustrated in FIG. 1 has the primary elements of one or more panels 102 , a plurality of long-term removable fasteners 104 , one or more studs 120 , a bottom track 122 , a “zip” tape 110 , and a tab 111 associated with the zip tape 110 .
The zip tape 110 used in practicing the present invention may be, for example, a releasable, removable self-adhering fiberglass mesh tape that has a mesh porosity such that the screw heads are not filled with compound 112 . Also, the present invention optionally provides that the screws 104 are treated to prevent the compound 112 from adhering to the screws 104 . The screws 104 can be treated before being used or after being installed. For example, treatment of the screws 104 before use may be by applying a Teflon® coat to the screw heads, or making the outer surface of the screws 104 of a non-sticking substance, or by making the entire screw 104 from a non-sticking substance. Further by example, treatment of the screws 104 after use may be by applying a spray Teflon® coat to the screw heads, or coating the outer surface of the screws 104 with a non-sticking substance. The non-sticking substance can be in any appropriate form, such as liquid, powder, etc. It can be appreciated by those skilled in the art that various and sundry combinations of the screws 104 and the non-sticking substances may be used depending on the situation.
The wall system 100 of the present invention provides that the studs 120 are engaged for support in the “floor” or bottom track 122 and optionally in a “head” or top track 123 , or the like. Optionally, the wall system 100 provides that a top track 123 or the like may not be attached to or reach the ceiling and likewise the bottom track 122 or the like may not be attached to or reach the floor. It can be appreciated by those skilled in the art that the type of studs 120 , top track 123 , and bottom track 122 can be varied depending on the project need and requirements. The panels 102 are affixed to the studs 120 at the panel edges to form a seam 103 . The “long-term, removable” fasteners 104 are used to secure the adjacent panels 102 to the studs 120 A, 120 C. The long-term, removable fasteners 104 H at the head trim 131 and the long-term, removable fasteners 104 F at the floor trim 130 are optional, and releasable adhesive can be used in their place. The studs 120 can be of any shape, dimension, or material. Various shapes, dimensions, and materials are readily known to those skilled in the art. When referring to the tab 111 , it is any portion of the zip tape used to disengage the zip tape 110 from the panel 102 . The panels 102 can be placed on either or both sides of the studs 120 . The height of the wall system 100 can by varied and there is no need for the wall system 100 to be full height.
The joint or seam 103 A is required to be conditioned so as to be a smooth congruent surface 114 A with the adjacent panels 102 A. To form the smooth congruent surface 114 A, the seam 103 A and long-term removable fasteners 104 A are covered with the “zip” tape 110 A and floated with mud compound 112 A. The “zip” tape 110 A is sufficiently strong to be removed as a single piece, in unison. Further, the zip tape 110 can be of varying porosity depending on the application of the present invention. The “zip” tape 110 A is removed as a single piece in unison by pulling a tab 111 A. As the tab 111 A is pulled, the “zip” tape 110 A and the mud compound 112 A disengage from the panels 202 thereby exposing the short term removable fasteners 104 A. Once the short term removable fasteners 104 are exposed, the fasteners 104 A can be easily removed. Since short term removable fasteners 104 A are covered by the zip tape 110 A before the mud compound 112 A is applied, the heads of the long-term permanent fasteners 104 A are kept clean for easy engagement and removal. Also, the “zip” tape 110 A is sufficiently unporous to prevent mud compound 112 A from penetrating through the tape 110 A to fill the heads of the fasteners 104 A. As one skilled in the art can appreciate, the “zip” tape 110 A can be installed in various ways. The tab 111 A is typically at the extremity of the zip tape 110 A and normally under a removable trim at the base 130 or under other trim such as removable crown trim at the head or removable chair rail trim.
Another embodiment of the tab 111 of the zip tape 110 is to locate the zip tape 110 so that an “incision” can be made in the smooth sanded surface 114 so as to form a tab 111 . The incision can be made without damage to the panel 102 . The zip tape 110 can be pried up so as to form a tab (not shown) that can be pulled up so as to disengage the whole length of the zip tape 110 together with the mud compound 112 .
FIG. 1A is a plan view cross section of the seam 103 A in FIG. 1 illustrating the methodology in concealing and securing the seams 103 A between panels 102 in a wall system 100 . The panels 102 are abutted at a seam 103 A. Thereafter, a zip tape 110 A is applied over the seam 103 A. Thereafter, finish mud 112 A is applied or floated over the zip tape 110 A. Thus, anything under the zip tape 110 A is accessible by removal of the zip tape 110 A. The panels 102 are joined so that the seam 103 A between the panels 102 is turned into a smooth surface 114 A, and the abutting panels 102 form a single, continuous unitary panel 102 , yet demountable.
FIG. 1B is a flow chart describing the wall 100 of the present invention as illustrated in FIG. 1 . The flow chart describes the treatment of the seam 103 A. FIG. 1B describes the wall 100 where the supports or studs 120 A, 120 C are at the panel 102 edges. The seam 103 A is treated to form a continuous, unitary panel 102 having a smooth surface 114 A, yet demountable.
FIG. 1C is an illustration of a preferred embodiment of the wall system 100 of the present invention using releasable adhesive 106 with the supports or studs 120 at the panel edge 103 including an invisible seam 114 and a bottom track 122 .
FIG. 1 D is an illustration of a preferred embodiment of the wall system 100 of the present invention with the supports or studs 120 at the panel edge 103 including an invisible seam 114 .
FIG. 2 : releasable adhesive is at intermediate stud or support. FIG. 2 is an alternate embodiment of the wall system 200 of the present invention where the releasable adhesive 206 B is used at the intermediate supports or studs 220 B. The wall system 200 illustrated in FIG. 2 has the primary elements of one or more panels 202 , a plurality of long-term removable fasteners 204 , one or more studs 220 , a “zip” tape 210 , one or more short-term removable fasteners 208 , and a tab 211 associated with the zip tape 210 .
With respect to the structure of the wall 200 at the seam 203 A, all the description of FIG. 1 is applicable for FIG. 2 . The long-term removable fasteners 204 H, 204 F are typically used along the alternate perimeters to secure the upper and lower portion of the panels 202 . Preferably, the panels 202 are removably secured to the intermediate stud 220 B using a releasable adhesive 206 B. An option of the present invention is to omit the intermediate stud 220 B altogether. (See FIG. 1 ). To provide for the removable, although affixed, securement of the panel 202 to the intermediate stud 220 B, one or more short-term removable fasteners 208 B are used. After the removable adhesive 206 B cures so as to secure the panel 202 to the stud 220 B, the short-term removable fasteners 208 B can be easily removed. To cover the holes left by the short-term removable fasteners 208 B, a mud compound 213 B is applied or “floated” over the holes and sanded to a smooth surface 214 B. The short-term removable fasteners 208 B are used to hold the panels 220 in place while the releasable adhesive 206 B cures. The short-term removable fasteners 208 B are fasteners that only remain in the wall system 200 during the time required for the releasable adhesive 206 B to cure.
As described in FIG. 1 , 1 A, 1 B and also described here for clarity the joint or seam 203 A is required to be conditioned so as to be a smooth congruent surface 214 A with the adjacent panels 202 A. The joint or seam 203 A is required to be conditioned so as to be a smooth congruent surface 214 A with the adjacent panels 202 A. To form the smooth congruent surface 214 A, the seam 203 A, and long-term removable fasteners 204 A are covered with the “zip” tape 210 A and floated with mud compound 212 A. The “zip” tape 210 A is sufficiently strong to be removed as a single piece, in unison. The zip”tape 210 A is removed as a single piece in unison by pulling a tab 211 A. As the tab 211 A is pulled, the “zip” tape 210 A and the mud compound 212 A disengage from the panels 202 thereby exposing the short term removable fasteners 204 A. Once the short term removable fasteners 204 are exposed, the fasteners 204 A can be easily removed. Since short term removable fasteners 204 A are covered by the zip tape 210 A before the mud compound 212 A is applied, the heads of the long-term permanent fasteners 204 A are kept clean for easy engagement and removal. Also, the “zip” tape 210 A is sufficiently unporous to prevent mud compound 212 A from penetrating through the tape 210 A to fill the heads of the fasteners 204 A. As one skilled in the art can appreciate, the “zip” tape 210 A can be installed in various ways. The tab 211 A is typically at the extremity of the zip tape 210 A and normally under a removable trim at the base 230 or under other trim such as removable crown trim at the head or removable chair rail trim.
Another embodiment of the tab 211 of the zip tape 210 is to locate the zip tape 210 so that an “incision” can be made in the smooth sanded surface 214 so as to form a tab 211 . The incision can be made without damage to the panel 202 . The zip tape 210 can be pried up so as to form a tab (not shown) that can be pulled up so as to disengage the whole length of the zip tape 210 together with the mud compound 212 .
To form a smooth congruent surface, the seam 203 A and removable fasteners 204 A are covered with the zip tape 210 A. The zip tape 210 A is sufficiently strong to be removed as a single piece, in unison. The zip tape 210 A is removed as a single piece in unison by pulling the tab 211 A. As the tab 211 A is pulled, the zip tape 210 A, and the mud compound 212 A disengage from the panels 202 thereby exposing the short term removable fasteners 204 A. Once the short term removable fasteners 204 are exposed, the fasteners 204 A can be easily removed. The short term removable fasteners 204 A being covered by the zip tape 210 A before the mud compound 212 A is applied keeps the heads of the fasteners 204 A clean for easy engagement and removal. Also, the zip tape 210 A is sufficiently unporous to prevent mud compound 212 A from penetrating through the tape 210 A to fill the heads of the fasteners 204 A. The zip tape 210 A can be installed in various ways.
FIG. 2A is illustrated in FIG. 1A and described here for clarity.
FIG. 2A is a plan view cross section of the seam 203 A illustrated in FIG. 2 showing the methodology of securing the seams 203 A between panels 202 in a wall system 200 . The panels 202 are abutted to form the seam 203 A. Thereafter, a zip tape 210 A is applied over the seam 203 A. Also, the zip tape 210 A is applied over any long-term removable fastener 204 A that may be securing the panels 202 . Thereafter, the finish mud 212 A is applied or floated over the zip tape 210 A. The panels 202 are joined so that the joint 203 A between the panels 202 is transformed into a smooth surface 214 A, and the abutting panels 202 form a single, continuous unitary panel 202 having a smooth surface 214 A, yet demountable. A finishing mud compound 212 A is placed over the zip tape 210 at all portions except for a tab 211 A. The tab 211 A is lifted away from the wall 200 for removing the zip tape 210 A from the panels 202 . Thus, the zip tape 210 A can be accessed and pulled away removing the mud compound 212 A and exposing any long-term removable fasteners 204 A.
The zip tape 210 used in practicing the present invention may be, for example, a releasable, removable self-adhering fiberglass mesh tape that has a mesh porosity such that the screw heads are not filled with compound 212 . Also, the present invention optionally provides that the screws 204 are treated to prevent the compound 212 from adhering to the screws 204 . The screws 204 can be treated before being used or after being installed. For example, treatment of the screws 204 before use may be by applying a teflon® coat to the screw heads, or making the outer surface of the screws 204 of a non-sticking substance, or by making the entire screw 204 from a non-sticking substance. Further by example, treatment of the screws 204 after use may be by applying a spray Teflon® coat to the screw heads, or coating the outer surface of the screws 204 with a non-sticking substance. The non-sticking substance can be in any appropriate form, such as, liquid, powder, etc. It can be appreciated by those skilled in the art that various and sundry combinations of the screws 204 and the non-sticking substances may be used depending on the situation.
FIG. 2B is a flow chart describing the wall 200 of the present invention as illustrated in FIG. 2 . The flow chart illustrates the relationship between the panels and supports or studs that are not at the panel edges. FIG. 2B describes the wall 200 illustrated in FIG. 2 where the supports or studs 220 A, 220 C are not at the panel 202 edges.
FIG. 2C is an illustration of a preferred embodiment of the wall system 200 of the present invention using releasable adhesive 206 with the supports or studs 220 at the panel edge 203 including an invisible seam 214 and a bottom track 222 .
FIG. 2D is an illustration of a preferred embodiment of the wall system 200 of the present invention with the supports or studs 220 at the panel edge 203 including an invisible seam 214 .
FIG. 3 : Zip tape at intermediate studs or supports. FIG. 3 illustrates yet another preferred embodiment of the wall system 300 of the present invention where zip tape is used at intermediate supports or studs 320 B. The wall system 300 provides a system similar to the wall systems 100 , 200 in FIGS. 1 and 2 with the difference being that the panel 302 is secured to the intermediate stud 320 B using long-term removable fasteners 304 B in conjunction with the zip tape 310 B. The wall system 300 comprises the elements of the earlier discussed wall system 100 including the seam-related parts: the panels 302 , the end studs 320 A, 320 C, the removable fasteners 304 A, the zip tape 310 A, the mud compound 312 A, the smooth sanded surface 314 A, as well as the intermediate-panel-related parts: the long-term removable fasteners 304 B, the intermediate stud 320 B, the zip tape 310 B, the floated mud compound 312 B and the smooth sanded surface 314 B. Also, the wall system 300 uses a tab 311 A, 311 B which is at an extremity of the zip tape 310 A, 310 B. While the end studs 320 A, 320 C are used to affix the panels 302 at the seams 303 , the intermediate stud 320 B is used to affix to the panels 302 between seams. The panels 302 are removably secured to the intermediate stud 320 B using the removable fasteners 304 B. The removable fasteners 304 B are covered with the zip tape 310 A. The zip tape 310 B is provided so that it is strong enough and unporous enough to protect the removable fasteners 304 B from being held inoperable due to the mud compound 312 B. The zip tape 310 B is covered with or floated over with the mud compound 312 B. When the mud compound 312 B dries, it can be sanded. The mud compound 312 B can be sanded to a smooth surface 314 B. The smooth surface 31 4 B hides the location of the removable fasteners 304 B.
With respect to the studs 320 , typically at a remote end of each stud 320 is a tab 311 of the zip tape 310 . The tab 312 is provided so that it can be pulled to disengage the mud compound 312 from the panel 302 such that the removable fasteners 304 are exposed and readily removed to disengage the panel 302 from the studs 320 . Further, the zip tape 310 removes the excess mud compound 312 from the panel 302 so that the panel 302 is essentially pristine.
It can be appreciated that the tab 311 of the zip tape 310 can be utilized in different ways. A first utilization of the tab 311 of the zip tape 310 is to expose the tab 311 in an area that is not covered or floated with mud compound 312 . FIG. 1 , FIG. 2 , and FIG. 3 illustrate a tab 111 , 211 , 311 being located so as to be covered by the removable base trim 330 . The tab 311 can be readily accessed by removing the removable base trim 330 . Thereafter, the tab 311 can be lifted from the bottom of the panel 302 expose the removable fasteners 304 by disengaging the mud compound 312 from the panels 302 . The tab 311 can be found and pulled so as to disengage the whole length of zip tape 310 which coincides with the dimension of the panel 302 and further removes the mud covering 312 .
As described in FIG. 1 and FIG. 2 and also described here for clarity the joint or seam 303 A is required to be conditioned so as to be a smooth congruent surface 314 A with the adjacent panels 302 A. The joint or seam 303 A is required to be conditioned so as to be a smooth congruent surface 314 A with the adjacent panels 302 A. To form the smooth congruent surface 314 A, the seam 303 A and long-term removable fasteners 304 A are covered with the zip tape 310 A and floated with mud compound 312 A. The zip tape 310 A is sufficiently strong to be removed as a single piece, in unison. The zip tape 310 A is removed as a single piece in unison by pulling a tab 311 A. As the tab 311 A is pulled, the zip tape 310 A and the mud compound 312 A disengage from the panels 302 thereby exposing the short term removable fasteners 304 A. Once the short term removable fasteners 304 are exposed, the fasteners 304 A can be easily removed. Since short term removable fasteners 304 A are covered by the zip tape 310 A before the mud compound 312 A is applied, the heads of the long-term permanent fasteners 304 A are kept clean for easy engagement and removal. Also, the zip tape 310 A is sufficiently unporous to prevent mud compound 312 A from penetrating through the tape 310 A to fill the heads of the fasteners 304 A. As one skilled in the art can appreciate, the zip tape 310 A can be installed in various ways. The tab 311 A is typically at the extremity of the zip tape 310 A and normally under a removable trim at the base 330 or under other trim such as removable crown trim at the head or removable chair rail trim. Another embodiment of the tab 311 of the zip tape 310 is to locate the zip tape 310 so that an incision can be made in the smooth sanded surface 314 so as to form a tab 311 . The incision can be made without damage to the panel 302 . The zip tape 310 can be pried up so as to form a tab (not shown) that can be pulled up so as to disengage the whole length of the zip tape 310 together with the mud compound 312 . The wall system 300 is a fire rated wall.
As In the other embodiments, the zip tape 310 used in practicing the present invention may be, for example, a releasable, removable self-adhering fiberglass mesh tape that has a mesh porosity such that the screw heads are not filled with compound 312 . Also, the present invention optionally provides that the screws 304 are treated to prevent the compound 312 from adhering to the screws 304 . The screws 304 can be treated before being used or after being installed. For example, treatment of the screws 304 before use may be by applying a Teflon® coat to the screw heads, or making the outer surface of the screws 304 of a non-sticking substance, or by making the entire screw 304 from a non-sticking substance. Further by example, treatment of the screws 304 after use may be by applying a spray Teflon® coat to the screw heads, or coating the outer surface of the screws 304 with a non-sticking substance. The non-sticking substance can be in any appropriate form, such as, liquid, powder, etc. It can be appreciated by those skilled in the art that various and sundry combinations of the screws 304 and the non-sticking substances may be used depending on the situation.
FIG. 3A is a plan view cross section of the seam 303 illustrated in FIG. 3 showing the methodology of securing the seams 302 between panels 302 in the wall system 300 .
FIG. 3B is a flow chart describing the wall system 300 illustrated in FIG. 3 where the support or stud 320 is not at the panel 302 edges and the panel 302 is secured at the extremities by long term fasteners 304 (a fire rated wall). The panel 302 is secured by removable means 304 . The zip tape 310 is applied over the removable means 304 . The mud 312 is floated over the zip tape 310 and then sanded smooth to form a smooth surface 314 .
FIG. 3C is an illustration of a preferred embodiment of the wall system 300 of the present invention using releasable adhesive 306 with the supports or studs 320 at the panel edge 303 including an invisible seam 314 and a bottom track 322 . The wall system 300 is a fire rated wall.
FIG. 4 : Removable substance at panel edge supports or studs to form an invisible seam. FIG. 4 is an illustration of yet another wall system 400 of the present invention. The wall system 400 uses panels 402 , studs 420 , long-term removable fasteners 404 , short-term removable fasteners 408 , and a removable substance 442 . The panels 402 are abutted one adjacent the other to form the seam 403 . The panels 402 are held using the studs 420 A, 420 C, and optionally the stud 420 B. Typically on alternate sides of the studs 420 are panels 402 . The panels 402 are secured to the stud 420 A, which is aligned with the seam 403 A by a plurality of long-term removable fasteners 404 A and short-term removable fasteners 408 B. Also, the panels 402 are optionally secured along the upper perimeter using by a plurality of removable fasteners 404 H. Similarly, the panel 402 is optionally secured along the lower portion along with the removable fasteners 404 F. The panels 402 are typically disposed on alternate sides of a bottom track 422 . The studs 420 rest in the bottom track 422 such that the panels 402 are displaced one from the other an equal distance along the surface of the panels 402 . The removable substance 442 is applied over the seam 403 A and the removable fasteners 404 A. As the removable substance 442 dries, it may shrink in size. If the removable substance 442 shrinks, additional layers may be required. Thus, a first layer 442 AA of the removable substance 442 is applied, and allowed to cure. Thereafter, a second layer 442 AB of the removable substance 442 is applied, and allowed to dry. Thereafter, a third layer 442 AC of the removable substance 442 is applied, and allowed to dry. The sequence is continued until such time as the entire gap formed by the seam 403 A is filled so as to form a flush surface or concave surface, if so desired. The removable substance 442 may be a composition that can then be sanded to provide a smooth surface 414 A with the panel 402 .
The intermediate stud 420 B is affixed to the panels 402 using a releasable adhesive 406 B. The panels 402 are secured to the intermediate stud 420 B using the temporary short-term fasteners 408 B. After the releasable adhesive 406 B secures the panels 402 to the intermediate stud 420 B, the temporary fasteners 408 B are removed. The holes left by the temporary short-term fasteners wall system 400 where the supports or studs 420 A, 420 C are at the panel 402 edges. The seam 403 A is treated using the removable substance 442 to form a continuous, unitary panel 102 having a smooth surface 114 A.
FIG. 4C is a flow chart of the wall system 400 of the present invention as illustrated in FIG. 4 where the support or stud 420 is not at the panel 402 edges. More particularly, FIG. 4C describes the wall system 400 where the supports or studs 420 A, 420 C are intermediate of the panel 402 edges.
FIG. 4D is an illustration of a preferred embodiment of the wall system 400 of the present invention as illustrated in FIG. 4 , but without the extensive bottom track 422 . Alternately, a releasable adhesive 406 may be used with the supports or studs 420 at the panel edge 403 in place of the long-term screws 404 , but in conjunction with the short-term screws 408 .
FIG. 5 : Releasable adhesive at panel edge supports or studs; Invisible seam optional. FIG. 5 is yet another embodiment of a wall system 500 of the present invention where releasable adhesive 506 A is used at the panel edge supports or studs 520 A. The wall system 500 includes the panels 502 , the studs 520 , the long-term removable fasteners 504 H, 504 F, the short-term removable fasteners 508 A, 508 B, the releasable adhesive 506 , the float mud compound 516 A, 513 B or removable substance, and the bottom track 522 . The bottom track 522 receives the studs 520 . The panels 502 are typically placed on alternate sides of the studs 520 and the bottom track 522 . The panels 502 are removable secured to the studs 520 using the releasable adhesive 506 . The panels are allowed to engage the releasable adhesive 506 and the studs 520 in a fixed manner by using the removable short-term fasteners 508 . After the releasable adhesive 506 cures, the removable short-term fasteners 508 can be removed. Thereafter, a float mud compound 516 A, 513 B or the removable substance is used to fill the holes created by the removable short-term fasteners 508 . In the shown embodiment of the wall system 500 illustrated in FIG. 5 , the seam 503 A is not filled or treated. Thus, the bevel 505 A formed at the seam 503 A between the two abutting panels 502 is left unchanged so as to provide a decorative linear effect. Also, the use of the removable fasteners 504 H at the top of the panel 502 and the removable fasteners 504 F at the bottom of the panel 502 are optional.
FIG. 5A is a perspective, cross section of the seam 503 A associated with the two abutting panels 502 as illustrated in FIG. 5 . The seam 503 A provides that the bevel 505 A yields a linear decorative effect. In an alternate embodiment, there may also be a gap between the two panels 502 .
FIG. 5B is a flow chart of the wall system 500 of the present invention as illustrated in FIG. 5 where the support or stud 520 is at the panel 502 edges and the seam 503 A is visible. More particularly, FIG. 5B describes the wall system 500 where the supports or studs 520 A, 520 C are at the panel 502 edges. The seam 503 A is not treated, but rather left to provide a decorative linear wall design.
FIG. 5C is a flow chart of the wall system 500 of the present invention as illustrated in FIG. 5 where the support or stud 520 is not at the panel 502 edges. More particularly, FIG. 5C describes the wall system 500 where the supports or studs 520 A, 520 C are intermediate of the panel 502 edges.
FIG. 5D is an illustration of a preferred embodiment of the wall system 500 of the present invention using releasable adhesive 506 with the supports or studs 520 at the panel edge 503 including an invisible seam 514 and a bottom track 522 .
FIG. 6 : Vertical cross-section of the wall system. FIG. 6 illustrates a cross section of the wall system 600 of the present invention. FIG. 6 illustrates a wall panel 602 removably engaged with a removable floor or bottom track 622 and a removable head track 623 . The floor track 622 is removably engaged with a subfloor 665 . The wall panels 602 have at one extreme a removable base trim 630 and at the other extreme a removable head trim 631 . The removable base trim 630 and the removable head trim 631 typically cover the removable long-term fasteners 604 . The removable long-term fasteners 604 removably engage the wall panels 602 and the stud 620 with the floor track 622 and the head track 623 . When the wall panels 602 and the studs 620 are secured, one or more cavity 660 is created between the opposing wall panels 602 , the studs 620 the top track 623 and the bottom track 622 , respectively. The base trim 630 and the subfloor 665 are removably engaged. A floor finish or carpet 666 is typical. The removable top track 623 is typically engaged with a T support 661 . The T support 661 is suspended in place by a hanger or support cable 662 . The T support 661 is provided for accepting a plurality of ceiling tiles 663 . When the ceiling tiles 663 are engaged with the T support 661 , a space 664 is created between the ceiling tiles 663 and the head track 662 . Preferably, the head trim 631 abuts the ceiling tile 663 . A data channel 622 A is provided in the floor track 622 .
FIG. 7 : Removable ceiling and removable stacked wall panels. FIG. 7 is an illustration of a portion of a ceiling, overhead using the system 700 of the present invention; and similarly, FIG. 7 illustrates a tall wall system 700 having a number of stacked panels 702 . A plurality of removable ceiling panels 702 made of conventional sheet rock material or other suitable material may be used. The ceiling panels 702 are removably engaged with the supports or ceiling studs 720 . The removable ceiling panels 702 are affixed to the ceiling studs 720 using long-term removable fasteners 704 . With respect to the intermediate ceiling studs 720 B, the ceiling panels 702 are typically affixed to the intermediate studs 720 B using a releasable adhesive 706 . Optionally, zip tape with long-term removable screws and mud compound may be used where fire code or other circumstances require it. To provide a curing time for the ceiling stud 720 B with respect to the releasable adhesive 706 , one or more short-term removable fasteners 708 are used. The releasable adhesive 706 is applied to the intermediate ceiling studs 720 B and the ceiling panels 702 with compression using the short-term fasteners 708 . After the releasable adhesive 706 has sufficiently cured, the short-term removable fasteners 708 are removed and the holes are patched with a mud compound 716 or removable substance. The ceiling studs 720 which are congruent with the edges of each of the ceiling panels 702 are secured using long-term removable fasteners 704 . The long-term removable fasteners 704 are covered using the zip tape 710 . After the zip tape 710 is applied to cover the seams and adjacent long-term removable fasteners 704 , the mud compound 712 is applied. After the mud compound 712 cures, the ceiling 700 is sanded smooth and/or finished appropriately.
After the ceiling or wall 700 is appropriately finished, the zip tape 710 can be located by incision or tab as described in FIGS. 1 , 2 , and 3 . After the zip tape 710 or tab is located, it can be pulled to separate the mud compound 712 from the ceiling panels 702 , thereby exposing the long-term removable fasteners 704 . The long-term fasteners 704 can be removed thereby removing the respective ceiling panels 702 . In an opposite and like manner, the removed ceiling panels 702 can be reaffixed.
FIG. 8 : Top Track. FIG. 8 is a partial cutaway of an upper portion of the wall system 800 of the present invention. Illustrated in FIG. 8 is a head track 823 in association with the wall panels 802 . The wall panels 802 are removably affixed to the head track 823 using removable long-term fasteners 804 H. The long-term removable fasteners 804 H are optional and may be used or not. The removable head trim 831 is typically used to cover the removable long-term fasteners 804 , although zip tape may be used in lieu of head trim.
FIG. 9 : Bottom track. FIG. 9 is a partial section illustrating a lower portion of the wall system 900 of the present invention. FIG. 9 illustrates a removable bottom track 922 in association with the wall panels 902 . The wall panels 902 are removably secured to the removable bottom track 922 and a stud 920 using the removable long-term fasteners 904 F. Also, a releasable adhesive 906 maybe used to secure the wall panel 902 with the stud 920 . The removable long-term fasteners 904 F are typically covered using the removable base trim 930 , and zip tape may be used in lieu of base trim 930 . A floor finish 966 is typically used adjacent the removable base trim 930 .
FIG. 10 : Alternate bottom track. FIG. 10 illustrates yet another embodiment of a wall system 1000 of the present invention, showing a partial cross-section of a wall panel 1002 in association with a removable bottom track 1022 . The wall panel 1002 is typically secured to the removable bottom track 1022 using the removable long-term fasteners 1004 F. Similarly as discussed above, a removable base trim 1030 is used to cover the removable long-term fastener 1004 F. A floor finish 1066 is typically used adjacent the removable base trim 1030 . The bottom track 1022 is removably affixed to the subfloor using various methods; and for the present invention the bottom track 1022 can be secured using the releasable adhesive 1006 . Also, the bottom track 1022 can be affixed to a subfloor using a removable fastener or knockoff fasteners 1024 .
FIG. 11 is an illustration of a tri-channel head track 1123 for use in association with the wall system of the present invention. The tri-channel head track 1123 provides for accepting wall panels 1102 A, 1102 B on alternate sides of a stud 1120 . The wall panels 1102 are secured to the stud 1120 and the tri-channel head track 1123 using removable long-term fasteners 1104 . The tri-channel head track 1123 has a plurality of channels, with the embodiment illustrated having three channels 1123 A, 1123 B, 1123 C. The outermost channels 1123 A, 1123 B are disposed on alternate sides of the middle channel 1123 C. The removable long-term fasteners 1104 can be treated as described herein in other embodiments of the present invention. For example, the removable long-term fasteners 1104 can be taped and floated, covered with caulking, etc.
FIG. 11A is a cut-away illustration of the tri-channel head track 1123 for use in association with the wall system 1100 of the present invention as illustrated in FIG. 11 having an unfeathered extension 1123 D and a releasable adhesive 1106 .
FIG. 11B is an illustration of the tri-channel head track 1123 for use in association with the wall system 1100 of the present invention as illustrated In FIG. 11 having a feathered extension 1123 D and a releasable adhesive 1106 .
FIG. 12 is a sectional illustration of a tri-channel bottom track 1222 used in association with the wall system of the present invention. The tri-channel bottom track 1222 has two protrusions 1222 D on its upper surface 1222 E such that the stud 1204 is accepted into the channel 1222 F formed by the two protrusions 1222 D in the bottom track 1222 . The wall panels 1202 A, 1202 B are accepted on the outer portion on the upper surface 1222 E of the bottom track 1222 . The tri-channel bottom track 1222 has knockouts 1222 B and an isolated data cavity 1222 A. Further, the tri-channel bottom track 1222 has a roughened surface 1222 C in which a releasable adhesive can be used to secure the tri-channel bottom track 1222 to a floor or subfloor. Typically, a knock-off 1224 is used to removable secure the track 1222 .
FIG. 12A is a sectional illustration of a tri-channel bottom track 1222 used in association with the wall system of the present invention having an enclosed data channel 1222 A and using removable adhesive 1206 .
FIG. 13 is a sectional view of a quad-channel bottom track 1322 used with the wall system of the present invention. The quad-channel bottom track 1322 comprises an isolated data cavity 1322 A, knockouts 1322 B, beveled edges 1322 D in association with the upper channels, and a roughened surface 1322 C. The roughened surface 1322 C is used to removably secure the quad-channel bottom track 1322 to a floor or subfloor. The isolated data channel 1322 A is used in association with the knockouts 1322 B to pull wiring and cable for data, phones, or lights. The three open channels are used for accepting a stud 1320 in the middle channel, and for accepting wall panels 1302 in the outermost channels. Optionally, the quad-channel bottom track 1322 can be secured to the wall panels 1302 using long term removable fasteners 1304 . As still a further option, the long term removable fasteners 1304 can be covered with a zip tape 1310 and a mud compound 1316 so that they can be later accessed for easy disassembly of the wall panels 1320 and the quad-channel bottom track 1322 . Also a cover plate 1322 BB is removably engaged in selected punch outs 1322 B. The cover plates 1322 BB can be of various shapes, sizes, and affixed in various ways, for example, snap on, glue on, screw on, etc.
FIG. 13A is a sectional illustration of a tri-channel bottom track 1322 used in association with the wall system of the present invention having an enclosed data channel 1322 A and using removable adhesive 1306
FIG. 14 is yet another embodiment of the tri-channel bottom track 1422 for use with the wall system of the present invention. The tri-channel bottom track 1422 comprises a bottom track 1422 A, one or more knockouts 1422 B, and a roughened surface 1422 C. The bottom track 1422 A, preferably receives a stud 1420 . The stud 1420 has one or more knockouts 1420 A. The combination of the stud knockouts 1420 A and the track knockouts 1422 B provide for easy access of wires and cables within a stud cavity 1460 between two wall panels 1420 A, 1420 B. Also a cover plate 1422 BB is removably engaged in selected punch outs 1422 B. The cover plates 1422 BB can be of various shapes, sizes, and affixed in various ways, for example, snap on, glue on, screw on, etc. Typically, a knock-off 1424 is used to removably secure the track 1422 .
FIG. 14A is a sectional illustration of a tri-channel bottom track 1422 used in association with the wall system of the present invention having an enclosed data channel 1422 A and using removable adhesive 1406 .
FIG. 15 is a sectional illustration of another tri-channel bottom track 1522 used in association with the wall system of the present invention having an enclosed data channel 1522 A.
FIG. 15A is a sectional illustration of the tri-channel bottom track 1522 used in association with the wall system of the present invention having an enclosed data channel as illustrated in FIG. 15 and having an unfeathered extension 1522 D and releasable adhesive 1506 .
FIG. 15B is a sectional illustration of the tri-channel bottom track used in association with the wall system of the present invention having an enclosed data channel as illustrated in FIG. 15 and having a feathered extension 1522 D and a releasable adhesive 1506 and a slotted data channel 1522 A.
FIG. 16 is yet another embodiment of the tri-channel bottom track 1622 for use with the wall system of the present invention having a slotted data channel 1622 A for receiving the studs 1620 . The tri-channel bottom track 1622 is adapted for use with load-bearing walls.
FIG. 16A is a sectional illustration of another tri-channel bottom track 1622 used in association with the wall system of the present invention having a slotted data channel 1622 as illustrated in FIG. 16 and having an unfeathered extension 1622 D and a releasable adhesive 1606 .
FIG. 17 illustrates a cross section of a wall system 1700 of the present invention with a wall panel 1702 removably engaged with a removable electrical fixture 1762 and a plumbing fixture 1764 .
FIG. 18 is a sectional illustration of a tri-channel bottom track 1822 used in association with the wall system of the present invention having elements that are of bendable metal.
FIG. 19 is a sectional illustration of another embodiment of a tri-channel bottom track 1922 used in association with the wall system of the present invention having elements that are bendable metal.
FIG. 20 is a sectional illustration of yet another embodiment of a tri-channel bottom track 2022 used in association with the wall system of the present invention having elements that are bendable metal.
FIG. 21A is a sectional illustration of another channeled bottom track 2122 used in association with the wall system of the present invention having a data channel 2122 A. The bottom track 2122 has flush base trim 2130 with a raised channel seat for accepting the stud 2120 . As in the other embodiments, the base trim 2130 is affixed to the bottom track 2122 , but not the panel 2102 , for easy removal. As with the other embodiments of the present invention, treated screws 2104 F may be used.
FIG. 21 AA is a sectional illustration of another channeled bottom track 2122 used in association with the wall system of the present invention having a data channel 2122 A. The bottom track 2122 has flush base trim 2130 with a raised channel seat for accepting the stud 2120 . As in the other embodiments, the base trim 2130 is affixed to the bottom track 2122 , but not the panel 2102 , for easy removal. As with the other embodiments of the present invention, treated screws 2104 F may be used.
FIG. 21 AAA is a sectional illustration of yet another channeled bottom track 2122 used in association with the wall system of the present invention having a data channel 2122 A. The bottom track 2122 has flush base trim 2130 with a raised channel seat for accepting the stud 2120 . As in the other embodiments, the base trim 2130 is affixed to the bottom track 2122 , but not the panel 2102 , for easy removal. As with the other embodiments of the present invention, treated screws 2104 F may be used.
FIG. 21B is a sectional illustration of another channeled bottom track 2122 used in association with a load-bearing wall system of the present invention having a data channel 2122 A. The bottom track 2122 has flush base trim 2130 with a raised channel seat for accepting the stud 2120 . As in the other embodiments, the base trim 2130 is affixed to the bottom track 2122 , but not the panel 2102 , for easy removal. As with the other embodiments of the present invention, treated screws 2104 F may be used.
FIG. 22A is a sectional illustration of another channeled bottom track 2222 used in association with a wall system of the present invention having a data channel 2222 A. The bottom track 2222 has flush base trim 2230 with a raised channel seat for accepting the stud 2220 . As in the other embodiments, the base trim 2230 is affixed to the bottom track 2222 , but not the panel 2202 , for easy removal. As with the other embodiments of the present invention, treated screws 2204 F may be used.
FIG. 22 AA is a sectional illustration of an alternate embodiment of the one piece base track with a raised channel-seat for the stud.
FIG. 22B is a sectional illustration of another channeled bottom track 2222 used in association with a wall system of the present invention having a data channel 2222 A. The bottom track 2222 has flush base trim 2230 with a raised channel seat for accepting the stud 2220 . As in the other embodiments, the base trim 2230 is affixed to the bottom track 2222 , but not the panel bottom track 2122 has flush base trim 2130 with a raised channel seat for accepting the stud 2120 . As in the other embodiments, the base trim 2130 is affixed to the bottom track 2122 , but not the panel 2102 , for easy removal. As with the other embodiments of the present invention, treated screws 2104 F may be used.
FIG. 21B is a sectional illustration of another channeled bottom track 2122 used in association with a load-bearing wall system of the present invention having a data channel 2122 A. The bottom track 2122 has flush base trim 2130 with a raised channel seat for accepting the stud 2120 . As in the other embodiments, the base trim 2130 is affixed to the bottom track 2122 , but not the panel 2102 , for easy removal. As with the other embodiments of the present invention, treated screws 2104 F may be used.
FIG. 22A is a sectional illustration of another channeled bottom track 2222 used in association with a wall system of the present invention having a data channel 2222 A. The bottom track 2222 has flush base trim 2230 with a raised channel seat for accepting the stud 2220 . As in the other embodiments, the base trim 2230 is affixed to the bottom track 2222 , but not the panel 2202 , for easy removal. As with the other embodiments of the present invention, treated screws 2204 F may be used.
FIG. 22B is a sectional illustration of another channeled bottom track 2222 used in association with a wall system of the present invention having a data channel 2222 A. The bottom track 2222 has flush base trim 2230 with a raised channel seat for accepting the stud 2220 . As in the other embodiments, the base trim 2230 is affixed to the bottom track 2222 , but not the panel
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A demountable and remountable wall assembly for partitioning room space between an overhead and a floor, the major elements of which are reusable. The assembly provides one or two walls, at lease one of which has an outer fastener-free surface. Additionally, the fastener-free surface may be made substantially smooth and seamless. The walls are arranged in planar congruence, separated by internal spacers or studs, and vertically positioned between the overhead and floor of the room space to be partitioned. Removable tracks or spacers at the top and bottom of the wall assembly serves to interface the wall assembly with the floor and ceiling of the space. The walls are constructed of either finished or unfinished wall panels (e.g., fabric covered or sheet rock panels) which are incorporated into the assembly using a combination of removable fasteners and releasable adhesives. The finished or exposed area of a wall surface includes no fasteners. Any fasteners used to fix a wall panel in place is covered by a removable trim or other removable feature, which make the fasteners readily exposable and easy to remove.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to provisional U.S. Patent Application Ser. No. 62/043,615 filed on Aug. 29, 2014, the application of which is incorporated herein by reference in its entirety.
FEDERAL SPONSORSHIP
Not Applicable
JOINT RESEARCH AGREEMENT
Not Applicable
TECHNICAL FIELD
This invention pertains generally to food containers and food dispensing trays. More particularly, the invention pertains to a food tray that may be used to more efficiently and quickly dispense food in uniform quantities while providing a tray assembly that is easily cleaned and stackable for storage.
BACKGROUND
Over the years various food containers have been devised to display food in an attractive manner while also providing a functional vessel to dispense food. At times it may be desirable to elevate the container to provide a heat source under the container while aesthetically displaying food within the container. A wire frame may be utilized to elevate the container a desired distance above the heat source. The container may be modified to couple in mating relation with the wire frame. At times, serving food from the container may require a separate ladle, however scooping food from the container may lead to inconsistent serving sizes and may also result in unintentional spills. Alternatively, containers with spouts have been devised, however when multiple containers are stacked for stowage, the containers require additional height to accommodate stacked containers.
SUMMARY
Embodiments according to aspects of the invention provide a food tray usable during the food production, display and dispensing of food product. Without limitation intended, the food tray of the present invention is particularly useful when making, displaying and dispensing mini donuts. The tray of the present invention includes a removable ramp that provides for efficient dispensing of food products into smaller point of sale containers including, for example, bags or buckets.
In accordance with aspects of the invention, an embodiment of the food dispensing tray assembly includes a tray and a removable ramp. Additionally, the assembly may include a wire frame stand or support to elevate the tray above a working surface. The tray includes a bottom, sides extending upward from the bottom and a lip extending outward from an upper end of the sides around a perimeter of an open top of the tray. Also, a cutout is formed in the tray to define a discontinuity in the lip and to provide an opening in a side of the tray for the ramp to couple to the tray. The removable ramp has a base, angled sides extending from edges of the base, interlocking rims that lock with an upper edge of the lip of the tray, and flanges extending between the base and the rim that engage inner walls of the tray adjacent the cutout in the side of the tray. A separation distance between the sides of the ramp is slightly less than a width of the cutout formed in the tray such that the ramp couples to the tray within the cutout in a mating relationship. A support extending outwardly from a bottom of the base of the ramp includes a groove in the support that engages a lower edge of the cutout of the tray.
Additionally, in accordance with aspects of the invention the food dispensing tray assembly may include a tray, removable ramp, and support. The tray includes a bottom, sides extending upward from the bottom and a lip extending outward from an upper end of the sides around a perimeter of an open top of the tray, wherein a cutout is formed in the tray defining a discontinuity in the lip. The removable ramp has a base, angled sides extending from edges of the base, interlocking rims that lock with an upper edge of the lip of the tray, and flanges extending between the base and the rim that engage inner walls of the tray adjacent the cutout in the side of the tray. A separation distance between the sides of the ramp is slightly less than a width of the cutout formed in the tray to provide a desired fit between the ramp and tray. A support extending outwardly from a bottom of the base of the ramp includes a groove in the support that engages a lower edge of the cutout of the tray. A wire frame or stand may be further incorporated into the assembly to elevate the tray and ramp above a working surface.
The accompanying drawings, which are incorporated in and constitute a portion of this specification, illustrate embodiments of the invention and, together with the detailed description, serve to further explain the invention. The embodiments illustrated herein are presently preferred; however, it should be understood, that the invention is not limited to the precise arrangements and instrumentalities shown. For a fuller understanding of the nature and advantages of the invention, reference should be made to the detailed description in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
In the various figures, which are not necessarily drawn to scale, like numerals throughout the figures identify substantially similar components.
FIG. 1 is an exploded perspective view of a tray and ramp in accordance with an embodiment of the invention elevated above a wire frame;
FIG. 2 is a perspective view of the ramp elevated above the tray and having the ramp removed in accordance with an embodiment of the invention;
FIG. 3 is a bottom end perspective view of the tray illustrating the cutout and having the ramp or chute removed;
FIG. 4 is a front right perspective view of the ramp in accordance with an embodiment of the invention;
FIG. 5 is a front left perspective view of the ramp of the type shown in FIG. 4 and in accordance with an embodiment of the invention;
FIG. 6 is a back perspective view of the ramp of the type shown in FIG. 4 ; and
FIG. 7 is a bottom back perspective view of the ramp of the type shown in FIG. 4 .
DETAILED DESCRIPTION
The following description provides detail of various embodiments of the invention, one or more examples of which are set forth below. Each of these embodiments are provided by way of explanation of the invention, and not intended to be a limitation of the invention. Further, those skilled in the art will appreciate that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. By way of example, those skilled in the art will recognize that features illustrated or described as part of one embodiment, may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention also cover such modifications and variations that come within the scope of the appended claims and their equivalents.
A food dispensing tray assembly 10 particularly well suited for point of sale production, display and dispensing of food stuffs, includes a wire stand or frame 14 , tray 16 and detachable ramp or chute 18 . The ramp is particularly well suited to re-direct food stuff from the tray into point of sale bags, buckets, or other point of sale containers. Additionally, the ramp is easily removed to clean the ramp prior to stowage.
With reference to FIGS. 1-3 , the tray 16 includes a bottom 28 , discontinuous sides 30 extending upward from the bottom 28 , a lip 34 extending outward from an upper end of the sides 30 . A rim 32 extends downward from an outer end of the lip 34 . The lip 34 extends around a perimeter of an open top of the tray 16 . A cutout or void 38 is formed in an end side of the tray 16 , defining a discontinuity in the sides 30 and lip 34 . The cutout 38 of the tray 16 extends from the lip 34 downward to a curved intersecting portion 40 of the bottom 28 and sides 30 of the tray 16 . The sides 30 of the tray 16 slope outward from the bottom 28 of the tray to reduce the amount of food particles retained on the sides 30 .
With reference to FIGS. 4-7 , the removable ramp or food chute 18 includes a base 50 , angled sides 52 extending from edges of the base 50 , and interlocking curved clips or fingers 56 that lock with an upper edge of the lip 34 and rim 32 of the tray 16 . Flanges 54 extend between the base 50 and the clip 56 and is dimensioned to engage an inner side wall of the tray 16 adjacent the cutout 38 in the side 30 of the tray 16 . A separation distance between the sides 52 of the ramp 18 is slightly less than a width of the cutout 38 formed in the tray 16 . A support 58 extends outwardly from a bottom of the base 50 of the ramp 18 , wherein a groove 60 in the support 58 engages a lower edge 42 of the cutout 38 of the tray 16 . The lower edge 42 of the cutout engages in the groove to further retain the ramp 18 in a fixed position relative to the tray. The flange 54 extends from the base 50 forming an angle between the base 50 and the flange 54 , the angle being obtuse.
Use of the food dispensing tray assembly 10 will next be described in conjunction with the production, sale and dispensing of mini donuts. Those skilled in the art will appreciate that other food stuffs may be equally dispensed efficiently from the tray 16 of the present invention. During the production of mini donuts a donut machine ejects fried donuts into the tray 16 , where the donuts may be sugared or otherwise coated while they cool. Donuts are easily dispensed from the tray by pushing or sliding the donuts on to ramp 18 . A bag or bucket may be placed under the ramp to collect the desired number of donuts to be sold. When the tray is empty and cleanup is required, the ramp 18 is detached from the lip 34 of the tray 16 and quickly cleaned. Multiple trays 16 may be stacked together and multiple ramps 18 may be stowed in the open tray portion of the upper most tray of stacked trays.
These and various other aspects and features of the invention are described with the intent to be illustrative, and not restrictive. This invention has been described herein with detail in order to comply with the patent statutes and to provide those skilled in the art with information needed to apply the novel principles and to construct and use such specialized components as are required. It is to be understood, however, that the invention can be carried out by specifically different constructions, and that various modifications, both as to the construction and operating procedures, can be accomplished without departing from the scope of the invention. Further, in the appended claims, the transitional terms comprising and including are used in the open ended sense in that elements in addition to those enumerated may also be present. Other examples will be apparent to those of skill in the art upon reviewing this document.
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A food tray is described that may be used to more easily remove food product from the tray. The device allows for emptying of the tray with the use of a removable ramp or spout that easily cleaned and coupled to the tray.
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FIELD OF INVENTION
This invention relates to an airstream ionizer for neutralizing static charge on objects within the airstream, and more particularly, to a circuit which automatically and passively causes the unit to emit equal amounts of positive and negative ions creating an ion balance in the air stream exiting the unit.
BACKGROUND OF INVENTION
Air ionizers which emit a flow of positively and negatively charged ions have to date, proven most effective in neutralizing accumulated static charge on a non-conductive object within the ionized airstream. Typically, airstream ionizers place a high voltage potential on one or more emitter points to initiate the ionization process or corona, in the hopes of emitting an airstream containing an equal number of positive and negative ions. Measurements have shown, however, that various factors influence the generation of a balanced ion stream and cause the ionizer to output an airstream which is itself charged. For example, the greater mobility of negative ions, and ground planes formed by the metal case of the ionizer in close proximity to the emitters, cause an imbalance in the positive and negative ions emitted by the ionizer. This charge imbalance is subsequently transferred to any object in the path of the airstream, thereby adding to the problem that the air ionizer was designed to eliminate. In addition, dirt on the emitter points as well as humidity in the air affect the ionization process.
Various mechanical techniques are known to balance the production of positive and negative ions delivered by the ionizer at a given moment under given conditions. Such techniques include adjusting the position of the emitters relative to the collector or using external sensors and feedback mechanisms. However, continuously changing environmental conditions as well as the constant accumulation of dirt on the emitters make these approaches ineffective.
Attempts have been made to achieve a passively balanced ionized air stream by causing the ion emitters to give off positive and negative ions equally. In such a system, the one or more emitter points are capacitively isolated from the high side of an AC power source. Although negative ions are generally easier to produce and can be produced at lower voltages because of the physics involved in air ionization, a system utilizing capacitively coupled emitters overcomes this excess negative ion production. In such a system, the emitter points become slightly positively charged. This positive charge adds algebraically to the positive charge present during the positive going portion of the AC waveform, thus producing more positive ions. The increased production of positive ions continues until an equal number of positive and negative ions are generated.
Even though the emitter circuit is now generating a balanced amount of positive and negative ions, it has been found that the charge of the ionized airstream exiting the ionizer is not balanced.
SUMMARY OF INVENTION
It is therefore an object of this invention to provide an automatically self-balancing air ionizer which emits a truly balanced ionized airstream under all operating conditions.
It is a further object of this invention to provide a self-balancing air ionizer which balances the ion collection to insure constant ion balance in the air stream.
It is a still further object of this invention to provide a reliable self-balancing air ionizer which passively balances the ionized airstream thereby reducing the cost and complexity of the system.
This invention results from the realization that ions exiting an air ionizer are collected unevenly, thus introducing an imbalance in the ionized airstream, and from the further realization that in order to balance an ion collector circuit, the collector circuit must be isolated from all external sources or sinks of charge, thereby preventing an excess of positive or negative charge from building up in the circuit and subsequently being emitted into the airstream.
This invention features a self-balancing circuit for convection air ionizers including one or more ion emitter points and an ion collector. The emitter points and the collector are isolated from external charge sources and sinks for maintaining balance in the positive and negative charge emitted from the emitter points and collected by the collector, for maintaining a charge balanced ionized airstream.
In one embodiment, the emitter points and collector are isolated from external charge sources and sinks by a first capacitor means in series with the emitter points. Also included is a second capacitor in series with the collector and ground. Alternatively, the air ionizer may include a circuit in which the emitter points and collector are united in one ungrounded circuit and a capacitor isolates the emitter points and collector from external charge sources of sinks for maintaining charge balance. In addition, an isolation transformer isolates the AC power source from the emitter and collector circuit.
DESCRIPTION OF PREFERRED EMBODIMENT
Other objects, features and advantages will occur from the following description of a preferred embodiment and the accompanying drawings, in which:
FIG. 1 is a block diagram of a self-balancing air ionizer according to this invention.
FIG. 2 is a schematic representation of a self-balancing ion emitter and collector according to this invention;
FIG. 3 is a schematic view of an another embodiment of a balanced air ionizer according to the present invention using only a single capacitor; and
FIG. 4 is a schematic representation of yet another embodiment of a balanced air ionizer according to the present invention with separate positive and negative emitters.
A self-balancing air ionizer according to this invention may be accomplished by providing an energy source for placing a voltage potential between one or more ion emitter points and an ion collector. A fan or other airflow device provides an airstream flowing past the ion emitter points and ion collector. The air ionizer also includes isolation means for isolating the emitter points and the collector from external charge sources, for maintaining a balanced positive and negative ionized air stream. The isolation means may include capacitor means in series with the emitter and with the collector. Alternatively, the capacitor means may be placed between an ungrounded emitter-collector circuit and ground. The isolation means may also include an isolation transformer as well as a non-metallic air ionizer enclosure.
A self-balancing air ionizer 10. FIG. 1, includes energy source 12 which provides a voltage potential between emitter points 14 and collector 16 to promote ionization. Air flow source 15 provides a constant source of air 17 flowing past emitter points 14 and collector 16. Airflow 17 is directed towards charged object 19, whose static charge is to be neutralized. Isolation means 13 isolates emitter points 14 and collector 16 from energy source 12 as well as other external charge sources or sinks. Isolation means 13 may also include insulative enclosure 23 which completely surrounds emitters 14 and collector 16 to prevent any object near the ionizer from acting as an unwanted ion collector.
A self-balancing air ionizer circuit 20, FIG. 2, includes AC power source 12 for providing a high voltage potential of typically 5000 volts between emitter points 14 and collector 16. Primary collector 16 may be a solid sheet of metal material placed near the ion emitter and parallel with the airflow so as not to interfere with the airflow characteristics. In addition, collector 16 may be any surface within the unit that airborne ions give up their charge to. First capacitor 24 is in series with emitter points 14 and secondary winding 22 of transformer 25; while second capacitor 26 is connected in series between collector 16 and ground. AC power source 12 is connected to primary winding 18 of transformer 25. Secondary winding 22 charges capacitor 24 and places a voltage potential between emitter points 14 and collector 16. Between primary winding 18 and secondary winding is transformer core 21.
Air has naturally occurring positive and negative ions in equal numbers, and is therefore normally in a balanced condition. Placing a high voltage potential between emitter points 14 and collector 16, however, initiates ionization. This ionization process occurs when a voltage potential is placed between two adjacent locations. Once ionization is initiated, the accelerated movement of the ions or free electrons during their attraction and repulsion from the charged emitter points and collector, causes them to collide with other molecules, thus creating more ions. This avalanche effect continues up to a maximum limit.
Insuring that an equal number of ions are produced by emitter 14, however, does not insure that an equal number of positive and negative ions are emitted into the airstream. Since the ions must travel past collector 16 when exiting the ionizer, most ions are lost to the oppositely charged collector. Further, since negative ions are more mobile, it has been found that if the collector is held at ground potential, more negative ions are lost to the collector than positive ions. By providing capacitor 26 in the collector circuit, the capacitor stores the negative charge and attracts more positive ions and repels more negative ions until a balance is achieved.
Balancing of the ions emitted and lost to the collector plate takes place over a minimum number of cycles with a steady state condition being achieved within a few seconds time.
An additional embodiment of a self-balancing air ionizer circuit 30, FIG. 3, includes AC power source 12, primary winding 18 and secondary winding 22. Secondary winding 22 is isolated from transformer core 21. Ion emitter point 14a and collector 16 are connected directly to secondary winding 22 of transformer 25. To prevent any extraneous charges from entering the circuit from ground which would unbalance the ionized airstream, capacitor 28 is connected between the circuit and ground. In this way, no charge may flow to an adjoining grounded point such as might occur between the transformer high voltage windings and the transformer core, if the voltage on the windings near the core exceed the isolation value of the transformer. Any imbalance in the circuit results in a charge stored on capacitor 28 and serves as a restoring force or negative feedback during the next AC cycle of opposite polarity.
Another embodiment of a self-balancing air ionizer circuit 40, FIG. 4, includes AC power source 12 and transformer 25 having primary winding 18 and secondary winding 22. Although similar in operation to the circuit in FIG. 1, rectifier diode 34 allows emitter points 14c to charge positively during the positive cycle of the AC wave form; while rectifier diode 36 allows emitter points 14b to charge negatively during the negative cycle of the AC wave form. Capacitors 24 and 26 serve to balance the ion production and collection of emitters 14b and 14c as well as collector 16. Since emitters 14b, 14c and collector 16 are isolated from other ambient conducting sources or sinks, any net charge exiting by means of the front air exit results in a restoring force or feedback charge accumulating on capacitors 24 or 26, and no net charge flows to or from ground. Capacitors 31 and 32 serve to filter or smooth out the rectified voltage applied to positive emitters 14c and negative emitters 14b.
Although specific features of the invention are shown in some drawings and not others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention.
Other embodiments will occur to those skilled in the art and are within the following claims:
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A self-balancing circuit for convection air ionizers with a passively balanced ion emitter and collector including a circuit in which the ion emitter and the collector are capacitively isolated from external charge sources or sinks for maintaining balance in the positive and negative charge for producing a zero average current flow and a charge balanced ionized airstream.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for operating a laser spark plug, as well as to a computer program and a control and/or regulating device for implementing such a method.
[0003] 2. Description of the Related Art
[0004] Ignition systems for internal combustion engine are known, in which a fuel-air mixture present in a combustion chamber is ignited with the aid of a laser spark plug. In this context, it is a matter of attaining burn-through of the fuel-air mixture in the combustion chamber that is as rapid as possible, in order to achieve a low fuel consumption and improved knock characteristics. Particularly in the case of stationary gas engines, which operate with the aid of conventional high-voltage ignition, it is known that a precombustion chamber may be additionally provided for more rapid ignition of the fuel-air mixture.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention starts out from the assumption that the use of a laser spark plug may improve the ignition of an internal combustion engine, in particular, in the case of simultaneous use of a precombustion chamber for the laser spark plug. In order to achieve optimum burn-through of the fuel-air mixture in a combustion chamber of the combustion engine, the present invention proposes that within an operating cycle of the combustion engine, the laser spark plug irradiate an ignition location situated inside the precombustion chamber with a plurality of laser ignition pulses temporally offset from one another.
[0006] In this context, it is taken into account that often, ignition already occurs while a piston of the combustion engine is still moving upwards. In this state, the fuel-air mixture (mixture) situated in the combustion chamber is increasingly compressed; a portion of the mixture being pressed into the precombustion chamber via overflow bore holes present there. If a first ignition by the laser spark plug takes place in this state, then a flame core generated by it is displaced in the flow direction of the mixture streaming into the precombustion chamber. In this context, the flame core increasing in size and the corresponding center of the flame core may therefore be moved away from the ignition location, at least temporarily. By this means, depending on the specific flow conditions, an ignitable mixture may be present once more at the ignition location. In this context, the ignition location of the laser spark plug is the point at which the light energy (laser ignition pulse) emitted by the laser spark plug is present in focused form at a high energy density. In this manner, the flow conditions in the precombustion chamber may be advantageously used for igniting more than one flame core, and thereby for igniting the mixture present in the precombustion chamber and, consequently, also in the main combustion chamber, particularly rapidly.
[0007] Thus, an advantage of the method of the present invention is that a particularly rapid burn-through in the precombustion chamber and in the combustion chamber of the combustion engine may be achieved with the aid of a laser spark plug; a fuel consumption being able to be reduced, and a susceptibility of the combustion engine to knocking being able to be improved.
[0008] Of course, depending on the operating mode of the combustion engine, it may also be sufficient to emit only one single laser ignition pulse of the laser spark plug during an operating cycle of the combustion engine, in order to ignite the mixture present in the combustion chamber. That is, it is also possible to implement the operating method of the present invention using the plurality of laser ignition pulses, in only some operating modes of the combustion engine.
[0009] In addition, it is proposed that the number of laser ignition pulses and/or a time interval between at least two of the laser ignition pulses be changed between different operating cycles of the combustion engine. This advantageously provides an option of exercising considerable influence over the ignition process and, therefore, improving the operation of the laser spark plug and the combustion engine, without an increased degree of structural complexity being necessary. The time interval between two laser ignition pulses, i.e., the spatial distance between the generated flame cores resulting due to the flow conditions in the precombustion chamber, may be selected as a function of the size of the precombustion chamber. In principle, it can be advantageous when the generated flame cores contact a wall of the precombustion chamber, or the flame cores contact one another, as late as possible, in order to consequently keep the burning time in the precombustion chamber and in the main combustion chamber as brief as possible. From this, it follows that the interval of the laser ignition pulses and the flame cores generated by them should be selected to be appropriately large.
[0010] Influence may be exerted on the number and the time interval of the laser ignition pulses, for example, by changing a pump current for operating the laser spark plug, or by changing a power of a pump pulse. In this context, for instance, a Q-switch of a solid-state laser of the laser spark plug may be caused to break down several times. The time interval of the generated laser ignition pulses may also be changed by dynamically varying the power of the pump pulse.
[0011] In combustion engines, which are used, for example, in a motor vehicle and are, consequently, dynamically loaded, it may be advantageous for the number of laser ignition pulses and/or the time interval between them to be changed, as described. However, in the case of combustion engines that are operated in a steady state, it may be sufficient to set the number of laser ignition pulses and/or the time interval between them one time and not change them during operation.
[0012] According to the present invention, it is proposed that the number of laser ignition pulses and/or the time interval between two laser ignition pulses be selected as a function of at least one of the following variables: a mixture composition of a fuel at the ignition location; a supercharging pressure at an inlet of a cylinder of the combustion engine; a gas pressure in the cylinder of the combustion engine; a rotational speed of the combustion engine; a load situation of the combustion engine; a torque of the combustion engine; a variable of an exhaust gas of the combustion engine, in particular, an exhaust gas temperature and/or the excess-air factor lambda; a temperature of a combustion chamber; a flow velocity of the mixture composition in the precombustion chamber; a geometry of the precombustion chamber; and/or a location of a center of a flame core. The variables are preferably variables, which may be ascertained or also adjusted comparatively easily, e.g., metrologically, at the combustion engine, and which have an effect on the flow velocity and/or the mixture composition in the precombustion chamber and at the ignition location. In this manner, a relationship to the required number and to the time intervals between the laser ignition pulses to be generated may be established with the objective of adapting a necessary pressure increase in the precombustion chamber to a requirement of the combustion engine at a current operating point. In this context, an objective may be to achieve as large as possible a pressure increase with short burning times.
[0013] In this manner, the method may advantageously be adapted dynamically to the operation of the combustion engine. Therefore, the interval between at least two of the consecutive laser ignition pulses is changed in accordance with current operating variables of the combustion engine. In this context, a specific ignition energy of an individual laser ignition pulse is, preferably, substantially equal to the others; in each instance, this ignition energy having to be high enough to ignite the mixture present at the ignition location. However, according to the present invention, it is also possible to generate the laser ignition pulses so as to have different ignition energies, which is possibly advantageous in the case of plasma-generating pre-ignition systems.
[0014] For example, a mixture composition of the fuel at the ignition location may be ascertained or calculated with the aid of a model, and in this manner, a criterion may be acquired for ascertaining a time for a subsequent ignition pulse of the laser spark plug at the ignition location. In addition, a supercharging pressure at an inlet of a cylinder of the combustion engine may be ascertained, and a time span between two ignition pulses may be determined as a function of the ascertained supercharging pressure. A gas pressure in the cylinder of the combustion engine may also be utilized, in order to determine the time interval between at least two of the ignition pulses. Additionally, a rotational speed of the combustion engine is suitable for influencing the ignition of the laser spark plug of the present invention. Furthermore, a load situation, a torque or a variable of an exhaust gas of the combustion engine may be utilized as a criterion for ascertaining the time interval between at least two of the ignition pulses of the laser spark plug. In addition, this may be done as a function of a temperature of the combustion chamber.
[0015] In particular, a flow velocity of the mixture composition in the precombustion chamber is also a highly suitable criterion for determining the time interval between two ignition pulses. According to the flow of the mixture during the upward movement of the piston, and according to a velocity of an expansion of the flame core generated by the laser spark plug in the precombustion chamber, the corresponding center of the flame core changes its position inside of the precombustion chamber. According to a formula
[0000] time=distance/velocity
[0000] a temporal difference between two consecutive laser ignition pulses may now be specified. In this respect, the “velocity” is the velocity at which, in each instance, a previously generated flame core moves away from the ignition location. This velocity is also influenced considerably by a flow velocity of the mixture. For example, the flow velocity of the mixture may be between 5 m/s and 15 m/s (meters per second). If a desired spatial distance between two flame cores to be generated consecutively is, for example, 5 mm, then, according to the formula, a time interval of 1000 μs to 333 μs (microseconds) results. In general, a flow velocity of 5 m/s to 15 m/s is particularly suitable for reliable ignition of the mixture.
[0016] In addition, it may be a guide value that the greater the combustion engine is currently being loaded, that is, the higher the assumed flow velocity in the precombustion chamber, as well, the smaller the time interval should be selected to be between two consecutive laser ignition pulses. Furthermore, it may be considered a practical boundary condition that a mixture currently present at the ignition location at a specific ignition firing point should be ignitable.
[0017] Moreover, the time interval between two ignition pulses may be a function of a geometry of the precombustion chamber or the main combustion chamber. For example, it may be useful to also make the time interval between two ignition pulses a function of a variable of the precombustion chamber, e.g., its volume. In addition, a location of a center of a flame core may be used for specifying the temporal spacing with regard to, in each instance, a subsequent ignition pulse.
[0018] Of course, in the case of greater than two ignition pulses temporally offset, the time intervals between, in each instance, two consecutive ignition pulses do not necessarily have to be the same. For example, it may be useful to select a time interval between a first and a second ignition pulse to be greater than a time interval between the second and a third ignition pulse, or vice versa.
[0019] Additionally, it may be provided that characteristic curves and/or characteristics maps of a control and/or regulating device be used for ascertaining and/or evaluating the variables, as well as for ascertaining the number of ignition pulses and/or their time intervals. Therefore, the multitude of variables influencing the ignition may be advantageously taken into account with the aid of characteristics maps or tables, and computing power may be conserved, and costs may be reduced.
[0020] Furthermore, the present invention proposes that in an idling mode and/or a lean full-throttle mode of the combustion engine, approximately two to approximately five ignition pulses be generated during an operating cycle. In the same manner, the present invention provides that in a full-throttle mode of the combustion engine, a maximum of approximately two ignition pulses be generated during an operating cycle.
[0021] This is based on the consideration that, on one hand, it may be an objective of the present invention to obtain a maximum pressure increase in the precombustion chamber in comparison with the combustion chamber outside of the precombustion chamber, but that on the other hand, a reduction in the pressure increase may be advantageous in certain operating states. For example, for a so-called lean full-throttle of a stationary gas engine, the ignition system may be configured to emit three ignition pulses, in which case a maximum pressure increase may be achieved.
[0022] In another operational case of the combustion engine, it may be useful, for example, to set a reduced lambda value of the exhaust gas. In this instance, an overly rapid burn-through of the mixture present in the combustion chamber may cause instances of surface ignition or manifestations of knock of the combustion engine to occur. In this case, it may be useful to reduce the number of ignition pulses generated by the laser spark plug in comparison with an operational case having a lambda value of approximately one. This may be derived, for example, from characteristics maps that are stored in a control and/or regulating device of the combustion engine.
[0023] Furthermore, during a dynamic operation of the combustion engine, a number of three or four ignition pulses may be optimum in an idling mode, while a single ignition pulse may be sufficient in a full-throttle mode. In the case last mentioned, a range of ignition flares emerging from the precombustion chamber may thereby be reduced.
[0024] In addition, it is provided that in the propagation direction, a subsequent, second ignition pulse then be generated when the center of a flame core generated by a preceding, first ignition pulse is at a first distance a from a wall section of the precombustion chamber and at a second distance b from ignition location (ZP), a ratio of first distance a to second distance b being approximately 1:5 to approximately 5:1. Consequently, a range is advantageously specified, which is suitable for implementing the method of the present invention with regard to a flow velocity of the mixture present in the precombustion chamber, as well as with regard to a geometry or size of the precombustion chamber.
[0025] Furthermore, a laser spark plug is proposed, which is suitable for applying the method, the precombustion chamber preferably having a substantially cylindrical shape with respect to a longitudinal axis. Consequently, a particularly simple shape of the precombustion chamber is specified, with the aid of which the method may be implemented. In this manner, manufacturing costs of the laser spark plug and the precombustion chamber may be reduced.
[0026] One embodiment of the laser spark plug of the present invention provides that the precombustion chamber have a substantially axially symmetric shape with respect to a longitudinal axis of the laser spark plug, one wall section of the precombustion chamber having essentially a first radius along a first axial segment, and one wall section of the precombustion chamber having essentially a second radius along a second axial segment. This describes a particularly suitable embodiment of the precombustion chamber of the spark plug according to the present invention. According to this, the precombustion chamber has essentially two different radii, the precombustion chamber being constructed to be, on the whole, axially symmetric. The sections of the precombustion chamber having a first radius and a second radius merge, for example, integrally and continuously. For example, the first wall section of the precombustion chamber, which faces the combustion chamber, has a first radius that is less than a radius of a second wall section of the precombustion chamber that faces away from the combustion chamber. In this context, the wall section of the precombustion chamber facing the combustion chamber may include, for example, a hemispherically shaped dome at its end. On the whole, the precombustion chamber consequently has an approximately pear-shaped geometry and is particularly suitable for ignition via several time-staggered ignition pulses.
[0027] Additionally, one embodiment of the laser spark plug according to the present invention provides that a ratio of the first axial segment to the second axial segment be approximately 1:2 to approximately 2:1, and that a ratio of the first radius to the second radius be approximately 1:3 to approximately 3:1. This describes a particularly suitable range of values for the dimensions of a precombustion chamber of the laser spark plug according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 shows a first sectional view of a precombustion chamber of a laser spark plug, including an ignition location and three flame cores generated in a time-staggered manner.
[0029] FIG. 2 shows a second sectional view of the precombustion chamber of FIG. 1 , including an ignition location and a first generated flame core.
[0030] FIG. 3 shows a timing diagram including a pump pulse and two ignition pulses of the laser spark plug.
[0031] FIG. 4 shows a third sectional view of the precombustion chamber of FIG. 1 , including two ignition locations and three generated flame cores for each.
DETAILED DESCRIPTION OF THE INVENTION
[0032] In all of the figures, and even in the case of different specific embodiments, the same reference characters are used for functionally equivalent elements and variables.
[0033] FIG. 1 shows a sectional view of a precombustion chamber 12 of a laser spark plug 10 . Precombustion chamber 12 has a longitudinal axis 13 and is detachably or undetachably connected to laser spark plug 10 in a manner known per se. In addition, laser spark plug 10 is mounted, in a manner known per se, to a section of a cylinder head 14 not explained in further detail, the cylinder head being situated in the upper region of FIG. 1 . Laser spark plug 10 has a combustion chamber window 16 , through which concentrated laser light is emitted into combustion chamber 12 in the direction of an arrow 18 . In this context, the laser light is focused onto an ignition location ZP. For example, the laser light may be generated directly in laser spark plug 10 by a Q-switched, solid-state laser, or may also be supplied to laser spark plug 10 by a remotely situated laser source. Two lines 26 a and 26 b circumscribe a light cone of the incoming laser light. In the lower region in the drawing, precombustion chamber 12 has three approximately identical overflow bore holes 20 . Further overflow bore holes of precombustion chamber 12 are present, but are not visible in the sectional view, here.
[0034] In operation, while a fuel-air mixture (mixture) situated in a combustion chamber not identified in FIG. 1 is compressed by an upwardly moving piston (not shown), a mixture may enter the interior of precombustion chamber 12 from the combustion chamber in accordance with arrows 22 . The laser light entering precombustion chamber 12 in the arrow direction of arrow 18 is focused onto ignition location ZP and may ignite a portion of the mixture present in precombustion chamber 12 . In this state, a mixture normally continues to penetrate through overflow bore holes 20 into precombustion chamber 12 in accordance with arrows 22 . In this manner, in the drawing of FIG. 1 , an upward fluid flow is generated.
[0035] A flame core generated at ignition location ZP by a laser ignition pulse 34 moves up according to the flow direction of the mixture continuing to stream in in the drawing of FIG. 1 . At the same time, it continuously increases its diameter. The flame core has, at least initially, an approximately spherical shape. In the drawing of FIG. 1 , by way of example, three flame cores 24 a, 24 b and 24 c are drawn in, starting from ignition location ZP. In this context, the flame cores 24 a to 24 c drawn in FIG. 1 describe either an expansion over time of a single flame core generated at ignition location ZP, or, just as well, a simultaneous arrangement of three flame cores 24 a to 24 c generated consecutively in accordance with the present invention.
[0036] One can see how, by generating three flame cores, a correspondingly greater volume of the mixture may be advantageously ignited, that is, in a shorter time or more rapidly, which means that a maximized pressure increase in the precombustion chamber with respect to the combustion chamber and a correspondingly more rapid burn-through of the mixture may take place, and as a result of that, a fuel consumption of the combustion engine and a knock tendency may be reduced.
[0037] FIG. 2 shows a precombustion chamber 12 identical to that of FIG. 1 . A radius R 1 for a first axial segment 28 of precombustion chamber 12 in the drawing of FIG. 2 and a radius R 2 for a second axial segment 30 of precombustion chamber 12 in the drawing are illustrated with respect to longitudinal axis 13 . In the present case, a ratio of radius R 1 to radius R 2 is approximately 1:3.
[0038] Illustrated in FIG. 2 is an instant in which a flame core generated previously, along with its center of the flame core 24 , has already moved up in the drawing, away from ignition location ZP by a second distance b. At this time, center of the flame core 24 is at a first distance a from combustion chamber window 16 of cylinder head 14 . In this case, a ratio of first distance a to second distance b is approximately 1:2. In this context, the flame core drawn in FIG. 2 is the first of a sequence of two flame cores or ignition pulses to be generated.
[0039] A third distance c, which describes a minimum distance between ignition location ZP and a wall 29 of precombustion chamber 12 , is also recorded in FIG. 2 . Third distance c may be used for obtaining a guide value for the dimensioning of distance a, and therefore, for the chronological sequence of the laser ignition pulses. It is important that the flame cores reach wall 29 of precombustion chamber 12 as close as possible to the same time and as late as possible, and that consequently, rapid burn-through is achieved.
[0040] At the same time, the drawing of FIG. 2 shows the instant, at which a second flame core having a further center of the flame core 24 (not shown) may be generated at ignition location ZP. Using the ratio of distances a to b, a suitable time for the second laser ignition pulse may therefore be specified. In this context, the ratio of a to b may be advantageously ascertained in view of the following variables of the combustion engine:
a mixture composition of a fuel at ignition location ZP; a supercharging pressure at an inlet of a cylinder of the combustion engine; a gas pressure in the cylinder of the combustion engine; a rotational speed of the combustion engine; a load situation of the combustion engine; a torque of the combustion engine; a variable of an exhaust gas of the combustion engine; a temperature of a combustion chamber; a flow velocity of the mixture composition in precombustion chamber 12 ; a geometry of precombustion chamber 12 ; and/or a location of a center of a flame core 24 .
[0052] In this manner, several operating states of the combustion engine may be used for selecting, in each instance, an optimum number of, and optimum time intervals between, the laser ignition pulses of laser spark plug 10 .
[0053] FIG. 3 shows a timing diagram of a normalized amplitude NA of a laser pump pulse 32 and two ignition pulses 34 and 36 generated from it, as are produced by applying pump pulse 32 to a passive, Q-switched laser system known per se. In this context, the abscissa of the illustrated coordinate system designates time t, and the ordinate designates normalized amplitude NA. A pump pulse 32 , which has a time span tp in FIG. 3 , is generated at time t 0 . Using time t 0 as a starting point, a first laser ignition pulse 34 is generated after a time t 1 elapses. A second laser ignition pulse 36 is generated after a time t 2 elapses. Thus, in this case, laser ignition pulses 34 and 36 have a time interval dt=t 2 −t 1 . In the graph of FIG. 3 , a total of two ignition pulses are generated during a laser pump pulse 32 .
[0054] By increasing the pump current or the power of pump pulse 32 and/or the pumping duration via an increase in time span tp, more than two ignition pulses 34 and 36 may also be generated, if necessary, and used for the ignition, in that a Q-switch of a solid-state laser of laser spark plug 10 ( FIG. 1 ) is caused to break through multiple times. Likewise, time interval dt of generated laser ignition pulses 34 and 36 may also be changed by dynamically varying the power of pump pulse 32 during time span tp. However, this is not illustrated in the drawing of FIG. 3 .
[0055] It should be noted that the durations of ignition pulses 34 and 36 and/or the duration of pump pulse 32 , which are drawn in FIG. 3 , may not be illustrated to scale with respect to one another. For example, ignition pulses 34 and 36 have a duration of 1 ns to 10 ns (nanoseconds), and pump pulse 32 has a duration of 100 μs (microseconds) to 1000 μs.
[0056] FIG. 4 illustrates a mechanical construction of precombustion chamber 12 that is similar to that of FIGS. 1 and 2 . In this case, the laser light irradiated by laser spark plug 10 is focused in such a manner, that two ignition locations ZP 1 and ZP 2 different from one another are acted upon by it. The chronological sequence of the ignition pulses is similar to those of FIGS. 1 and 2 . In FIG. 4 , the generated flame cores are only alluded to (without reference numerals).
[0057] The ignition of the mixture situated in combustion chamber 12 may be improved by forming two different ignition locations ZP 1 and ZP 2 , in that two times the number of flame cores and centers of flame cores are generated. Accordingly, more rapid burn-through of the mixture situated in precombustion chamber 12 may be advantageously achieved, and the fuel consumption of the combustion engine, as well as a knock tendency, may be further reduced.
[0058] A further specific embodiment of laser spark plug 10 (not shown) for implementing the method of the present invention has a shape not axially symmetric with respect to longitudinal axis 13 . Due to a special design of an interior of precombustion chamber 12 , a tangential flow of the fuel-air mixture in front of combustion chamber window 16 is generated. Accordingly, the at least one flame core is moved, at least in the beginning, approximately perpendicularly to longitudinal axis 13 . The principle of the temporally repeated ignition of the present invention is generally applicable in the case of laser spark plugs not having a precombustion chamber, as well.
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In a method for operating a laser spark plug for a combustion engine, the laser spark plug having a precombustion chamber, within an operating cycle of the combustion engine, the laser spark plug irradiates an ignition location situated inside the precombustion chamber with a plurality of laser ignition pulses temporally offset from one another.
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FIELD OF THE INVENTION
This invention relates generally to air cleansing devices. More particularly, this invention relates to ultraviolet irradiation and filtration devices.
BACKGROUND OF THE INVENTION
Ultraviolet (UV) light in the form of germicidal lamps has been used since the early 1900's to kill the same types of microorganisms that typically cause the same types of problems today. Since then, UV radiation in the short wave or C band range (UVC) has been used in a wide range of germicidal applications to destroy bacteria, mold, yeast and viruses. After World War II, the use of UVC rapidly increased. UVC is generally understood to exist in the 180 nm to 280 nm wave length area. Typical examples included hospitals, beverage production, meat storage and processing plants, bakeries, breweries, pharmaceutical production and animal laboratories; virtually anywhere microbial contamination was of concern. Early UVC strategies primarily consisted of an upper air approach. This method directed a beam across the ceiling of a room.
During the 1950's when tuberculoses infections were on the rise, the use of UVC became a major component in the control and irradiation of TB. It was discovered that by placing UVC lamps in the air handling equipment, they could initially be more effective.
However, certain conditions found within the air handling systems drastically reduced UVC performance. Moving air, especially below 77° F., over the tubes decreased the output and service life of conventional UVC products and thus their ability to destroy viable organisms. The use of UVC and HVAC systems virtually disappeared over the next decade due to the introduction of new drugs, sterilizing cleaners and control procedures combined with the performance problems of UVC lamps and air handling systems (reduced output, short tube life, and high maintenance). In order for UVC to be effective in the “hostile” environment of indoor central air circulating systems (or HVAC systems), a new method of producing effective UV had to be developed.
The ability of ultraviolet light to decompose organic molecules has been known for a long time, but it is only recently that UV cleaning of surfaces has been explored. In 1972, it was discovered that ultraviolet light could clean contaminated surfaces. Plus, it was learned that there exists a predictable nanometer location of absorption of ozone and organic molecules. It was then learned that the combination of ozone and UV could clean surfaces up to two thousand times quicker than one or the other alone. However, from testing it can be seen that the destructive potential of a combination of UVC and ozone for system components is detrimental. The negative side effects of ozone are now known.
In 1972, tests were conducted using a quartz tube filled with oxygen. A medium pressure mercury (Hg) UV source which generated ozone was placed within centimeters of the tube. A several thousand angstrom thick polymer was exposed to this and was depolymerized in less than one hour. The major products of this reaction were water (H 2 O) and carbon dioxide (CO 2 ). It was discovered that UV (300 nm and below) and oxygen played a major role in depolymerization. In 1974, research concluded that during such cleaning, the partial pressure of O 2 decreased and that of CO 2 and H 2 O increased, suggesting breakdown.
It was also discovered that the absorption coefficient of O 2 increases rapidly below 200 nm with decreasing wave lengths. A 184.9 nm wave length (optimal spectral line for ozone generation) is readily absorbed by oxygen, thus leading to the generation of ozone (O 3 ). Ozone may be generated at undetectable levels at other wave lengths below 200 nm. Therefore, radiation emission below 200 nm was found undesirable.
Similarly, most organic molecules have a strong absorption band between 200 nm and 300 nm. A wave length of 253.7 nm is useful for exciting and disassociating contaminant molecules. 265 nm was thought to be the optimal spectral line for germicidal effectiveness. The 253.7 nm wave length is not absorbed by O 2 , therefore, it does not contribute to ozone generation, but it is absorbed by most organic molecules and by ozone (O 3 ). Thus, when both wave lengths are present, ozone is continually being formed and destroyed. Unfortunately, previously existing lamps operated between 250 nm and 258 nm, peaking at 254 nm, missing out on the optimal 265 nm goal.
With regard to HVAC systems, biological contaminants are difficult to control because they grow in our moist, indoor environment. The most common strategy is to try to use an effective air system filter to rid indoor air of biological contaminants. While this is an important element of cleaning air, this has its problems. Most filters are inadequate because of the many organisms that pass right on through the filter. Also, any organisms that collect on the filter can form germ colonies that may soon contaminate passing air. Further, if the filter should be too efficient, it blocks the passage of air and creates back pressure, causing the blower to struggle to move air through the system. Furthermore, when the system is turned off, natural temperature differences between the system and indoor air spaces cause convection or back draft flow into the supply ducts (bypassing the filter). This causes contaminants to be pulled back into the duct work, implanting microbes in the air flow duct cavity. These new cultures become added sources of contaminant.
In the past, to try to eliminate the biological contaminants in ducts, a common strategy was to clean the ducts followed by a biocide treatment. But this has its draw backs also. Most biological contaminants return and are active in the treated area within three months. Further, if the system is being treated for severe contamination such as legionela, an acid wash of the coil is common. This is not only expensive, but can shorten the life of the equipment. Furthermore, all biocide used in the ducts are chemical based, leaving potential toxic vapors and chemical pollutants circulating in the system as well. For obvious health reasons, the preferred way to control biological contaminants is through natural, non-polluting strategies.
As indicated above, the effective killing power of UV seemed to be greatest at 265 nm. However, conventional UV has its maximum intensity at 254 nm. Furthermore, the intensity degrades as a function of temperature and distance. This was due to the conventional tubes being designed as long, straight lamps.
The following prior art reflects the state of the art of which applicant is aware and is included herewith to discharge applicant's acknowledged duty to disclose relevant prior art. It is stipulated, however, that none of these references teach singly nor render obvious when considered in any conceivable combination the nexus of the instant invention as disclosed in greater detail hereinafter and as particularly claimed.
SUMMARY OF THE INVENTION
An air cleaning apparatus is disclosed including UV lamps, aluminum filters, and a polished aluminum housing. The UV lamps include a U-bend crystal of quartz, ruby, or sapphire contained within a quartz sleeve. Useful substances for containment within the U-bend bulb are mercury, argon, gallium, iron, xenon or krypton. Between the sleeve and lamp, certain gases (nitrogen or atmospheric gases) are contained therein or the area is possibly evacuated. There are advantages and disadvantages to each. By using a mixture of above gases and/or by varying the electrical charge, one can increase the bandwidth to about 240 nm to about 280 nm, including the 265 nm optimum wave length. Further, increased electrical charge can increase bandwidth and spectral line output from 240 nm to 360 nm for more germicidal effect (UVC/UVB).
Polished aluminum filters and chamber walls are also included in this invention. The treated, polished aluminum alloy provides enhanced reflectivity for the UV rays to enhance the irradiation of particulate flowing through the filters and by the lamps. The aluminum filters have an additional special feature in that one side of the filter is of a coarse mesh whereas the other side of the filter is of a fine mesh. Air flow is from the coarse side to the fine side of one filter, past the UV bulbs, through the fine side, and out the coarse side of another aluminum filter and then back into the duct work of an HVAC system. By providing treated, polished aluminum surfaces surrounding the UV lamps, irradiation is enhanced significantly.
An alternate embodiment in the form of a portable air cleaning device is also described herein. The purpose of the portable device is to clean a single room with a similar system as described hereinabove, but also including a fan built into the portable unit to move through the system.
Another embodiment is described wherein a UV lamp array is mounted exterior to a compressor coil of an HVAC system thereby allowing for cleansing of contaminants contained on the coil and fin structure of the compressor. It has been known that this is a breeding ground for microorganisms and cleansing of this breeding ground will enhance cleansing of the entire HVAC system.
OBJECTS OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide an ultraviolet ray actinism chamber for destroying contaminants thereby.
Another object of the present invention is to avoid the production of ozone in such a system.
Another object of the present invention is to provide increased UV bandwidth to so increase the “killing” power of the UV system.
Another object of the present invention is to maintain a substantially constant temperature around the UV bulb.
Another object of the present invention is to increase UV reflectivity in and around the UV bulbs to enhance the UV irradiation.
Another object of the present invention is to provide self cleaning filters for a UV system.
Another object of the present invention is to provide better, yet shorter lamp lengths to fit in conventional HVAC systems.
Yet another object of the present invention is to enhance the bulb life of a UV bulb for such a system.
Viewed from a first vantage point, it is an object of the present invention to provide an apparatus for purging impurities from ambient conditions, comprising, in combination, a source of radiation in operative communication with the ambient conditions, and means for maintaining the source in a preferred temperature range to promulgate radiation emissivity.
Viewed from a second vantage point, it is an object of the present invention to provide a method for sterilizing air, the steps including, passing the air adjacent a source of ultraviolet light, and resisting temperature drop of the ultraviolet light caused by the passage of the air.
Viewed from a third vantage point, it is an object of the present invention to provide a chamber for cleansing ambient air, comprising, in combination, an air inlet, an air outlet, the chamber interposed and communicating between the inlet and outlet, a source of radiation in the chamber, the chamber imperforate to the radiation, and the chamber having an interior surface with means for reflecting substantially all the radiation.
These and other objects will be made manifest when considering the following detailed specification when taken in conjunction with the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the UV lamp of the present invention.
FIG. 2 is a top view of the invention.
FIG. 3 is a cross-sectional front view taken along lines 3 — 3 of FIG. 2 .
FIG. 4 is a cross-sectional side view taken along lines 4 — 4 of FIG. 2 .
FIG. 5 is an exploded parts perspective view of the invention.
FIG. 6 is a perspective view of a portable alternate embodiment of the invention with a side panel and curved reflective plate projected.
FIG. 7 is a perspective view of an external alternate embodiment of the invention.
FIG. 8 is a perspective view of the electrode connection of the invention.
FIG. 9 is a cutaway view of the chamber of the invention showing rays bouncing within the chamber of the invention.
FIG. 10 is a top cutaway view of the coarse filter weave.
FIG. 11 is a top cutaway view of the fine filter weave.
DESCRIPTION OF PREFERRED EMBODIMENTS
Considering the drawings, wherein like reference numerals denote like parts throughout the various drawing figures, reference numeral 10 is directed to the air actinism chamber according to the present invention.
The invention consists of three main components: UV lamp 50 , photon chamber 34 and filters 20 . Each component will be described more particularly below.
As seen in FIGS. 1 and 8, UV lamp 50 consists of a U-shaped UV quartz, ruby, or sapphire crystal 12 (with quartz being preferred), a quartz sheath 14 , lamp coupling overlay 16 , lamp base 32 , U-shaped bulb gases 41 , and lamp gas 44 . U-shaped bulb 12 is preferably a quartz glass tube up to fifty inches long that is bent at the center to form a U-shaped bulb filled with one or more of the following: mercury, argon, iron, gallium, xenon or krypton. Aluminum metal or ceramic material is machined for the base 32 of the lamp for holding both the lamp tube 12 and electrode igniters 18 . That, preferably aluminum coupling 16 allows for good heat transference resulting from the heating of electrodes 18 inside the aluminum coupling 16 . That convection heat will be used to maintain its own stabilizing environment around the U-shaped bulb 12 and within the quartz sleeve 14 regardless of ambient temperatures.
Once the U-shaped bulb 12 is mounted onto the aluminum coupling 16 at the point where electrodes 18 extend from within the coupling 16 , a gas or gas mixture is sealed within quartz safety shield sleeve 14 . That gas or gas mixture is preferably comprised of nitrogen, ordinary air, or evacuated space. By using just air, an approximately 3% loss of intensity of UV is suffered, but certain other costs are lessened. The 3% loss could be eliminated by evacuating the space, however, heat convection does not work as well without gases. Nitrogen gas hermetically sealed under the shell 14 seems to be best, but manufacturing is more complicated.
By sealing the U-shaped quartz bulb 12 within shield 14 a constant temperature around bulb 12 is maintained at approximately 80° F. to 90° F. This has been found to be the case even when ambient air temperatures are as low as 45° F. The entire lamp 50 coupled to a proper power supply, as seen in FIGS. 1 and 5, then, for all normal intents and purposes, has the ability to maintain the highest level of intensity regardless of surrounding air temperature or air speed.
UV lamp 50 provides a broader bandwidth compared to conventional UV lamps. As described above, conventional UV lamps emit a bandwidth of about 250 nm to 258 nm. UV lamp 50 provides a bandwidth of about 240 nm to 280 nm, including the optimal 265 nm wavelength and provides approximately six times the UV intensity of conventional lamps at colder temperatures. Furthermore, this is achieved while ambient air temperature around UV lamp 50 is 45° F. to 90° F. Although more power may be required, it has also been discovered that operation at “medium-pressure” will achieve a bandwidth of 230 nm to 380 nm, with an excellent spike at 264 nm. Another optimum point has also been discovered between 310 nm and 340 nm. So, although greater power, and therefore cost, may be required, greater particulate destruction is possible.
The chamber is shown in FIGS. 2 through 5. Lamps 50 are then mounted into housing 28 that includes the electronics and power supply to drive the lamps 50 . The power supply is preferably either a matched 110 or 220 volt AC input power supply having a power cord 64 . To start the lamp, the power supply sparks the UV gas core 44 and ignites it from a cold start with a temporary voltage spike of about 3,000 volts passing through electrodes 18 and wires 19 to the substances contained within bulb 12 . Once the substances are ignited by this starting voltage, the power supply output voltage adjusts down to an operating voltage of about 200 volts to 240 volts AC. By inserting lamps 50 into a chamber of an HVAC unit, UV irradiation of air flowing over and by the lamps 50 is achieved. However, the actinism in the chamber can be enhanced by using special aluminum filters 20 and reflective surfaces within chamber 34 .
UV ray reflection can be accomplished by several surface types. Magnesium Oxide, for instance, has been found to achieve the greatest reflectivity (75% to 90%), but is not suited for normal use due to its negative properties. Polished aluminum alloy (treated with Alzak), on the other hand, can achieve up to 95% reflectivity and is well suited to production and manufacture. Typical duct liner reflects 0% to 1% of UV rays which is a draw back of the prior art. Even stainless steel only achieves 25% to 30% reflectivity. Therefore, treated aluminum alloy is preferred.
First, with regard to the filters, a two layered filter constructed of buffed aluminum is preferred. A first coarse layer 22 on an outside of the filter 20 and a second fine mesh layer 24 on the inside of the filter is preferred, wherein the mesh is a wavy aluminum strand weave 21 (FIGS. 10 and 11 ). That weave may also consist of ribbons of aluminum strands 21 A, 21 B, 21 C interwoven with other such ribbons 21 D, 21 E, 21 F, as shown in FIG. 10 . As air flows through the coarse mesh 22 large particulate can be captured and irradiated within the filter before exiting through fine mesh 24 . Additionally, because the mesh is polished aluminum and of a reflective nature, reflection of the UV rays is thereby enhanced. Particles trapped within the filter will be bombarded with UV until destroyed, thereby causing the filters to be self-cleaning within the effective irradiation range.
Furthermore, by providing curved side panels 26 running parallel to the lamp that are also made of treated aluminum and polished, reflection is additionally enhanced. The curvature tends to reflect UV rays back toward the central portion of the chamber 34 . By also providing wall 42 and bottom wall 40 of a polished aluminum material, maximum reflective irradiation is achieved. The UV rays will either strike particulate directly or be reflected about the chamber enhancing the irradiation bombardment. Certainly, by sizing the chamber 34 appropriately, it could be retrofitted within existing certain HVAC filter housings without modification to the existing housings. However, where an HVAC unit is of an unusual size, minor modifications may be rendered so to fit chamber 34 .
In use and operation, air A traveling through the duct work of a HVAC system will travel through a first aluminum filter 20 by way of its coarse mesh 22 and then its fine mesh 24 . Thereafter, the air enters chamber 34 and flows by UV lamps 50 , the whole time being irradiated. The air then exits the actinism chamber 34 through the mesh 24 of another aluminum filter 20 and out through coarse mesh 22 . Thereafter, having been irradiated and filtered, the air is returned to the HVAC ducts. Any particulate remaining in filter 20 mesh will continue to be irradiated until destroyed by UV lamps 50 as seen in FIG. 9 .
The above-described configuration is ideal for insertion into the return of an HVAC system. FIG. 6 depicts a similar, but alternative embodiment for portable use within a room. Fan 46 provides for the air flow A of this portable device through similar but smaller aluminum filters 20 . Between the filters 20 , again are maintained one or more UV lamps 50 . To transport this item, handle 48 is also provided. Reflective enhancement of the radiation is likewise caused by a plurality of polished aluminum surfaces throughout the inside of the chamber. This is an ideal apparatus for cleaning the air in a single room.
FIG. 7 depicts another alternate embodiment for use with an external HVAC device. An evaporative coil 54 coupled to a typical compressor 52 having fins 56 thereby is depicted in FIG. 7 . To prevent contamination build-up and to destroy contamination build-up on or about coil 54 , UV lamp or lamps 50 are mounted near coil 54 . By continuing the lamps 50 in an “on” setting, and additionally using the reflective properties of the aluminum fins, any contamination on or near the coils is eliminated. By maintaining this area in a clean manner, air flow over the area and into the duct work of an HVAC system will be less likely to carry such contamination.
Moreover, having thus described the invention, it should be apparent that numerous structural modifications and adaptations may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove and as described hereinbelow by the claims.
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An apparatus and method for ultraviolet irradiation of air for the purpose of removing contaminants from that air is disclosed. A U-shaped ultraviolet bulb enshrouded within a quartz tube provides enhanced contaminant destruction characteristics. By combining a plurality of those bulbs in a chamber that is of polished aluminum, and further combining aluminum filters therewith, added irradiation enhancement is achieved.
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FIELD OF THE INVENTION
The present invention relates to a process for preparing a thin film of a ferroelectric oxide or thin film of a para-dielectric oxide which is applicable to thin film capacitors, piezoelectric materials, pyroelectric materials, etc.
BACKGROUND OF THE INVENTION
Because of its characteristics such as ferroelectricity, piezoelectricity, pyroelectricity and electrooptical effect, thin ferroelectric films are known in many electronic fields. In recent years, its application to memory cell in DRAM has drawn attention along with the rapid development of circuit integration. Among these ferroelectric materials, barium strontium titanate has a higher dielectric constant than strontium titanate. It can vary Curie temperature with the composition ratio of barium and strontium and thus can be used as a dielectric material depending on the working temperature of devices. Thus, barium strontium titanate is particularly favorable material. The preparation of a thin oxide film has heretofore been accomplished by a dry process such as sputtering process and vacuum metallizing process or a wet process such as sol-gel process.
However, the dry process is disadvantageous in that it requires a very expensive apparatus. It is also disadvantageous in that it requires different vapor pressures with different elements, making it impossible to effect a stable production of a thin film excellent in stoichiometry. This results in the deterioration of crystallizability. Further, the productivity is lowered, raising the production cost. Thus, the dry process is far from practicable.
On the other hand, if the wet process is used, a sol-gel process employing an organic metal compound is advantageous in accurate control of chemical composition, uniformity in molecular level, reduction of process temperature, applicability to large area, reduction of apparatus cost, etc. However, the conventional sol-gel process is disadvantageous in that it requires the use of a lower alcohol such as methanol and ethanol as a solvent, making the organic metal compound solution extremely unstable. The organic metal compound solution can absorb water content in the atmosphere to undergo hydrolysis, making it difficult to prepare a homogeneous thin film. Further, since these lower alcohols exhibit a high vapor pressure, a thin film formed by, e.g., spin coating process is dried too fast to make a thin film having a uniform thickness. In recent years, J. Am. Ceram. Soc., 71, (5), C-280 (1988), etc. have proposed the use of ethylene glycol monomethyl ether in the preparation of a thin film of a ferroelectric material such as lead titanate. However, this approach is disadvantageous in that if this solvent is used for the synthesis of a thin film of an oxide represented by formula (Ba x Sr 1-x )TiO 3 (0≦x≦1), an organic metal compound of Ba and an organic metal compound of Ti undergo selective reaction, causing precipitation. Moreover, Advanced Ceramic Materials, 3, (2), 183 (1988), etc. propose to mix a solution of barium acetate in an aqueous solution of acetic acid with titanium isopropoxide. However, this approach is disadvantageous in that titanium isopropoxide and acetic acid react with each other, possibly causing precipitation. Further, in order to accomplish the accurate control and uniformity of composition, it is necessary to synthesize a composite alkoxide having a well-controlled metallic atom ratio as a precursor. However, since water is added to the starting material, the resulting precursor solution is unstable, making it difficult to control the chemical composition of the precursor.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a process for the stable preparation of a uniform stoichiometrically excellent thin film of a ferroelectric oxide or para-dielectric oxide applicable to thin film capacitors, piezoelectric materials, pyroelectric materials, etc. from an organic metallic compound on a substrate.
The foregoing and objects of the present invention will become more apparent from the following detailed description and examples.
As a result of studies, the inventors have found that a process for the preparation of a thin film of an oxide represented by formula (Ba x Sr 1-x )TiO 3 (0≦x≦1) which comprises dissolving organic metallic compounds comprising Ba, Sr and Ti, respectively, in a specific solvent or dissolving these compounds in a specific solvent in a specific order, applying the resulting mixture to a substrate to form a thin film, and then subjecting the thin film to thermal decomposition, followed by crystallization, makes it possible to prepare a uniform stoichiometrically excellent thin film of an oxide.
The first aspect of the present invention is a process for the preparation of a thin film of an oxide represented by formula (Ba x Sr 1-x )TiO 3 (0<x≦1), which comprises: adding to a solvent represented by formula (I-A)
R.sup.1' OR.sup.2 OH (I-A)
wherein R 1' represents an aliphatic hydrocarbon group having two or more carbon atoms; and R 2 represents a divalent aliphatic hydrocarbon group which may have an ether bond, two metallic alkoxide compounds represented by formulae (II) and (III) or three metallic alkoxide compounds represented by formulae (II), (III) and (IV):
Ba(OR.sup.3).sub.2 (II)
Ti(OR.sup.4).sub.4 (III)
Sr(OR.sup.5).sub.2 (IV)
wherein R 3 , R 4 and R 5 each represents an aliphatic hydrocarbon group, simultaneously or in an arbitrary order to make a mixture; heating the mixture so that it undergoes reaction; applying the resulting mixture solution to a substrate to form a thin film; and then subjecting the material to heat treatment.
The second aspect of the present invention is a process for the preparation of a thin film of an oxide represented by formula (Ba x Sr 1-x )TiO 3 (0<x<1), which comprises: dissolving in a solvent represented by formula (I-B)
CH.sub.3 OR.sup.2' OH (I-B)
wherein R 2' represents a divalent aliphatic hydrocarbon group, a barium alkoxide compound represented by formula (II)
Ba(OR.sup.3).sub.2 (II)
wherein R 3 represents an aliphatic hydrocarbon group; heating the solution so that it undergoes reaction; adding to the reaction product two metallic alkoxide compounds represented by formulae (III) and (IV):
Ti(OR.sup.4).sub.4 (III)
Sr(OR.sup.5).sub.2 (IV)
wherein R 4 and R 5 each represent an aliphatic hydrocarbon group; heating the mixture so that they undergo reaction; applying the mixture to a substrate to form a thin film, and then subjecting the material to heat treatment.
The third aspect of the present invention is a process for the preparation of a thin film of an oxide represented by SrTiO 3 , which comprises: adding to a solvent represented by formula (I)
R.sup.1 OR.sup.2 OH (I)
wherein R 1 represents an aliphatic hydrocarbon group; and R 2 represents a divalent aliphatic hydrocarbon group which may have an ether bond, two metallic alkoxide compounds represented by formulae (III) and (IV):
Ti(OR.sup.4).sub.4 (III)
Sr(OR.sup.5).sub.2 (IV)
wherein R 4 and R 5 each represents an aliphatic hydrocarbon group, simultaneously or in an arbitrary order to make a mixture; heating the mixture so that is undergoes reaction; applying the resulting mixture to a substrate to form a thin film; and then subjecting the material to heat treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE is an example of a structure of thin layer capacitor.
DETAILED DESCRIPTION OF THE INVENTION
In FIGURE, 1 represents a substrate, 2 represents an insulating layer, 3 represents a lower electrode, 4 represents a ferroelectric layer and 5 represents an upper electrode. The ferroelectric layer according to the present invention has a very high dielectric constant so that it can secure the capacity even if it has a small capacitor area and a thick layer.
The metallic alkoxide compound employable in the present invention is selected from the group consisting of compounds represented by formulae (II), (III) and (IV):
Ba(OR.sup.3).sub.2 (II)
Ti(OR.sup.4).sub.4 (III)
Sr(OR.sup.5).sub.2 (IV)
wherein R 3 , R 4 and R 5 each represent an aliphatic hydrocarbon group.
In the foregoing formulae (II), (III) and (IV), the aliphatic hydrocarbon group represented by R 3 , R 4 or R 5 is preferably a C 1-4 alkyl group. More preferably, R 3 is ethoxide or isopropoxide, R 4 is propoxide, and R 5 is ethoxide or isopropoxide. Specific examples of the metallic alkoxide compound include barium dimethoxide, barium diethoxide, barium dipropoxide, barium dibutoxide, strontium dimethoxide, strontium diethoxide, strontium dipropoxide, strontium dibutoxide, titanium tetramethoxide, titanium tetraethoxide, titanium tetrapropoxide, and titanium tetrabutoxide. However, the present invention is not limited to these compounds.
The metallic alkoxide compound according to the present invention is used in an amount of 0.01 to 10M, preferably 0.05 to 2.0M when synthesized.
The solvent to be used in the present invention is represented by formula (I)
R.sup.1 OR.sup.2 OH (I)
wherein R 1 represents an aliphatic hydrocarbon group; and R 2 represents a divalent aliphatic hydrocarbon group which may have an ether bond.
The aliphatic hydrocarbon group represented by R 1 is preferably a C 1-4 alkyl group. Preferred examples of the divalent aliphatic hydrocarbon group which may have an ether bond represented by R 2 include C 2-4 alkylene group, and C 4-8 divalent group having C 2-4 alkylene groups bonded to each other via ether bond.
Specific examples of the divalent aliphatic hydrocarbon group include ethylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monopropyl ether and ethylene glycol monobutyl ether; diethylene glycol monoalkyl ethers such as diethylene glycol monomethyl ether, diethylene glycol monoethyl ether; 1,2-propylene glycol monoalkyl ethers such as 1,2-propylene glycol monomethyl ether; and 1,3-propylene glycol monoalkyl ethers such as 1,3-propylene glycol monomethyl ether, 1,3-propylene glycol monoethyl ether and 1,3-propylene glycol monopropyl ether. The present invention is not limited to these compounds. These compounds may be used singly or in combination.
Among these compounds, examples of solvents represented by formula (I-B) include ethylene glycol monomethyl ether, and 1,3-propylene glycol monomethyl ether.
In formula (I-B), R 2' has the same definition as R 2 in formula (I).
In the present invention, the metallic alkoxide compounds represented by formulae (II), (III) and (IV) are added to the solvent represented by formula (I) simultaneously or in an arbitrary order to make a solution which is then heated to undergo reaction (e.g., distillation and reflux). If the solvent to be used in the reaction is one represented by the general formula (I) wherein R 1 is a methyl group, i.e., formula (I-B), care must be taken in the order of the addition of the foregoing metallic alkoxides. In some detail, the barium alkoxide compound represented by formula (II) is first added to the solvent to make a solution which is then heated to undergo reaction (e.g., distillation and reflux). In this reaction, Ba ligands are replaced by the solvent. To the solution are then added the titanium-containing metallic alkoxide compound represented by formula (III) and the strontium-containing metallic alkoxide compound represented by formula (IV). If such an order is not used, the solution suffers from precipitation, making it impossible to obtain a homogeneously mixed solution.
In the case where a thin film of an oxide represented by BaTiO 3 is prepared, two alkoxide compounds represented by formulae (II) and (III) may be used. In the case where a thin film of an oxide represented by SrTiO 3 is prepared, two metallic alkoxide compounds represented by formulae (III) and (IV) may be used.
The mixture thus obtained is advantageously distilled or refluxed to form a composite alkoxide as a precursor.
The mixture obtained by the reaction of metallic alkoxide compounds is applied to a substrate to form a thin film which is then subjected to heat treatment. In this case, the mixture may be hydrolyzed before being applied to the substrate. However, the mixture to which water and catalyst are not added as a coating solution, that is, a solution which is not hydrolyzed, is preferably used in the case that it is subjected to heat treatment at a high temperature such as 500° to 1200° C. in forming a thin layer, from the standview point of electric characteristics (especially, leak current characteristics).
As the substrate there may be used any material which can be used for the desired element. For example, ITO/SiO 2 glass, Pt/Ti/SiO 2 /Si, etc. may be used.
The application of the solution to the substrate can be accomplished by spin coating method, dipping coating method, spray coating method, screen printing method, ink jet method or the like.
The substrate thus coated is then subjected to heat treatment. In some detail, the substrate is heated at a rate of 0.1° to 500° C./sec. so that the coating layer is thermally decomposed at a temperature of 100° to 500° C., where no crystallization occurs. Subsequently, the substrate is heated at a rate of 0.1° to 500° C./sec. so that the thin oxide film is crystallized at a temperature of 300° to 1,200° C. If coating is repeated, the substrate thus coated is heated at a rate of 0.1° to 500° C./sec. so that the coating layer is thermally decomposed at a temperature of 100° to 500° C., where no crystallization occurs. The coating and thermal decomposition are repeated predetermined times. The thin oxide film is then crystallized at a temperature of 300° C. to 1,200° C. By this heat treatment, the desired thin oxide film is formed. The obtained thin oxide film generally has a thickness of 0.01 to 2 μm.
The present invention will be further described in the following examples, but the present invention should not be construed as being limited thereto.
EXAMPLE 1
Ba(OC 2 H 5 ) 2 was dissolved in ethylene glycol monomethyl ether which had been dehydrated by a molecular sieve to obtain a 0.6M solution. The solution was distilled at a temperature of 125° C. with stirring for 2 hours, and then refluxed for 22 hours to obtain Ba(OC 2 H 4 OCH 3 ) 2 . To the solution were then added Sr(OC 2 H 5 ) 2 and Ti(O-i-C 3 H 7 ) 4 in such amounts that the molar proportion of Ba:Sr:Ti was 0.5:0.5:1 to obtain a 0.6M solution. The solution was distilled at a temperature of 125° C. with stirring for 2 hours, and then refluxed for 22 hours to obtain a composite alkoxide (Ba 0 .5 Sr 0 .5)Ti(OC 2 H 4 OCH 3 ) 6 . The alcohol substitution reaction was confirmed by 1 H NMR spectrum. The solution had no precipitates and was a homogeneous light brown transparent liquid. The solution was spin-coated on an ITO/SiO 2 glass substrate. The substrate thus coated was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 300° C. for 2 minutes and then 700° C. for 1 hour. The resulting thin film of (Ba 0 .5 Sr 0 .5)TiO 3 made of single perovskite phase had an optically smooth and transparent surface.
COMPARATIVE EXAMPLE 1
Ba(OC 2 H 5 ) 2 , Sr(OC 2 H 5 ) 2 and Ti(O-i-C 3 H 7 ) 4 were simultaneously dissolved in ethylene glycol monomethyl ether which had been dehydrated by a molecular sieve in such amounts that the molar proportion of Ba:Sr:Ti was 0.5:0.5:1 to obtain a 0.6M solution. The solution was distilled at a temperature of 125° C. with stirring for 2 hours, and then refluxed for 22 hours. The solution produced precipitates when allowed to stand at room temperature for some time. Thus, a homogeneous solution was not obtained. As a result of an analysis, a large amount of Ba and Ti were detected in the precipitate. Further, Sr was detected in the solution in a higher ratio than the starting composition ratio. The results of analysis showed that a stoichiometrically excellent precursor cannot be synthesized by this comparative method.
EXAMPLE 2
Ti(O-i-C 3 H 7 ) 4 was dissolved in ethylene glycol monoethyl ether which had been dehydrated by a molecular sieve to obtain a 0.6M solution. The solution was distilled at a temperature of 135° C. with stirring for 2 hours. To the solution were then added Ba(O-i-C 3 H 7 ) 2 and Sr(OC 2 H 5 ) 2 in such amounts that the molar proportion of Ba:Sr:Ti was 0.6:0.4:1 to obtain a 0.6M solution. The solution was distilled at a temperature of 135° C. with stirring for 2 hours, and then refluxed for 22 hours to obtain a composite alkoxide (Ba 0 .6 Sr 0 .4)Ti(OC 2 H 4 OC 2 H 5 ) 6 . The alcohol substitution reaction was confirmed by 1 H NMR spectrum. The solution had no precipitates and was a homogeneous light brown transparent liquid. The solution was spin-coated on an ITO/SiO 2 glass substrate. The substrate thus coated was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 300° C. for 2 minutes and then 700° C. for 1 hour. The resulting thin film of (Ba 0 .6 Sr 0 .4)TiO 3 having a thickness of 0.1 μm was made of single perovskite phase had an optically smooth and transparent surface.
COMPARATIVE EXAMPLE 2
Ba(OC 2 H 5 ) 2 , Sr(OC 2 H 5 ) 2 and Ti(O-i-C 3 H 7 ) 4 were simultaneously dissolved in ethylene glycol monomethyl ether which had been dehydrated by a molecular sieve in such amounts that the molar proportion of Ba:Sr:Ti was 0.6:0.4:1 to obtain a 0.6M solution. The solution was distilled at a temperature of 125° C. with stirring for 2 hours, and then refluxed for 22 hours. The solution produced metalescent precipitates when allowed to stand at room temperature for some time. Thus, a homogeneous solution was not obtained. As a result of an analysis, a large amount of Ba and Ti were detected in the precipitate. Further, Sr was detected in the solution in a higher ratio than the starting composition ratio. The results of analysis showed that a stoichiometrically excellent precursor cannot be synthesized by this comparative method.
EXAMPLE 3
Ti(O-i-C 3 H 7 ) 4 was dissolved in ethylene glycol monomethyl ether which had been dehydrated by a molecular sieve to obtain a 0.6M solution. The solution was distilled at a temperature of 135° C. with stirring for 2 hours. To the solution were then added Ba(O-i-C 3 H 7 ) 4 in such amounts that the molar proportion of Ba:Ti was 1:1 to obtain a 0.6M solution. The solution was distilled at a temperature of 135° C. with stirring for 2 hours, and then refluxed for 18 hours to obtain a composite alkoxide BaTi(OC 2 H 4 OC 2 H 5 ) 6 . The alcohol substitution reaction was confirmed by 1 H NMR spectrum. The solution had no precipitates and was a homogeneous light brown transparent liquid. To the solution was then added water in such an amount that the molar ratio of Ba:water was 1:1 to obtain a homogeneous partially-hydrolyzed solution. The solution was spin-coated on a Pt/Ti/SiO 2 /Si substrate. The substrate thus coated was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 350° C. for 2 minutes and then 700° C. for 30 minutes. The resulting thin film of a ferroelectric material BaTiO 3 having a thickness of 0.1 μm was made of single perovskite phase and had an optically smooth and transparent surface.
COMPARATIVE EXAMPLE 3
Ba(OC 2 H 5 ) 2 and Ti(O-i-C 3 H 7 ) 4 were simultaneously dissolved in ethylene glycol monomethyl ether which had been dehydrated by a molecular sieve in such amounts that the molar proportion of Ba:Ti was 1:1 to obtain a 0.6M solution. The solution was distilled at a temperature of 125° C. with stirring for 2 hours, and then refluxed for 22 hours. The solution produced a large amount of precipitates when allowed to stand at room temperature for some time. Thus, a homogeneous solution was not obtained.
EXAMPLE 4
Sr(OC 2 H 5 ) 2 and Ti(O-i-C 3 H 7 ) 4 were simultaneously dissolved in ethylene glycol monomethyl ether which had been dehydrated by a molecular sieve to obtain a 0.5M solution. The solution was distilled at a temperature of 125° C. with stirring for 2 hours, and then refluxed for 22 hours to obtain a composite alkoxide SrTi(OC 2 H 4 OCH 3 ) 6 . The alcohol substitution reaction was confirmed by 1 H NMR spectrum. The solution had no precipitates and was a homogeneous light brown transparent liquid. The solution was spin-coated on a Si substrate. The substrate thus coated was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 300° C. for 2 minutes and then 700° C. for 1 hour. The resulting thin film of SrTiO 3 having a thickness of 0.1 μm was made of single perovskite phase and had an optically smooth and transparent surface.
In the present invention, a mixture prepared by adding to a solvent represented by formula (I) metallic alkoxide compounds containing Ba, Sr and Ti components is used. If as the solvent there is used one represented by formula (I-B), the foregoing metallic alkoxide compounds are added in a specific order. Thus, the resulting thin film of an oxide represented by formula (Ba x Sr 1-x )TiO 3 (0≦x≦1) is uniform and excellent in stoichiometry and applicable to thin film capacitors, piezoelectric materials, pyroelectric materials, etc.
EXAMPLE 5
The composite alkoxide solution obtained in Example 4 was spin-coated on an ITO/SiO 2 glass substrate. The substrate thus coated was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 300° C. for 2 minutes and then 600° C. for 30 minutes. In order to evaluate electric characteristics of the thin oxide film, Pt was attached onto the thin film and the leak current was measured. The leak current was 1×10 -6 A/cm 2 when the applied voltage was 2 V.
EXAMPLE 6
To the composite alkoxide solution obtained in Example 4 was added water in such amounts that the molar proportion of Ti:water was 1:1 to obtain a homogeneous partially-hydrolyzed solution. The solution was spin-coated on an ITO/SiO 2 glass substrate. The substrate thus obtained was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 300° C. for 2 minutes and then 600° C. for 30 minutes. Onto thus obtained thin film was attached Pt and the leak current was measured. The leak current was 1×10 -5 A/cm 2 when the applied voltage was 2 V.
EXAMPLE 7
Sr(OC 2 H 5 ) 2 and Ti(O-i-C 3 H 7 ) 4 were simultaneously dissolved in ethylene glycol monoethyl ether which had been dehydrated by a molecular sieve in such amounts that the molar proportion of Sr:Ti was 1:1 to obtain a 0.6M solution. The solution was distilled at a temperature of 135° C. with stirring for 2 hours, and then refluxed for 22 hours to obtain a composite alkoxide SrTi(OC 2 H 4 OC 2 H 5 ) 6 . The alcohol substitution reaction was confirmed by 1 H NMR spectrum. The solution had no precipitates and was a homogeneous light brown transparent liquid. The solution was spin-coated on an ITO/SiO 2 glass substrate. The substrate thus coated was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 300° C. for 2 minutes and then 600° C. for 30 minutes. Onto thus obtained thin film was attached Pt and the leak current was measured. The leak current was 5×10 -7 A/cm 2 when the applied voltage was 2 V.
EXAMPLE 8
To the obtained composite alkoxide obtained in Example 7 was added water in such amounts that the molar proportion of Ti:water was 1:1 to obtain a homogeneous partially-hydrolyzed solution. The solution was spin-coated on an ITO/SiO 2 glass substrate. The substrate thus obtained was then heated at a rate of 10° C./sec. so that it was kept at a temperature of 300° C. for 2 minutes and then 600° C. for 30 minutes. Onto thus obtained thin film was attached Pt and the leak current was measured. The leak current was 5×10 -6 A/cm 2 when the applied voltage was 2 V.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A process for preparing a thin film of (Ba x Sr 1-x )TiO 3 is provided, which comprises adding to a solvent represented by formula (I-A)
R.sup.1' OR.sup.2 OH (I-A)
wherein R 1' represents an aliphatic hydrocarbon group having two or more carbon atoms; and R 2 represents a divalent aliphatic hydrocarbon group, two metallic alkoxide compounds represented by the formulae (II) and (III) or three metallic alkoxide compounds represented by formulae (II) to (IV):
Ba(OR.sup.3).sub.2 (II)
Ti(OR.sup.4).sub.4 (III)
Sr(OR.sup.5).sub.2 (IV)
wherein R 3 , R 4 and R 5 each represent an aliphatic hydrocarbon group, to make mixture, heating the mixture, applying the resulting mixture to a substrate to form a thin film, and then subjecting the material to heat treatment.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of copending International Application No. PCT/EP99/09087, filed Nov. 24, 1999, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a device for connecting piping sections of a pipeline through which a medium flows. The invention contains a number of tension elements disposed so as to be distributed over the circumference of pipe ends of the pipeline. In this case, the expression pipeline refers in particular to a pipeline through which a hot medium, for example steam, under high pressure flows.
On account of the steam parameters to be expected in future power plants, having a steam or live-steam temperature of more than 600° C. and a steam pressure of more than 250 bar, correspondingly high demands will be imposed on the pipelines and piping connections. In such a steam feed line, the connecting point between pipe sections of the pipeline carrying steam may be configured to be welded and thus undetachable or may be configured to be detachable like a flange connection. Such connections are also provided between the pipeline and a steam inlet valve of a steam turbine and between the steam inlet valve and the turbine casing. Whereas known detachable connections, on account of the low residual material characteristics of conventional materials related to the temperature, can only be used to a limited extent, welded connections, in particular in the event of an inspection, have disadvantages with regard to ease of assembly and dismantling.
The use of conventional pipe connections like a flanged and screwed pipe joint, a screwed pipe joint by a cap nut or a clamped connection, is problematic at high and maximum steam states for different reasons. The flanged and screwed pipe connection requires the availability of a screw material of sufficient strength. In addition, on account of the round screw cross section, only a limited proportion of the flange surface, i.e. of the space available radially around the pipeline, can be utilized for applying tensile forces. Furthermore, the round supporting surface of the nut requires a minimum distance from adjacent constructional elements, so that a minimum flange outside diameter results from the outside diameter of the pipeline and the minimum distance between adjacent nuts on the pitch circle and also from the outside diameter of the supporting surface. The resulting distance between the pipe outer wall and the center of the screw bolt produces a relatively high flange moment, a factor that constitutes a considerable disadvantage in particular with low available material characteristics.
In a pipe connection using a cap nut, a stress concentration occurs in particular at the transition from the cylindrical region to the axial bearing region. With low material characteristics related to the temperature, a limit in the creep deformations in this region has to be taken into account in the configuration of the cap nut, a factor which leads at high steam states to relatively large components, which can therefore only be handled with difficulty. Since a flange, after the cap nut has been inserted, has to be welded to, for example, the valve to be connected, this has an adverse effect on both the production, when welding correspondingly large wall thicknesses, and on the overall length of the connection. In addition, a relatively large, radial and axial space is required at high temperatures.
The relatively large radial expansions also result in a clamped connection disclosed, for example, by Published, Non-Prosecuted German Patent Applications DE 197 11 580 A1 or by DE 24 52 770 A1, in which a clamped connection of a number of connecting elements in the form of claw-like or clamp-like ring segments are disposed on the circumference of the flange-like connection. In addition, in a flange connection with such connecting elements, there is the disadvantage that the latter do not have sufficient strength to absorb the tensile forces, especially as the connecting elements, as a result of radially surrounding the outsides of the flange, are also subjected to a bending load in addition to a tensile stress.
Specific cooling in the region of such pipe connections between the medium carried by the pipeline and the flange connection is also problematic, since flange cooling requires an additional radial distance between the flange and the pipeline for the cooling medium. In addition, heat losses may occur due to such cooling, and these heat losses, in a steam line, may lead to a loss of working capacity, that is to an energy loss of the medium carried in the pipeline.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a device for connecting piping sections which overcomes the above-mentioned disadvantages of the prior art devices of this general type.
With the foregoing and other objects in view there is provided, in accordance with the invention, a combination of a pipeline having connecting pipes with pipe ends and contact surfaces, with a device for connecting the pipes through which a medium flows. The device contains shaped elements disposed at the pipe ends of the pipes and a number of tension elements disposed distributed over a circumference of the pipe ends of the pipes. Each of the tension elements have a tension shank with ends and extend in a longitudinal direction of the pipes between the shaped elements and the tension elements are disposed adjacent to each other in a circumferential direction of the pipes. Each of the tension elements have shaped parts with one of the shaped parts disposed at each of the ends of the tension shank and the shaped parts extend in a transverse direction of the tension elements. The shaped parts engage in the circumferential direction of the pipes behind the shaped elements at an end remote from the contact surfaces of the pipe ends.
The object is achieved by a number of tension elements. The tension elements extend with their tension shanks in the longitudinal direction of the pipe between shaped elements which are disposed at the pipe ends and are disposed adjacent to each other in the circumferential direction of the pipe. Shaped parts provided at the ends of the tension shank of the respective tension element and extending on both sides of the tension element in its transverse direction engage behind or overlap the shaped elements provided at the pipe ends in the circumferential direction of the pipe preferably in a positive-locking manner.
The connecting device has a plurality of the tension elements preferably disposed so as to be uniformly distributed over the circumference of the piping sections to be connected. The connecting device has at the same time a high strength and also at a high temperature and a high pressure of the medium carried in the pipeline, ensures an especially compact configuration of the connecting elements with especially low radial expansion compared with the known flange connections, in particular compared with the known clamped connections. In addition, stress concentrations as a result of force deflections are reduced. Furthermore, an especially advantageous equilibrium of forces, while avoiding a bending load on the tension elements, is achieved on account of the symmetrical configuration and in particular on account of the symmetrical configuration of the tension and shaped elements.
By the suitable forming of the shaped parts of the tension element or of each tension element and of the shaped elements on the respective pipe end, an especially favorable ratio between tensile cross section of the tension element and the effective areas can be set inside the positive-locking connection.
With regard to the tension elements and their shaped parts and with regard to the shaped elements of the pipe sections, a variant in which the shaped elements are formed by radial projections which are attached to or integrally formed on the respective pipe end and are therefore discrete is especially advantageous. The radial projections may also be produced by incorporating grooves in an annular bead integrally formed on the pipe end. In this variant, the shaped parts preferably integrally formed on the ends of the tensile shank, extending between adjacent projections in the longitudinal direction of the pipe, of the respective tension element are expediently configured like a hammer head. The shaped parts, that are configured in mirror symmetry like an I-girder with regard to the longitudinal axis of the tension element and which therefore project on both sides of the tension element beyond its shank in the transverse direction, engage behind the shaped elements of the respective pipe section in the circumferential direction of the pipe at the end remote from the corresponding pipe orifice.
In an expedient configuration, each pipe end has a pipe wall thickness increasing toward its contact surface, whereas the tension shank of the tension element is channeled on the side facing the pipe ends and is therefore of necked-down or concave configuration. In both embodiments, the tension element has a tension shank extending between the shaped parts and having a ring-segment-like cross-sectional area. However, the cross-sectional area may also be trapezoidal, rectangular, kidney-shaped or hexagonal.
Alternatively, the shaped elements are formed as radial recesses in the pipe wall of the pipe end, the respective pipe end being of correspondingly thick-walled configuration. In this variant the tension elements, the shaped parts of which are inserted into the recesses in a positive-locking manner, are expendiently configured at the end like a double hammer root or a fir-tree root, as is conventional practice in the case of turbine blades. Further types of joining are also conceivable, for example a saw-tooth, a hooked or a dovetailed connection. The respective shaped part of the tension element then has a corresponding number of partial branches lying one behind the other in the longitudinal direction of the pipe and being in engagement in the recess in a parallel configuration and having an outer contour adapted to the contour of the recess, the partial branches in turn projecting in the circumferential direction of the pipe, i.e. extending in the circumferential direction of the pipe. An especially preferred embodiment of this variant is a fir-tree head on the respective end of the tension element.
The tension element itself is advantageously prestressed like a tie rod. This reliably prevents the pipe ends from lifting from one another during pressurizing. To compensate for tolerances and to compensate for operationally induced elongations of the tension elements, shims are expediently provided between the opposite effective areas of the shaped parts, on the one hand, and the shaped elements, on the other hand, at least at one end of the tension element. In this case, the shim or each shim may be produced to oversize. Alternatively or additionally, a spring-back sealing element may also be provided between the pipe ends. The effective areas opposite one another may also be configured to be inclined relative to one another in such a way that the shim is virtually drawn into the groove formed between the effective areas at a distance from one another. In addition, the configuration of an inclined or rising effective area on the shaped element and/or on the shaped part has the advantage that the shaped part of the tension element is held in position during assembly. The tie rods are preferably tightened by a hydraulic device or by thermal elongation.
To avoid stress concentrations as a result of notch effects on the tension shank, extending between the shaped parts, of the tension element, the latter, on its bearing surface facing the pipe ends, has rounded-off-surface edges preferably both in the region of the shaped parts and along the tension shank. Accordingly, the shaped element or each shaped element has surface corners rounded off at the transition to the pipe end and having a rounded portion corresponding to the rounded edge portions of the tension element and having a certain radius of curvature or a combination of radii. On the one hand, this avoids sharp surface edges, which promote notch effects, inside the connection. On the other hand, especially tight bearing of the respective tension element against the outer surface of the pipe ends is possible by a rounded portion of the surface edges and corners having radii adapted to one another.
The tension elements or each tension element may also be disposed at a distance from the pipeline with a defined radial gap. The introduction of heat from the medium carried in the pipeline via the pipe outer surface into the tension element is thus reduced. On account of the heat-transmission resistance between the medium and the tension element, only a comparatively small quantity of heat is to be dissipated here if the tension elements are cooled. This advantageously leads to only a slight reduction in the temperature of the medium in the pipeline. Therefore, each of the tension elements has a heating bore for transmitting heat.
The advantages achieved with the invention consist in particular in the fact that, by the pipe connection formed by the tension elements which are connected in a positive-locking manner to corresponding shaped elements on the pipe ends of piping sections to be connected, especially favorable division of the available circumferential area of the pipeline with at the same time especially high surface utilization is achieved.
Furthermore, due to specific adaptation of the radial extent of the connection and the advantageous division of the available area, especially small deformations of the tension elements and of the pipe ends and thus only slight mechanical stresses inside the connection occur owing to the fact that the tension elements lie in the radial flange grooves or radial grooves formed by the projections or by the recesses, the tension elements bear virtually directly against the pipe outer wall beyond which the shaped elements project on the pipe end side, with the result that the smallest possible radial expansion of the connection is achieved.
Advantageously used as an assembly aid and for fixing are clamping rings which enclose the tension elements and, as a result of the radial force thus produced, hold them in their position.
In accordance with an added feature of the invention, the tension shank has a cross-sectional area shaped like a segment of a circle.
In accordance with another feature of the invention, each of the pipe ends has a contact surface and a pipe wall thickness increases toward the contact surface, and the tension shank is channeled on a side facing the pipe ends.
In accordance with a concomitant feature of the invention, the tension elements have a symmetrical configuration in both a longitudinal direction and a transverse direction.
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 a device for connecting piping sections, 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.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a pipe connection having a number of tension elements disposed so as to distributed over a pipe circumference according to the invention;
FIG. 2 is a sectional view taken along the line II—II shown in FIG. 1 with a shim between a tension element and a shaped element of the pipe connection;
FIG. 3 is a partial, cross-sectional view of a circle segment of the pipe connection taken along the line III—III shown in FIG. 1;
FIG. 4 is a perspective view of a preferred embodiment of the tension element shown in FIG. 1;
FIG. 5 is a perspective view of pipe ends of piping sections having shaped elements configured as projections;
FIG. 6 is a longitudinal sectional view of a pipe end having shaped elements according to FIG. 4 and a modified configuration of the tension element; and
FIG. 7 is an illustration of an alternative embodiment of the pipe connection having a recess at the pipe end and having the tension element with a fir-tree-like shaped part.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case. Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a pipe connection 1 in a region of pipe ends 2 , 3 of two piping sections or pipe lengths 4 and 5 , respectively, only a segment of which is shown and which, in operation, carry, for example, hot live steam D under high pressure, and are referred to below as a pipeline. The steam D has, for example, a temperature of more than 600° C. and a pressure of more than 250 bar and thus a high steam state, as is to be expected in future power plants for the generation of electrical energy.
The pipe connection 1 has a number of tension elements 6 which are disposed so as to be distributed over a circumference of the pipe ends 2 , 3 and are connected in a positive-locking manner to shaped elements 7 and 8 , respectively, integrally formed on the pipe ends 2 , 3 . The tension elements 6 , which are preferably of symmetrical configuration in both a longitudinal direction L and a transverse direction Q, lie in the longitudinal direction L of the pipe in the final assembled state and in the process cover a parting seam 9 between the pipe ends 2 , 3 , i.e. between their contact surfaces, at least approximately equally. For this purpose, each tension element 6 has a shaped part 6 a , 6 b at each end, the shaped parts 6 a , 6 b being hammerhead-shaped in the exemplary embodiment, and a tension shank 6 c extends between and in one piece with them. The tension shank 6 c of the tension element 6 extends in the longitudinal direction L of the pipe between the shaped-element pairs 7 , 8 of the pipe ends 2 , 3 , the pairs being adjacent in the circumferential direction of the pipe. With its bearing surface 11 , preferably in an accurately fitting manner in a groove formed by the shaped elements 7 , 8 , the tension element 6 bears directly against the outside of a pipe wall 10 , i.e. against its corresponding bearing surface 11 ′ (FIG. 5 ). This is illustrated in FIG. 3 in a sectional representation taken along line III—III shown in FIG. 1 .
As illustrated in FIG. 3 with reference to the shaped elements 8 of the pipe end 3 and as can clearly be seen from FIG. 5, the shaped elements 7 , 8 are integrally formed on the pipe outer wall 10 of the respective pipe end 2 or 3 in the form of projections. Alternatively, an annular bead may also be integrally formed on the pipe ends 2 , 3 , grooves accommodating the tension elements 6 being made in the annular bead. Especially favorable utilization of space at the pipe circumference with little radial expansion of the pipe connection 1 , resulting in especially small lever arms, is achieved by the direct bearing of the tension elements 6 against the pipe outer wall 10 . It can also be seen that the ratio between tension cross sections F z of the tension elements 6 and pressure areas F p of the shaped elements 7 , 8 and the effective pressure areas F p ′ (see FIG. 4 ), corresponding with the latter, of the tension elements 6 can be optimized in a simple manner with regard to the material geometry.
FIG. 4 shows a preferred embodiment of the tension element 6 . The tension cross-sectional area F z and the pressure areas F p ′ are shown hatched here for the purposes of illustration. The tension element 6 corresponds in cross section to a segment of a circular ring. Surface edges 13 in a region of the bearing surface 11 of the tension shank 6 c of the tension element 6 are provided with a rounded portion R. Accordingly, surface edges 14 , 15 , adjoining the surface edges 13 , of the shaped parts 6 a and 6 b , respectively, are rounded off in the region of the bearing surface 11 , so that an especially favorable configuration from the notching point of view is provided for overall by the rounded portions 13 to 15 . A height H 1 and H 2 of the shaped parts 6 a and 6 b , respectively, is selected with regard to sufficiently low mechanical stresses, i.e. bending or shearing stresses resulting from a force at right angles to the shaped part 6 a , 6 b.
The advantage of this configuration of the tension elements 6 and of the shaped elements 7 , 8 of the pipe ends 2 and 3 , respectively, the shaped elements 7 , 8 corresponding with the tension elements 6 within the positive-locking connection, consists in particular in the fact that the force is transmitted very close to the pipe outside diameter and thus very close to the pipe outer wall 10 . As a result, the space available radially is utilized in an especially favorable manner. Such a compact type of construction of the pipe connection 1 has an advantageous effect in particular with the low material characteristics that exist at high temperatures. A considerably larger tension cross section F z can therefore be achieved overall compared with a flange connection. In addition, the connection has a favorable cross section F z +F p which can be utilized as a whole for the transmission of force. In this case, the ratio of the pressure areas F p , F p ′—and thus of the positive-locking areas—to the tension cross sections F z —and thus to the tension region—of the tension elements 6 may be selected in such a way that the respective stress limit values of the materials used for the tension element 6 and the pipe ends 2 , 3 can be utilized to an especially high degree.
The configuration of the shaped elements 7 , 8 on the pipe ends 2 , 3 of the pipeline 4 , 5 are shown in FIG. 5, which shows the pipe ends 2 , 3 with the projections or the shaped elements 7 and 8 , respectively, integrally formed thereon, without the tension elements 6 . Surface corners 13 ′ and 15 ′ are provided with a corresponding rounded portion R in the transition region between the shaped elements 7 , 8 and the outer circumference 11 ′ of the respective pipe end 2 and 3 , respectively. A height H 3 of the shaped elements 7 , 8 is established with regard to a sufficiently low stress level.
The radial extent and thus a width B, B′ (FIG. 4) of the shaped elements 7 , 8 and of the tension elements 6 , respectively, are determined from the active axial connecting force, which depends essentially on the internal pressure prevailing in the pipeline 4 , 5 , and from the admissible pressures and tensile stresses. By selecting the respective height H 3 and H 1 , H 2 , the projections or shaped elements 7 , 8 , which are subjected to bending stress, and the shaped parts 6 a , 6 b of the tension elements 6 can be configured in such a way that bending and shearing stresses and also corresponding deformations are sufficiently low. The configuration of the shaped parts 6 a , 6 b on both sides, preferably a symmetrical configuration of the same, on the tension element 6 avoids undesirable bending in the tension region, i.e. in the region of the tension shank 6 c . This corresponds to the design principle of the equilibrium of forces. The connecting device or pipe connection 1 with a symmetrical configuration of the shaped elements 7 , 8 and shaped parts 6 a , 6 b ensures that stress concentrations due to a force deflection are substantially reduced, and a region having only a tensile stress without bending is created. A mass of the tension element 6 is markedly smaller than the mass of a corresponding cap nut.
The tension elements 6 are preferably prestressed, so that the lifting of the pipe ends 2 , 3 from one another as a result of pressurizing is prevented. Tolerances of the components and unavoidable elongations of the tension elements 6 upon reuse after a long operating period under high temperatures are expediently compensated for by shims 16 (FIG. 1, FIG. 2 ). The shims 16 are preferably produced with due regard to the actual dimensions of the components, i.e. in particular with due regard to a distance between bearing surfaces 17 , 17 ′ of the shaped elements 7 and 8 (FIG. 5 ), respectively, of the pipe ends 2 , 3 , and the distance between the shaped parts 6 a , 6 b of the tension elements 6 . With reference to these dimensions, i.e. twice the height H 3 and a length l of the tension shank 6 c (FIG. 4 ), a requisite shim thickness d is determined and a corresponding shim 16 produced. This compensates for tolerances, and for creep deformations that occur during previous operation as a result of high temperatures, and additionally prestresses the tension elements 6 , which act as tie rods. This is expediently effected by the shims 16 being produced with oversize.
The effective or pressure areas F p , F p ′ opposite one another may also be configured to be inclined relative to one another in such a way that the shim 16 is virtually drawn into a chamber 12 formed between the effective areas F p , F p ′ at a distance from one another. This is illustrated in FIG. 2, which shows a section taken along line II—II shown in FIG. 1 . Here, the angles α 1 and α 2 of inclination of the pressure or effective areas F p and F p ′, respectively, are shown exaggerated. In addition, the configuration of an inclined or rising effective area F p , F p ′ on the shaped element 8 and/or on the shaped part 6 b has the advantage that the shaped part 6 b of the tension element 6 is held in position during assembly.
The angles α 1 and α 2 should be selected in accordance with the relationship α 1 ≦α 2 <90°.
Once the tension elements 6 have been inserted between the shaped elements 7 , 8 and the corresponding shaped parts 6 a have been brought into contact with the shaped elements 7 at one end, expediently the top end, and have been fixed there if need be, the tension elements 6 are expediently elongated thermally or hydraulically. The elongation is effected until the oversize of the shims 16 has been overcome and the shims 16 can be inserted. A heating bore 18 which passes through the respective tension element 6 in the longitudinal direction L is expediently provided for the thermal elongation (FIG. 4 ). The tension elements 6 are clamped after the elongation is neutralized. The connection 1 is released in the opposite sequence.
A spring-back seal 19 can compensate for any possible deformations of the connecting partners, i.e. of the pipe ends 2 , 3 and the tension elements 6 . FIG. 6 shows an example of configuration of the spring-back seal 19 . During assembly, a top and a bottom clamping ring 20 and 21 , respectively, are placed around the connection 1 , i.e. around the configuration of the tension elements 6 , so that the latter are fixed at least during assembly (FIG. 1 ).
The tension elements 6 may also be cooled. Due to the fact that heat conduction from the hot steam D to the tension elements 6 is only indirect, the tension elements 6 can be cooled in a simple manner, for example by cooling ribs or by axial cooling bores. On account of the heat-transmission resistance between the medium D carried in the pipeline 4 , 5 and the tension elements 6 , only a comparatively small quantity of heat is to be dissipated, so that only a correspondingly slight reduction in the temperature of the medium D in the pipeline 4 , 5 is effected. For the cooling, the tension elements 6 may be configured with a defined radial gap 22 (FIG. 1) relative to the pipeline 4 , 5 in order to additionally reduce the heat conduction.
The rounding-off of the surface edges 13 to 15 of the tension element 6 and of the surface corners 13 ′ to 15 ′, corresponding with the latter, on the pipe outer surface 10 is of considerable importance with regard to a favorable configuration of the connecting partners 6 and 7 , 8 from the notching point of view, in particular in the case of low residual material characteristics. The prestressing can be set in operation when required by specific heat control, e.g. by a permanent temperature difference between the tension elements 6 and the pipe ends 2 , 3 . Any differences in the thermal expansion when using different materials for the tension elements 6 on the one hand and the pipe ends 2 , 3 on the other hand can be at least partly compensated for by temperature control, i.e. by specific cooling or heating, or also by shims 16 having high coefficients of expansion.
FIG. 6 shows a variant of the pipe connection 1 according to FIG. 1, having an undisturbed pipe wall thickness w increasing toward the parting seam 9 and thus toward a contact surface 23 of the respective pipe end 2 , 3 . This permits an especially favorable transmission of the load directed into the shaped elements 7 , 8 . An annular groove 24 for accommodating the spring-back seal 19 is formed in the contact surface 23 .
The tension shank 6 c of the tension element 6 —as shown by a dash-lined contour in the left-hand half of FIG. 6 —is channeled on its side facing the pipe ends 7 , 8 and therefore has a concave bearing surface 11 in this region. The tension element 6 therefore has a notch-free region at the level of the contact surface 23 of the pipe end 7 , 8 , adjoining which notch-free region, in the direction of the respective shaped part 6 a or 6 b , is a region of enlarged cross section for reducing the notch stress.
This embodiment has the advantage that large cross sections are provided in the region of the force deflection, namely in the region between the shaped parts 6 a , 6 b and the tension shank 6 c between the shaped elements 7 , 8 and the pipe ends 2 and 3 , respectively, these cross sections producing an especially low stress concentration at these locations. This therefore provides for an especially favorable configuration with regard to notch effects.
FIG. 7 shows an alternative embodiment of the pipe connection 1 with reference to a detail of one of the pipe ends 2 , 3 . In this case, the shaped elements are formed by radial recesses 7 ′, 8 ′ on the respective pipe end 2 , 3 , only the shaped part 6 a ′, for example, which rests in the recess 7 ′ of the pipe end 2 , of the tension element 6 ′ being shown here. The tension element 6 ′ is also of a symmetrical configuration in this embodiment. The shaped parts 6 a ′, 6 b ′ of the respective tension element 6 ′ have a number of partial branches 25 lying one behind the other in the longitudinal direction L of the pipe and being in engagement in the recess 7 ′, 8 ′ in a parallel configuration. In the exemplary embodiment, the shaped parts 6 a ′, 6 b ′ are shaped like a fir-tree root, as often used in blade roots of turbine blades (fir-tree-root connection). Other shapes are also conceivable, the outer contour of the respective shaped part 6 a ′, 6 b ′ being adapted in each case to the inner contour of the recess 7 ′ and 8 ′, respectively.
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To connect piping sections of a pipeline through which a hot and highly compressed medium flows, a number of tension elements are provided. The tension elements extending with their tension shanks in a longitudinal direction of the pipe between shaped elements which are provided at the pipe ends and are adjacent in the circumferential direction of the pipe. Shaped parts are provided at the ends of the tension shank and extend on both sides of the tension element in its transverse direction engaging behind the shaped elements in the circumferential direction of the pipe.
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BACKGROUND OF THE INVENTION
This invention relates generally to textile fabrics having conductive polymer films thereon, and in particular to fabrics having a pattern formed by conductive and non-conductive areas.
Textiles, such as fibers, yarns and fabric, having a conductive polymer coating, are disclosed by Kuhn et al. in U.S. Pat. No. 4,803,096. These electrically conductive textiles have been suggested for use in the control of static electricity, attenuation of electromagnetic energy and resistance heating. For some applications, it has been found to be desirable to provide a textile fabric having anisotropic electrical conductivity. In Pittman et al, U.S. Pat. No. 5,102,727 and Gregory et al, U.S. Pat. No. 5,162,135, textiles having a conductivity gradient were prepared by blending conductive and non-conductive yarns, or by contacting the conductive textile with a chemical reducing agent, respectively. While satisfactory for some applications, the methods used to produce conductivity gradients do not readily lend themselves to the manufacture of more complex patterns.
Alternatively, patterned electrically conductive textiles, that is fabrics having a pattern of conductive and non-conductive areas, may be provided by selectively removing portions of the conductive polymer film with, for example, high velocity water jets, as in Adams, Jr. et al, U.S. Pat. No. 5,292,573 and U.S. Pat. No. 5,316,830. A characteristic of the water jet process is that some, but not all of the conductive polymer film is removed from the textile fiber. Accordingly, the difference in conductivity between treated and untreated areas of the fabric may not be as distinct as desired. Further, the process requires the use of relatively sophisticated equipment, which is not readily available.
A limitation on the application of conductive polymers in general has been their lack of stability to environmental conditions resulting in a decline in conductivity with age. The influence of temperature, humidity and oxidation level on the stability of conductive polymers was discussed in Munstedt, H., "Aging of Electrically Conducting Organic Materials", Polymer, Vol. 29, page 296-302 (February, 1988). It has been proposed to apply a protective film or laminate to the conductive polymer to exclude oxygen and otherwise limit environmental exposure. However, one of the advantages of conductive textile fabric is its flexibility, which may be diminished by the application of protective coatings to the fabric.
SUMMARY OF THE INVENTION
Therefore, an object of the invention is to provide a conductive textile fabric having conductive and non-conductive areas which form a pattern. Another object of the invention is to provide a method of manufacturing conductive textile fabric, which may be adapted to the formation of complex patterns of conductive and non-conductive areas. Another object of the invention is to provide a patterned conductive textile with high resolution between conductive and non-conductive areas. Yet, another object of the invention is to provide a conductive textile with a protective coating over the polymer film. Another object of the invention is to protect a conductive polymer film on a textile substrate, with a minimum impact on the flexibility of the substrate.
Accordingly, a fabric having patterned conductivity is provided by depositing a conductive polymer film on the fabric; coating selected areas of the fabric with a second polymer film which is resistant to a chemical etching agent used to degrade the conductive polymer; and applying a chemical etching agent to the fabric to degrade the conductive polymer on areas of the fabric which have not been coated with the second polymer film, thereby creating areas of low conductivity adjacent the areas of high conductivity.
In addition to meeting the aforementioned objectives, the composition and method of the present invention has the advantage that only those areas of the fabric which retain the conductive polymer film are coated with the protective polymer film (second polymer), thereby maximizing the flexibility of the fabric and conserving use of the protective polymer coating. Further, the invention preferably comprises one or more of the following features:
the tolerance for placement of areas of high conductivity and the areas of low conductivity is ±2 mm or less, preferably ±0.5 mm or less;
the areas of low conductivity are devoid of the conductive polymer film;
the areas of low conductivity are devoid of the protective polymer film coating;
the areas of high conductivity have a resistivity of 1000Ω per square or less;
the protective polymer film is an oxygen barrier; and
the ratio of conductivity between the areas of high conductivity and the areas of low conductivity is 100 or greater.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a woven fabric having a conductive polymer film which is selectively coated with a protective film.
FIG. 2 is a woven fabric which has been treated with a chemical etching agent to remove the conductive polymer from unprotected areas.
FIG. 3 is a cross section of a woven fabric showing areas of high conductivity which have a protective film thereon, and areas of low conductivity.
DETAILED DESCRIPTION OF THE INVENTION
Without limiting the scope of the invention, the preferred embodiments and features are hereinafter set forth. Unless otherwise indicated, all parts and percentages are by weight and conditions are ambient i.e. one atmosphere of pressure and 25° C. The terms aryl and arylene are intended to be limited to single and fused double ring aromatic hydrocarbons. Unless otherwise specified, aliphatic hydrocarbons are from 1 to 12 carbon atoms in length, and cycloaliphatic hydrocarbons comprise from 3 to 8 carbon atoms.
The fabric of the present invention may have a woven, knit or non-woven construction. The fibers comprising the fabric have a conductive polymer film deposited thereon. By way of example, the conductive polymer may be selected from polypyrrole, polyaniline, polyacetylene, polythiophthene, poly-p-phenylene, poly(phenylene sulfide), poly(1,6-heptadiyne), polyazulene, poly(phenylene vinylene), and polyphthalocyanines. Preferably, the conductive polymer is selected from polypyrrole, polyaniline and polythiophthene.
As used herein, the terms polypyrrole, polyaniline, polythiophthene, etc. are intended to include polymers made not only from the polymerization of pyrrole, aniline, and thiophthene respectively, but also polymers made from substituted pyrrole, aniline, and thiophthene monomers, as is known to those skilled in the art. By way of example; polypyrrole may be synthesized from the following monomers or combinations thereof; pyrrole, 3- and 3,4-alkyl or aryl-substituted pyrrole, N-alkylpyrrole, and N-arylpyrrole. Similarly, by way of example, the following monomers or combinations thereof are suitable for polyaniline synthesis: aniline, 3, and 3,4-chloro, bromo, alkyl or aryl-substituted aniline.
Fabrics having an electrically conductive polymer film deposited thereon are referred to generally herein as conductive fabrics. Methods of depositing a conductive polymer film on a textile fiber are disclosed in the following patents: Kuhn et al, U.S. Pat. No. 4,803,096; Kuhn, U.S. Pat. No. 4,877,646; and U.S. Pat. No. 4,981,718, all of which are incorporated by reference. The fibers may be treated according to the aforementioned methods in the form of staple, continuous monofilament, spun yarn, continuous multifilament yarn or in the form of a fabric. Preferably, the textile is in the form of a woven or knit fabric constructed from continuous, multifilament yarn, when the fabric is treated to provide a conductive polymer film on the fibers.
The conductive polymer is formed on the textile material in amounts corresponding to about 0.5% to about 4%, preferably 1.0% to about 3% and most preferred about 1.5% to about 2.5%, by weight based on the weight of the textile. Thus, for example, for a fabric weighing 100 grams, a polymer film of about 2 grams may be formed on the fabric.
A wide variety of natural and synthetic fibers may be used as the textile substrate. By way of example, the following substrates may be employed: polyamide fibers, including nylon, such as nylon 6 and nylon 6,6, and aramid fibers; polyester fibers, such as polyethylene terephthalate (PET), polyolefin fibers, such as polypropylene and polyethylene, acrylic fibers, polyurethane fibers, cellulosic fibers, such as cotton, rayon and acetate; silk and wool fibers, and high modulus inorganic fibers, such as glass, quartz and ceramic fibers.
Electrically conductive textiles having a resistivity of 1000Ω per square or less, preferably 500Ω per square or less find utility in the present invention. Standard test methods are available in the textile industry and, in particular, AATCC test method 76-1982 is available and has been used for the purpose of measuring the resistivity of textile fabrics. According to this method, two parallel electrodes 2 inches long are contacted with the fabric and placed 1 inch apart. Resistivity may then be measured with a standard ohm meter capable of measuring values between 1 and 20 million ohms. Measurements must then be multiplied by 2 in order to obtain resistivity in ohms on a per square basis. While conditioning of the samples may ordinarily be required to specific relative humidity levels, it has been found that conditioning of the samples made according to the present invention is not necessary since conductivity measurements do not vary significantly at different humidity levels. The measurements reported are, however, conducted in a room which is set to a temperature of 70° F. and 50% relative humidity. Resistivity measurements are reported herein and in the examples in ohms per square (Ω/sq) and under these conditions the corresponding conductivity is one divided by resistivity.
The next step of the process is to coat selected areas of the conductive fabric with a protective film, where it is desired to maintain electrical conductivity (areas of high conductivity). The protective film is resistant to a chemical etching agent which is subsequently applied to degrade the conductive polymer film on those areas of the fabric which have not been protected (areas of low conductivity). The protective film has a second function as well, that is to serve as an oxygen and moisture barrier, thereby increasing the stability of the conductive polymer film underneath. The protective film is preferably non-conductive.
Any of a large number of compositions may be useful in coating selected areas of the conductive fabric with a protective film. By way of example, the composition may comprise compounds selected from poly(vinyl chloride), parrafin, poly(vinylidene chloride)-poly(acrylic acid) copolymer (PVdC-PAA), poly(vinylidene chloride) (PVdC), polyester and polyolefin. Preferably, the composition is a polymer.
Conventional coating techniques may be employed for providing a conductive film on the conductive fabric in a desired pattern. Examples include screen printing, transfer printing, lamination and masking. Preferably, both sides of the conductive fabric are treated as mirror images, so that areas of high conductivity are protected on both the face and back of the fabric.
The protective composition may be applied to the fabric in the form of a dispersion, emulsion, plastisol, solution, molten, fine particulate or film. The protective compositions may be cured to form a continuous film by techniques known to those in the coating, printing or lamination arts and depending on the form of the composition applied, may include one or more of the following processes: heated to remove volatile components; melted; cooled to solidify; polymerized or cross linked in situ by heating, catalyzation and/or free radical initiation. For example, emulsions of PVdC-PAA copolymer are heat-set at temperatures of between 300° and 400° F. for approximately 1 to 3 minutes to cure the resin.
Generally, the protective film add on, when cured, to those areas of high conductivity intended to be protected is from 10 to 200 wt. %, preferably 20 to 150 wt. % per side of fabric, based on the weight of the fabric, and may range from 0.01 to 0.2 mm in thickness, preferably 0.02 to 0.1 mm, per side of fabric.
Referring to FIG. 1, conductive fabric 1 having a conductive polymer film thereon is coated in selected areas 2 with a protective film. Other areas of fabric 1, designated as uncoated area 3, remain unprotected.
Next, the conductive fabric having selected areas coated with a protective film, is subjected to a chemical etching agent which degrades the conductive polymer film in the unprotected areas. The use of reducing agents to degrade a conductive polymer film is disclosed in Gregory et al, U.S. Pat. No. 5,162,135, incorporated by reference. Examples of suitable reducing agents are zinc formaldehyde sulfoxylate, sodium formaldehyde sulfoxylate, thiourea dioxide, sodium hydrosulfite, sodium borohydride, zinc, hydrazine, stannous chloride, and ammonium hydroxide. Preferably, the reducing agent contains a zinc ion. More preferably, the reducing agent is zinc formaldehyde sulfoxylate. Aqueous solutions of the reducing agent are also preferred.
Alternatively, oxidizing agents may be used as the chemical etching agent to remove the conductive polymer film from unprotected areas. By way of example, suitable oxidizing agents include sodium hypochlorite and hydrogen peroxide. Aqueous solutions of the oxidizing agent are preferred.
The fabric may be contacted with the chemical etching agent by any of a number of methods, including emersion, padding, spraying or by transfer roller. The contact time required to degrade the conductive polymer film the desired degree, depends on the reactivity, concentration, and temperatures, among other factors. For example, a 11/2% aqueous solution of sodium hypochlorite will remove a polypyrrole film in 2 minutes at 25° C.
Following treatment with the chemical etching agent, the fabric may be treated with a neutralizing or deactivating solution or simply rinsed.
Referring to FIG. 2, patterned conductive fabric 4 results from application of a chemical etching agent to the conductive fabric 1 of FIG. 1. The unprotected area 5 of patterned conductive fabric 4 is devoid of the conductive polymer film and now represents an area of low conductivity, and is essentially non-conductive, that is the conductivity is not substantially different from the fabric substrate. Area 2, which is coated with the protective film, represents an area of high conductivity, which is substantially equivalent to the conductivity of the conductive fabric prior to a application of the chemical etching agent.
FIG. 3, is a cross section along plane A--A of FIG. 2. Yarns 6 are devoid of any coating in the area 5 of low conductivity and have conductive polymer 7 and protective film 8 in the area 2 of high conductivity.
The "tolerance" is used herein to describe the variance between the desired position of a particular area of high conductivity or low conductivity, and the position which is actually achieved by the process. For example, if the specification called for a 2 cm×2 cm square area of high conductivity, with a resolution of ±2 mm, a 1.8 cm×1.8 cm square up to a 2.2 cm×2.2 cm square would be acceptable. By employing the present invention, it is possible to achieve tolerances of ±1 mm or less, and in particular tolerances of ±0.5 mm or less.
Higher resolutions may best be achieved by employing fabrics which weigh less than 4 ounces per square yard, preferably less than 3 ounces per square yard. Additionally, fabrics made with yarns having a denier of 70 to 420 are preferred for achieving the best resolutions.
An infinite number of patterns of conductive and non-conductive areas may be created by using the present invention. The ratio of conductive to non-conductive areas may range any where from 1:99 to 99:1, and is preferably between 30:70 and 70:30, respectively.
The invention may be further understood by reference to the following examples but is not intended to be unduly limited thereby.
EXAMPLE 1
A woven fabric consisting of 70 denier textured polyester yarns, weighing 2 ounces per square yard was made conductive by coating the fabric with polypyrrole according to Kuhn et al, U.S. Pat. No. 4,803,096. A mixture consisting of 88 parts PVdC-PAA copolymer emulsion (40 wt. % solids), 2 parts guar gum thickener and 10 parts water, was applied by flat screen printing in a predetermined pattern to the fabric. A mirror image screen was affixed to the back of the fabric and the mixture was next screen printed onto the back side of the fabric also. The fabric was removed and allowed to air dry, until the PVdC-PAA polymer composition was dry to the touch (approximately 30 minutes), and then the fabric was cured at 300° F. for 10 minutes.
The fabric was then immersed in a 1% sodium hypochlorite solution for 2 minutes and removed. The fabric was allowed to drip dry for approximately 2 minutes rinsed with copious amounts of water, and allowed to air dry.
EXAMPLE 2
The following example demonstrates the improved stability of the conductive polymer film on fabric, when the film has been coated with a protective polymer.
A knitted mesh fabric consisting of 150 denier, textured polyester yarn and weighing approximately 2 ounces per square yard was made conductive by coating the fabric with polypyrrole according to Kuhn et al, U.S. Pat. No. 4,803,096. The fabric's microwave attenuation was measured at 8-10 GHz and recorded.
The conductive fabric was cut in half and one of the halves was immersed in an aqueous dispersion of PVdC, removed and cured to provide a uniform coating, with approximately 40 wt. % solids pickup, based on the weight of the conductive fabric.
Next, both the coated and uncoated halves of the conductive fabric were placed in an accelerated aging chamber. After 200 kJ of exposure, the samples were removed and the microwave attenuation was measured. The coated fabric sample retained 72% of its initial attenuation, whereas the uncoated fabric retained less than 5% of its initial attenuation properties.
There are, of course, many alternate embodiments and modifications of the invention, which are intended to be included in the scope of the following claims.
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A patterned conductive textile is provided by depositing a conductive polymer film on the fabric to provide a resistivity of 1000 ohms per square or less, coating selected areas of the fabric with a protective film, to protect the conductive polymer from a chemical etching agent, to provide an oxygen barrier and to retain areas of high conductivity, applying a chemical etching agent to the fabric thereby degrading the conductive polymer film on areas of the fabric which have not been coated with the protective film and create areas of low conductivity and rinsing the fabric to remove any residual etching agent.
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[0001] This application is a Divisional patent application of U.S. patent application Ser. No. 14/920,132 filed Oct. 22, 2015, now U.S. Pat. No. 9,677,835, which is incorporated by reference in its' entirety.
FIELD OF THE INVENTION
[0002] This invention relates to firearms and, in particular, to devices, apparatus, systems, and methods for locking and preventing handgun and long gun firearms from being able to discharge.
BACKGROUND AND PRIOR ART
[0003] Millions of persons own firearms that are considered valuable and potentially dangerous when in the wrong hands. These firearms are usually stored in homes or on private property where access to individuals other than the owner becomes a problem.
[0004] Owners of firearms should be concerned that their weapons are safely stored to eliminate the possibility of inadvertent or intentional use that is improper or unauthorized. For example, children shoot themselves or each other; impulsive users of guns during stress or in the heat of domestic squabbles results in tragedies; troubled or mentally unbalanced individuals are found responsible for mass killings, and outright theft of weapons causes economic loss.
[0005] In 2011, the state of Florida enacted Florida Statute 790.174 entitled, “Safe storage of firearms required,” to address a growing concern for weapons or firearms accessible to minors (children). The statute states in part—
“(1) A person who stores or leaves, on a premise under his or her control, a loaded firearm, . . . and who knows or reasonably should know that a minor is likely to gain access to the firearm without the lawful permission of the minor's parent or the person having charge of the minor, or without the supervision required by law, shall keep the firearm in a securely locked box or container or in a location which a reasonable person would believe to be secure or shall secure it with a trigger lock, except when the person is carrying the firearm . . . (2) It is a misdemeanor of the second degree, . . . if a person violates subsection (1) by failing to store or leave a firearm in the required manner and as a result thereof a minor gains access to the firearm, without the lawful permission of the minor's parent or the person having charge of the minor, and possesses or exhibits it, without the supervision required by law: (a) in a public place; or (b) in a rude, careless, angry, or threatening manner . . . . This subsection does not apply if the minor obtains the firearm as a result of an unlawful entry by any person. (3) As used in this act, the term “minor” means any person under the age of 16.”
[0009] The Florida statute 790.174 is one example of legislative recognition of the potential danger of firearms in the wrong hands. The further statutory requirement of locked storage or a trigger lock encourages the manufacture, sale and use of locking devices for the safe storage of firearms.
[0010] A number of such devices are shown in the following United States Patents.
[0011] U.S. Pat. No. 557,522 to Blake issued Mar. 31, 1896, shows a padlock with a rigid hasp or flexible chain hasp and a number of notches or holes in a key made to correspond with a number of tumblers in a locking mechanism.
[0012] U.S. Pat. No. 3,018,576 to Riechers issued Jan. 30, 1962, shows a rectangular-shaped device that is locked onto the firearm making it impossible to load shells or cartridges into the firearms.
[0013] U.S. Pat. No. 3,857,491 to Townsend et al issued Dec. 31, 1974, describes a vehicle mounted gun rack with key operated lock for operating a slidable C-shaped clamp mechanism to lock the stock portion of the gun to the rack.
[0014] U.S. Pat. No. 4,776,471 to Elkins issued Oct. 11, 1988, shows a gun rack for a vehicle or wall with upwardly opening cradles within which a gun can be supported and a restraining latch that holds the gun in the cradle in a manner which children find difficult to open. The cradle design prevents a firearm from being inadvertently bumped, jarred or otherwise removed from the cradle. There is no provision for a locking mechanism.
[0015] U.S. Pat. No. 5,138,786 to Fischer issued Aug. 18, 1992, discloses a wall mountable safety guard for a rifle, shotgun or handgun consists of thick steel plate housing hinged with side flaps and tongue that is designed to be burglar proof. The steel plate housing encloses a trigger guard for the weapon and employs a combination lock or padlock.
[0016] U.S. Pat. No. 5,475,993 to Kuo issued Dec. 19, 1995, discloses a locking device with links that do not form an outwardly direct acute angle that is easily broken, for securing objects of regular or irregular shape. Kuo does not teach or suggest locking a trigger or magazine chamber of a firearm.
[0017] U.S. Pat. No. 5,544,505 to McIntosh et al. issued Aug. 13, 1996, shows a lock bracket in two parts held together by a hinge preferably offset to one side; the two parts come together as a shackle, each part overlapping and cooperating to receive a padlock. The lock bracket encloses objects to be secured, such as gates, bicycles to bike racks and the like.
[0018] U.S. Pat. No. 6,044,669 to Levi issued Apr. 4, 2000, shows a strap and lock body wherein the strap has a free end portion, a hinge and a lock. The strap is adjustable; the lock engages a series of teeth or a pair of chain-like links located on the strap and prevents withdrawal without disengagement by the user. A pair of hinges allow the hinge portion to lie flush against the lock body and tightly secure an object without rattling or inadvertent disengagement.
[0019] U.S. Pat. No. 6,330, 815 to Duncan issued Dec. 18, 2001, shows a mounting device for securing a firearm to a support structure such as a motor vehicle. The device has a base with protruding posts to mount a gun, a cover with lock and key to secure the firearm between the base and cover.
[0020] U.S. Pat. No. 6,427,497 to Mossberg, Jr. et al. issued Aug. 6, 2002, shows a wall-mounted locking system for firearms that provides a box-like enclosure with a wall-mounted base plate, a breech hook, hinged primary and secondary latch doors and a barrel ring to receive the barrel of the firearm mounted to the wall above the base plate.
[0021] What is missing in the prior art is a comprehensive and versatile safety devices that locks both handgun and long gun firearms so that it becomes impossible to discharge the weapon. Thus, it is apparent that a continuing need exists for a safety device for firearms that is useful on a variety of firearms, such as handguns, long guns, is affordable economically, and absolutely prevents the discharge of a firearm.
SUMMARY OF THE INVENTION
[0022] A primary objective of the present invention is to provide devices, apparatus, systems, and methods for locking and preventing both handgun and long gun firearms from being able to discharge.
[0023] A secondary objective of the present invention is to provide devices, apparatus, systems, and methods for locking a firearm that is simpler, compact and easy to manufacture.
[0024] A third objective of the present invention is to provide devices, apparatus, systems, and methods for locking a firearm that removes the working magazine from both handguns and long guns that use magazines, and replaces the working magazine with a non-working magazine that is locked onto the weapon.
[0025] A fourth objective of the present invention is to provide devices, apparatus, systems, and methods for locking the trigger of both handgun and long gun firearms in a non-fire position.
[0026] A fifth objective of the present invention is to provide devices, apparatus, systems, and methods for locking and preventing pump action shot gun from being fired.
[0027] A sixth objective of the present invention is to provide methods, systems, apparatus and devices for mounting and locking a firearm onto a stable surface, such as a wall.
[0028] In the various embodiments described below, the present invention solves the problem of completely disabling a firearm and accomplishes the above objectives by providing a locking device that can be used as a singular device or in varying multiples on a firearm so that it becomes virtually impossible for the firearm to be discharged.
[0029] A first embodiment provides a firearm locking system with a lock housing attached to a ratchet style belt to lock up a non-working magazine in the machine gun or rifle wherein the working magazine has been removed. Not only is there no ammunition in the gun, but the non-working magazine assures that there are no rounds to be discharged.
[0030] A second embodiment provides a wall mount for a handgun or a long gun using the lock housing with a detachable mounting device that is attached to a stable surface, such as a wall. The detachable mounting device locks into one end of the lock housing that is opposite to the end having a belt cavity and an attached ratchet belt. The locking system can be rotated in ninety degree increments without changing the orientation of the wall mount device.
[0031] A third embodiment provides a separate trigger lock for handguns and long guns.
[0032] A fourth embodiment provides a ratchet belt lock for a pump action shot gun.
[0033] A fifth embodiment provides for combining two or more ratchet belt locks per firearm to insure that all means for discharging the weapon are disabled or locked.
[0034] Further objects and advantages of this invention will be apparent from the following detailed description of preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0035] FIG. 1 is a front perspective view of an Armalite (AR) style rifle. (Prior Art)
[0036] FIG. 2 shows the working magazine removed from the rifle shown in FIG. 1 and a non-working magazine slide assembly (NWMS) of the present invention before it is inserted into the rifle.
[0037] FIG. 3 shows the non-working magazine slide assembly (NWMS) of the present invention after it is inserted into the rifle shown in FIG. 1 .
[0038] FIG. 4 is a front perspective view of the fully assembled non-working magazine slide assembly (NWMS) of the present invention.
[0039] FIG. 5 is an exploded view of the non-working magazine slide assembly (NWMS) of the present invention showing all parts.
[0040] FIG. 6 is a front view of the fully assembled non-working magazine slide assembly (NWMS) of the present invention.
[0041] FIG. 7 is a side view of the fully assembled non-working magazine slide assembly (NWMS) of the present invention.
[0042] FIG. 8 is a front perspective view of the non-working magazine slide assembly (NWMS) of the present invention inserted into an AR style rifle and the lock housing with attached ratchet belt in position before it is fed into the non-working magazine slide assembly (NWMS).
[0043] FIG. 9 shows the lock housing with attached ratchet belt after the ratchet belt is inserted into the non-working magazine slide assembly (NWMS).
[0044] FIG. 10 is a front perspective view of the lock housing with attached ratchet belt wherein the belt is in position to be inserted into the belt cavity of the lock housing.
[0045] FIG. 11 is a rear perspective view of the lock housing with attached ratchet belt showing the ratchet belt in position to be inserted into the belt cavity located on the end opposite to the wall mount attachment of the lock housing.
[0046] FIG. 12 is a front perspective view of the lock housing with attached ratchet belt wherein the belt is snug around the rifle and pulled through the belt cavity of the lock housing which secures the non-working magazine slide assembly (NWMS) to the rifle and lock housing.
[0047] FIG. 13 is a rear perspective view of the lock housing with attached ratchet belt wherein the belt is snug around the rifle and pulled through the belt cavity of the lock housing which secures the non-working magazine slide assembly (NWMS) to the rifle and lock housing. The rear perspective view also shows the wall mount attachment of the lock housing.
[0048] FIG. 14 is a rear perspective view of the lock housing with attached ratchet belt wherein the belt is pulled through the belt cavity of the lock housing with the key in the “all locked” position; the rear perspective view also shows the wall mount attachment of the lock housing.
[0049] FIG. 15 is a rear perspective view of the lock housing with attached ratchet belt wherein the belt is released from the belt cavity of the lock housing with the key in the “belt unlocked” position; the rear perspective view also shows the wall mount attachment of the lock housing.
[0050] FIG. 16 is a rear perspective view of the lock housing with attached ratchet belt wherein the belt is released from the belt cavity of the lock housing with the key in the “wall-mount unlocked” position showing the wall mount attachment disengaged from the lock housing.
[0051] FIG. 17 shows a wall-mounted long gun or rifle in a vertical configuration using the lock housing with a detachable mounting device that is attached to a stable surface, such as a wall; the firearm locking system has a lock housing attached to a ratchet style belt that locks up a non-working magazine in a rifle wherein the working magazine has been removed.
[0052] FIG. 18 shows a wall-mounted long gun or rifle in a vertical configuration wherein the lock housing is detached from the mounting device that is attached to a stable surface, such as a wall; the firearm locking system has a lock housing attached to a ratchet style belt that locks up a non-working magazine in a rifle wherein the working magazine has been removed.
[0053] FIG. 19 shows a wall-mounted long gun or rifle in a horizontal configuration using the lock housing with a detachable mounting device that is attached to a stable surface, such as a wall; the firearm locking system has a lock housing attached to a ratchet style belt that locks up a non-working magazine in a rifle wherein the working magazine has been removed.
[0054] FIG. 20 shows a wall-mounted long gun or rifle in a horizontal configuration wherein the lock housing is detached from the mounting device that is attached to a stable surface, such as a wall; the firearm locking system has a lock housing attached to a ratchet style belt that locks up a non-working magazine in a rifle wherein the working magazine has been removed.
[0055] FIG. 21A is a top perspective view of the ratchet belt disengaged from the belt cavity of the lock housing showing the belt links having belt latch catches cut into the links.
[0056] FIG. 21B is an exploded view of the ratchet belt showing how individual links can be removed or added in order to obtain a lock belt length appropriate to the firearm being secured.
[0057] FIG. 22 is a rear view of the firearm locking system with a lock housing attached to a ratchet style belt wherein the belt is pulled through the belt cavity on one end of the lock housing and the wall mount attachment is on the opposite end of the lock housing. Arrows are provided as a guide to the cross-sectional FIGS. 23A and 24A .
[0058] FIG. 23A is a cross-sectional view of the ratchet belt of FIG. 22 along arrow 23 X pulled through the belt cavity of the lock housing showing how the belt latch interfaces with the catches on the links of the ratchet belt.
[0059] FIG. 23B is an enlarged cross-sectional view of the belt latch interfacing with the series of teeth or catches on the ratchet belt to prevent withdrawal of the belt without disengagement by the user.
[0060] FIG. 24A is a cross-sectional view of the belt latch rotated upward thereby disengaging the catches on the link and allowing the ratchet belt of FIG. 22 along arrow 24 X to be removed from the belt cavity of the lock housing.
[0061] FIG. 24B is an enlarged cross-sectional view of the belt latch when rotated upward thereby disengaging the catches on the link of the ratchet belt.
[0062] FIG. 25 is a cross-sectional view of the wall mount attachment secured to the lock housing with a closed rectangular clasp holding the enlarged head of a male member of the wall-mount attachment, the key that controls the clasp and the ratchet belt pulled through the belt cavity of the lock housing are also shown.
[0063] FIG. 26 is a cross-sectional view of the wall mount attachment detached from the lock housing with an opened rectangular clasp releasing the enlarged head of a male member of the wall-mount attachment, the key that controls the clasp and the ratchet belt pulled through the belt cavity of the lock housing are also shown.
[0064] FIG. 27 is a front perspective view of the of the fully assembled pistol trigger lock belt slide assembly (PLTS) of the present invention.
[0065] FIG. 28 is an exploded view of the pistol trigger lock belt slide assembly (PLTS) of the present invention showing all parts.
[0066] FIG. 29 is a front view of the pistol trigger lock belt slide assembly (PLTS) of the present invention.
[0067] FIG. 30 is a right side view of the pistol trigger lock belt slide assembly (PLTS) of the present invention.
[0068] FIG. 31 is a bottom view of the pistol trigger lock belt slide assembly (PLTS) of the present invention.
[0069] FIG. 32 is a front perspective view of the pistol lock configuration showing the pistol trigger lock assembly in position to engage the trigger and trigger guard of a pistol; the lock housing with attached ratchet belt is included as part of the pistol lock system.
[0070] FIG. 33 is a front perspective view of the pistol lock configuration showing the pistol trigger lock engaging the trigger and trigger guard of the pistol before the attachment of the lock housing with attached ratchet belt.
[0071] FIG. 34 shows the pistol trigger lock engaging the trigger and trigger guard and the lock housing with attached ratchet belt in position for the ratchet belt to be inserted into the cavity of the pistol trigger lock.
[0072] FIG. 35 shows the ratchet belt of the lock housing engaging the cavity of the pistol trigger lock.
[0073] FIG. 36 shows the ratchet belt of the lock housing fed through the cavity of the pistol trigger lock and into the belt cavity of the lock housing securing the pistol.
[0074] FIG. 37 is a front perspective of a shotgun positioned for the lock housing with attached ratchet belt to wrap around the barrel behind the pump handle of a shotgun. No slide assembly is used in this configuration.
[0075] FIG. 38 is a front perspective of a shotgun wherein the lock housing with attached ratchet belt is wrapped around the barrel behind the pump handle of a shotgun and locked. No slide assembly is used in this configuration.
[0076] FIG. 39 shows the lock housing of the present invention with a button pad lock.
[0077] FIG. 40 shows the lock housing of the present invention with a biometric lock, such as a fingerprint reader.
[0078] FIG. 41 shows the lock housing of the present invention with a barrel combination lock.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0079] Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
[0080] Listed below are the components of the firearm locking system as shown in FIGS. 1-41 :
10 Armalite (AR) style rifle (Prior Art) 20 Rifle magazine (Prior Art) 30 Non-working magazine slide assembly (NWMS) 40 Belt cavity of non-working magazine slide assembly (NWMS) 50 Screw 60 Non-working magazine 70 Nut 80 Lock housing 90 Ratchet belt 100 Lock housing body 110 Lock housing belt cavity 120 Key 130 Mounting device 135 Mounting screw 140 Key lock 150 Mounting device latch cavity (female member) 160 Mounting device latch catch 170 Mounting device latch (male member) 180 Wall 190 Link assembly with ratchet belt catches 200 Link pin 210 Link 220 Flexible link pad 230 Set screw secures link pin 240 Threaded hole in link holds set screw. 250 Link knuckle 260 Link assembly without belt latch catches 270 Flexible lock housing pad 280 Mounting holes in mounting device 290 Ratchet belt latch catches 295 Ratchet belt latch 300 Pistol trigger lock slide assembly 310 Pistol trigger lock 320 Alignment key slide rails for ratchet belt cavity attachment to the non-working magazine slide (NWMS) assembly 330 Alignment slot in trigger lock for ratchet belt slide 340 Alignment slot in rifle magazine for ratchet belt slide 350 Pistol 360 Trigger lock guard posts 370 Shotgun 372 Barrel 374 Pump handle 380 Lock housing assembly with button pad lock 385 Push button lock pad 390 Lock housing assembly with barrel combination lock 395 Barrel combination lock 400 Lock housing assembly with finger print reader lock 405 Finger print reader.
[0128] It would be useful to discuss the meanings of some words used herein and their application before discussing the firearm locking system of the present invention.
[0129] “Ammunition,” “cartridge”, “shell” and “round” are used interchangeably to mean a cylindrical, usually metal casing containing the primer and powder charge and bullet for a firearm. Spent cartridge and spent shell includes the cylindrical casing after the bullet is fired therefrom.
[0130] “Firearm,” “rifle”, and “pistol” are used interchangeably to refer to all weapons having either a tubular and/or box style magazine and barrel in which the firing mechanism and grip or stock are located behind the trigger group.
[0131] “Hand gun” is used to refer to a firearm designed to be handheld, in either one or both hands. A pistol and a revolver are types of handguns.
[0132] “Long gun” is used to refer to the general class of firearms which are generally designed to be fired when the stock is braced against the shoulder of the user. The actual lengths of the barrels of a long gun are subject to various laws in many jurisdictions. Examples of various long guns include, but are not limited to, rifles, shotguns, machine guns, carbines, and the like.
[0133] “Shotgun” is used to refer to class of firearms having a pump action with a single barrel above a tube magazine into which shells are inserted. New shells are chambered by pulling a pump handle (fore-end) attached to the tube magazine toward the user, then pushing it back into place to chamber the cartridge.
[0134] “Ratchet belt” is used to refer to the elongated strap or belt attached to the lock housing of the present invention. The ratchet has a toothed surface that is shaped to engage a pivoted lever to permit motion in one direction only and to prevent the belt from slipping in a reverse direction.
[0135] The directional terms “horizontal,” “vertical,” “front,” “forward,” “rear,” “rearward,” “right,” and “left” refer to the firearm when held in the normal firing position. When firing, the rear end of the firearm is close to or in close proximity to the body of the user, while the front end is farthest from the user and the point at which the ammunition exits the firearm.
[0136] FIGS. 1-13 illustrate the first embodiment of the present invention wherein a lock housing with an attached ratchet belt locks up the non-working magazine in an AR style rifle.
[0137] FIGS. 14-20 show the second embodiment of the present invention wherein the lock housing with an attached ratchet belt and a detachable wall mounting device is used to mount the locked firearm on a stable surface such as a wall.
[0138] FIGS. 21A-26 provide detail of the lock housing, attached ratchet belt, locking mechanism and detachable wall mounting device.
[0139] FIGS. 27-36 illustrate the third embodiment of the present invention wherein a trigger lock is shown for use on handguns and long guns; only handguns are shown in the figures provided.
[0140] FIGS. 37-38 show the fourth embodiment of the present invention wherein the lock housing with attached ratchet belt is used to lock a pump action shot gun.
[0141] FIGS. 39-41 show a variety of locks useful in the lock housing of the present invention.
[0142] FIG. 1 shows an Armalite (AR) style rifle 10 with an inserted magazine 20 which is known in the Prior Art. FIG. 2 shows the inserted magazine 20 removed from the rifle 10 and a non-working magazine slide assembly (NWMS) 30 of the present invention (such as a solid or hollow structure), before it is inserted into the rifle 10 . The insertion of the non-working magazine slide assembly (NWMS) 30 of the present invention as it is shown in FIG. 3 insures that there is no ammunition in the rifle 10 and the firearm cannot be discharged.
[0143] FIG. 4 provides a front perspective view of the fully assembled non-working magazine slide assembly (NWMS) 30 of the present invention. The non-working magazine 60 can be made of an epoxy resin and formed by additive manufacturing (or alternatively formed from metal, combinations of metal and plastic and the like), and be a solid block that fits into the magazine of a rifle. On an end of the non-working magazine 60 that is not inserted into the rifle, two alignment slots 340 are formed to receive the alignment key slide rails 320 formed on the underside of the ratchet belt cavity 40 and held in place by a screw 50 .
[0144] An exploded view of the non-working magazine slide assembly (NWMS) 30 of the present invention shows all parts, including the non-working magazine 60 with a nut 70 centrally positioned between two parallel alignment slots 340 that receive the alignment key slide rails 320 formed on the underside of the ratchet belt cavity 40 and when fully assembled, the ratchet belt cavity 40 is held in place by screw 50 .
[0145] FIG. 6 is a front view of the fully assembled non-working magazine slide assembly (NWMS) 30 of the present invention wherein the non-working magazine 60 with alignment slots 340 are fitted with alignment key slide rails 320 integrally attached to the ratchet belt cavity 40 . FIG. 7 provides a side view of the fully assembled non-working magazine slide assembly (NWMS) 30 of the present invention showing the non-working magazine 60 attached to the ratchet belt cavity 40 .
[0146] FIG. 8 is a front perspective view of the non-working magazine slide assembly (NWMS) 30 of the present invention inserted into an AR style rifle 10 and the lock housing 80 with attached ratchet belt 90 in a position to be fed into the non-working magazine slide assembly (NWMS). The lock housing body 100 has a lock housing belt cavity 110 , a key 120 , a key lock 140 for locking and unlocking various parts, a mounting device 130 for mounting the locked firearm to a stable surface, such as a wall, and a flexible lock housing pad 270 on the side of the lock body 100 that is opposite the mounting device 130 .
[0147] FIG. 9 shows the lock housing 80 with all of its incorporated features, namely, a lock housing body 100 , a lock housing belt cavity 110 , a key 120 , key lock 140 , a mounting device 130 , and a flexible lock housing pad 270 attached to ratchet belt 90 after the ratchet belt 90 is fully inserted into the ratchet belt cavity 40 of the non-working magazine slide assembly (NWMS) 30 . The ratchet belt 90 can be pulled into selected length positions.
[0148] FIG. 10 is a front perspective view of the lock housing 80 with lock housing body 100 , a lock housing belt cavity 110 , a key 120 , key lock 140 , a mounting device 130 , and a flexible lock housing pad 270 attached to ratchet belt 90 after the ratchet belt 90 is inserted into the ratchet belt cavity 40 of the non-working magazine slide assembly (NWMS) 30 and wrapped around the rifle 10 with the unattached end of the ratchet belt in position to be inserted into the belt cavity 110 of the lock housing 80 .
[0149] FIG. 11 provides a rear perspective view what is shown in FIG. 10 . The flexible lock housing pad 270 is not visible in this view; instead the detachable wall-mount device 130 is shown and the mounting holes 280 in the mounting device can be seen. The ratchet belt 90 is in position to be inserted into the belt cavity 110 located on the end opposite to the wall mount attachment 130 of the lock housing 80 .
[0150] Referring now to FIGS. 12 and 13 wherein FIG. 12 is a front perspective view and FIG. 13 is a rear perspective view of the lock housing 80 with lock housing body 100 attached to ratchet belt 90 wherein the ratchet belt 90 is snug around the rifle 10 and pulled through the belt cavity 110 of the lock housing 80 which secures the non-working magazine slide assembly (NWMS) 30 to the rifle 10 and lock housing 80 with a locking means or key lock 140 . The rear perspective view in FIG. 13 also shows the wall mount attachment 130 and the mounting holes 280 in the mounting device.
[0151] FIGS. 14-20 illustrate the locking and unlocking features of the ratchet belt from the lock body housing and the locking and unlocking of the mounting device that is detachable from the lock housing body. Both the ratchet belt and the detachable wall-mount device can be inserted into their respective cavities regardless of the position of the key.
[0152] FIG. 14 is a rear perspective view of the lock housing 80 with ratchet belt 90 attached to flexible lock housing pad 270 wherein the belt 90 is pulled through the belt cavity of the lock housing 110 and locked and the wall mount attachment 130 with mounting holes 280 is also locked onto the housing body 100 when the key 120 in key lock 140 is in the “all locked” position.
[0153] FIG. 15 is the same view as FIG. 14 with the key 120 rotated clockwise in the “belt unlocked” position and the ratchet belt 90 is released; the wall mount attachment 130 of the lock housing 80 is still attached to lock housing body 100 . FIG. 16 is also the same view as FIG. 14 with the key 120 rotated counter-clockwise wherein the ratchet belt 90 is released from the belt cavity 110 of the lock housing body 100 with the key in the “wall-mount unlocked” position showing the wall mount attachment 130 disengaged from the lock housing body 100 .
[0154] FIG. 17 shows a wall-mounted long gun or rifle 10 in a vertical configuration using the lock housing 80 wherein the lock housing body 100 has a detachable mounting device 130 that is attached to a stable surface, such as a wall 180 ; the key 120 is in the “all lock” position, thus locking the ratchet belt 90 , non-working magazine slide (NWMS) 30 assembly and the mounting device 130 onto a rifle 10 that is held vertically on a wall 180 .
[0155] FIG. 18 shows the same configuration as FIG. 17 except that the key 120 is turned counter-clockwise to the “wall-mount unlocked” position which releases the locked rifle from the wall mount 130 having mounting holes 280 , mounting screws 135 and a mounting device latch 170 from the lock housing body 100 . The wall mount 130 remains on the stable surface such as a wall 180 .
[0156] FIG. 19 shows a wall-mounted long gun or rifle 10 in a horizontal configuration using the lock housing 80 with a detachable mounting device 130 that is attached to a stable surface, such as a wall 180 ; the ratchet style belt 90 wraps around a non-working magazine slide (NSWM) 30 assembly and is fed through the belt cavity 110 of the lock housing body 100 in a rifle 10 . The key 120 is in the “all lock” position, thus locking the ratchet belt 90 , non-working magazine slide (NWMS) 30 assembly and the mounting device 130 onto a rifle 10 that is being held horizontally on a wall 180 .
[0157] FIG. 20 shows the same horizontal configuration as shown in FIG. 19 except that the key 120 is turned counter-clockwise to the “wall-mount unlocked” position which releases the locked firearm from the wall mount 130 having mounting holes 280 , mounting screws 135 and a mounting device latch 170 from the lock housing body 100 . The wall mount 130 remains on the stable surface such as a wall 180 .
[0158] The wall-mount attachment of the present invention separates from the lock housing assembly when unlocked with a key and mounts to a wall or other secure surface. The wall-mount attachment is also designed such that the firearm stored or mounted with this attachment can be rotated in ninety degree increments without changing the orientation of the wall-mounting device that is attached to a wall or other stable surface.
[0159] Although the support surface is described as a wall, any support surface, that is either vertical, horizontal, slanted and the like, can be used. Additionally, the support surface can be inside of a container, such as inside of a lock safe and the like. Ratchet belt and locking detail. The universal features in all embodiments of the present invention include the use of the ratchet belt and a locking mechanism.
[0160] The operation of the ratchet belt 90 with key lock 140 with belt latch 295 , belt latch catches 290 shown in FIGS. 23A-24B, 14-16 can be a ratchet locking system, such as but not limited to the system described in U.S. Pat. No. 6,044,669 to Clark Levi issued Apr. 4, 2000, the teachings of which are incorporated herein by reference.
[0161] The operation of the locking mechanism in this invention, using the key lock 140 with wall block latch cavity 150 , wall block latch catch 160 and wall block latch 170 shown in FIGS. 15-20, 25-26 , it is as explained and described in U.S. Pat. No. 3,018,576 to W. H. Riechers issued Jan. 30, 1962, the teachings of which are incorporated herein by reference.
[0162] FIG. 21A is a top perspective view of the lock housing 80 with an attached mounting device 130 , a key lock 140 , and a ratchet belt 90 attached to a flexible lock housing pad 270 , wherein the ratchet belt 90 is disengaged from the belt cavity 110 of the lock housing body 100 showing the belt links without belt latch catches 260 and belt links with belt latch catches cut into the links 190 .
[0163] FIG. 21B is an exploded view of the ratchet belt with belt latch catches 290 cut into the links 190 showing how individual links 210 can be removed by taking out set screws 230 that secure link pins 200 that are threaded through link knuckles 250 at the joining end of each link 210 . Individual links can be added by joining individual links 210 in order to obtain a lock belt length appropriate to the firearm being secured. Each link 210 is designed with identical symmetry and features including multiple knuckles 250 on a horizontal side of the link, a flexible link pad 220 on the underside side of the link, threaded screw holes 240 in link to hold the set screws 230 to secure the link pin 200 that is used to attach the desired number of individual links 210 . A preferred embodiment of the lock belt 90 can include a plurality of generally identical segments (of plural link assembly 190 ).
[0164] FIG. 22 is a rear view of the firearm locking system with a lock housing attached to a ratchet style belt wherein the belt is pulled through the belt cavity on one end of the lock housing and the wall mount attachment is on the opposite end of the lock housing. Arrows are provided as a guide to the cross-sectional FIGS. 23A and 24A .
[0165] FIG. 23A shows a cross-section of the ratchet belt 90 pulled through the belt cavity 110 of the lock housing 80 with a mounting device 130 on the lock housing body 100 . The ratchet belt 90 comprises a link assembly without belt latch catches 260 and link assembly with ratchet belt catches 190 on the end that is pulled through the belt cavity 110 . This cross-sectional view shows how the ratchet belt latch 295 interfaces with the catches on the links of the ratchet belt. FIG. 23B is an enlarged cross-sectional view of one link assembly with ratchet belt catches 190 , link knuckles 250 , and the belt latch 295 that is positioned inside the lock housing body 100 adjacent to the lock housing belt cavity 110 and interfaces with the series of teeth or catches 290 on the ratchet belt to prevent withdrawal of the belt without disengagement by the user.
[0166] FIG. 24A is a cross-sectional view similar to the view shown in FIG. 23A , the difference is that the belt latch 295 is rotated upward thereby disengaging the catches 290 on the link assembly with ratchet belt catches 190 and allows the ratchet belt 90 composed of a link assembly with ratchet belt catches 190 and a link assembly without ratchet belt catches 260 to be removed from the belt cavity 110 of the lock housing 80 .
[0167] FIG. 24B is an enlarged cross-sectional view of the belt latch 295 when rotated upward to a position within the lock housing body 100 thereby completely disengaging the catches on the link assembly of the ratchet belt which is no longer in the lock housing belt cavity 110 .
[0168] FIG. 25 is a cross-sectional view of the lock housing 80 with lock housing body 100 , a lock housing belt cavity 110 , key lock 140 , a mounting device 130 with mounting holes 280 , and a flexible lock housing pad 270 attached to ratchet belt 90 comprising a link assembly with ratchet belt catches 190 and a link assembly without ratchet belt catches 260 wherein the link assembly with ratchet belt catches 190 is pulled through the belt cavity 110 of the lock housing 80 . The wall mount attachment 130 has a mounting device latch 170 known as a male member that fits into a mounting device latch cavity 150 known as a female member located in the top center of the lock housing body 100 . The mounting device latch cavity 150 is surrounded by a movable mounting device latch catch 160 that moves in and out around the mounting device latch 170 that is inserted in the female member 150 . FIG. 25 shows the mounting device latch catch 160 moved to an inward position from the walls of the lock housing body 100 thus holding the mounting device latch 170 within the mounting device latch cavity 150 . The inward and outward movement of the rectangular-shaped, mounting device latch catch 160 is a direct result of turning the key lock 140 .
[0169] FIG. 26 is the same cross-sectional view of the lock housing 80 as shown in FIG. 25 ; however, FIG. 26 shows the mounting device latch catch 160 moved to an outward position against the walls of the lock housing body 100 thus releasing the mounting device latch 170 from the mounting device latch cavity 150 . Thus, by turning the key lock 140 , the wall mount attachment 130 is detached from the lock housing 80 .
[0170] It is to be understood that the third embodiment of this invention is not limited to use on handguns, but is also suitable for use on long guns. FIGS. 27-30 , show various views of the pistol trigger lock slide (PTLS) assembly.
[0171] FIG. 27 is a front perspective view of the of the fully assembled pistol trigger lock belt slide assembly (PLTS) 300 of the present invention. The pistol trigger lock 310 has trigger lock guard posts 360 and alignment slots in the trigger lock 330 to receive the alignment key slide rails 320 integrally attached to the ratchet belt cavity 40 held in place with screw 50 .
[0172] FIG. 28 is an exploded view of the pistol trigger lock belt slide assembly (PLTS) 300 of the present invention showing all parts which include a pistol trigger lock 310 , trigger lock guard posts 360 , a nut 70 centrally positioned between two parallel alignment slots 330 that receive the alignment key slide rails 320 formed on the underside of the ratchet belt cavity 40 and when fully assembled, the ratchet belt cavity 40 is held in place by screw 50 .
[0173] FIG. 29 is a front view of the pistol trigger lock belt slide assembly (PLTS) 300 of the present invention showing a pistol trigger lock 310 , trigger lock guard posts 360 , two parallel alignment slots 330 that receive the alignment key slide rails 320 formed on the underside of the ratchet belt cavity 40 . FIG. 30 is a right side view of the pistol trigger lock belt slide assembly (PLTS) 300 of the present invention showing a pistol trigger lock 310 , trigger lock guard posts 360 , and a side edge of the ratchet belt cavity 40 . FIG. 31 is a bottom view of the pistol trigger lock belt slide assembly (PLTS) 300 of the present invention showing the bottom sides of a pistol trigger lock 310 and the bottom of the trigger lock guard posts 360 .
[0174] FIGS. 32-33 show the insertion of the trigger lock on a pistol. FIGS. 34-36 show the process for locking or securing a pistol using the lock housing with attached ratchet belt.
[0175] FIG. 32 is a front perspective view of the pistol lock configuration showing the pistol trigger lock assembly 300 with pistol trigger lock 310 , trigger lock guard posts 360 , and ratchet belt cavity 40 in position to engage the trigger and trigger guard of a pistol 350 . Included in FIG. 32 as part of the pistol lock system is the lock housing 80 with lock housing body 100 , a lock housing belt cavity 110 , key lock 140 , a mounting device 130 , and a flexible lock housing pad 270 attached to ratchet belt 90 comprising a link assembly with ratchet belt catches 190 and a link assembly without ratchet belt catches 260 wherein the link assembly has a flexible link pad 220 on each link and the link assembly with ratchet belt catches 190 is pulled through the belt cavity 110 of the lock housing 80 . FIG. 33 shows the same front perspective view of the pistol lock configuration as FIG. 32 , wherein the difference in FIG. 33 is that the pistol trigger lock assembly 300 is fully engaging the trigger and trigger guard of the pistol 350 before attachment of the lock housing 80 with attached ratchet belt 90 .
[0176] FIG. 34 shows the pistol trigger lock assembly 300 engaging the trigger and trigger guard of pistol 350 and the lock housing 80 with lock housing body 100 , a lock housing belt cavity 110 , key lock 140 , a mounting device 130 , and a flexible lock housing pad 270 attached to ratchet belt 90 comprising a link assembly with ratchet belt catches 190 and a link assembly without ratchet belt catches 260 wherein the link assembly has a flexible link pad 220 on each link and the link assembly with ratchet belt catches 190 is in position to be pulled through the belt cavity of the pistol trigger lock assembly 300 .
[0177] FIG. 35 has the same components as FIG. 34 and shows the progressive insertion of the link assembly with ratchet belt catches 190 into the cavity of the pistol trigger lock 300 . FIG. 36 completes the locking sequence showing the same components as FIG. 34 with the difference that the ratchet belt 90 of the lock housing 80 has been fed through the cavity of the pistol trigger lock 300 and into the lock housing belt cavity 110 thereby securely locking the pistol 350 .
[0178] FIGS. 37 and 38 illustrate the use of the locking system of the present invention on a shotgun. FIG. 37 is a front perspective of a shotgun 370 positioned for the lock housing 80 with attached ratchet belt 90 to wrap around the barrel 372 behind the pump handle 374 of a shotgun 370 . No slide assembly is used in this configuration.
[0179] FIG. 38 is a front perspective of a shotgun 370 wherein the lock housing 80 with mounting device 130 and attached ratchet belt 90 is wrapped around the barrel 372 behind the pump handle 374 of a shotgun 370 and locked with key 120 . No slide assembly is used in this configuration.
[0180] Locks.
[0181] Although a key lock is used in the illustration of the present invention, any suitable locking and disengagement device may be used. Alternatively, for example, FIG. 39 shows lock a housing assembly with a button pad lock 380 and push button lock pad 385 . FIG. 40 shows a lock housing assembly with finger print reader locks 400 and finger print reader 405 . Any other biometric locking device may be used such as voice or eye recognition. FIG. 41 shows a lock housing assembly with lock housing assembly 390 and barrel combination lock 395 .
[0182] Although certain embodiments show the lock systems, devices and apparatus only around long guns, the invention can be used with handguns and pistols. For example, the embodiment of FIGS. 1-13 can be used with pistols and handguns having removable magazines. For example, the embodiment of FIGS. 27-36 while shown with triggers on pistols and handguns, can also be used with triggers on long guns, such as rifles and the like. For example, the wall mounts of FIGS. 17-20 for mounting long guns/rifles on support surfaces, can be used to mount pistols and long guns on support surfaces.
[0183] Although the embodiments show single applications of the novel lock systems, devices, and apparatus, the invention can be used with a combination of two or more lock housings with attached ratchet belts with or without the non-working magazine slide assembly (NWMS) per weapon.
[0184] Alternatively, the embodiments can be used with additional mounting brackets, which can include but are not limited to bent pieces of metal type material that screw or bolt into a surface and further prevents the firearm from movement.
[0185] The invention embodiments can be used with or without slide assemblies.
[0186] For example, the trigger locking mechanism could be used on a long gun, as illustrated in FIGS. 27-36 in combination with the lock housing with attached ratchet belt on the barrel a pump action shot gun as shown in FIGS. 37-38 . Also, for example, two locking devices, apparatus and systems can be used with a single firearm.
[0187] While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of claims here appended.
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Devices, apparatus, systems and methods for locking ratchet belts about handguns and long guns with a ratchet belt and locking box. An embodiment can remove the working magazine from pistols and long guns replacing it with a non-working magazine that is locked onto the firearm. Another embodiment locks the trigger of handgun and long gun firearms. Another embodiment locks the firearm to support surfaces such as a wall, and the like. A still another embodiment can lock and prevent the pull handle of a shot gun from being pumped. Embodiments can be used alone or in combination so that handguns and long guns are locked and prevented from being discharged.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 08/972,705, filed Nov. 18, 1997, now abandoned which is a continuation of U.S. patent application Ser. No. 08/411,130, filed Mar. 27, 1995, now abandoned.
TECHNICAL FIELD
The invention pertains to the field of testing of compounds to ascertain their activity. The invention is particularly concerned with the laboratory testing of large quantities of compounds in a rapid manner.
BACKGROUND ART
Many organizations, in particular pharmaceutical organizations, over many years have synthesized a number of compounds for various research projects. Accordingly therefore, a large collection of compounds have been collected which includes a database of their structures and chemical properties. Frequently, these compounds are screened for biological assays to ascertain the activity of a compound with respect to the assay. A previous method of delivering the compounds involved selecting small numbers of compounds and weighing out the individual samples which were then sent for a single screen. With the advent of automated screening technology, the delivery method became inadequate. A single screen could test hundreds of compounds in a day, while each technician dispensing samples could only deliver a few dozen in a day.
New equipment became available to speed up the testing techniques. One technique was to manually dispense estimated amounts of individual compounds into small tubes that fit into a 96-well plate format. While automated equipment could dissolve the samples and mix them into the reaction wells, they still required a very substantial period of time to go through a screening process. The problem still remained as to how to have the substantial numbers of compounds to be screened for various assays. Preparation of the testing plates and the testing of the compounds per se was extremely labor intensive. It had previously been estimated that it would take almost a year to test approximately 100,000 compounds following this approach.
PCT Publication No. WO93/13423, published Jul. 8, 1993, describes an automated analysis equipment and assay method for detecting cell surface protein and/or cytoplasmic receptor function. The publication teaches an automated measuring apparatus which can decrease substantial worker effort. The publication indicates that for each drug that needed to be screened, the materials were tested one by one, even though an automated apparatus permitted the rapid detection of activity for the compounds tested.
U.S. Pat. No. 5,281,540 teaches a test array for performing assays. A semi-automated biological sample analyzer is described for simultaneously performing a plurality of enzyme immunoassays for human IgE class antibodies specific to a panel of preselected allergens in each of a plurality of biological samples. The technique, while having multiple biological samples in a well, uses a coating of an elongated cellulosic body such as a strip of paper which will contact the multiple samples to ascertain which antibodies are specific for the coated allergens and which will then, in turn, bind to the appropriate bands or islands. The bands or islands are then analyzed for the presence of labeled antibodies. The technique describes testing done in a seriatim basis, namely, a number of samples, one after the other, even though multiple samples are present in a reaction vessel. The use of antibodies which bind to a specific sample is required for the system to be effective. The samples may be detected by use of optical reading capabilities.
Other patents that test multiple compounds in a seriatim fashion utilizing automated equipment are described in U.S. Pat. Nos. 4,039,286 and 4,166,095.
It is an object of the present invention to simultaneously test a plurality of compounds utilizing at least two separate arrays of the same collection of compounds in each array.
SUMMARY OF THE INVENTION
Described is a method of simultaneously testing a plurality of compounds for activity comprising the steps of:
(a) placing a plurality of the compounds into at least two arrays, each having a plurality of test zones, with multiple compounds in each zone;
(b) determining the location of each compound in each test zone;
(c) subjecting the array to a testing screen; and
(d) ascertaining those compounds that had a positive response to the testing screen.
Also described is an apparatus for simultaneously determining the activity of a plurality of compounds comprising:
(a) a first array of a plurality of test zones, each zone having an ability to contain a plurality of compounds to be tested;
(b) a second array of a plurality of test zones, each zone having an ability to contain a plurality of compounds to be tested;
(c) means for simultaneously testing the compounds in the test zones; and
(d) means for ascertaining which compound in each array has a positive response to a testing screen after it has been determined that a compound has tested positive or negative for the activity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the creation of the first array called an X plate utilized in the present invention;
FIG. 2 is a schematic diagram showing the creation of the second array called a Y plate utilized in the present invention;
FIG. 3 is a schematic diagram depicting the utilization of FIGS. 1 and 2 in the mass screening techniques of the present invention using an orthogonal array;
FIG. 4 is a combination array of a single row A of the X and Y master plates of FIGS. 1 and 2; and
FIG. 5 is a master plate activity report showing hypothetical activity for the X and Y plates.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention can generally be characterized as a mass screening technique using an orthogonal array method (see FIG. 3 ). A simple plate ( 10 ) of FIGS. 1 and 2 utilizes ten columns across the top row A (of FIG. 3 ). The outermost columns ( 1 and 12 column numbers) are not used or are used for controls. Therefore, 80 compounds (8 rows of A-H with ten columns of 2 - 11 ) are placed into a 96-well plate called a “simple plate”. The X master plate ( 12 ) is made up by placing an aliquot from each well from simple plate # 1 into column 2 of the X master plate ( 14 ) and continued for the remainder of the ten simple plates.
The Y master plate ( 16 ) is prepared by taking the same contents of the ten simple plates ( 10 ) and placing the contents of each plate on top of each other so that the rows and columns of each simple plate fit within the test wells of the Y master plate (the rows and columns are the same for simple plate and Y master plate).
A master plate containing 800 compounds (the X Plate 12 ), such as a 96-well plastic plate, is prepared. A Y-Plate ( 16 ), identified as the orthogonal array master plate, likewise can contain 800 compounds. As can be seen from FIG. 3, if there is a compound that has activity such as hypothetical compound 727 , it is present on the X Plate in well H 4 . On the Y Plate, it is found at well H 8 . Therefore, the activity has to correspond to a common compound, hypothetical compound 727 in this example. The method likewise is equally applicable for multiple active materials in a well.
In its most preferred feature, the current method is to make two plates that contain the same 800 compounds. One plate is the same as described above (“X Master plate”), and the other is arranged by turning the array of the first plate 90 degrees (“Y Master plate”). A Beckman robot was used to consolidate ten plates with one compound in each of 80 wells (“Simple Plate”) using columns 2 - 11 and leaving columns 1 and 12 empty, into one plate with 10 compounds in each of 80 wells (“X Master plate”) using columns 2 - 11 and leaving columns 1 and 12 empty (see FIG. 1 ). The consolidation begins by transferring a 50 μl aliquot from column 2 “Simple Plate” number one into column 2 of “X Master plate” number one, then transferring a 50 μl aliquot from column 3 “Simple Plate” number one into column 2 of “X Master plate” number one, etc., ending with transferring a 50 μl aliquot from column 11 “Simple Plate” number one into column 2 of “X Master plate” number one. The result is that an aliquot from each well of “Simple Plate” number one ( 10 ) exists in column 2 of “X Master plate” ( 12 ) number one ( 14 ). The same process is used for the remaining “Simple Plates” two through ten, such that an aliquot from each well of “Simple Plate” number two exists in column 3 of the “X Master plate”, etc., ending with an aliquot from each well from “Simple Plate” number 10 existing in column 11 of the “X Master plate”. The nature of the process ensures that every compound in row A of “Simple Plate” one through ten exists in row A of “X Master plate” number one, likewise through row H.
A Tomtec Quadra 96-100 (trademark of Tomtec, Inc. for automated well filling lab equipment) was used to consolidate each of the ten “Simple Plates” with one compound in each of 80 wells, into one plate with 10 compounds in each of 80 wells (“Y Master plate”) using columns 2 - 11 and leaving columns 1 and 12 empty (FIG. 2 ). The consolidation begins by transferring a 50 μl aliquot from each of the 80 wells from “Simple Plate” number one into each of the 80 wells of “Y Master plate” number one, with the well location of the source “Simple Plate” matching the well location of the receiving “Y Master plate”. This process continues for the remaining “Simple Plates” two through ten, such that an aliquot from each well of remaining simple plates is dispensed in the “Y Master plate”, with the well location of the source “Simple Plate” matching the well location of the receiving “Y Master plate”. The nature of the process ensures that every compound in row A of “Simple Plate” one through ten exists in row A of “Y Master plate” number one, likewise through row H. This process also ensures that the same 100 compounds are in row A of the “X Master plate” and in row A of the “Y Master plate”, likewise through row H.
Both the “X Master plate” and the “Y Master plate” have 10 compounds in each well while each compound appears once on each plate. However, no two compounds have the same pair of well locations. When the plates are tested and the results compared, the individual compounds responsible for any activity can be determined. For convenience of assigning a location for each well, Applicant has devised an array combining the X and Y plates as shown in FIG. 4 which is an array of 10×10. For example, after testing “X Master plate” # 1 , well A 2 is determined to be active (containing compounds 1 through 10 , inclusive) and after testing “Y Master plate”, well A 11 is determined to be active (containing compounds 10 , 20 , 30 , 40 , 50 , 60 , 70 , 80 , 90 and 100 ). Only compound number 10 is common between the two wells determined to be active. Therefore, compound number 10 is assumed to be the active compound. FIG. 3 shows a similar hypothetical arrangement. If multiple wells are found in one row on one of the two plates and a single well is found on the corresponding row on the other plate, then one can ascertain the active compounds. For example, if, in addition to the active wells stated above, well A 3 from the “X Master plate” is determined to be active (containing compounds 11 through 20 , inclusive), then both compound number 10 and compound number 20 are common between the two plates. When multiple wells are determined to be active in the same row on both plates, then estimates may be made of the active material. That is, if well A 2 and well A 11 from both plates were determined to be active, then compounds number 1 , 10 , 91 and 100 would be derived from the orthogonal array. However, if only compound numbers 1 and 100 were active, the same four wells would show activity; likewise if only compound numbers 10 and 91 were active.
The advantage of this, even given the probability of testing inactive compounds, is that the biological testers can go directly to quantitative screening with individual compounds. There is no need to create plates that contain the individual compounds. The same plate pairs can be sent to multiple screens, without need to create differently arranged plates for each screen.
How to Identify the “Hit” Compounds From the X Y Plate Results
In this system, each row can be treated as a distinct entity. That is, any compound that is in row C on a simple plate, will also fall in row C on both the X plate and the Y plate. The same 100 compounds are in row C on both the X plate and the Y plate. There is no overlap between rows. So each master plate set actually carries eight completely separate 100 compound arrays.
Compounds in all types of plates are dissolved in DMSO (dimethyl sulfoxide), which means they can be transferred using pipeting rather than as solids, which makes it much easier to handle the mixing of very small amounts. However, for follow-up screening of the hit compounds, individual samples are weighed out dry from the sample collection. It is to be appreciated that any inert solvent may be used that is compatible with the testing screen. Such solvents include water, dimethyl formamide, N-methylpyrrolidone, glycols such as diethylene glycol, and the alkyl ether derivatives or the lower alkyl ester derivatives such as the Cellosolve solvents (trademark of Union Carbide).
A Master Plate Activity Report (FIG. 5) shows the hypothetical test results on the X and Y master plates.
On the X plate report ( 20 ), in row C, there were two hits, in column 3 and in column 9 . Now review the list of plate contents shown below in Table I.
Since the columns in the X plate were filled in order from left to right, with aliquots from simple plates in numerical order, we know that all ten compounds in well 3 C on the X plate came from simple plate 1181 , and they were all in row C. This narrows the choice to ten compounds from the content list, marked as “pink”.
On the Y plate, in row C, there were also two hits, in columns 5 and 9 . Turn to the list of plate contents again. Since the wells in the Y plate were all filled using aliquots from the same wells in the simple plates, we can scan the list of plate contents for all compounds in well 5 C, in any simple plate, marked as “yellow”.
Now compare the compounds that were marked. The only compound that was marked “pink” and “yellow”, was in simple plate 1181 , well 5 C. The number of this compound is 108240.
When only one well is checked on each plate, in a given row, then its easy to narrow the hit to one compound. It is a little more complicated when two wells are checked on each plate, in a given row.
Look back at row C on the X plate. There were two boxes checked. Using the same method to locate all the compounds in the X plate's well 3 C, the compounds in well 9 C are marked as “green”. All the compounds in the X plates' column 9 came from simple plate 1187 . It is seen that one of these ten compounds is also marked as “yellow”, because it was in well 5 C in the Y plate.
Now look again at row C on the Y plate. There were two boxes checked there as well. The second box checked was 9 C. Using the same method to locate all the compounds in the Y plate's well 5 C, all the compounds from 9 C have been marked as “blue”. Each of the compounds in the Y plate's well 9 C was also in well 9 C on the simple plates it came from. It is seen that not only is one of these compounds marked as “green”, there is also one that is marked as “pink”.
So, there are four compounds that were marked twice. Therefore, four hits need to be followed up on. Each of the twice-marked compounds had one mark because it was in a Y plate hit well, and one mark because it was in an X plate hit well. The number of hits in a given row, is actually the product of the number of hits in that row in the X plate multiplied by the number of hits in that row in the Y plate.
TABLE I
Plate
Compound #
No.
Col.
Row
Tested
1180
2
A
100001
1180
2
B
100002
1180
2
C
100003
1180
2
D
100004
1180
2
E
100005
* * *
1180
4
G
107917
1180
4
H
107918
1180
5
A
107921
1180
5
B
107923
1180
5
C
107924
Yellow
1180
5
D
107934
1180
5
E
107935
* * *
1180
9
A
108022
1180
9
B
108031
1180
9
C
108037
Blue
1180
9
D
108050
* * *
1181
2
A
108145
1181
2
B
108147
1181
2
C
108151
Pink
1181
2
D
108154
1181
2
E
108160
* * *
1181
3
A
108169
1181
3
B
108171
1181
3
C
108172
Pink
1181
3
D
108174
1181
3
E
108175
* * *
1181
4
A
108190
1181
4
B
108194
1181
4
C
108197
Pink
1181
4
D
108200
1181
4
E
108206
* * *
1181
5
A
108238
1181
5
B
108239
1181
5
C
108240
Pink-Yellow
1181
5
D
108241
1181
5
E
108242
* * *
1181
6
B
108255
1181
6
C
108259
Pink
1181
6
D
108261
1181
6
E
108268
* * *
1181
7
A
108290
1181
7
B
108295
1181
7
C
108296
Pink
1181
7
D
108302
1181
7
E
108306
* * *
1181
8
B
108331
1181
8
C
108332
Pink
1181
8
D
108334
1181
8
E
108335
* * *
1181
9
B
108355
1181
9
C
108357
Blue-Pink
1181
9
D
108366
1181
9
E
108379
* * *
1181
10
B
108418
1181
10
C
108426
Pink
1181
10
D
108428
1181
10
E
108433
* * *
1181
11
B
108445
1181
11
C
108446
Pink
1181
11
D
108451
1181
11
E
108452
* * *
1182
5
A
108569
1182
5
B
108571
1182
5
C
108578
Yellow
1182
5
D
108585
* * *
1182
9
A
108769
1182
9
B
108771
1182
9
C
108779
Blue
1182
9
D
108788
* * *
1183
5
A
109116
1183
5
B
109125
1183
5
C
109126
Yellow
1183
5
D
109132
* * *
1183
9
A
109271
1183
9
B
109272
1183
9
C
109277
Blue
1183
9
D
109278
* * *
1184
5
A
109509
1184
5
B
109510
1184
5
C
109511
Yellow
1184
5
D
109513
* * *
1184
9
A
109659
1184
9
B
109666
1184
9
C
109667
Blue
1184
9
D
109672
* * *
1185
5
A
109933
1185
5
B
109940
1185
5
C
109941
Yellow
1185
5
D
109942
* * *
1185
9
A
110082
1185
9
B
110089
1185
9
C
110096
Blue
1185
9
D
110097
* * *
1186
5
A
110270
1186
5
B
110272
1186
5
C
110275
Yellow
1186
5
D
110276
* * *
1186
9
A
110420
1186
9
B
110421
1186
9
C
110422
Blue
1186
9
D
110423
* * *
1187
2
A
110525
1187
2
B
110527
1187
2
C
110529
Green
1187
2
D
110538
* * *
1187
3
A
110567
1187
3
B
110568
1187
3
C
110582
Green
1187
3
D
110584
* * *
1187
4
A
110595
1187
4
B
110596
1187
4
C
110598
Green
1187
4
D
110604
* * *
1187
5
A
110612
1187
5
B
110614
1187
5
C
110616
Yellow-Green
1187
5
D
110617
* * *
1187
6
A
110639
1187
6
B
110644
1187
6
C
110650
Green
1187
6
D
110652
* * *
1187
7
A
110674
1187
7
B
110676
1187
7
C
110684
Green
1187
7
D
110685
* * *
1187
8
A
110702
1187
8
B
110707
1187
8
C
110713
Green
1187
8
D
110716
* * *
1187
9
A
110747
1187
9
B
110749
1187
9
C
110750
Blue-Green
1187
9
D
110760
* * *
1187
10
A
110793
1187
10
B
110803
1187
10
C
110807
Green
1187
10
D
110809
* * *
1187
11
A
110825
1187
11
B
110836
1187
11
C
110838
Green
1187
11
D
110841
* * *
1188
5
A
110936
1188
5
B
110940
1188
5
C
110941
Yellow
1188
5
D
110945
* * *
1188
9
A
111051
1188
9
B
111052
1188
9
C
111053
Blue
1188
9
D
111054
* * *
1189
5
A
111249
1189
5
B
111260
1189
5
C
111261
Yellow
1189
5
D
111262
* * *
The number of compounds in each test well can vary from 5 to 20, preferably 8-12/well or zone. Ten compounds per well may be an optimum number. If the number of compounds in each well is increased, the number of active wells will increase, and the number of compounds that need to be followed up increases exponentially. However, if three or more arrays (such as a “Z” plate) were used, then more compounds per well could be inserted. The Z plate could be arranged 90° from the “Y” plate for convenience.
Mathematically, the determination of a “hit” can be expressed as follows. Each compound involved in the screening can be uniquely represented by three variables (i,j,k), where k is the simple plate in which the compound is located, and i and j are the row and column, respectively, in which the compound is located in the kth simple plate. Using these variables, a matrix S k [i,j] representative of the compounds located on the kth simple plate can be formed. Thus, ten matrices can be formed for the embodiment using 800 compounds located on ten simple plates: S i [i,j], S 2 [i,j], . . . , S 10 [i,j]. Since eight rows and ten columns are employed on each simple plate in this embodiment, the variable i ranges from 1 to 8 and the variable j ranges from 1 to 10.
The X plate and Y plate are also represented by matrices, namely X[i,j] and Y[i,j]. The X[i,j] and Y[i,j] matrices are based upon the matrix representation S k [i,j] of the compounds in the ten simple plates. Specifically, the ten compounds within the ith row and jth column of the X plate are represented by S j [i,1], S j [i,2], S j [i,3], . . . , S j [i,10]. Similarly, the ten compounds within the ith row and jth column of the Y plate are represented by S 1 [i,j], S 2 [i,j], S 3 [i,j], . . . , S 10 [i,j].
As a result, it can be seen that the compound represented by (i,j,k) is located in row i, column k of the X plate, and in row i, column j of the Y plate. This means that a hit due to the compound located in row i, column j of the kth simple plate results in a hit in row i, column k of the X plate, and a hit in row i, column j of the Y plate. Inversely, a hit observed in row i, column k of the X plate and a hit in row i, column j of the Y plate is potentially due to the (i,j,k) compound.
Visually, when a hit is observed at a well in the Y plate, one can conclude that the hit resulted due to an active compound located at the same well location in one of the ten simple plates. A hit in the same row of the X plate can then be used to determine which of the ten simple plates contains the active compound. Specifically, the column number of the hit represents the simple plate which contains the active compound.
Pseudo-code for a procedure for determining the potentially active compounds is as follows.
Do for each row i=1, 2, . . . , 8:
Let k 1 , k 2 , . . . be the column numbers of the hits in row i of X plate;
Let j 1 , j 2 , . . . be the column numbers of the hits in row i of the Y plate;
The potentially active compounds are (i,j 1 ,k 1 ), (i,j 1 ,k 2 ), (i,j 2 ,k 1 ), (i,j 2 ,k 2 ), . . . 10 simple plates: S, [i,j], S 2 [i,j], . . . , S 10 [i,j] where
i=1,2, . . . , 8
j=1,2, . . . , 10
[i,j]: [ 1 , 1 ] [ 1 , 2 ] [ 1 , 3 ] … [ 1 , 10 ] [ 2 , 1 ] [ 2 , 2 ] [ 2 , 3 ] … [ 2 , 10 ] [ 3 , 1 ] [ 3 , 2 ] . ⋮ ⋮ ⋮ [ 8 , 1 ] [ 8 , 2 ] … [ 8 , 10 ]
For X plate: x [ i , j ] = S j [ i , 1 ] + S j [ i , 2 ] + S j [ i , 3 ] + … + S j [ i , 10 ] = ∑ k = 1 10 S j [ i , k ]
For Y plate: y [ i , j ] = S 1 [ i , j ] + S 2 [ i , j ] + S 3 [ i , j ] + … + S 10 [ i , j ] = ∑ k = 1 10 S j [ i , k ]
∴ code each compound as ( i , j , k ) < -- > S k [ i , j ] < -- > row i , column j of plate k
This compound is in:
row i, column k of X plate, and
row i, column j of Y plate.
=> Inversely, if there is a hit for x[i,j] and a hit for y[i,j], then the compound in S k [i,j] may be the cause.
The current technique for screening large numbers of compounds is applicable for a variety of screens, most preferably biological screenings. By a screen is meant a biological assay that is developed to determine the biological activity of a material.
The collection of materials that are available may be tested against an assay. In this fashion, it can be said that a database of materials can be screened for a particular assay to determine the activity of the portions of the database underneath the assay.
For example, an assay may be followed to determine if a material may be a cholesteryl ester transfer protein inhibitor (CETP). The test is described as follows.
CETP is a 74 kDa plasma glycoprotein responsible for the reciprocal exchange of neutral lipids between circulating lipoproteins. Net alteration in lipoprotein core lipid composition is a complex process. The modifications are influenced by lipoprotein concentration, lipoprotein residence time, and the activities of lecithin:cholesteryl acyl transferase (LCAT), hepatic lipase, lipoprotein lipase, and CETP. In general, in species lacking CETP activity, and humans genetically-deficient in CETP, the equilibrium favors elevation of anti-atherogenic (HDL) and diminution of atherogenic (LDL) lipoproteins. Therefore, plasma CETP inhibition could be an advantageous pharmacological target for the treatment of dyslipidemic patients at risk for coronary heart disease.
Recent studies of a Japanese family with deficiency in plasma CETP have shown that the deficiency was associated with marked elevation of HDL, its associated apolipoproteins (apoA-I, apoE, apoA-IV) and a rarity of coronary artery disease. The defect has been identified as a G (guanine) to A (adenine) substitution in the fourteenth intron of CETP pre-messenger RNA (ribonucleic acid). This splice donor defect is also the cause of the deficiency in additional Japanese families identified. In other studies, the deficiency (both homozygous and heterozygous) has been shown to be associated with a large proportion of Japanese with hyperalphalipoproteinemia.
Also, a missense mutation at nucleotide 1506 (G for A) has been identified in exon 15 of the CETP gene, resulting in a substitution of a glycine for aspartic acid at amino acid 442. The two subjects heterozygous for the missense mutation had three times the normal HDL (high density lipoprotein) levels. Overall, these studies suggest that even partial reduction in CETP levels, as found in heterozygous individuals, is associated with elevated HDL. This apparently benign condition (CETP deficiency) has been coined the “longevity syndrome”.
A variety of species, which lack CETP activity, including mice, rats, and dogs, have HDL as their major lipoprotein. When fed atherogenic diets, transgenic mice expressing human or cynomologus monkey CETP develop atherogenic lipoprotein profiles, including elevation of apoB containing lipoproteins (VLDL and β-VLDL) and reduction of HDL. These mice also develop atherosclerotic lesions. In the transgenic mice, CETP plasma activity has also been shown to be directly correlated with apoB and inversely correlated with apoA-I levels. Infusion of antibodies to CETP into rabbits results in a more favorable lipoprotein profile, including elevated HDL cholesterol and particle size. Conversely, infusion of CETP into rats results in a less favorable lipoprotein profile, including elevation of VLDL and LDL cholesterol and apoB, and diminution of apoE-rich HDL cholesterol and HDL size.
Preparation of CETP
The d>1.21 g/ml fraction was isolated from rabbit (Pel-Freez Biologicals, Rogers, Ark.) or human plasma and dialyzed against 50 mM Tris, 150 mM NaCl, 2 mM EDTA (ethylene diamine tetracetic acid), pH 7.4 buffer (1XDB, pH 7.4). Aliquots were stored frozen at −20° C. Chinese Hamster Ovary cells transfected with human recombinant CETP may be obtained by license agreement from Columbia University, New York. Media from these cells grown in 10% fetal bovine serum in Hams F-12 was used as a source of human CETP without further purification. The human CETP inhibitory monoclonal antibody TP2 (Mab TP2) may be obtained from Dr. Ross Milne and Yves Marcel (University of Ottawa Heart Institute). Mab TP2 is also known to inhibit rabbit CETP.
Radioisotopic Whole Plasma CETP Assays
Inhibitor screens were performed in 102.5 or 205 μl total volumes in deep 96-well polypropylene plates (1.2 ml capacity/well) or glass tubes, respectively. Compounds (final concentrations up to 100 μM) were added in 2.5 or 5.0 μl DMSO and pre-incubated for 1 hour at 37° C. with previously frozen human plasma (25 or 50 μl). 3 H-CL-HDL 3 (20,000 or 40,000 dpm) in 75 or 150 μl of 1XDB, pH 8.0 was added and incubated at 37° C. Wells were harvested periodically up to 24 h by the addition of a 1.0 ml solution (per 102.5 μl incubation) containing 10 mg/ml bovine serum albumin, 1.29 mg/ml bovine intestinal mucosa heparin (Sigma Chemical Co., St. Louis, Mo.) in 0.14 M MnCl 2 .4H 2 O in 1XDB pH 8.0. Samples were mixed and after 10 minutes centrifuged at 2200 rpm for 30 minutes at 10° C. in an IEC PR-6000 centrifuge to precipitate apoB containing lipoproteins. Supernatant aliquots were counted by liquid scintillation spectroscopy to determine radioactivity remaining in HDL 3 . See JOURNAL OF LIPID RESEARCH, Vol. 34, 1993, pp. 1625-1634, entitled “Use of Fluorescent Cholesteryl Ester Microemulsions and Cholesteryl Ester Transfer Protein Assays” by C. L. Bisgaier et al.
The invention herein may likewise be used in the spectrophotometric microtiter-based assay for the detection of hydroperoxy derivatives of linoleic acid. See, ANALYTICAL BIOCHEMISTRY, 201, 375-380 (1992) by B. J. Auerbach et al.
An assay for the detection of hydroperoxy derivatives of linoleic acid formed by the action of 15-lipoxygenase is described. The assay developed is based on a method first reported by Ohishi et al (1985) BIOCHEM. INT. 10, 205-211, with some modifications. The assay described herein takes advantage of the ability of (9Z,11E)-13-hydroperoxyoctadecadienoic acid (13-HPODE), the product of the action of 15-lipoxygenase on linoleic acid, to oxidize N-benzoyl leucomethylene blue to methylene blue in the presence of hemoglobin. The resultant blue color is stable to light and air and can be quantified spectrophotometrically at 660 nm. The linear range of the assay is 1.6-3.2 nmol (0.5-10 μg) of 13-DPODE. The utility of the assay can be extended to detect other peroxides as well as inhibitors of 15-lipoxygenase. The assay is a rapid, reliable method for the detection of lipid hydroperoxide production.
The methods and the materials utilized for this assay are as follows:
Materials. The following chemicals were purchased and used as received: linoleic acid (NuCheck Prep), 13(S)-HPODE, NDGA (nordihydroguaiaretic acid), ETYA (5,8,11,14-Eicosatetraynioc acid), 14,15-methano-LTA 4 (leukotriene A 4 ), (Biomol Research Labs), N-benzoyl leucomethylene blue (Tokyo Kasei Kogyo Co., Ltd.), dimethylformamide (DMF; Aldrich), sodium cholate, Triton X-100, 30% H 2 O 2 , 70% t-butyl hydroperoxide, and hemoglobin, bovine (Sigma). Probucol and indomethacin were prepared at Parke-Davis.
Methylene Blue Method For Peroxide Detection. The assay is performed in a 96-well microtiter plate. Each well contains 40 μl of substrate solution consisting of 160 μM linoleic acid, 5% ethanol, 0.2% sodium cholate in PBS without EDTA, inhibitor, if included, and 0.16 U enzyme isolated from phenylhydrazine-treated rabbit reticulocyte preparations (21) [1 U=1 nmol linoleic acid utilized/min at 4° C.] for a total volume of 50 μl. The plate is then incubated at 4° C. for 10 minutes followed by the addition of 100 μl of LMB color reagent consisting of 5 mg LMB dissolved in 8 ml DMF, which is then added to a 0.05 M potassium phosphate buffer (pH 5) containing 1.4 g Triton X-100 and 5.5 mg hemoglobin in a total volume of 100 ml. After 5 minutes at room temperature, the samples can be read at 660 nm on a microtiter plate reader. Under these conditions, approximately 20% of the substrate is converted to product.
HPLC (High Pressure Liquid Chromatography) Method For 13(S)-HPODE Detection. For verification of the assay, HPLC analysis of the products was performed after incubation under the above-described conditions. The assay is terminated by the addition of an equal volume HPLC mobile phase (acetonitrile:water:methanol:acetic acid, 350:250:150:1). The samples are then injected onto a C18 column (Perkin-Elmer) with conjugated dienes monitored at 235 nm and keto-derivatives at 270 nm. A postcolumn chemiluminescence reaction was utilized to detect hydroperoxy fatty acid derivatives.
The invention can likewise be used for determining the epidermal growth factor receptor kinase activity.
The present invention may be used as an assay for Acetylcholinesterase (AChE) activity. See, for example, the Ellman method (Ashour et al, 1987, ANAL. BIOCHEM. 166, 353-360).
The invention may equally be useful as a assay for mutant reverse transcriptase. This test is a determination of inhibitors of viral DNA polymerase and reverse transcriptase. See, VIROLOGY, 114, 52 (1981: entitled “Mechanism of Inhibition of Epstein-Barr Virus Replication” by A. K. Datta et al.
The present invention can be used in an RNA enzyme assay system. The assay is a commercially available assay from Amersham entitled “RNase H(3H)-SPA Enzyme Assay System”.
The test is equally applicable for looking for inhibitors of Hepatitis B virus. A typical technique is called Hepatitis B virus reverse transcriptase assay. The assay procedure is a commercially available assay procedure.
The invention is equally applicable to detect HIV protease enzyme. There is a commercially available testing identified as Amersham's HIV protease [125]I-SPA assay system.
The invention is equally applicable to determining the ability of materials for rust-removing activity, or the ability to dye various textile materials, or the ability to clean substrates, or the ability of material to decompose in the presence of bacteria such as soiled bacteria and the like.
The invention is equally applicable to determining a compound's ability to hybridize to a library of genes, or whether particular materials are sensitive to mammals and the like.
The invention is equally applicable to determining sunscreening activity or immune response in mammals. Various Elisa (enzyme link immuno sorbant activity) which enzyme can detect for the presence of a number of biologic materials such as various components of the blood such as T-cells, B-cells, interleukins, and the like.
The invention is equally applicable for determining the presence or absence of a gene which is associated with a particular malady or a gene that is associated with an absence of a biological response in mammals. The test could be applicable for determining the permeability of materials to a membrane such as a cellular membrane. The test is applicable for determining the activity of a cell to transduce signals over the ability of different materials to bind two cells or to bind enzymes or antibodies. See, CELLULAR AND MOLECULAR IMMUNOLOGY (2nd Edition) 1994 by A. K. Abbas, pp. 56-60.
It is to be appreciated that a wide variety of a compound's activities could be determined such as:
the activity to be tested of the compounds is a rust remover activity;
the activity is the ability to dye textile materials;
the activity is to clean substrates;
the activity is the ability to decompose in the presence soil bacteria;
the activity is the ability of compounds to hybridize to a library of genes;
the activity is the ability to detect sun screen activity; the sun screens are also detected for sensitivity to mammals;
the activity is the ability to induce an immune response in mammals;
the activity is presence of a gene associated with a malady;
the activity is absence of a gene associated with a malady;
the activity is presence of a gene associated with a biological response in mammals;
the activity is the absence of a gene associated with a biological response in mammals;
the activity is permeability of a membrane;
the activity is effecting a signal transduction of a cell;
the activity is ability to bind to a cell;
the activity is ability to bind to an enzyme; and
the activity is ability to bind to an antibody.
The present invention is equally applicable to determining an optimized dosage or weight for active compounds. In other words, the present invention can assist in quantitatively determining active materials and their degree of activity. In this manner, identical or differential amounts of a compound(s) to be tested are placed in various unique well locations.
For a discussion of applicability of the present invention to the simultaneous synthesis of compositions, reference may be made to the concurrently filed patent application entitled “A Method for the Synthesis of Mixtures of Compounds” commonly owned, attorney's case #PD5116, Ser. No. 08/923,801, hereby incorporated by reference.
While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. It is not intended herein to mention all of the possible equivalent forms or ramifications of the invention. It is understood that the terms used herein are merely descriptive rather than limiting and that various changes may be made without departing from the spirit or scope of the invention.
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Described is a method of simultaneously testing a plurality of compounds for activity comprising the steps of: (a) placing a plurality of the compounds into at least two arrays, each having a plurality of test zones, with multiple compounds in each zone; (b) determining the location of each compound in each test zone; (c) subjecting the array to a testing screen; and (d) ascertaining those compounds that had a positive response to the testing screen. Also described are apparatus for performing simultaneous testing of a plurality of compounds in a plurality of arrays containing the compounds to be tested for their activity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the modification and manipulation of the triboelectric properties of filter material to provide fabrics having predictable triboelectric properties for use as filter media. More particularly, the invention relates to the modification or adjustment of filter fabric media according to predictably calibrated triboelectric properties for use in dust collection operations so as to optimize the performance of the filters in relation to the particulate matter to be filtered.
2. Description of the Prior Art
The U.S. Environmental Protection Agency (EPA), in 1970, originally set forth a National Ambient Quality standard for particulate matter. Since that time, U.S. industry has commenced practices which reduced the mass of particulates on an average by 20% by the early 1980's, despite increased industrial developments. In view of further industrial expansion and especially in view of the projected greater use of coal to generate electrical power, particulate pollutants will have a tendency to increase unless appropriate control measures are taken. As regulations became more stringent, especially in regard to particle size, control devices for removing particulate matter became more restricted. The most common methods in increasing order of apparent potential acceptability based on performance are: mechanical collectors, particulate wet scrubbers, electrostatic precipitators, and fabric filters. Fabric filtration is a process not greatly different in principle of operation from that of the common home vacuum cleaner. Particulate matter is removed from a dirty air (gas) stream by virtue of separation processes that occur at or near the fabric surface. Five such mechanisms are identified in the separation process: inertial deposition, brownian movement, direct interception, gravitational sedimentation and electrostatics. Except for the electrostatic involvement feature, each of these has been well described in the prior art. Because filtration is among the most reliable, efficient and economical methods for removing particulate matter from gases, baghouses are being applied more universally for controlling emissions. As an example, baghouses may be applied to coal-fired utility boilers, and are one of the few air pollution control techniques easily capable of meeting the more stringent anticipated emission standards.
Although fabric filters are well known as being capable of collecting very small particulates, a high level of removal from industrial process gases is not routinely achieved. One reason for this is that not all fibers used in constructing the filter perform in the same manner, even where the chemical composition of the fibers is presumably identical in a favorably constructed fabric. Additionally, it appears that natural electrical forces clearly influence the filtration process. In fact, it appears that substantially all industrial processes produce particulate matter with charges, positive and negative. Although considerable information on the mechanics of the filtration process for uncharged particles is available, very little has been provided with regard to natural electrical effects in fabric filtration. This is despite the fact that particulate matter reaching the fabric filter is rarely uncharged and the medium itself is rarely devoid of an electric field. Accordingly, particles entering conventional collectors are mostly charged, sometimes far more extensively than at other times, but usually of mixed polarity. The type of generating process determines the magnitude of the charge, with grinding and other energy intensive operations producing particulate matter with extremely high levels of charge.
It is generally accepted that electrostatic attraction draws particles from the gas stream to fibers if the two are oppositely charged. Even if only one of the particles or filtering fabric is charged, a naturally induced charge will be created on the other. This results in a polarizing force that causes attraction and particle movement from the gas stream to the oppositely charged fiber. However, although as stated above, the particulate matter and/or the fabric filter may have electrostatic charges thereon, the polarity, magnitude and durability of the triboelectrically induced charge depends upon the inherent properties of the materials, including their chemical make-up and the electrical resistivity.
Electrical augmentation, the practice of electrically charging the gas-entrained particles and/or applying an electric field to the collecting medium, can provide excellent filtration features. These artificial charging conditions are, however, applicable only to non-combustible, electrically chargeable particles. Another limitation is that they require special processing and collection facilities, electrodes, electrical circuits, and the like. The most commonly proposed electrical augmentation techniques utilize a corona discharge to impress a charge on the particulate matter and/or a high D.C. voltage on wire electrodes appropriately located on or near the surface of the collecting fabric. One of the more serious limitations of electrode systems proposed for such augmentation is the short life of the circuitry.
A very significant portion of the improved filtration performance gained by electrical augmentation or artificial charging may be achievable simply by balancing the natural charging properties of the fabric with those provided by the particulate matter. By utilizing natural charges, that is by using a fabric filter medium of appropriate inherent triboelectric properties relative to those of the particulate matter being collected, it is possible to deposit a low air-flow resistant cake without electrical augmentation. By suitably balancing the natural triboelectric properties of the medium in relation to those of the particles being collected, conditions are realized for approaching the ultimate level of filtration performance now attained only by electrical augmentation.
Practically all of the commercial fibers used for filtration fabrics respond to contact electrification and because of molecular variations, gain or lose electrons differently. Different fibers, therefore, become charged at different polarities. When listed in a downward order from electropositive to electronegative, a series may be developed, referred to as the triboelectric series (TE), and any material fabric or dust, may be included according to its electrostatic polarity relative to others in the list. Triboelectrification is the frictional process by which substances such as fabrics, particles, and the like, when abraded or rubbed by other substances and separated, develop electrostatic charges. Polarity of the acquired charge on the rubbed material to that on the rubbing substance depends upon the inherent character of the rubbed substance. The magnitude of the acquired charge depends upon various qualities of both the rubbed and the rubbing materials including the differences in their spacing in the triboelectric series, the roughness of their surfaces, the environment to which they are exposed and other parameters. Natural charging refers to the charging process that occurs naturally in the course of handling materials of all types. Particulate matter acquires electrostatic charges by contact with or rubbing against other substances such as the walls of ducting or during formation/production as generated at high temperatures, grinding, and the like. The triboelectric properties of fabrics generally are either not significant or have not been recognized to be critical or useful in their normal service applications.
In dry filtration, however, this characteristic of the medium appears to control the process and dictate its performance. An ideal balance between the electrostatic charges on the collecting filter medium provides optimal or near optimal filtration parameters in terms of pressure drop, efficiency, gas flow-through, fabric cleanability and other dependent variables. Although non-electrically augmented filtration operations presently are anticipated to be the most common collection methods, controlling the filter operation by balancing the electrostatic properties of the particles and of the filter medium has received little or no consideration.
The opportunity to utilize natural electrostatic effects fully has been restricted to some extent by non-availability of appropriate media and most seriously by the triboelectric limitations of commercially available fabrics. The most serious problems have included triboelectric non-uniformity among even supposedly identical fabrics, and the limitations of the inherent triboelectric properties of an otherwise suitable fabric. The fabrics marketed for filter media use presently do not always permit the choice of the desired triboelectric properties, neither are the fabrics constructed from blends of fibers having a selectable preferred balance of electropositive and electronegative fibers for filtering gas entrained particles of both charges, to optimize the process.
SUMMARY OF THE INVENTION
The present techniques overcome the triboelectric limitations imposed on commercially available fabrics by preferentially and specifically adjusting or modifying the triboelectric properties of fabric filter media in order to realize optimal or near optimal filtration performance in the collection of precharged particulate matter. The selection of the preferred filter fabric may then be made on the basis of electrical properties as well as upon the need to meet the temperature, chemical, economic and other requirements.
A simple modification process to provide consistent, desirable triboelectric properties is described. The process modifies useful fabrics such that they may be consistently and accurately categorized and assigned to a specific position in the triboelectric series. This position then corresponds to one which is most optimal for a particulate being filtered. Additionally, fibers may be modified triboelectrically and a fabric produced from a blend of fibers having the desirable properties for use as filter fabrics wherein the particulate being filtered has various electrical charges. For example, DACRON polyester fibers vary greatly in their triboelectric properties, and although ideal as filter medium for other reasons, may not be most favorably utilized unless appropriately modified in their electrical properties to provide consistent performance. Accordingly, the utilization of DACRON based upon its triboelectric properties is not always practical unless the fiber or the fabric made of the fiber is preferentially altered to provide the desired TE qualities.
The described alteration may be made chemically by conventional chemical means, and more preferentially by dyeing. Dyeing provides the necessary chemical changes while further providing a simple and accurate identification method for the chemically altered fabrics. In either case, the alteration must be durable in order to withstand the conditions of service. Dyes are preferentially applied since in addition to achieving the needed electrical features routinely in commercially available facilities, the presence of a colorfast specific color denoting a position in the triboelectric series has considerable appeal. With prior knowledge of the subject particulates charge features, the filter fabric required to provide optimal collection parameters can be determined easily. For example, the advantage of having a highly electropositive red fabric and a very electronegative blue fabric or, perhaps, a blend of the fibers or yarns from the two base fibers in a fabric having a purple shade, would have specifically useful features. The first two would offer the needed triboelectric properties for optimally collecting negative triboelectric, commonly known as TE(-), or positive TE, known as TE(+) particles. The fabric containing the blend mixture of fibers/yarns would serve best in collecting dust in which half of the particles were positively charged and half were negatively charged. It would be apparent that the desirable blend will be governed by the actual charge distribution of particles in the particulate matter to be filtered.
A method is disclosed, therefore, by which the TE properties of fibers in fabric filter media may be determined and changed predictably to meet requirements dictated by the TE properties of the particulate matter being collected and, thereby, to attain optimal or near optimal collection parameters.
Any alteration of a fiber's TE property must be realized by a process that makes the change relatively permanent. Since charges are generated and carried on the surface of the fibers, an unbonded surface coating is useless for charge modification. But two fundamentally different types of treatment have been shown to be effective. One of these is by coordinate bonding through chemical addition or substitution with the substrate fiber to form a new, different and chemically bonded finish with suitable ionic qualities to influence the TE as desired. There are several processes of this type, two of which have been used and described below with the TE results indicated in Table 2 and another which is mentioned.
Disperse dyes are prime examples of those agents that modify the surface by absorption to become a new and relatively permanent part of the fiber. Other dyes that become part of a fiber's surface and provide new and different ionic features influence the TE properties of these modified fibers differently.
Chemical Reactions for TE Modification
Any reagent capable of reacting with the fiber substrate, polymeric or monomeric, and providing a characteristic ionic group, will serve to modify the TE properties of that fiber. For modifying polyester as well as other polymeric fibers with active hydrogen atoms or those with bonded water molecules, it is possible to effect modification with such reagents as the isocyanates, silanes and Grignards which become a new part of the fiber and, therefore, may alter its TE properties. Evidence is provided in NATURE, 349: 683 (1991) that water forms hydrogen bonds to the aromatic pi electrons of certain organic compounds like the polyesters and RYTON, for example. With isocyanate on RYTON: ##STR1## With dimethyldichlorosilane on RYTON to produce a silicone complex: ##STR2##
Isocyanate Reactions
The ability of isocyanates to perform in this way has been demonstrated clearly by the treatment applied by Mobay Chemical Company to samples of the CS&S, bulk knitted polyester filament yarn filter fabric. The extremely high TE (+) properties imparted by some of the treatments as identified below is verification that new surfaces with cationic features have been achieved by direct reaction with the polymeric or monomeric reagents to form a durable, abrasion resistant, reacted finish.
Isocyanate Reaction With Other Active H Atoms
Examples are given utilizing polyester, or pe.
{RN=C═O+R*OH(pe)→RONHR*(pe)+CO 2 }
Reference should be made to Table 2 for the relative TE positions of treated fabrics.
Mobay A-(pe)+Bayhydrol 123 (reaction with polymeric pe)
Mobay B-(pe)+Desmodur E-21 (MDI=methylenediphenyldiisocyanate) (crosslinks through active H/moisture on pe)
Mobay C-(pe)+Desmodur N-1 (HDI=hexamethylenediisocyanate) (crosslinks through active H/moisture on pe)
Mobay D-(pe)+Impranil DLN polyurethane (15%)
Mobay E-(pe)+Bayhydrol 123 (15%)
Mobay F-(pe)+Desmodur N-75 and Desmophen (670A-80) (Desmophen N-75 crosslinks with Desmophen (670A-80 on pe))
With reference to Table 2, the differences in TE contributions of those treatments which react with the polyester polymer and produce a strong cationic influence compared to those that provide a less strong cationic surface coating will be apparent from the locations of such treated CS&S knitted (pe) Dacron fabrics in the series. The more or less electropositive contributions of those reagents that become part of the fiber and provide an amine or amide (TE+) end group is apparent.
Silane Reactions
Silanes react with moisture, loosely or pi-bonded to a complex polymer, for example, HOH: ##STR3## and with pi-bonded water of pe, or RYTON: ##STR4##
Grignard Reactions
Among other reagents capable of changing the TE properties of fibers are those of the Grignard type. These are formed from alkyl halides with metallic magnesium, usually in the presence of anhydrous ethyl ether, other higher series ethers, tertiary amines and even hydrocarbons:
R*MgX+(HOH, ROH, RHO, or RNH 2 )→(HOMgX, ROMgX, RHMgX, or NHMgX)+R*H
The reactions allow Grignard reagents to modify fibers with a variety of endgroups including active hydrogens, pi-bonded or otherwise attached water molecules, primary and secondary amines, acidic groups, alkyl halides and those containing acetylenic groups. The reactions may be considered as follows:
with an active hydrogen RH+R'MgX→RMgX+R'H
with water HOH+R'MgX→HOMgX+R'H
with amines --NHH+R'MgX→--NHMgX+R'H
with acids --C═O--OH+R'MgX→--C═O--OMgX+R'H
with halide RX+R'MgX→RMgX 2 +RR'
with acetylinic groups --C.tbd.CH+R'MgX→--C.tbd.CMgX+R'H
Dyeing Processes
Dyes become part of the fiber surface by absorption. Any dye, therefore, capable of penetrating and changing the fiber's TE properties by introducing a different ionic group, offers a means for predictably modifying this property for achieving optimal or near optimal filtration performance, especially for collecting the agglomerating types of particulate matter. MAXILON RED GRL-BR(HC)200 from Ciba-Geigy Corporation is an Azo dye made from an aryl quaternary amine and sodium napthyl sulfonate producing a triazide nitrogen. The dye becomes part of the polyester fiber, absorbing into the polymer's surface, dissolving therein, but not chemically bonded. The dye is fast, i.e., it resists fading by washing, and the like, and can be expected to remain an effective component of the polyester fiber/fabric used in the normal filtration environments to which it is exposed. The presence of amine and/or amide groups account for this dye's ability to confer electropositive TE qualities. The surface solution or adsorption of the dye contributes to the fastness or durability of the modification. RITE REACTIVE YELLOW B-RLN as supplied by Rite Industries Inc. is a difunctional dye of vinyl sulfone and monochlorotriazine. The presence of chlorine in this dye is believed to contribute to the TE (-) quality that it confers to the CS&S polyester. Another example is RIT ALL PURPOSE CONCENTRATED TINT AND DYE, produced by Special Products, an Affiliate of CPC International Inc. While the compositions of these dyes have not been revealed, it will be obvious from the locations of the RIT-dyed polyester fabric in Table 2, the various dyes not only provide different colors but also impart markedly different TE properties.
Firestone's Solution Dyed Polyester Fibers/Fabrics
Fabrics with yellow solution dyed polyester filament yarns in the filling and different colored solution dyed polyester filament yarns in the warp as provided by Firestone Fibers and Textiles Company, Box 450, Hopewell, Va. 23860, were evaluated triboelectrically. Not only were the positions of the six different fabrics in the TE series found to be quite different but the samples also produced substantial variations in generated voltage when rubbed by the reference material. These effects are indicated as follows:
______________________________________color TE Total V*______________________________________blue +4.1 14.0green +2.5 6.5orange +0.1 9.4red/orange +0.04 14.2yellow +2.5 6.5white +1.5 15.5black +1.3 15.2______________________________________
While the types of dye used on these polyester filament yarns are not identified except that they are of the solution type, it will be evident that each has a different influence on the TE properties of the same polyester fiber and, therefore, might be used to alter such features predictably.
The process thus provides a method for selecting a fabric filter by preferentially and specifically adjusting the TE properties of known fabric filter media to conform to a specific charge polarity and magnitude calibrated for the collection of known charged particulate matter.
Additionally, the process provides a grouping of filter fabrics modified through the preferential adjustment of the TE properties of available useful fabrics for selective adoption in filtering particulate matter having charged particles attracted optimally to materials only having certain TE properties.
Modification of the TE properties of known fibers to specific locations in the TE series is disclosed, such that a fabric may be constructed having a blend of fibers of various selective TE properties for use as a filter medium in filtering particulate matter having particles of various charge distribution.
A method is also provided to select a filter for a particular filtration application, the method including the steps of determining and changing the TE properties of a fabric to conform to a specific charged polarity and magnitude, constructing filters from materials calibrated to such properties, determining the charge polarity and magnitude of particulate matter to be filtered, and selecting filters calibrated to optimally attract such particles and cause aggregation of those that are subject to such transformation. Accordingly, the present invention includes the determination of the TE properties of fabrics having other desirable filter media characteristics, modifying the TE properties of these fabrics and utilizing, selectively, modified fabrics as the filter medium for optimally attracting gas entrained electrically charged particles to the surface of the filter. The invention also includes the determination and modification of the TE properties of fibers utilized in fabrics having other desirable filter media characteristics and blending yarns of selected fibers so modified into a fabric for use in filtering particulate matter comprising particles having various electrical charges, the yarn blend being such that certain of the fibers best attract others of the particles to the surface of the fabric.
These and other particular features and advantages of the present invention will become more fully understood upon reference to the presently preferred embodiments thereof and the examples set forth.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Particle separation by filter media occurs-by more than the simple process of entrapment of the individual particles, since the voids in most fabrics are usually many times greater than the size of the collected individual particles. Ordinarily, the separation process is relatively poor until a suitable layer or particulate matter is collected and forms a bridging type accumulation across the openings. Once a particulate base or cake is formed over the fabric surface, the collection efficiency increases to a value approaching 100%, depending on the medium, the particulate and processing conditions. Particulate matter that agglomerate on the collecting surface can be removed while some cake may remain. For those particulates that do not agglomerate on the collecting surface, less effective cleaning must be accepted in order to achieve high collection efficiency.
It is generally accepted that electrostatic attraction draws particles from the gas stream to fibers when the two are oppositely charged. When electrostatic forces of attraction are suitable, particle-to-particle contact and, thereby, agglomeration is enhanced. This is believed to be the primary basis for the porous type structure of the deposits collected under favorable conditions of electrostatic charging. In the process of separating gas entrained particulate matter by fabric filtration, efficiency of particle removal, the rate of gas flow through the fabric and the effectiveness of the cake removal operation are all maximized by formation of such a porous deposit of collected particulate matter. The ideal type of deposition is realized by optimizing the electrostatic balance between particles being collected and the collecting filter medium. Electrical augmentation by artificial charging can lead to ideal collection parameters, but for general use, the durability of the electrical circuitry and non-applicability to a combustible environment is a limitation of these processes. By balancing the particulate and fabric natural charges, a significant portion of improved contact is determined by the inherent properties of the fibers that make up the fabric, by the construction of the fabric, by the particulate itself, and by operating conditions. Therefore, the natural TE properties of the medium may be employed to deposit a low air flow resistant cake without electrical augmentation to approach the ultimate level of filtration performance now achieved by such augmentation. However, the opportunities to utilize natural electrostatic effects fully are limited to a large extent by the availability of appropriate media and more so by the variability of commercial fabrics. Accordingly, by predetermined modification of the TE properties of the medium, media may be selected to provide the best filtration performance for given particulates produced by a given process.
Consequently, an electrical balance is required between the filter media and the particles being collected, and it is important to realize that the strong electrical charge imbalance between the filter media and the particles contributes not only to attract the particles, but to attract these particles so effectively as to cause aggregation of those types of particulate matter that can undergo such a transformation. It is this aggregation or change in the effective particle size on the surface and not the inside the fabric structure, that is the key to the process provided by electrostatic interactions. Such interactions may be provided by the utilization of naturally generated electrostatic charges on the particles and on the collecting fabric. The advantage of increasing the particles size by agglomeration is evident on the basis of size alone, but such change also leads an increase in density for many types of particulate matter. This added feature assists in the removal of the collected cake during the cleaning phase of the filtration cycle simply by reason of the gravitational effect; moreover, the greater density contributes to a reduction in particle reentrainment, i.e. the drawing of collected particles or dust back up into the filter bag of a baghouse.
The triboelectric properties include the relative position, positive to negative, in the series, the magnitude of the charge generated and the rate of charge dissipation. The latter is significant since fabrics which discharge at low rates, although useful for agglomerating difficult-to-aggregate dust, are also more difficult to clean. The determination of the TE properties of fabrics may be accomplished by a controlled rubbing (or contact) and separation test as fully described in the American Dyestuff Reporter, Volume 57, No. 15, pages 31-33 dated Jul. 15, 1968. The method is quite simple, in that a narrow strip of test fabric is positioned in a frame and rubbed by a strip of reference fabric mounted on a rotatable insulated disk. The reference fabric is engaged with the test fabric and rotated through a fixed number of revolutions or time period. The test fabric is then contacted by a probe connected to an electric meter which measures the generated electrostatic voltage with respect to both polarity and magnitude. Using reference fabrics of known, predetermined and established polarity which preferably have the same construction, e.g., woven in the same pattern of essentially the same fiber/yarn sizes, other fabrics may then be located in a series relative to the reference materials by their charges when rubbed with these reference materials. Examples of these reference materials are NYLON, which is electropositive and a dinitrile, DARLAN, which is electronegative. As the trials are repeated by rubbing and separating different samples of fabric, each may then be located in this same TE series. Through repetition of this process with other fabrics, a TE series may be prepared by locating the various test fabrics relative to the reference fabrics. Such a series is shown in Table 1, which is similar to the table in EPA Report 600/7-78-142b. It should be noted that the 10 volt scale is strictly arbitrary, selected for ease in calculating values. 1000 or 5000 would be equally appropriate and possibly more realistic.
It is critical, in carrying out these tests, that the reference and test sample fabrics be clean since most foreign substances will confer different surface features. Subsequent to the TE position testing, a charge dissipation rate of the fabric is determined in order to determine the voltage remaining on the test samples after a fixed period of time, which is arbitrarily set at two minutes. This charge dissipation rate is measured as a percentage of the voltage derived from the tests made to determine the TE series. Thus, it gives a value which is a percentage of the charge lost in two minutes and again is considered to be arbitrary.
The scale for the values is arbitrarily established by setting values with respect to the known electropositive and electronegative reference fabrics and comparing the test fabrics therewith as more fully described in U.S. Pat. No. 3,487,396. Table 1 may thus establish TE positions of the various filter fabrics. The numbers included in brackets after the fabric name represent the relative TE discharge rate at 50% relative humidity. Most of the fabrics in Table 1 are wovens, while certain of the yarns are spun and others are continuous filament.
TABLE 1______________________________________A TRIBOELECTRIC SERIES(Estimated Triboelectric Positions of Some Filter Fabrics)(an arbitrary scale)______________________________________(+) very electropositive (+)+8 protein (WOOL A) 20%!+7 protein (WOOL B) 80%! polyphenylene sulfide (RYTON, st.) 20%!+6 ---- polyamide (NYLON) {afc 800b- REF.} fiberglass 35%!+5 polyester (DACRON O) 50%!+4 polyester (DACRON A) 90%!+3+2 polyester (KODEL) 20%!, polyester (DACRON) 40%!+1 aramid (NOMEX) 60%! acrylic {copolymer} (ORLON) 30%!-1 acrylic homopolymer! (DRALON T) 30%!-2 polyester (DACRON B) 30%!, polypropylene 50%!-3-4 ---- acrylic dinitrile! (DARLAN) {afc 5546-REF.}-5 ptfe (TEFLON) 0%!-6 ectfe (HALAR) 20%! aramid (KEVLAR) 45%!(-) very electronegative (-)______________________________________ Note: All locations above +6 and below -4 are approximate. %! = apparent rate of charge dissipation.
In filtration, because the charges that are acquired by particles in normal processing should be neutralized at the fabric surface to promote aggregation, this condition is best achieved by means of the fabric which offers the greatest attraction, i.e., most widely separated from the dust in the TE series. All materials, including particulate matter, can be located in the TE series. Fibers with consistent TE properties offer features for accurate prescription in the collection of certain dusts. Consider, for example, the opportunities provided for filtration of a given dust at elevated temperatures, e.g., 400° F. For electropositive properties, fiberglass media is available to attract and agglomerate electronegative particles. Similarly, because of its electronegative properties, a TEFLON fabric offers those TE features well suited for attracting and aggregating electropositive particles. For a mixture of positive and negative particles, NOMEX may be expected to offer somewhat better conditions, or agglomerating features, than either of these other high temperature media.
It would appear evident that in the filtration of a dust in which the particles carry both electronegative and electropositive charges, the more ideal medium will be that which can attract particles of both polarity. Ideally, this fiber blended yarn would consist of a negative TE polarity fiber concentration equivalent to 100% minus the percent concentration of negatively charged particles and a positive TE polarity of a concentration of 100% minus the percent concentration of the positively charged particles, assuming all particles carry charges.
One clear indication of the variability in TE properties among polyester fabrics and how this influences the filtration process was indicated experimentally in a test comparing three polyester fabrics having substantially the same permeability, having relative TE positions of -2.5, +4.8 and +1.4. Electric furnace dust was utilized as the test material. The filter medium having the TE position of -2.5 short cycled and essentially failed after collecting a small amount of the dust; the filter medium having the TE location of +4.8 performed somewhat better but not well; and the filter fabric having the midrange TE position of +1.4 performed very well and could have been used for a substantial period of time to collect considerable dust.
Since DACRON fibers vary greatly in their TE properties, and are generally ideal as a filter medium for other reasons, they may not be used most favorably in every appropriate application without modification in electrical properties. Since inherent chemical properties determine the electrical characteristics that dictate the location of the material in the TE series, it is evident that the DACRON fiber types that appear in different positions in the TE series must possess different surface chemical features. Accordingly, the prescription of DACRON, based upon TE properties, is not always practical unless the fiber/fabric is preferentially altered, chemically, to provide the desired TE qualities. Chemical modification, whether by conventional chemical means or by dyeing, therefore, is the principle for adjusting the TE properties of the fabric (fibers) therein to meet known and preferred locations in the TE series as related to those of the collected particulate matter.
In aqueous processes involving fabrics, chemical alteration is often accomplished by anionic or cationic reagents. The anionic treatment allows either retention or causes an enhancement of the electronegative properties of the processed fabric while the cationic finishes alter or enhance electropositive features. When these ionically active agents are applied to media for filtration applications, they produce similar changes and also provide either the same TE polarity or a reversal in the polarity of the original substrate. For example, the reaction of a polyester fabric having inherent TE properties that locate it in the mid position of the series, with an anionic treatment, causes the fabric to become far more electronegative. Similarly, when the same basic fabric substrate is reacted with a cationic reagent, it becomes more electropositive in the TE series. Anionic reagents are those that in a liquid subjected to an electric potential, collect at the anode. These reagents are represented by such chemicals as those containing hydroxide, carbonate and phosphate. Cationic reagents in a liquid subjected to electric potential collect at the cathode. These agents are represented by chemical makeup of such active positive ions as the amines and amides. It is thus evident that the reaction may be a simple chemical, an active modifying or resin-forming agent or a reactive dye. These reactions and the resulting change brought about by them in the TE position of the fabric has been verified by applying a cationic dye to the near mid-TE position, such as -0.5 DACRON (No. 107), to become very a electropositive medium at a position of +5. Referring to Table 2, an anionic dye, applied to the same near mid-TE position caused the fabric to change to a new TE position of -4.
EXAMPLES AND TESTING
In testing using two household dyes, such as RIT manufactured by Special Products, an affiliate of CPC International, one that was labeled navy blue and another scarlet, although not recommended for polyester or acrylic fibers, were applied successfully to pre-cleaned, woven, napped polyester fabric. Canadian Wheelabrator Fry No. S350/154, piece No. 35900 was utilized for this test and was cleaned using nonionic detergent, a 140° F. wash and a thorough rinse. This fabric in the cleaned condition had a TE position of -0.1. When dyed with the blue dye, the fabric's TE position was raised to the +0.3 location. The change in the scarlet dyed sample was found to be downward to a more negative polarity of -0.7 in the TE series. Not only are these noted polarity differences real and significant, but the magnitude of the charges generated by rubbing the three fabrics with NYLON in one instance and with DARLAN in another also differ greatly. The charge developed by rubbing against NYLON was -8.8 volts for the blue sample, -14.1 volts for the undyed fabric and -15.7 volts for the scarlet sample. Similarly for the test materials rubbed with DARLAN, the blue sample responded with -6.5 volts, the undyed with -9.2 volts and the scarlet dyed fabric with +7.9 volts. The TE data are shown graphically in Table 2.
TABLE 2______________________________________A TRIBOELECTRIC SERIESShowing Positions of Some Fabricsbefore and after Modification(an arbitrary scale)______________________________________(+) very electropositive (+)+8+7 *CS&S+C.G.Max.RedGRL *W.F.154+C.G.Max.RedGRL*RYTON, st. *CS&S+MobayC+6 ---- polyamide (NYLON) {afc 800b- REF} *CS&S+MobayD *CS&S+MobayE+5 *DACRON107+cat.dye *CS&S+MpbayA+4 *FIR.ST.(b)+3 *CS&S *FIR.ST.(gr), *FIR.ST.(wh)+2 *CS&S+MobayF, *FIR.ST.(ye)+1 *FIR.ST.(bk) *W.F.#154+RIT(b) *FIR.ST.(ro)0 *W.F.#154 *FIR.ST (o) *W.F.#154+RIT(s)-1-2-3-4 ---- acrylic dinitrile! (DARLAN) {afc 5546-REF.} *DACRON#107+an.dye-5 *CS&S+RITE(y)*CS&S+dmdcsi *W.F.#154+dmdcsi-6 *RYTON, st.+dmdcsi(-) very electronegative (-)______________________________________ Note: All locations above +6 and below -4 are approximate. Legend: CS&S = BEANE, bulk knit, fil.; W.F. = WHEELABRARTOR FRY, st., woven napped; FIR.ST. = FIRESTONE solution dyed filling yarns; Mobay = MOBAY CHEMICAL CO. with A,B,C,D,E & F urethane finishes; st. = staple (short) fiber; fil. = filament fiber; b = blue; bk = black; o = orange; r = red; wh = white; ye = yellow; C.G.MAX.GRL = CIBA GEIGY MAXILON RED GRLBR; RITE = RITE REACTIVE (yellow) from RITE INDUSTRIES INC.; RIT = RI TINT AND DYE, Special Products of CPC INTERNATIONAL INC.; cat. = cationic an = anionic; dmdcsi = dimethyldichlorosilane.
These test results indicate conclusively that polyester and other fiber based fabrics may be altered to become either electronegative or electropositive in the TE series with a preselected dye or chemical, which is selected specifically for its effect on the fibers. Other fibers and fabrics are also amenable to the changes by dyeing or chemical alteration. Accordingly, any fiber that can be modified chemically, whether directly or by means of a bridging coupler or by means of a pre-etch, should respond to appropriate treatment and provide predetermined TE properties. Although tests were directed toward conveying NYLON-like TE properties to polyesters, it should be relatively easy to make NYLON more electronegative by chemical modification or dyeing. Only the non-reactivity of the fiber limits the opportunities for TE adjustment. Thus, fibers of TEFLON and the olefins would be expected to present more difficulties in the modification process; even so, some modifications should be possible.
Once the TE properties of the desired material have been adjusted as desired, that material may be utilized as the filter medium for dusts having particulates most attractive to its polarity and magnitude. Or stated in another manner, the position of a particulate in the TE series may be determined and the filter medium having the most attractive opposite polarity TE position can be selected from the modified fabrics.
A variety of techniques are available for determining the TE properties of particles. For example, in EPA Report No. 600/7-78-142a, September, 1978, G. W. Penney described impingement methods for charging dust with sequent charge determination. One test utilized a tungsten carbide target on which the dust (silica) impinged at high velocity. The charge was read on an electric meter connected to the tungsten target. Penney later used a fabric filter as the target as supported on a metal screen which was connected directly to an electric meter. The current collected by the screen was measured by the meter and the rate of air flow through the filter was determined by means of a calibrated orifice. While an indirect approach for the determination of TE properties of the particles is described herein, the data obtained by appropriate particulate detection/measurement systems is preferred, at least for comparative data. Once the TE properties of the filter media are known, filtration tests may be conducted with such media selected for particular TE features. If, for example, different media of essentially the same construction, but made with fibers with TE properties ranging from those that are electropositive to those that are more electronegative are evaluated under the same controlled conditions, the influence of the TE position becomes evident. As pressure drop remains low and flow rates remain high without dust leakage, the more ideal media are found and the TE characteristics of these media specify those preferred for optimum performance. Once so located, the apparent TE features of the dust are indicated approximately and the most ideal fabric filter medium may be specified, especially as the filtration tests are extended to fine-tune the analysis.
Accordingly, a method is provided for selecting a filter for filtration application, the method including the steps of determining the TE properties of a fabric, chemically changing the TE properties to conform to specific desired properties, and utilizing fabric selected with the desired properties for media to filter dust and other particulate matter having TE characteristics most attracted to the fabric for promoting agglomeration on the surface of the media and an increase in density for the particulate so filtered.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A method is provided for specifying and altering the electrical properties of fibers and fabrics. This allows the prescription of filter media prepared from these constituents for consistently optimum or near optimum performance in the collection of particulate matter. The method may include the steps of determining the triboelectric properties of fabrics having other desirable filter media characteristics, modifying the triboelectric properties of these fabrics as needed to preferentially selected properties and utilizing, selectively, modified fabrics as the filter medium for optimally attracting gas entrained electrically charged particles to the surface of the filter. The modification of the triboelectric properties may be realized chemically or by dyeing the fibers and fabric. The selected fabric has triboelectric characteristics that provide maximum attraction for the dust to be filtered so that when possible, as is most common, agglomeration of the particles on the surface of the filter is promoted, and the density of the particulate on the surface of the filter is increased. Additionally, determination and modification techniques are proposed for fabrics utilized as filter media and the blending of the included fibers, filaments or yarns of selected fibers so modified. These are then combined into a medium for use in filtering particulate matter having particles of various electric charges.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a power transmission apparatus. More particularly, the invention is suitably used while being assembled in a compressor of a car air conditioner and operated from an external power source, such as an engine, through a belt.
2. Description of the Related Art
A refrigerant compressor of a car air conditioner is driven from an external power source such as an engine through a belt and a pulley. To cut off connection between the engine and the compressor, an electromagnetic clutch may be interposed between them. However, the electromagnetic clutch is not interposed in many cases because the production cost can be decreased when an electromagnetic clutch is not disposed. In this case, a torque limiter (power cutoff member) is disposed in the power transmission apparatus of the compressor for the car air conditioner operated through the belt to avoid disadvantage such as belt damage when the compressor seizes.
The torque limiter uses screw meshing for a part of a power transmission route and utilizes an excessive axial force that occurs at the screw meshing portion, owing to the excessive torque when the compressor seizes (refer to Japanese Unexamined Patent Publication No. 2003-206950, for example). Because this torque limiter system utilizes friction for cutoff, however, it involves the problem that the operation torque of the torque limiter changes with the passage of time because the coefficient of friction changes due to corrosion of the friction surface, as a contact surface, and the adhesion of grease.
In the power transmission apparatuses of the prior art such as the one described above, another torque limiter is known with sealing the friction surface and which avoids the problem described above. The power transmission apparatus of this type has a structure in which a part of the power transmission portion has screw coupling. The torque limiter system utilizing this screw coupling breaks a part of the power transmission route and cuts off the power transmission route by utilizing an excessive axial force occurring at the screw coupling portion by the excessive torque that occurs when the compressor seizes.
The requirement for reducing the power losses of the compressor and the power transmission apparatus are high at present. A technology of reducing a diameter of a shaft is known to reduce the loss of a shaft seal device and a bearing as a sliding loss of a shaft of a compressor. In the power transmission apparatus of the prior art having the torque limiter described above, the reduction of the diameter of a rotary shaft on the output side invites another problem. When the diameter of the rotary shaft is decreased in the fastening structure between a hub and the compressor of the power transmission apparatus of the prior art for transmitting power to the compressor, the problem occurs in that the torque limiter mechanism does not operate.
FIG. 5 is a partial sectional side view of an embodiment of the fastening structure of the prior art. In the case of the power transmission apparatus 50 for fastening the rotary shaft 5 of the compressor having a slide portion 5 d with the shaft seal device having a relatively large outer diameter, seat faces (bearing surfaces) 8 a and 8 b of a washer 8 sufficient for power transmission can be arranged. The power cutoff member 3 is fastened at its screw portion 3 d to the rotary shaft 5 and the hub 2 mechanically fitted is coupled or meshed with the power cutoff member 3 . It can be appreciated from FIG. 5 in this construction that a support surface having a sufficient area for the axial force generated as the torque transmitted from the pulley is converted can be formed on the seat faces 8 a and 8 b of the washer 8 and on the seat face (bearing surface) 5 a of the rotary shaft 5 . Therefore, the surface pressure acting on the seat faces 8 a and 8 b and the seat face 5 a can be limited to a low level.
FIG. 6 shows the power transmission apparatus 60 when the fastening structure shown in FIG. 5 is extended to a rotary shaft having a small diameter. FIG. 7 is an enlarged view of the fastening portion in FIG. 6 . The area of the seat face 5 a of the rotary shaft 5 becomes small, the axial force supporting area of the seat faces 8 a and 8 b (particularly 8 b ) of the washer 8 becomes small, and a high torque occurs in the screw fastening direction in the screw portion 3 d of the power cutoff member 3 and in the screw portion 5 b of the rotary shaft 5 during the high torque operation due to the high load operation of the compressor, so that the seat face 5 a of the rotary shaft 5 and the seat faces 8 a and 8 b of the washer 8 undergoes plastic deformation and the continuous operation cannot be made. Also, the seat face 5 a of the rotary shaft 5 and the seat faces 8 a and 8 b of the washer 8 undergo deformation due to the high torque resulting from the seizure of the compressor and the notch portion 3 c provided to the power cutoff member 3 cannot cut-off power. Incidentally, reference numerals of the constituent portions of the prior art examples shown in FIGS. 5 to 7 correspond to the reference numerals of similar constituent portions in the embodiment shown in FIGS. 1 and 2 .
Another prior art technology that makes portions in the proximity of the rotary shaft compact in the power transmission apparatus for the compressor is known (Japanese Unexamined Patent Publication No. 2001-173759, for example) but the reference does not disclose the present invention.
SUMMARY OF THE INVENTION
In view of the circumstances described above, the invention provides a power transmission apparatus for a compressor capable of securing high fastening strength and having a rotary shaft having a small diameter and, eventually, a power transmission apparatus capable of being fitted to a compressor having a low power loss. More specifically, the invention provides a power transmission apparatus for a normal operation type compressor for a car air conditioner operated from an external power source, such as an engine, through a belt and not having an electromagnetic clutch but having a torque limiter, which power transmission apparatus transmits power from the outside to the compressor through a pulley and has a hub fitted to the rotary shaft of the compressor requiring a small diameter shaft by screw fastening means. The power transmission apparatus can operate the torque limiter at a desired torque and can transmit a high torque even by using a rotary shaft having a small diameter.
According to one aspect of the invention, there is provided a power transmission apparatus ( 10 ) comprising a rotary portion ( 1 ) to which a turning driving force from a driving source is transmitted and which can rotate; a power cutoff member ( 3 ) mechanically connected to the rotary portion ( 1 ) and one of the ends of a rotary shaft ( 5 ) of a driven apparatus, and cutting off transmission of an excessive torque between the rotary portion and the rotary shaft; and a cap ( 4 ) connected to one end of the rotary shaft ( 5 ) on one hand and fastened by screw meshing to the power cutoff member ( 3 ) on the other hand to transmit power from the power cutoff member ( 3 ) to the rotary shaft ( 3 ). The rotary portion ( 1 ), the power cutoff member ( 3 ), the cap ( 4 ) and the rotary shaft ( 5 ) rotate integrally with one another. The cap ( 4 ) has a flange ( 4 h ) protruding in a radial direction with respect to an axis of the rotary shaft ( 5 ). The torque transmitted from the rotary portion ( 1 ) to the rotary shaft ( 5 ) is converted to an axial force in the axial direction of the rotary shaft ( 5 ) as the cap ( 4 ) and the power cutoff member ( 3 ) are fastened with each other through screw meshing, and the flange ( 4 h ) supports the axial force.
When the power transmission apparatus employs the construction described above, the power cutoff member (torque limiter) and the cap provided to the distal end of the rotary shaft of the driven apparatus are fastened and the torque limiter can be operated at a desired torque. Therefore, the power transmission apparatus can be used for an apparatus having a rotary shaft of a smaller diameter. In the power transmission apparatus having the torque limiter, therefore, the invention can solve the disadvantage such as the collapse of the seat face in the proximity of the rotary shaft due to the axial load and can transmit a high torque. As a result, the invention provides a power transmission apparatus that can be fitted to a compressor having a low power loss.
In the invention, the power transmission apparatus further comprises a hub ( 2 ) connected to the rotary portion ( 1 ) on one hand and to the power cutoff member ( 3 ) on the other hand, and transmitting power from the rotary portion ( 1 ) to the power cutoff member ( 3 ), and wherein the rotary portion ( 1 ), the hub ( 2 ) and the power cutoff member ( 3 ) rotate integrally with one another.
This discloses a more concrete construction of the power cutoff apparatus according to the invention.
The cap ( 4 ) is fastened to the rotary shaft ( 5 ) in such a fashion as to encompass the rotary shaft ( 5 ). This arrangement further embodies the power transmission apparatus of the invention.
The cap ( 4 ) and the rotary shaft ( 5 ) are fastened to each other through screw meshing. This arrangement further embodies the fastening structure of the cap ( 4 ) and the rotary shaft ( 5 ) in the invention.
The flange portion ( 4 h ) is formed on the cap ( 4 ) on the side opposing the power cutoff member ( 3 ). This arrangement further embodies the structure of the cap ( 4 ) of the invention.
The power transmission apparatus is connected to a compressor of a car air conditioner as the driven apparatus.
The present invention may be more fully understood from the description of preferred embodiments of the invention, as set forth below, together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a longitudinal sectional view showing a schematic construction of a power transmission apparatus according to a first embodiment of the invention;
FIG. 2 is a partial enlarged view of a portion near a rotary shaft in FIG. 1 ;
FIG. 3 is an enlarged sectional view of a portion near a rotary shaft fastening portion of a power transmission apparatus according to a second embodiment of the invention;
FIG. 4 is an enlarged sectional view of a cap of a modified embodiment of the second embodiment of the invention;
FIG. 5 is a partial longitudinal sectional view of a fastening structure of a power transmission apparatus according to the prior art;
FIG. 6 is a partial longitudinal sectional view showing an example when the fastening structure shown in FIG. 5 is expanded to a rotary shaft having a small diameter; and
FIG. 7 is a partial enlarged sectional view of the fastening portion in FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the invention will be hereinafter explained in detail with reference to the accompanying drawings. FIGS. 1 and 2 schematically show a power transmission apparatus according to the first embodiment of the invention, wherein FIG. 1 is a sectional side view showing a schematic construction of a power transmission apparatus 10 according to the first embodiment and FIG. 2 is a partial enlarged view of a fastening portion of a rotary shaft and a cap in the proximity of the rotary shaft. Referring to FIGS. 1 and 2 , the same reference numeral will be used to identify the same constituent element in FIGS. 1 and 2 as that of the prior art example shown in FIGS. 5 to 7 .
The power transmission apparatus 10 according to the first embodiment of the invention is used for a car air conditioner and is an apparatus for transmitting the rotating force of an external driving source such as an engine to a compressor of a car air conditioner. The power transmission apparatus 10 has a power cutoff member (torque limiter) 3 . In the power transmission apparatus 10 , power from the external power source such as the engine is transmitted to a pulley 1 (corresponding to a rotary portion) through a belt not shown in the drawing. Power is transmitted to an inner hub 2 d of a hub 2 as a fitting portion 2 a formed of an elastic member provided to an outer periphery of the hub 2 meshes with a fitting portion 1 a of the pulley. The pulley 1 is supported by a casing 7 of the compressor, not shown, through a bearing 6 in such a manner as to be capable of rotating. Power is further transmitted from the hub 2 to the power cutoff member 3 disposed inside the hub 2 , then from the power cutoff member 3 to the cap 4 meshing with the power cutoff member 3 , and thereafter to the rotary shaft 5 of the compressor meshing with the cap 4 .
FIG. 2 is an enlarged view of the fastening portion shown in FIG. 1 . The cap 4 of the metal shown in FIG. 2 is fitted to the distal end (one of the ends) of the rotary shaft 5 having a small diameter in the construction of the embodiment described above. The inner hub 2 d of the hub 2 and the power cutoff member 3 are fitted through faucet joint of a hexagonal shape or a rectangular shape at the fitting portion 2 e of the inner hub 2 d and the fitting portion 3 a of the power cutoff member, and transmit power from the hub 2 to the power cutoff member 3 owing to this construction. A first screw portion 4 e is formed around an outer peripheral portion of the cap 4 and meshes with the screw portion 3 d of the power cutoff member 3 . A second screw portion 4 d formed on the inner peripheral side of the cap 4 meshes with a screw portion 5 on the outer peripheral side of the rotary shaft 5 . When the screw portion 5 b of the rotary shaft 5 is screwed into the second screw portion 4 d , an end face 5 c at the distal end of the rotary shaft comes into touch with a seat face (bearing surface) 4 b formed inside the cap 4 as shown in FIG. 2 , thereby inhibiting further screw-in of the second screw portion 4 d.
Next, the operation of the power transmission apparatus 10 when an excessive torque acts thereon will be explained. The torque (power) is transmitted from the hub 2 to the power cutoff member 3 through the faucet joint portion, to the cap 4 through the respective screw portions 3 d and 4 e of the power cutoff member 3 and the cap 4 and to the rotary shaft 5 through the respective screw portions 4 d , 5 b of the cap 4 and the rotary shaft 5 . Power transmission between the cap 4 and the rotary shaft 5 is made through the frictional force due to the axial force between the end face 5 a and the seat face 4 b resulting from the contact of the end face 5 a of the distal end of the rotary shaft 5 and the seat face 4 b of the cap 4 in addition to the screw portions 4 b , 5 b.
In the torque transmission between the power cutoff member 3 and the cap 4 , on the other hand, power is converted to the axial force as the seat face 3 f of the power cutoff member 3 comes into touch with the seat surface (bearing surface) 2 g of the inner hub 2 d . The cap 4 has a disc-like flange portion 4 h that is disposed on the opposing side to the power transmission member, and the flange portion 4 h protrudes in a radial direction with respect to the axis of the rotary shaft 5 . The axial force acting on the inner hub 2 d on the seat face 2 g is borne by the seat face (bearing surface) 4 g on the inner hub side in the axial direction of the flange portion 4 h as can be appreciated from FIG. 2 . In the power transmission apparatus 60 of the prior art described already, this axial force is received by the seat face (bearing surface) 5 a through the washer 8 . The axial force transmitted from the inner hub 2 d to the power cutoff member 3 through the seat face (bearing surface) 3 f is borne by the first screw portion 4 e of the cap 4 through the screw portion 3 d . Furthermore, the axial force is transmitted to the rotary shaft 5 through the contact of the seat face 4 b of the cap 4 with the end face 5 c of the rotary shaft 5 and through fastening between the second screw portion 4 d of the cap 4 and the screw portion 5 b of the rotary shaft 5 and, at the same time, the torque is transmitted.
The power cutoff member 3 has a notch portion 3 c having a reduced section and a notch. Therefore, the screw portions 3 d and 4 e are fastened by the excessive torque that occurs when the compressor undergoes seizure, and the notch portion 3 c provided to the power cutoff member 3 undergoes breakage to cut-off power and to avoid the problem that the belt of the car is damaged. In this instance, the contact surface of the seat surface 4 g as the axial force bearing surface of the flange portion 4 h of the cap 4 and the inner hub 2 d can form a sufficient area, as shown in FIG. 2 , and can suppress the surface pressure acting on the seat face 4 g to a sufficiently low level. Though the axial force acting on the seat faces 4 b and 5 c increases, it is easy to set the strength of the cap 4 and the rotary shaft 5 against this axial force to be greater than the breaking strength of the notch portion 3 c . According to such a construction, it becomes possible to avoid the problem of the prior art described already in that the seat face 5 a of the rotary shaft 5 and the seat faces 8 a and 8 b of the washer 8 undergo plastic deformation such as sinking and consequently, the torque limiter does not operate. Furthermore, this construction can eliminate the washer 8 that has been necessary in the prior art example.
FIG. 3 is a partial enlarged sectional view of a portion in the proximity of the rotary shaft fastening portion of a power transmission apparatus according to the second embodiment of the invention. When the cap structure shown in FIG. 2 is employed in the first embodiment described above, the escape portion 4 c shown in FIG. 2 is necessary for processing the screw portion 4 e , but it is also possible to form a portion (head portion) 4 a having a tool portion disposed at the cap 4 into a separate component and to couple it with the cap 4 by means such as push-in, welding, etc. The rest of the constructions of this embodiment are the same as those of the first embodiment. Therefore, an explanation will be omitted.
FIG. 4 shows an enlarged sectional view of a cap in a modified example of the second embodiment. In the cap 4 shown in FIG. 4 , the first screw portion 4 e capable of coupling with the screw portion 3 d of the power cutoff member 3 is formed around the cap outer peripheral portion but means for coupling with the rotary shaft 5 of the compressor inside the cap 4 may be a spline structure 4 k in place of the screw in this embodiment. The construction of this embodiment may be applied to the first embodiment.
Referring to FIGS. 3 and 4 , like reference numerals are used to identify like constituent elements as in the first embodiment shown in FIGS. 1 and 2 .
Next, the effects and operations of the embodiments described above will be explained.
The following effects can be expected by the power transmission apparatus according to the first embodiment of the invention.
In the power transmission apparatus having the power cutoff member (torque limiter) installed inside the hub, the torque limiter can be operated at a desired torque by arranging the cap having the flange at the distal end portion of the rotary shaft of the compressor.
Therefore, in the power transmission apparatus having the torque limiter, it becomes possible to eliminate the problems such as sinking of the seat face in the proximity of the rotary shaft owing to the axial load, to transmit the high torque without affecting the power cutoff performance of the power cutoff member and eventually to fit the power transmission apparatus to a compressor having a low power loss.
The power transmission apparatus according to the second embodiment of the invention can provide the following effect in addition to the effects of the first embodiment.
Namely, processing of the screw portion of the cap becomes easier.
The power transmission apparatus of the modified embodiment of the second embodiment of the invention can provide the fastening structure of the cap and the rotary shaft of the compressor that can expect the same effects as those of the first embodiment.
The embodiments given above represent the example where the invention is used as the power transmission apparatus for the compressor of the car air conditioner but the invention may be used for other applications. In other words, the application of the invention is not limited to the car air conditioner.
In the embodiments described above or shown in the accompanying drawings, power of the driving source is transmitted through the belt and the pulley but the invention is not limited thereto. Namely, power may be transmitted through other mechanisms such as gears.
While the invention has been described by reference to specific embodiments chosen for purposes of illustration, it should be apparent that numerous modifications could be made thereto, by those skilled in the art, without departing from the basic concept and scope of the invention.
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A power transmission apparatus ( 10 ) includes a rotary portion ( 1 ) to which turning driving force from a driving source is transmitted and which can rotate, a power cutoff member ( 3 ) mechanically connected to the rotary portion ( 1 ) and one of the ends of a rotary shaft ( 5 ) of a driven apparatus and cutting off transmission of excessive torque between them, and a cap ( 4 ) connected to the end of the rotary shaft ( 5 ) on one hand and fastened by screw meshing to the power cutoff member ( 3 ) on the other hand, and transmitting power from the power cutoff member ( 3 ) to the rotary shaft ( 5 ). The rotary portion ( 1 ), the power cutoff member ( 3 ), the cap ( 4 ) and the rotary shaft ( 5 ) all rotate integrally with one another. The cap ( 4 ) has a flange portion ( 4 h ) protruding in a radial direction with respect to an axis of the rotary shaft ( 5 ) and supporting an axial force.
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FIELD OF THE INVENTION
This invention relates generally to lubrication devices and, more particularly, to an improved lubrication device particularly useful with pivot joints of articulated, off-highway mobile machines such as agriculture tractors.
BACKGROUND OF THE INVENTION
Certain types and sizes of mobile machines, e.g., large rubber-tired, off-highway construction loaders, agricultural tractors and the like, include frames or sections capable of limited movement with respect to one another. This capability makes the machine much more maneuverable. Such frames are connected by one or more hinges, sometimes called pivot joints, permitting such movement and machines so constructed are said to be "articulated." In the vernacular, they bend in the middle.
The frames or sections of such machines are at least capable of relative movement in a single plane as would occur when the machine is articulated on a flat surface. Such frames are also capable of oscillatory movement one with respect to the other; that is, the frames can "twist" to a limited extent with respect to one another. Such twisting motion occurs when the machine moves over undulating terrain.
Machines of the foregoing type frequently operate under dirty conditions. Airborne dust, mud particles, grain chaff and the like collect on the machine and one place where such contaminants accumulate is on oily, greasy surfaces including those of the pivot joints. As a consequence, such joints are prone to accelerated wear. The machine manufacturer typically provides an external grease fitting (sometimes called a "zerk" fitting) at such joints for periodic joint greasing by the machine operator using, e.g., a hand-operated grease gun. These grease fittings are very similar to those used to lubricate the chassis of an automobile.
Such conventional joint arrangements are characterized by at least two disadvantages. On is that for continuing joint lubrication and reasonable joint life (particularly in dirty operating environments--the usual case), the joint must be lubricated frequently, e.g., every ten hours or so of operation. Experience has demonstrated that many machine users simply fail to follow the manufacturer's instructions in this regard.
Another disadvantage is that the lubricant channels (through the zerk fitting and connecting passages into the joint) often become packed with a mixture of dirt and grease. Such mixture hardens and is difficult to remove--mere application of pressurized lubricant from a grease gun may well be insufficient to dislodge it. As a result, the machine operator may believe that s/he is effectively lubricating the joint when, in fact, no fresh lubricant is being introduced to the vital sliding friction surfaces. Premature joint wear and failure result.
An improved pivot joint lubrication device which accommodates oscillating and articulating movement, which is readily filled with lubricant and which lubricates vital pivot joint parts while obstructing entry of dust and dirt into the joint would be an important advance in the art.
OBJECTS OF THE INVENTION
It is an object of the invention to overcome some of the problems and shortcomings of the prior art including but not limited to those mentioned above.
Another object of the invention is to provide an improved lubrication device which helps assure continuing joint lubrication.
Still another object of the invention is to provide such an improved device which accommodates oscillating and articulating movement.
Yet another object of the invention is to provide an improved lubrication device which obstructs entry of dirt into the joint.
Yet another object of the invention is to provide such a device which scrapes dirt from certain joint surfaces.
Another object of the invention is to provide an improved device which is readily filled with lubricant.
Still another object of the invention is to provide an improved pivot joint lubrication device which obviates the need for frequent manual lubrication of the joint. How these and other objects are accomplished will become apparent from the following detailed description taken in conjunction with the drawing.
SUMMARY OF THE INVENTION
The improved lubrication device is particularly useful with mobile machinery, e.g., an agricultural tractor, having front and rear frames and a joint coupling member extending from each frame. A pivot joint connects such members in hinge fashion. Typically, the first member has parallel, spaced upper and lower extensions defining a slot between them. A single "tongue" or tongue-like second member fits between the extensions with clearance. A joint pin couples the extensions and the tongue, joining them together. The joint also has a primary bearing concentric with the pin and having a spherical surface permitting relative oscillating and articulating movement of the members one to the other.
The tongue-like member includes a cavity configured as a cylindrical hole through the member. Confined in the cavity is a joint assembly comprised of the primary bearing and an outer race. Such bearing and race define an "interface," i.e., the area where the bearing and race substantially contact one another and, desirably, are separated only by a thin film of grease. The outer race (and, consequently, the primary bearing) are confined in the cavity by a pair of annular disc-shaped retaining plates, each of which has an outer face.
In a joint of the foregoing type, lubricant is injected through an external fitting and along a passage to a bearing race. The race has a circumferential grease groove connected to a hole extending to the interface. Assuming a clean, dust-free environment, grease is injected into the foregoing path to lubricate the interface.
In the improvement, a pivot joint lubrication device has a secondary bearing with a spherical surface in motion-accommodating sealing engagement with the device. The device also has a lubricant flow path extending toward the spherical surface of the primary bearing whereby such surface is lubricated and entry of dirt to the surface is obstructed. The device includes a panel perforated by several holes and a cover mating with but spaced from the panel to form a reservoir-like chamber in which lubricant is placed. Mounting is by a retaining ring positioned between the cover and the panel. The ring is secured by bolts through holes in the lower panel and the holes are substantially larger than the bolts.
Such ring secures the panel with slight clearance between the panel and the ring. The device is mounted in sliding relationship to an outer face of a retaining plate and the ring-panel clearance and the enlarged holes accommodate oscillating movement of the machine frames. The ring-panel clearance also permits slight panel movement away from the face, thereby enabling lubricant to flow between the device and the interface. The ring-panel clearance creates a path through which lubricant can flow in either of two directions, i.e., from the device to the interface (as the joint is continually being lubricated) or from the interface to the device as the chamber is filled or replenished with lubricant.
When the improved lubrication device is installed on a joint, it is contiguous with an annulus partially defined by the device. The annulus is in a lubricant-transferring relationship to the interface so that lubricant confined in the annulus lubricates the interface. And as lubricant is depleted from the annulus, it is replenished from the chamber.
A lubricant injection path--through which the chamber is filled with lubricant--includes the path described above as to a known joint. In a joint using the inventive device, the path also includes the annulus and the clearance space. Additionally, the device cover includes an auxiliary fill port whereby lubricant may be placed into the chamber.
The device also includes a resilient scraper seal around its outer perimeter. When the device is installed on a joint, such seal is in sliding contact with an outer face of a retaining plate. During oscillatory motion of the machine frames, the seal wipes or "scrapes" dirt off of the plate.
Further details regarding the device are set forth in the detailed descriptions taken in conjunction with the drawing.
DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective view of the new lubrication device shown in conjunction with a joint attaching member.
FIG. 2A is a cross-sectional side elevation view of a joint fitted with two assembled lubrication devices like that shown in FIG. 1, with parts broken away and other parts shown in dashed outline.
FIG. 2B is is a cross-sectional side elevation view, enlarged, of a portion of the structure shown in FIG. 2A with parts broken away.
FIG. 3 is a representative cross-sectional rear elevation view showing the relative positions of two lubrication devices with respect to the hinge-like joint members connecting machine frames. In FIG. 3, the frame members are shown as they would be in the absence of oscillating motion. Parts are shown in full representation and others are broken away.
FIG. 4 is a representative cross-sectional rear elevation view similar to that of FIG. 3 but showing the frame members during oscillating motion.
FIG. 5 is a simplified side elevation view, with parts broken away, of a large, articulated agricultural tractor on which the invention is suitable for use.
FIG. 6 is a side elevation view, partly in cross-section and with parts broken away, showing a known type of pivot joint. Parts are shown in full representation and others are broken away.
FIG. 7 is a simplified top plan view of the machine shown in FIG. 5 taken along the viewing axis VA-7 to illustrate articulating movement.
FIG. 8 is a simplified view of the machine shown in FIG. 5 taken along the viewing axis VA-8 to illustrate one type of oscillating movement.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Before describing the inventive pivot joint structure 10, it will be helpful to understand aspects of a typical machine and conventional machine pivot joint on which the structure 10 could be used. Referring to FIG. 5, a machine embodied as a large rubber-tired agricultural tractor 11 includes a front frame 13 housing the engine, a rear frame 15 and an operator's cab 17. The frames 13, 15 are connected together by a pair of hinges--or pivot joints 19 as they are sometimes called--which permit the frames 13, 15 to articulate or "swing" laterally with respect to one another. Such pivot joints 19 also permit oscillating, twisting motion of the frames 13, 15 with respect to one another. The tractor 11 illustrated in FIG. 5 is of the Model 9270/9280 series made by Case Corporation of Racine, Wis.
Referring additionally to FIG. 6, each frame 13, 15 has an attachment member 21, 23, respectively, extending toward the other frame 15, 13, respectively. The first attachment member 21 has parallel, spaced upper and lower extensions 25a, 25b defining a slot 27 between them. A single tongue-like second member 23 extends from the other frame 15 and fits between the extensions 25a, 25b with clearance. In large machines, such extensions 25a, 25b and members 21, 23 are fabricated of steel plates that may be on the order of one inch thick. Such members 21, 23 are required to be very strong to withstand the rigors of machine operation.
The member 23 includes a cavity 29 configured as a cylindrical hole through it. A joint assembly 31 is received in the cavity 29 and has a primary bearing 33 and an outer race 35. The inner surface of the outer race 35 is conformably shaped to the spherical surface 37 of the bearing 33 to permit articulating and oscillating motion. The bearing 33 and race 35 define an interface 39 i.e., the area where the bearing 33 and the race 35 substantially contact one another and are separated only by a thin film of grease. The terms "spherical" and "spherical surface" are used herein even though the surface or surfaces referred to (e.g., surface 37) are truncated, rather than complete, spheres.
The race 35 and bearing 33 are confined in the cavity 29 by a pair of annular, disk-shaped retaining plates 41. Each plate 41 is bolted to the member 23 and has an inner perimeter 43 which slightly overlaps the outer race 35 for secure race and bearing retention. Each plate 41 has an inward face 45 in contact with the member 23 and an exposed outer face 47.
The primary bearing 33 is interposed between a pair of sleeves 49, each of which has a flared end 51. The extensions 25a, 25b include mounting bosses 53 spaced to accept the member 23 and the sleeves 49 with slight clearance. Each boss 53 has a hole through it for receiving a coupling pin 55 secured by a nut 57. The pin 55 is prevented from rotation by an arm 59 secured to an extension 25a.
The member 23 includes a passage 61 extending from a zerk grease fitting 63 radially inward to a circumferential grease channel 65 in the outer race 35. The outer race 35 has a radial passage 67 extending to the interface 39 and grease injected into the zerk fitting 63 propagates inward through the passages 61, 67, across the interface 39 and emerges at the open spaces 69 above and below the interface 39. The grease in the spaces 69 is exposed to ambient airborne contaminants.
With this type of conventional joint configuration, one can readily understand how the joint 19 can become packed with dust and other contaminants which adhere to the grease and the fitting 63. The contaminant-laden grease often becomes hard and caked so that it is difficult or impossible to properly grease the joint 19. And contaminants migrate into the interface 39 and cause premature wear.
Turning now to the invention, the improved lubrication device 12 solves these difficult lubrication problems in a unique way. Referring to FIGS. 1, 2A and 2B, the improved lubrication device 12 is mounted in sealing, motion-accomodating relationship to a secondary bearing 71. As shown in FIGS. 2A, 3 and 4 the joint 19 includes two such bearings 71 and the primary bearing 33 is interposed therebetween. Each such bearing 71 has a spherical surface 73 sealing with the device 12. Such device 10 is described below in connection with the upper device 10 shown in FIGS. 1 and 2A.
The device 12 is a ring-like structure and includes an annular lower panel 75 with several enlarged holes 77 formed in it and upwardly-turned inner and outer edges, 79, 81, respectively. The device 12 also includes an annular cover 83 having a downwardly turned outer edge 85 and a circular inner edge 87, the diameter of which is only slightly greater than the diameter of the spherical surface 73 of the bearing 71.
A resilient wiper seal 89 is supported by the edges 79, 87 to be in sliding, wiping contact with the surface 73. As described in further detail below, such construction permits the device 12 to accommodate articulating, oscillating movement of the joint 19 while yet sealing against the spherical surface 73 to obstruct entry of dirt. A resilient scraper seal 91 is retained between the edges 81, 85 and during oscillating movement, slides across the outer face 47 of the retaining plate 41, scraping dirt from it.
It is important that the device 12 be able to move with respect to the member 23 and the retaining plates 41 (to accommodate articulating and oscillating motion) while yet retaining its dirt-obstructing integrity. Referring further to FIGS. 1 and 2A, seal 89 is installed within the inner edge 79 of plate 75. The device 12 is mounted by an annular, scalloped retaining ring 93 having bolt holes 95 which are in registry with the enlarged holes 77 in the lower panel 75. Mounting is by stacking the panel 75 and the retaining ring 93 so that when the cover 83 is in place, the ring 93 is between the panel 75 and the cover 83.
Prior to installing bolts 97, spacers 99 are positioned between the ring 93 and the outer face 47 of the retaining plate 41 and in registry with each bolt 97. Such spacers 99 have a thickness slightly greater than the thickness of the lower panel 75. Preferably, such difference in thickness is about 0.031-0.032 inches. When the panel 75, spacers 99 and ring 93 are positioned as described, the bolts 97 are inserted through the ring 93, the spacers 99, the holes 77, the plate 41 (in that order) and threaded into the member 23 for secure attachment of the device 10 and plate 41. After attachment as described and after the seals 89, 91 are installed, the cover 83 is mounted using fasteners 101. It is to be appreciated that each of the holes 77 in the lower panel 75 is very substantially larger than the diameter of a spacer 99. The reason for this difference is explained below.
Referring additionally to FIG. 2B, several new features of the device 12 will now be described. When 30 the improved lubrication device 12 is installed on a joint 19, it is contiguous with an annulus 103 partially defined by such device 12. And because there is slight clearance between the ring 93 and the panel 75, the panel 75 is capable of slight movement away from the outer face 47 to create a clearance 105 between the lower surface of the panel 75 and the outer face 47. As described below, such clearance 105 provides a path through which lubricant can flow.
Referring further to FIGS. 1, 2A and 2B, it is assumed that two devices 10 are installed on a pivot joint 19, one each above and below the member 23. After the machine is so assembled but prior to its shipment, the joint 19 must be lubricated as a step in preparing it for use when delivered to the customer. Accordingly, grease is injected through the fitting 63, the passage 61, the channel 65 and the passage 67 to propagate up, down and around the interface 39. With continued lubricant injection, grease flows out of the interface 39 and fills each annulus 103. With still further injection, the slight pressure created in the annulus 103 will "lift" the lower panel 75 as shown in FIG. 2B to open the clearance 105. Grease flows through the clearance 105 and through the holes 77 to fill the lubricant reservoir 107. To assure complete reservoir filling, the device 12 may also be filled through a removable plug 109 in the cover 83.
In operation and as the lubricant 111 is depleted from the interface 39, that lubricant 111 in the annulus 103 propagates into the interface 39. And as lubricant 111 is depleted from the annulus 103, it is replenished from the reservoir 107.
FIG. 3 shows the relative device 12--joint 19 position for a machine sitting on a flat surface. That is, even though the frames 13, 15 may be angled in the same plane with respect to one another during articulating movement as shown in FIG. 7, they are not twisted with respect to one another. To state it another way, the machine may be experiencing articulating movement but not oscillating movement.
FIG. 4 illustrates the relative device 12--joint 19 position when the machine experiences a type of oscillating motion. It will be noted that each device 12 is tilted with respect to the joint axis 113 but nevertheless maintains sealing engagement with a secondary bearing 71. The device 12 thereby continues to lubricate the joint 19 and obstruct dirt entry even during oscillating motion. It is to be appreciated that oscillating motion may take any (or a combination) of several forms, all of which are characterized by relative movement of the frames 13, 15 in other than the same plane.
It will also be noted that the device 12 exhibits sliding motion with respect to a plate 41 and the position of the scraping seal 91 has changed with respect to such plate 41. Sliding, scraping movement of the seal 91 across the outer face 47 of a plate 41 helps scrape dirt so as to fall away from the joint 19 rather than working its way into the joint 19.
While the principles of this invention have been described in connection with specific embodiments, it should be understood clearly that these descriptions are made only by way of example and are not intended to limit the scope of the invention.
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The invention is a ring-like lubrication device used in a pivot joint of the type connecting two members such as on an articulated agricultural tractor or wheeled loader. Such joint has a joint pin and a bearing permitting relative oscillating and articulating movement of the members one to the other. The device includes a hollow, annular reservoir-like chamber which holds lubricant for the joint/bearing sliding surfaces. The device also seals the joint to obstruct the entry of dirt. In a highly preferred arrangement, a device is mounted at the top and bottom of a joint for lubrication and obstruction of dirt entry. The device is configured and arranged to accommodate oscillating and articulating movement between the joined members.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an epoxy resin composition which provides a cured product having a high glass transition point, an extremely low coefficient of expansion, good crack resistance, and low stress. More particularly, it is concerned with an epoxy resin composition suitable for use as an encapsulator for semiconductor devices.
2. Description of the Prior Art
An epoxy resin composition which is composed of a curable epoxy resin, a curing agent, and a variety of additives is used for encapsulating semiconductor devices because it is superior to other thermosetting resins in moldability, adhesion, electrical properties, mechanical properties, and moisture resistance. However, there is presently a need for it to meet new requirements arising from the recent advance in semiconductor devices. With the development of smaller and thinner electronic machines and equipment, the package of semiconductor devices has become diversified. On the other hand, the electronics technology has produced semiconductor devices in which semiconductor elements are bonded directly to a printed circuit board or heat sink. Such semiconductor devices encounter some problems when encapsulated with a conventional epoxy resin composition because of the difference in the coefficient of thermal expansion between the printed circuit board and the epoxy resin composition. The difference in the coefficient of thermal expansion exerts a great stress on the semiconductor element, resulting in cracking and deformation, which would deteriorate the performance and appearance of the element.
In order to solve this problem, an epoxy resin composition composed of a curable epoxy resin and organopolysiloxane (Japanese patent Laid-open No. 129246/1981) and an epoxy resin composition incorporated with a block copolymer composed of an aromatic polymer and organopolysiloxane (Japanese patent Laid-open No. 21417/1983), has been proposed. These epoxy resin compositions produce a lower level of stress than the conventional ones. However, there are some instances where even these new epoxy resin compositions do not meet the severe requirements for an encapsulator of sophisticated semiconductor devices. Thus there still is a demand for a new encapsulator which is more reliable and less likely to exert stress to the semiconductor element. The present invention was completed under the above-mentioned circumstance.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a new epoxy resin composition which has good flowability and provides a cured product having a high glass transition point, a low coefficient of thermal expansion, good crack resistance, and less likely to exert stress on the semiconductor element.
To achieve the above-mentioned object, the present inventors carried out a series of researchers which led to the finding that an epoxy resin composition incorporated with a copolymer formed by the reaction of a compound represented by the formula (1) below or an oligomer thereof with a specific organopolysiloxane represented by the formula (2) below, provides a cured product having a glass transition point 10° to 20° C. higher than that of a conventional cured product, a lower coefficient of thermal expansion, good crack resistance, and less likely to exert stress to the semiconductor devices. This epoxy resin composition exhibits its distinct characteristics when used as an encapsulator for semiconductor devices, especially in the case where the element is bonded directly to a printed circuit board or heat sink. In other words, it is very unlikely that a semiconductor device encapsulated with it would become warped. Thus the epoxy resin composition of the present invention can be advantageously applied to semiconductor devices of DIP type, flat pack type, PLCC type, and SO type, and also to semiconductor devices in which the element is bonded directly to a printed circuit board or heat sink.
According to the present invention, there is provided an epoxy resin composition which comprises a curable epoxy resin, a curing agent, and a block copolymer formed by the reaction of a compound represented by the formula (1) below or an oligomer thereof, ##STR1## (where R 1 denotes a hydrogen atom, ##STR2## or a monovalent organic group including an alkenyl group; R 2 denotes a monovalent hydrocarbon group having 1 to 10 carbon atoms of the same or different kind; X denotes a halogen atom; l denotes an integer of 1 or 2; m and n each denote an integer of 0 to 2; and l+m+n≦5) with an organopolysiloxane represented by the formula (2) below,
R.sup.3.sub.a R.sup.4.sub.b SiO.sub.(4-[a+b])/2 ( 2)
(where R 3 denotes a hydrogen atom, halogen atom, hydroxyl group, alkoxyl group, or substituted monovalent hydrocarbon group; R 4 denotes a monovalent organic group of the same or different kind; 0.001≦a≦2, 1≦b<3, and 1.001≦a+b≦3.)
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a semiconductor device used to measure the amount of warpage.
FIG. 2 is a sectional view of a warped semiconductor device.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in more detail in the following.
The epoxy resin composition of the present invention is composed of a curable epoxy resin, a curing agent, and a block copolymer formed by the reaction of a compound of the formula (1) or an oligomer thereof with an organopolysiloxane of the formula (2).
One component used for preparing the copolymer of the present invention is a compound represented by the formula (1) below or an oligomer thereof. ##STR3## (where R 1 denotes a hydrogen atom, ##STR4## or a monovalent organic group including an alkenyl group; R 2 denotes a monovalenyt hydrocarbon group having 1 to 10 carbon atoms of the same or different kind; X denotes a halogen atom; l denotes an integer of 1 or 2; m and n each denote an integer of 0 to 2; and l+m+n≦5)
Examples of the R 1 , which is a monovalent organic group including an alkenyl group, include ##STR5## and --CH 2 CH═CH 2 .
Examples of the R 2 , which is a monovalent hydrocarbon group, include a methyl group, ethyl group, propyl group, allyl group, i-propyl group, t-butyl group, octyl group, and nonyl group.
The oligomer of the compound (1) may preferably be a dimer, a trimer or a tetramer of the compound (1).
Examples of the compound (1) and the oligomer thereof include the following compounds. ##STR6##
These compounds can be synthesized according to the process disclosed in U.S. Pat. No. 4,394,496.
Another component used for preparing the copolymer is an organopolysiloxane represented by the formula (2) below.
R.sup.3.sub.a R.sup.4.sub.b SiO.sub.(4-[a+b])/2 (2)
(where R 3 denotes a hydrogen atom, halogen atom, hydroxyl group, alkoxy group having 1 to 5 carbon atoms, or substituted monovalent hydrocarbon group having 1 to 10 carbon atoms; R 4 denotes a monovalent organic group having 1 to 10 carbon atoms of the same or different kind; 0.001≦a≦2, 1≦b<3, and 1.001≦a+b≦3.)
Examples of the R 3 , which is a substituted monovalent hydrocarbon group, include: ##STR7##
Examples of the R 4 , which is a monovalent organic group, include a methyl group, ethyl group, phenyl group, and benzyl group.
The organopolysiloxane represented by the formula (2) has at least one .tbd.SiR 3 group per molecule. Examples of such a compound include: ##STR8##
The copolymer used in the present invention is prepared from a compound represented by the formula (1) or an oligomer thereof and an organopolysiloxane represented by the formula (2) through the reaction shown in the following. ##STR9##
In the above equations, R 5 represents: --H and ##STR10##
Y represents a halogen atom, hydroxyl group, and alkoxyl group; R 6 represents a divalent hydrocarbon group such as methylene, ethylene, and propylene: and p represents 0 or 1.
The block copolymer mentioned above is incorporated into an epoxy resin composition composed of a curable epoxy resin and a curing agent. The amount of the copolymer may be 1 to 100 parts by weight, preferably 2 to 60 parts by weight, for 100 parts by weight of the total amount of the epoxy resin and curing agent. With an amount less than 1 part by weight, the copolymer is not effective in the improvement of the epoxy resin composition (such as glass transition point, crack resistance, an flowability). With an amount in excess of 100 parts by weight, the copolymer may lower the mechanical strength of the epoxy resin composition.
According to the present invention, the curable epoxy resin is one which has two or more epoxy groups per molecule. It is not specifically limited in molecular structure and molecular weight so long as it is capable of curing with a curing agent mentioned later. Any of the known ones can be used. They include, for example, epoxy novolak resins such as one synthesized from epichlorohydrin and bisphenol, triphenol-alkane type epoxy resin or polymer thereof, alicyclic epoxy resin, and epoxy resins having halogen atoms (such as chlorine and bromine). These epoxy resins may be used alone or in combination with one another.
The above-mentioned epoxy resin may be used in combination with a monoepoxy compound according to need. Examples of the monoepoxy compound include styrene oxide, cyclohexene oxide, propylene oxide, methylene glycidyl ether, ethyl glycidyl ether, phenyl glycidyl ether, allyl glycidyl ether, octylene oxide, and dodecene oxide.
Examples of the curing agent include amine-type curing agent such as diaminodiphenyl-methane, diaminodiphenylsulfone, and metaphenylenediamine; acid anhydride-type curing agents such as phthalic anhydride, pyromellitic anhydride, and benzophenone tetracarboxylic anhydride; phenol novalac-type curing agents having two or more hydroxyl groups per molecule such as phenol novolak and cresol novolak; and triphenol alkanes.
The curing agent may be used in combination with an accelerator which promotes the reaction of the curing agent with the epoxy resin. Examples of the accelerator include imidazole and derivatives thereof, tertiary amine derivative, phosphine derivatives, and cycloamidine derivatives. The curing agent and accelerator may be used in conventional amounts, although the amount of the curing agent may preferably be 20 to 100% based on the equivalent of the epoxy group of the epoxy resin.
The epoxy resin composition of the present invention may be incorporated with an inorganic filler. It may be selected from a wide variety according to the application of the epoxy resin composition. Examples of such an inorganic filler include natural silica (crystalline or amorphous silica), synthetic high-purity silica, synthetic spherical silica, talc, mica, silicon nitride, boron nitride, and alumina. They may be used alone or in combination with one another. The amount of the inorganic filler is not specifically limited. It should preferably be 100 to 1000 parts by weight for 100 parts by weight of the total amount of epoxy resin and curing agent. With an amount less than 100 parts by weight, the resulting epoxy resin composition may decrease in stress and have low crack resistance. With an amount in excess of 1000 parts by weight, the resulting epoxy resin composition has such poor flowability that the inorganic filler is not readily dispersed.
The epoxy resin composition of the present invention may be incorporated with a variety of additives according to its intended use and application. Examples of the additives include waxes, fatty acids (e.g., stearic acid), release agent (e.g., metal salt), pigment (e.g., carbon black), dye, antioxidant, flame retardant, and surface treating agent (e.g., γ-glycidoxypropyltrimethoxysilane).
The epoxy resin composition of the present invention should be prepared such that the cured product has a coefficient of expansion smaller than 2.0×10 -5 /°C., preferably smaller than 1.9×10 -5 /°C., at 25° to 180° C. The epoxy resin composition is used for encapsulating semiconductor devices of such type that the semiconductor elements are bonded directly to a printed circuit board. It prevents the semiconductor devices from warping, twisting, or cracking. Thus it prevents the semiconductor devices from becoming deteriorated in performance.
The epoxy resin composition of the present invention is prepared by mixing the above-mentioned components at 70° to 95° C. using a kneader, roll mixer, extruder, or the like. The resulting mixture is cooled and crushed. The sequence of adding the components is not specifically limited.
As mentioned above, the epoxy resin composition of the present invention is composed of a curable epoxy resin, a curing agent, and a block copolymer obtained from the reaction of a compound represented by the formula (1) or an oligomer thereof with an organopolysiloxane represented by the formula (2). It provides a cured product having good mechanical properties (such as flexural strength and flexural modulus), a low coefficient of expansion, a high glass transition point, and good crack resistance. By virtue of this feature, it is advantageously used for encapsulating semiconductor devices such as ICs and LSIs of DIP type, flat pack type, PLCC type and SO type, transistors, thyristors and diodes. It is especially suitable for semiconductor devices of such type that the semiconductor element is bonded directly to a heat sink or printed circuit board. The semiconductor devices encapsulated with the epoxy resin composition of the present invention are not very susceptible to warpage and have extremely good dimensional stability. In addition, the composition of the present invention may also be applied to hydrid ICs of full mold type.
For encapsulating semiconductive devices, conventionally employed molding techniques such as, for example, transfer molding, injection molding and casting techniques may be used. Preferably, the molding temperature for the epoxy resin composition is in the range of from 150° to 180° C. and the post curing is effected at a temperature of from 150° to 180° C. for 2 to 16 hours.
To further illustrate the present invention, and not intended to be limited thereby, the following examples are provided. The block copolymers used in the examples and comparative examples were prepared as shown in the following production examples.
PRODUCTION EXAMPLES 1 TO 4
In a 500-ml four-neck flask equipped with a reflux condenser, thermometer, stirrer, and dropping funnel were placed 75 g of the organic polymer (a compound (1) type) as shown in Table 1, 0.10 g of chloroplatinic acid solution (containing 2% platinum and modified with 2-ethylhexanol), 100 g of methyl isobutyl ketone, and 200 g of toluene. After complete dissolution of the organic polymer, reaction was carried out by azeotropic dehydration for 1 hour. To the reaction product was added 25 g of an organopolysiloxane represented by the formula below from the dropping funnel over 2 hours. Reaction was continued for 6 hours under refluxing. The reaction product was washed with water and the solvent was removed by distillation under reduced pressure. Thus there were obtained four block copolymers as shown in Table 1. ##STR11##
TABLE 1__________________________________________________________________________Production Example 1 2 3 4*__________________________________________________________________________Organic polymer i ii iii ivBlock copolymer I II III IVProperties Brown Brown Brown Brown opaque opaque opaque clear solid solid solid solidViscosity of 50% MIBK 28 32 40 25solution (cs. 25° C.) **Ignition loss 0.84 0.72 0.80 0.73(%, 150° C./1 hr)__________________________________________________________________________Remarks: *Comparative Example,**MIBK indicates methyl isobutyl ketone.Organic polymer (i)Organic polymer (ii) ##STR12##Organic polymer (iii) ##STR13##Organic polymer (iv) ##STR14##(where q/r = 12/1)
In the same four-neck flask as used in Production Example 1 to 4 were placed 75 g of the organic polymer (a compound (1) type) shown in Table 2, 0.05 g of triphenyl phosphine, and 200 g of diethylene glycol dimethyl ether. After complete dissolution of the organic polymer, 25 g of an organopolysiloxane represented by the formula below was added through the dropping funnel over about 20 minute, while keeping the flask at 130±5° C. ##STR15##
Reaction was continued at the same temperatures for 4 hours. The reaction product was removed by distillation washed with water and the solvent was under reduced pressure. Thus there were obtained three flask copolymers as shown in Table 2.
TABLE 2______________________________________Production Example 5 6 7*______________________________________Organic polymer v vi viiBlock copolymer V VI VIIProperties Brown Brown Brown opaque opaque opaque solid solid solidViscosity of 50% MIBK 20 21 18solution (cs. 25° C.)Ignition loss 0.93 0.87 0.88(%, 150° C./1 hr)______________________________________Remarks: *Comparative Example,Organic polymer (v) ##STR16##XD 7342 (a product of Dow Chemical)Organic polymer (vi) ##STR17## ##STR18##Organic polymer (vii)Epoxidized cresol novolacEOCN 1020-65 (a product of Nippon Kayaku)
Eight types of epoxy resin compositions were prepared by uniformly melting and mixing the components shown in Table 3 using a two-roll mixer. The thus obtained epoxy resin compositions were examined for the following six items of performance. The results are shown in Table 3.
(1) Spiral flow
Measured at 160° C. and 70 kg/cm 2 using a mold conforming to the EMMI standard.
(2) Mechanical properties (flexural strength and flexural modulus)
Measured using a specimen (10 by 4 by 100 mm) molded under the conditions of 160° C. 70 kg/cm 2 , and 3 minutes, followed by post-curing at 180° C. for 4 hours, according to JIS K6911.
(3) Coefficient of expansion and glass transition point
Measured using a dilatometer. A specimen (4 mm in diameter and 15 mm long) was heated at a rate of 5° C. per minute.
(4) Crack resistance
Measured by subjecting IC package specimens (50 pieces) to 50 heat cycles, each cycle consisting of 1 minute at -196° C. and 30 seconds at 260° C. The specimen was prepared by bonding a silicon chip measuring 9.0 by 4.5 by 0.5 mm to a 14-pin IC frame (42 alloy), followed by molding with the epoxy resin composition at 160° C. for 3 minutes and post-curing at 180° C. for 4 hours.
(5) Deformation of aluminum electrodes
Measured by subjecting IC package specimens to 200 heat cycles, each cycle consisting of 1 minute at -196° C. and 30 seconds at 260° C. The specimen was prepared by bonding a silicon chip measuring 3.4 by 10.2 by 0.3 mm (provided with deposited aluminum electrodes) to a 14-pin IC frame (42 alloy), followed by molding with the epoxy esin composition at 180° C. for 2 minutes and post-curing at 180° C. for 4 hours.
(6) Warpage
A semiconductor device as shown in the figure was prepared by transfer molding under the conditions of 165° C., 70 kg/cm 2 , and 2 minutes. Warpage (δ) that took place after post curing at 180° C. for 4 hours was measured. In the figures, there are shown glass epoxy resin 1, semiconductor element 2, and encapsulator 3.
TABLE 3__________________________________________________________________________Example No. 1 2 3 4 5 1* 2* 3*__________________________________________________________________________Epoxy cresol novolak resin 28 46 30 29 28 30 29 58Phenol novolak resin 33 15 31 32 33 31 32 35Brominated epoxy cresol novolak resin 7 7 7 7 7 7 7 7Type of block copolymer I II III V VI IV VII --Amount of block copolymer 32 32 32 32 32 32 32 --Fumed silica 290 290 290 290 290 290 290 2903-Glycidoxypropyltrimethoxysilane 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5Carnauba wax 1 1 1 1 1 1 1 1Carbon black 1 1 1 1 1 1 1 1Triphenyl phosphine 1 1 1 1 1 1 1 1Antimony trioxide 10 10 10 10 10 10 10 10Spiral flow (inches) 31 30 28 31 33 32 31 34Flexural strength (kg/mm.sup.2) 13.7 13.2 13.3 13.4 13.6 12.9 12.8 13.8Flexural modulus (kg/mm.sup.2) 1200 1230 1210 1240 1230 1250 1260 1350Coefficient of expansion (× 10.sup.-5 /°C.) 1.8 1.9 1.8 1.7 1.8 2.1 2.1 2.3at 25 to 180° C.Glass transition point (°C.) 182 180 185 182 188 166 168 162Crack resistance (%) 0 0 0 0 0 0 0 62Deformation of aluminum (μm) 0 0 0 0 0 0.4 0.6 1.5Amount of warpage (μm) 10 15 10 10 13 380 350 600__________________________________________________________________________ Remarks: *Comparative Examples; Quantities in parts by weight
It is noted from Table 3 that the epoxy resin composition of the present invention provides a cured product having a high glass transition point, good crack resistance, and a low coefficient of expansion. It is also noted that the epoxy resin composition as an encapsulator has a minimum of liability to deforming aluminum electrodes in a semiconductor device and to warping a semiconductor device.
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An epoxy resin composition which comprises a curable epoxy resin, a hardener, and a block copolymer formed by the reaction of a triphenol-alkane type resin or a polymer thereof with a specific organopoly-siloxane. The composition provides a cured product having a high glass transition point, a low coefficient of expansion, good crack resistance, and is less likely to exert stress to the semiconductor devices. It exhibits distinct characteristics when used as a sealing compound for semiconductor devices, especially in the case where the element is bonded directly to a printed circuit board or heat sink. It is very unlikely that a semiconductor device sealed with it would become warped.
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BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The present invention relates to a laser processing apparatus for processing a workpiece such as a semiconductor wafer by applying a laser beam thereto.
[0003] Description of the Related Art
[0004] In a process of manufacturing a plurality of semiconductor device chips by using a laser processing apparatus, a plurality of crossing division lines are formed on the front side of a substantially disk-shaped semiconductor wafer to thereby define a plurality of separate regions where a plurality of semiconductor devices such as integrated circuits (ICs) and large scale integration (LSI) circuits are each formed. The semiconductor wafer is cut along the division lines by applying a laser beam to thereby divide the regions where the semiconductor devices are formed from each other, thus obtaining the individual semiconductor device chips.
[0005] The laser processing apparatus includes a chuck table for holding a workpiece, laser beam applying means for applying a laser beam to the workpiece held on the chuck table, and feeding means for feeding the chuck table, wherein the laser beam applying means includes a laser oscillator for oscillating a laser beam, focusing means, focusing means for focusing the laser beam oscillated by the laser oscillator to thereby apply the focused laser beam to the workpiece held on the chuck table, and an attenuator provided between the laser oscillator and the focusing means for adjusting the power of the laser beam, thereby performing desired laser processing to the workpiece (see Japanese Patent Laid-open No. 2010-158691, for example).
[0006] Further, in many cases, the laser oscillator used in the laser processing apparatus is so designed as to oscillate a laser beam having a relatively large power for the purpose of supporting various kinds of processing. Accordingly, the attenuator is generally used to adjust the power of the laser beam to a reduced power suitable for the workpiece.
SUMMARY OF THE INVENTION
[0007] As described above, the laser beam generated from the laser oscillator in the laser processing apparatus is used after adjusting the power of the laser beam to a reduced power. For example, ½ or less of the power that can be originally exhibited by the laser oscillator is used for laser processing of the workpiece. In this case, ½ or more of the power of the laser beam oscillated by the laser oscillator is wasted. Thus, the performance of the laser oscillator cannot be sufficiently exhibited to cause poor economy.
[0008] It is therefore an object of the present invention to provide a laser processing apparatus which can sufficiently exhibit the performance of a laser oscillator capable of oscillating a laser beam having a large power.
[0009] In accordance with an aspect of the present invention, there is provided a laser processing apparatus including a first chuck table for holding a first workpiece; first X moving means for moving the first chuck table in an X direction; first Y moving means for moving the first chuck table in a Y direction perpendicular to the X direction; first focusing means for focusing a first laser beam to the first workpiece held on the first chuck table; a second chuck table for holding a second workpiece; second X moving means for moving the second chuck table in the X direction; second Y moving means for moving the second chuck table in the Y direction; second focusing means for focusing a second laser beam to the second workpiece held on the second chuck table; a laser oscillator for oscillating an original laser beam; and an optical system for branching the original laser beam oscillated by the laser oscillator into the first laser beam and the second laser beam and leading the first and second laser beams to the first and second focusing means, respectively.
[0010] Preferably, the optical system includes a first optical path for leading the first laser beam to the first focusing means; a second optical path for leading the second laser beam to the second focusing means; a beam splitter for branching the original laser beam oscillated by the laser oscillator into the first laser beam and the second laser beam and leading the first and second laser beams to the first and second optical paths, respectively; a first beam shutter provided on the first optical path for interrupting the first laser beam; a first attenuator provided on the first optical path for adjusting the power of the first laser beam; a second beam shutter provided on the second optical path for interrupting the second laser beam; and a second attenuator provided on the second optical path for adjusting the power of the second laser beam.
[0011] Preferably, the optical system further includes first wavelength setting means provided on the first optical path for setting the wavelength of the first laser beam; and second wavelength setting means provided on the second optical path for setting the wavelength of the second laser beam.
[0012] According to the laser processing apparatus of the present invention, the power of the single laser oscillator is branched to configure substantially two laser processing apparatuses. Accordingly, the performance of the laser oscillator can be sufficiently exhibited and good economy can therefore be attained. Further, since the laser oscillator for generating a laser beam is expensive, the cost of the laser processing apparatus can be reduced to substantially the half.
[0013] Further, the optical system constituting the laser processing apparatus of the present invention includes the beam splitter for dividing the original laser beam generated by the single laser oscillator into the first laser beam and the second laser beam. The first optical path of the first laser beam is provided with the first beam shutter and the first attenuator. Similarly, the second optical path of the second laser beam is provided with the second beam shutter and the second attenuator. Accordingly, the laser processing apparatus having the single laser oscillator can be used as one laser processing apparatus or two laser processing apparatuses. Further, in the case that the first and second optical paths are provided with the first and second wavelength setting means, respectively, the wavelengths of the first and second laser beams can be made different from each other and the first and second workpieces can therefore be laser-processed at the different wavelengths.
[0014] The above and other objects, features and advantages of the present invention and the manner of realizing them will become more apparent, and the invention itself will best be understood from a study of the following description and appended claims with reference to the attached drawings showing a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a laser processing apparatus according to a preferred embodiment of the present invention;
[0016] FIG. 2 is a perspective view showing an essential part of the laser processing apparatus shown in FIG. 1 ;
[0017] FIG. 3 is a block diagram of laser beam applying means included in the laser processing apparatus shown in FIG. 1 ;
[0018] FIG. 4 is a perspective view of first and second cassette table mechanisms included in the laser processing apparatus shown in FIG. 1 ;
[0019] FIG. 5 is a perspective view of first and second temporary setting means included in the laser processing apparatus shown in FIG. 1 ;
[0020] FIG. 6 is a perspective view of first and second handling means included in the laser processing apparatus shown in FIG. 1 ;
[0021] FIG. 7 is a perspective view of first and second transfer means included in the laser processing apparatus shown in FIG. 1 ;
[0022] FIG. 8 is a perspective view showing a condition where the first handling means is positioned so as to take a semiconductor wafer out of a first cassette set on the first cassette table mechanism in the laser processing apparatus shown in FIG. 1 ;
[0023] FIG. 9 is a view similar to FIG. 8 , showing a condition where the semiconductor wafer handled by the first handling means is temporarily set on the first temporary setting means;
[0024] FIG. 10 is a view similar to FIG. 8 , showing a condition where the semiconductor wafer temporarily set on the first temporary setting means is held by the first transfer means;
[0025] FIG. 11 is a view similar to FIG. 8 , showing a condition where the semiconductor wafer held by the first transfer means is transferred and set on a first chuck table included in the laser processing apparatus shown in FIG. 1 ; and
[0026] FIG. 12 is a perspective view showing a condition where the laser processing apparatus shown in FIG. 1 is enclosed by a housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] A preferred embodiment of the laser processing apparatus according to the present invention will now be described in detail with reference to the attached drawings. FIG. 1 is a perspective view of a laser processing apparatus 1 according to this preferred embodiment. The laser processing apparatus 1 shown in FIG. 1 includes a stationary base 2 , a first chuck table mechanism 3 for holding a first workpiece, the first chuck table mechanism 3 being provided on the stationary base 2 so as to be movable in an X direction shown by an arrow X, a second chuck table mechanism 3 ′ for holding a second workpiece, the second chuck table 3 ′ being provided on the stationary base 2 in parallel to the first chuck table mechanism 3 so as to be movable in the X direction, and a laser beam applying unit 4 provided on the stationary base 2 in a central region defined between the first and second chuck table mechanisms 3 and 3 ′. A first laser mechanism 1 a including the first chuck table mechanism 3 is formed on the front side as viewed in FIG. 1 , and a second laser mechanism 1 b including the second chuck table mechanism 3 ′ is formed on the rear side as viewed in FIG. 1 .
[0028] FIG. 2 is a perspective view for illustrating the structure of the laser processing apparatus 1 shown in FIG. 1 in detail. That is, FIG. 2 shows a condition obtained by demounting first and second cassette table mechanisms 7 and 7 ′, first and second temporary setting means 8 and 8 ′, first and second handling means 9 and 9 ′, and first and second transfer means 10 and 10 ′ from the stationary base 2 . As shown in FIG. 2 , the laser beam applying unit 4 is provided at a substantially central position on the stationary base 2 , and the first chuck table mechanism 3 is provided on the front side of the laser beam applying unit 4 as viewed in FIG. 2 . The first chuck table mechanism 3 includes a pair of parallel guide rails 31 provided on the stationary base 2 so as to extend in the X direction, a moving base 32 slidably provided on the guide rails 31 so as to be movable in the X direction, a slide block 33 slidably provided on the moving base 32 so as to be movable in a Y direction shown by an arrow Y perpendicular to the X direction, a cover table 35 supported by a cylindrical member 34 standing on the slide block 33 , and a first chuck table 36 (first holding means) for holding the first workpiece. The first chuck table 36 has a vacuum chuck 361 formed of a porous material. The first workpiece is adapted to be held under suction on the upper surface of the vacuum chuck 361 as a holding surface by operating suction means (not shown). The first chuck table 36 is rotatable by a pulse motor (not shown) provided in the cylindrical member 34 . The first chuck table 36 is provided with clamps 362 for fixing an annular frame F (see FIG. 1 ) supporting a semiconductor wafer W as the first workpiece through a protective tape T.
[0029] The lower surface of the moving base 32 is formed with a pair of guided grooves 321 for slidably engaging the pair of guide rails 31 mentioned above. A pair of parallel guide rails 322 are provided on the upper surface of the moving base 32 so as to extend in the Y direction. Accordingly, the moving base 32 is movable in the X direction along the guide rails 31 by the slidable engagement of the guided grooves 321 with the guide rails 31 . The first chuck table mechanism 3 further includes first X moving means 37 for moving the moving base 32 in the X direction along the guide rails 31 . The first X moving means 37 includes an externally threaded rod 371 extending parallel to the guide rails 31 so as to be interposed therebetween and a pulse motor 372 as a drive source for rotationally driving the externally threaded rod 371 . The externally threaded rod 371 is rotatably supported at one end thereof to a bearing block 373 fixed to the stationary base 2 and is connected at the other end to the output shaft of the pulse motor 372 so as to receive the torque thereof. The externally threaded rod 371 is engaged with a tapped through hole formed in an internally threaded block (not shown) projecting from the lower surface of the moving base 32 at a central portion thereof. Accordingly, the moving base 32 is moved in the X direction along the guide rails 31 by operating the pulse motor 372 to normally or reversely rotate the externally threaded rod 371 .
[0030] The first chuck table mechanism 3 is provided with X position detecting means (not shown) for detecting the X position of the first chuck table 36 . The X position detecting means is so configured as to transmit a pulse signal of one pulse every 1 μm, for example, to control means (not shown). The control means counts the number of pulses as the pulse signal input from the X position detecting means to thereby detect the X position of the first chuck table 36 . In the case that the pulse motor 372 is used as the drive source for the first X moving means 37 as in this preferred embodiment, the number of pulses as a drive signal output from the control means to the pulse motor 372 may be counted by the control means to thereby detect the X position of the first chuck table 36 . In the case that a servo motor is used as the drive source for the first X moving means 37 , a pulse signal output from a rotary encoder for detecting the rotational speed of the servo motor may be sent to the control means, and the number of pulses as the pulse signal input from the rotary encoder into the control means may be counted by the control means to thereby detect the X position of the first chuck table 36 .
[0031] The lower surface of the slide block 33 is formed with a pair of guided grooves 331 for slidably engaging the pair of guide rails 322 provided on the upper surface of the moving base 32 as mentioned above. Accordingly, the slide block 33 is movable in the Y direction along the guide rails 322 by the slidable engagement of the guided grooves 331 with the guide rails 322 . The first chuck table mechanism 3 further includes first Y moving means 38 for moving the slide block 33 in the Y direction along the guide rails 322 . The first Y moving means 38 includes an externally threaded rod 381 extending parallel to the guide rails 322 so as to be interposed therebetween and a pulse motor 382 as a drive source for rotationally driving the externally threaded rod 381 . The externally threaded rod 381 is rotatably supported at one end thereof to a bearing block 383 fixed to the upper surface of the moving base 32 and is connected at the other end to the output shaft of the pulse motor 382 so as to receive the torque thereof. The externally threaded rod 381 is engaged with a tapped through hole formed in an internally threaded block (not shown) projecting from the lower surface of the slide block 33 at a central portion thereof. Accordingly, the slide block 33 is moved in the Y direction along the guide rails 322 by operating the pulse motor 382 to normally or reversely rotate the externally threaded rod 381 .
[0032] The first chuck table mechanism 3 is provided with Y position detecting means (not shown) for detecting the Y position of the first chuck table 36 . The configuration of the Y position detecting means is similar to that of the X position detecting means mentioned above. That is, the Y position detecting means is so configured as to transmit a pulse signal of one pulse every 1 μm, for example, to the control means. The control means counts the number of pulses as the pulse signal input from the Y position detecting means to thereby detect the Y position of the first chuck table 36 . In the case that the pulse motor 382 is used as the drive source for the first Y moving means 38 as in this preferred embodiment, the number of pulses as a drive signal output from the control means to the pulse motor 382 may be counted by the control means to thereby detect the Y position of the first chuck table 36 . In the case that a servo motor is used as the drive source for the first Y moving means 38 , a pulse signal output from a rotary encoder for detecting the rotational speed of the servo motor may be sent to the control means, and the number of pulses as the pulse signal input from the rotary encoder into the control means may be counted by the control means to thereby detect the Y position of the first chuck table 36 .
[0033] As shown in FIG. 2 , the second chuck table mechanism 3 ′ is provided on the rear side of the laser beam applying unit 4 located in the central region of the stationary base 2 . That is, the laser beam applying unit 4 is interposed between the first chuck table mechanism 3 and the second chuck table mechanism 3 ′ in the Y direction. As similar to the first chuck table mechanism 3 , the second chuck table mechanism 3 ′ includes a second chuck table 36 ′ (second holding means) for holding the second workpiece, second X moving means 37 ′ for moving the second chuck table 36 ′ in the X direction, and second Y moving means 38 ′ for moving the second chuck table 36 ′ in the Y direction. In FIG. 2 , substantially the same parts as those of the first chuck table mechanism 3 are denoted by the same reference numerals with primes “′,”and the operation of the second chuck table mechanism 3 ′ is substantially the same as that of the first chuck table mechanism 3 , so that detailed description thereof will be omitted herein.
[0034] The laser beam applying unit 4 includes a support member 41 provided on the stationary base 2 and a casing 42 supported to the support member 41 . The casing 42 includes a pair of branch portions 42 a and 42 b horizontally extending toward the first and second chuck table mechanisms 3 and 3 ′, respectively. An optical system constituting laser beam applying means 5 to be hereinafter described is stored in the branch portions 42 a and 42 b . A pair of first and second focusing means 51 and 51 ′ constituting a part of the laser beam applying means 5 are provided on the branch portions 42 a and 42 b , respectively. Further, a pair of first and second imaging means 6 and 6 ′ for detecting a target area to be laser processed are also provided on the branch portions 42 a and 42 b , respectively, wherein the first and second imaging means 6 and 6 ′ are located in the vicinity of the first and second focusing means 51 and 51 ′, respectively. Each of the first and second imaging means 6 and 6 ′ includes illuminating means for illuminating a workpiece, an optical system for capturing an area illuminated by the illuminating means, and an imaging device (charge-coupled device (CCD)) for imaging the area captured by the optical system. An image signal output from each of the first and second imaging means 6 and 6 ′ is transmitted to the control means.
[0035] The laser beam applying means 5 will now be described in more detail with reference to FIG. 3 . The laser beam applying means 5 includes pulsed laser beam oscillating means 52 , a half-wave plate 53 provided on an optical path to be branched, a polarization beam splitter 54 , first and second beam shutters 55 and 59 , first and second attenuators 56 and 60 , first and second wavelength setting means 57 and 61 , first and second half-wave plates 58 and 62 provided on first and second optical paths branched, and the first and second focusing means 51 and 51 ′.
[0036] The pulsed laser beam oscillating means 52 includes a laser oscillator and repetition frequency setting means (both not shown), wherein the pulsed laser beam oscillating means 52 oscillates a laser beam LB having a wavelength of 1064 nm and a repetition frequency of 50 kHz, for example. The laser beam LB is branched into a first laser beam LB 1 (first optical path) and a second laser beam LB 2 (second optical path) by the polarization beam splitter 54 , wherein the first laser beam LB 1 is S polarized light reflected by the polarization beam splitter 54 , and the second laser beam LB 2 is P polarized light transmitted through the polarization beam splitter 54 .
[0037] The half-wave plate 53 is interposed between the pulsed laser beam oscillating means 52 and the polarization beam splitter 54 . The rotational angle of the half-wave plate 53 is adjusted by rotational angle adjusting means (not shown), thereby allowing rotation of the polarization plane of the light emerging from the half-wave plate 53 . Accordingly, by rotating the half-wave plate 53 , the ratio in intensity between the first laser beam LB 1 as S polarized light and the second laser beam LB 2 as P polarized light to be output from the polarization beam splitter 54 can be continuously changed.
[0038] The first and second beam shutters 55 and 59 are provided on the optical paths of the first and second laser beams LB 1 and LB 2 output from the polarization beam splitter 54 , respectively. Each of the first and second beam shutters 55 and 59 is provided with a shutter driving apparatus (not shown), wherein the first beam shutter 55 can be driven to a position where the first laser beam LB 1 is interrupted and a position where the first laser beam LB 1 is not interrupted, and the second beam shutter 59 can be driven to a position where the second laser beam LB 2 is interrupted and a position where the second laser beam LB 2 is not interrupted. Accordingly, the first and second beam shutters 55 and 59 can be operated so as to suitably select a mode where only the first laser beam LB 1 is applied to the first workpiece, a mode where only the second laser beam LB 2 is applied to the second workpiece, or a mode where both the first and second laser beams LB 1 and LB 2 are applied to the first and second workpieces.
[0039] The first and second laser beams LB 1 and LB 2 passed through the first and second beam shutters 55 and 59 are adjusted in intensity by the first and second attenuators 56 and 60 , respectively. Each of the first and second attenuators 56 and 60 may be provided by a variable attenuator for a laser beam known in the art, wherein the laser intensity can be variably adjusted according to the processing conditions required for each workpiece.
[0040] The first and second wavelength setting means 57 and 61 are provided on the optical paths of the first and second laser beams LB 1 and LB 2 passed through the first and second attenuators 56 and 60 , respectively. For example, the wavelength (1064 nm) of the laser beam oscillated from the laser beam oscillating means 52 can be converted into a wavelength of 532 nm by passing the laser beam through a nonlinear crystal or converted into a wavelength of 355 nm by passing the laser beam through a single crystal. The first and second wavelength setting means 57 and 61 can be operated so as to suitably select a mode where the transmission wavelength (1064 nm) to each workpiece is used to form a modified layer inside each workpiece or a mode where the absorption wavelength (355 nm) to each workpiece is used to perform ablation to the upper surface of each workpiece. Accordingly, by providing the first and second wavelength setting means 57 and 61 on the first and second optical paths, the wavelengths of the first and second laser beams LB 1 and LB 2 can be set different from each other.
[0041] The first and second half-wave plates 58 and 62 are provided on the optical paths of the first and second laser beams LB 1 and LB 2 passed through the first and second wavelength setting means 57 and 61 , respectively. Each of the first and second half-wave plates 58 and 62 is provided with rotational drive means (not shown). Accordingly, the first half-wave plate 58 can be rotated to adjust the direction of the polarization plane of the first laser beam LB 1 according to the material of the first workpiece. Similarly, the second half-wave plate 62 can be rotated to adjust the direction of the polarization plane of the second laser beam LB 2 according to the material of the second workpiece.
[0042] The first and second laser beams LB 1 and LB 2 passed through the first and second half-wave plates 58 and 62 enter the first and second focusing means 51 and 51 ′ provided at the ends of the first and second optical paths, respectively. Each of the first and second focusing means 51 and 51 ′ includes a focusing lens. Accordingly, the first laser beam LB 1 is focused to the first workpiece held on the first chuck table 36 by the focusing lens of the first focusing means 51 . Similarly, the second laser beam LB 2 is focused to the second workpiece held on the second chuck table 36 ′ by the focusing lens of the second focusing means 51 ′.
[0043] The optical system of the laser beam applying means 5 mentioned above is stored in the branch portions 42 a and 42 b of the casing 42 located at the substantially central position on the stationary base 2 so as to be interposed between the first and second chuck table mechanisms 3 and 3 ′. The first and second focusing means 51 and 51 ′ are provided at the ends of the branch portions 42 a and 42 b where the first and second focusing means 51 and 51 ′ can be opposed to the first and second chuck tables 36 and 36 ′, respectively. That is, the first and second focusing means 51 and 51 ′ are located so as to be opposed to first and second processing areas where laser processing is performed to the first and second workpieces held on the first and second chuck tables 36 and 36 ′, respectively.
[0044] In this preferred embodiment, each of the X and Y moving means mentioned above includes an externally threaded rod parallel to a pair of guide rails, an internally threaded block including a tapped through hole provided on the lower surface of a moving base or a slide block and threadedly engaged with the externally threaded rod, and a pulse motor as a drive source for rotationally driving the externally threaded rod. However, this configuration is merely illustrative. For example, each of the X and Y moving means may be provided by a so-called linear shaft motor including a linear rail extending in the X direction or the Y direction in place of the externally threaded rod and a coil movable element movably engaged with the linear rail in such a manner that the linear rail is inserted through the coil movable element, wherein the coil movable element is mounted on a moving base or a slide block above which a chuck table is provided.
[0045] Referring back to FIG. 1 , there are provided on the stationary base 2 the first and second cassette table mechanisms 7 and 7 ′ for mounting first and second cassettes 70 and 70 ′ in which a plurality of first workpieces such as semiconductor wafers and a plurality of second workpieces such as semiconductor wafers are each stored, the first and second temporary setting means 8 and 8 ′ for temporarily setting the first and second workpieces taken out of the first and second cassettes 70 and 70 ′, the first and second handling means 9 and 9 ′ for taking the first and second workpieces out of the first and second cassettes 70 and 70 ′ before processing and for returning the first and second workpieces into the first and second cassettes 70 and 70 ′ after processing, and the first and second transfer means 10 and 10 ′ for transferring the first and second workpieces from the first and second temporary setting means 8 and 8 ′ to the first and second chuck tables 36 and 36 ′ before processing and for transferring the first and second workpieces from the first and second chuck tables 36 and 36 ′ to the first and second temporary setting means 8 and 8 ′ after processing.
[0046] These cassette table mechanisms 7 and 7 ′, temporary setting means 8 and 8 ′, handling means 9 and 9 ′, and transfer means 10 and 10 ′ will now be described in detail. As shown in FIGS. 1 and 4 , the first cassette table mechanism 7 is provided adjacent to a first standby area where the first workpiece is held on the first chuck table 36 of the first chuck table mechanism 3 before processing or unheld from the first chuck table 36 after processing. Similarly, the second cassette table mechanism 7 ′ is provided adjacent to a second standby area where the second workpiece is held on the second chuck table 36 ′ of the second chuck table mechanism 3 ′ before processing or unheld from the second chuck table 36 ′ after processing. The first and second cassette table mechanisms 7 and 7 ′ include first and second cassette tables 71 and 71 ′ for mounting the first and second cassettes 70 and 70 ′, respectively. Each of the first and second cassette tables 71 and 71 ′ is vertically movable by elevating means (not shown).
[0047] The first and second temporary setting means 8 and 8 ′ will now be described with reference to FIGS. 1 and 5 . The first and second temporary setting means 8 and 8 ′ are located adjacent to the first and second cassette table mechanisms 7 and 7 ′ in the X direction, respectively. More specifically, the first temporary setting means 8 is located directly above the first standby area where the first workpiece is held or unheld with respect to the first chuck table 36 . Similarly, the second temporary setting means 8 ′ is located directly above the second standby area where the second workpiece is held or unheld with respect to the second chuck table 36 ′. As shown in FIG. 5 , the first temporary setting means 8 includes a pair of parallel, sectionally L-shaped support rails 81 a and 81 b extending in the X direction and support rail moving means 82 for supporting end portions of the support rails 81 a and 81 b so as to allow the movement of the support rails 81 a and 81 b in the Y direction, thereby changing the spacing between the support rails 81 a and 81 b . Similarly, the second temporary setting means 8 ′ includes a pair of parallel, sectionally L-shaped support rails 81 a ′ and 81 b ′ extending in the X direction and support rail moving means 82 ′ for supporting end portions of the support rails 81 a ′ and 81 b ′ so as to allow the movement of the support rails 81 a ′ and 81 b ′ in the Y direction, thereby changing the spacing between the support rails 81 a ′ and 81 b ′. The spacing between the support rails 81 a and 81 b is set so that when the support rails 81 a and 81 b are moved toward each other, this spacing becomes smaller than the outer diameter of the annular frame F supporting the semiconductor wafer W as the first workpiece through the protective tape T (more specifically, this spacing is the spacing between horizontal portions of the support rails 81 a and 81 b ), whereas when the support rails 81 a and 81 b are moved away from each other, this spacing becomes larger than the outer diameter of the annular frame F. Similarly, the spacing between the support rails 81 a ′ and 81 b ′ is set so that when the support rails 81 a ′ and 81 b ′ are moved toward each other, this spacing becomes smaller than the outer diameter of the annular frame F supporting the semiconductor wafer W as the second workpiece through the protective tape T (more specifically, this spacing is the spacing between horizontal portions of the support rails 81 a ′ and 81 b ′), whereas when the support rails 81 a ′ and 81 b ′ are moved away from each other, this spacing becomes larger than the outer diameter of the annular frame F.
[0048] The first and second handling means 9 and 9 ′ will now be described with reference to FIGS. 1 and 6 . The first handling means 9 includes a handling arm 91 , a catch member 92 provided at an end portion of the handling arm 91 on the side opposed to the first cassette table mechanism 7 for catching the annular frame F supporting the semiconductor wafer W as the first workpiece stored in the first cassette 70 , and arm moving means 93 for supporting the handling arm 91 so as to allow the movement of the handling arm 91 in the X direction. Similarly, the second handling means 9 ′ includes a handling arm 91 ′, a catch member 92 ′ provided at an end portion of the handling arm 91 ′ on the side opposed to the second cassette table mechanism 7 ′ for catching the annular frame F supporting the semiconductor wafer W as the second workpiece stored in the second cassette 70 ′, and arm moving means 93 ′ for supporting the handling arm 91 ′ so as to allow the movement of the handling arm 91 ′ in the X direction. Each of the catch members 92 and 92 ′ is driven by air pressure supplied from an air cylinder (not shown), thereby catching the annular frame F.
[0049] The first and second transfer means 10 and 10 ′ will now be described with reference to FIGS. 1 and 7 . The first transfer means 10 includes a plurality of suction pads 11 for holding the annular frame F supporting the semiconductor wafer W as the first workpiece under suction, a transfer arm 12 having a front end where the suction pads 11 are located, an operating rod 13 for vertically moving the transfer arm 12 , and elevating means 14 for vertically moving the operating rod 13 . Similarly, the second transfer means 10 ′ includes a plurality of suction pads 11 ′ for holding the annular frame F supporting the semiconductor wafer W as the second workpiece under suction, a transfer arm 12 ′ having a front end where the suction pads 11 ′ are located, an operating rod 13 ′ for vertically moving the transfer arm 12 ′, and elevating means 14 ′ for vertically moving the operating rod 13 ′. For example, each of the elevating means 14 and 14 ′ is provided by an air piston. In this preferred embodiment, four suction pads 11 are supported to the transfer arm 12 , and four suction pads 11 ′ are supported to the transfer arm 12 ′. Each of the suction pads 11 and 11 ′ is biased downward by a coil spring or the like and connected through a flexible pipe to a vacuum distributor (not shown), which is connected to suction means (not shown).
[0050] All of the laser beam applying means 5 , the cassette table mechanisms 7 and 7 ′, the temporary setting means 8 and 8 ′, the handling means 9 and 9 ′, and the transfer means 10 and 10 ′ mentioned above are provided on the stationary base 2 as shown in FIG. 1 . The operation of the first laser mechanism 1 a including the first chuck table mechanism 3 , a part of the laser beam applying means 5 , the first cassette table mechanism 7 , the first temporary setting means 8 , the first handling means 9 , and the first transfer means 10 will now be described with reference to FIG. 1 and FIGS. 8 to 11 . The operation of the second laser mechanism 1 b including the second chuck table mechanism 3 ′, a part of the laser beam applying means 5 , the second cassette table mechanism 7 ′, the second temporary setting means 8 ′, the second handling means 9 ′, and the second transfer means 10 ′ is substantially the same as that of the first laser mechanism 1 a , and the detailed description thereof will be omitted herein.
[0051] As shown in FIGS. 1 and 8 , the first cassette table mechanism 7 is located adjacent to the first chuck table mechanism 3 in the X direction. The first temporary setting means 8 is located directly above the first standby area where the first workpiece is held or upheld with respect to the first chuck table 36 . The first handling means 9 is located on one side of the first standby area, i.e., on one side of the first temporary setting means 8 in the Y direction. The first transfer means 10 is located on the other side of the first standby area in the Y direction, i.e., on the side opposite to the first handling means 9 with respect to the first chuck table mechanism 3 .
[0052] There will now be described a wafer setting step of taking the semiconductor wafer W as the first workpiece out of the first cassette 70 and then setting the semiconductor wafer W on the first chuck table 36 . As shown in FIG. 8 , the support rail moving means 82 of the first temporary setting means 8 is operated to move the support rails 81 a and 81 b toward each other, thereby reducing the spacing between the support rails 81 a and 81 b according to the outer diameter of the annular frame F supporting the semiconductor wafer W. Thereafter, the first cassette table 71 is vertically moved to adjust the height of the semiconductor wafer W stored in the first cassette 70 to the height of the catch member 92 of the first handling means 9 because the height of the catch member 92 is fixed.
[0053] After adjusting the height of the semiconductor wafer W stored in the first cassette 70 to the height of the catch member 92 , the handling arm 91 is moved toward the first cassette 70 until the catch member 92 comes into engagement with the annular frame F supporting the semiconductor wafer W stored in the first cassette 70 . In this condition, the catch member 92 is driven by the air pressure supplied by the air cylinder (not shown), thereby catching the annular frame F. Thereafter, the arm moving means 93 is operated to move the handling arm 91 away from the first cassette table mechanism 7 , thereby taking the semiconductor wafer W out of the first cassette 70 and carrying it to the support rails 81 a and 81 b of the first temporary setting means 8 as shown in FIG. 9 . Thereafter, the operation of the catch member 92 catching the annular frame F is canceled to temporarily set the semiconductor wafer W on the support rails 81 a and 81 b.
[0054] After temporarily setting the semiconductor wafer W on the support rails 81 a and 81 b of the first temporary setting means 8 , the elevating means 14 of the first transfer means 10 is operated to lower the operating rod 13 . As described above, the transfer arm 12 having the suction pads 11 at the front end is connected to the upper end of the operating arm 13 . Accordingly, when the operating rod 13 is lowered, the suction pads 11 provided at the front end of the transfer arm 12 come into abutment against the annular frame F supporting the semiconductor wafer W temporarily set on the first temporary setting means 8 . As described above, each suction pad 11 is biased downward by a coil spring (not shown), so that when each suction pad 11 comes into abutment against the annular frame F, each suction pad 11 is moved slightly upward relative to the transfer arm 12 . When the suction pads 11 come into abutment against the annular frame F, the lowering motion of the operating rod 13 is stopped and a vacuum is supplied through the vacuum distributor (not shown) to the suction pads 11 , thereby holding the semiconductor wafer W through the annular frame F to the suction pads 11 under suction.
[0055] After holding the semiconductor wafer W through the annular frame F to the suction pads 11 , the support rail moving means 82 of the first temporary setting means 8 is operated to increase the spacing between the support rails 81 a and 81 b to a size greater than the outer diameter of the annular frame F as shown in FIG. 11 . Thereafter, the operating rod 13 is further lowered to place the semiconductor wafer W on the upper surface of the first chuck table 36 set in the first standby area. Further, the supply of the vacuum to the suction pads 11 is stopped and the operating rod 13 is next raised to the retracted position shown in FIG. 9 . Thereafter, the suction means (not shown) is operated to hold the semiconductor wafer W through the protective tape T on the upper surface of the first chuck table 36 under suction. Thereafter, the clamps 362 are operated to fix the annular frame F to the first chuck table 36 . Thereafter, the X moving means 37 of the first chuck table mechanism 3 is operated to move the first chuck table 36 to the first processing area directly below the first focusing means 51 of the laser beam applying unit 4 .
[0056] Thus, the wafer setting step by the first laser mechanism 1 a has been described. As described above, the second laser mechanism 1 b has substantially the same configuration as that of the first laser mechanism 1 a , and the operation of the second laser mechanism 1 b is similar to that of the first laser mechanism 1 a . That is, the second laser mechanism 1 b includes the second chuck table mechanism 3 ′, a part of the laser beam applying means 5 , the second cassette table mechanism 7 ′, the second temporary setting means 8 ′, the second handling means 9 ′, and the second transfer means 10 ′. Accordingly, the description of a wafer setting step by the second laser mechanism 1 b will be omitted herein. All of the cassette table mechanisms 7 and 7 ′, the temporary setting means 8 and 8 ′, the handling means 9 and 9 ′, and the transfer means 10 and 10 ′ are controlled by control signals output from an output interface (not shown) included in the control means.
[0057] There will now be described a laser processing step by the first laser mechanism 1 a.
[0058] When the first chuck table 36 holding the semiconductor wafer W is set in the first processing area, the first imaging means 6 and the control means perform an alignment step of detecting a target area of the semiconductor wafer W to be laser-processed. That is, the first imaging means 6 and the control means perform image processing such as pattern matching for making the alignment between the target lines extending in a first direction on the semiconductor wafer W and the first focusing means 51 of the laser beam applying means 5 for applying a laser beam along the target lines, thus performing the alignment step of detecting the target lines extending in the first direction. Similarly, this alignment step is performed for the other target lines extending in a second direction perpendicular to the first direction on the semiconductor wafer W, thereby detecting the target lines extending in the second direction.
[0059] After performing the alignment step to detect all of the target lines formed on the semiconductor wafer W held on the first chuck table 36 , the first chuck table 36 is moved to position one end of a predetermined one of the target lines directly below the first focusing means 51 . Thereafter, the focused spot of a pulsed laser beam to be focused by the focusing lens of the first focusing means 51 is set at a predetermined height inside the semiconductor wafer W, wherein the pulsed laser beam has a transmission wavelength to the semiconductor wafer W. Thereafter, the pulsed laser beam is applied from the first focusing means 51 to the semiconductor wafer W, and at the same time the first chuck table 36 is moved at a predetermined speed in the X direction shown in FIG. 1 . When the other end of the predetermined target line has reached the position directly below the first focusing means 51 , the application of the pulsed laser beam is stopped and the movement of the first chuck table 36 is also stopped. As a result, a modified layer is formed inside the semiconductor wafer W along the predetermined target line. After performing such laser processing along the predetermined target line, the Y moving means 38 is operated to move the first chuck table 36 in the Y direction, and the laser processing is repeated along all of the other target lines extending in the first direction. Thereafter, the laser processing is similarly performed along all of the target lines extending in the second direction. A laser processing step by the second laser mechanism 1 b is substantially the same as that by the first laser mechanism 1 a mentioned above, so the detailed description thereof will be omitted herein.
[0060] After finishing the laser processing step, the semiconductor wafer W held on the chuck table 36 is returned to the original position in the first cassette 70 in the following procedure reverse to that of the wafer setting step described with reference to FIGS. 8 to 11 . That is, after processing the semiconductor wafer W in the first processing area, the first chuck table 36 holding the semiconductor wafer W is moved from the first processing area to the first standby area shown in FIG. 11 by operating the X moving means 37 . Thereafter, the operating rod 13 of the first transfer means 10 is lowered until the suction pads 11 come into abutment against the annular frame F supporting the semiconductor wafer W held on the chuck table 36 . Thereafter, a vacuum is applied to the suction pads 11 to hold the semiconductor wafer W under suction. Thereafter, the suction holding of the semiconductor wafer W is canceled and the fixed condition of the annular frame F by the clamps 362 is also canceled. Thereafter, the operating rod 13 is raised to a vertical position higher than the support rails 81 a and 81 b of the first temporary setting means 8 .
[0061] Thereafter, the support rail moving means 82 of the first temporary setting means 8 is operated to reduce the spacing between the support rails 81 a and 81 b according to the outer diameter of the annular frame F. Thereafter, the operating rod 13 of the first transfer means 10 is lowered to place the semiconductor wafer W held by the suction pads 11 onto the support rails 81 a and 81 b as shown in FIG. 10 . Thereafter, the vacuum applied to the suction pads 11 is canceled to thereby temporarily set the semiconductor wafer W on the support rails 81 a and 81 b . Thereafter, the operating rod 13 is raised to the highest vertical position, i.e., the retracted position shown in FIG. 9 .
[0062] Finally, the handling arm 91 of the first handling means 9 is moved from the position shown in FIG. 9 to the position shown in FIG. 8 . At this time, the annular frame F supporting the semiconductor wafer W is pushed by the handling arm 91 , so that the operation of the catch member 92 is not required. Thus, the semiconductor wafer W is pushed by the handling arm 91 and thereby returned to the original position in the first cassette 70 as shown in FIG. 8 .
[0063] As shown in FIG. 12 , the laser processing apparatus 1 including the laser mechanisms 1 a and 1 b shown in FIG. 1 has a housing 200 for covering the laser mechanisms 1 a and 1 b . The housing 200 has a side wall opposed to the cassette table mechanisms 7 and 7 ′ in the X direction (see FIG. 1 ). This side wall of the housing 200 is provided with a first door 201 opposed to the first cassette table mechanism 7 and a second door 204 opposed to the second cassette table mechanism 7 ′. The first and second doors 201 and 204 are arranged in parallel in the Y direction. The first and second doors 201 and 204 are configured like a so-called double door such that the first door 201 is adapted to open to the left and the second door 204 is adapted to open to the right as viewed in FIG. 12 . When the first door 201 is opened, an operator can make access to the first standby area defined by the first cassette table mechanism 7 of the first laser mechanism 1 a and the position where the first workpiece is held or unheld with respect to the first chuck table 36 . Similarly, when the second door 204 is opened, the operator can make access to the second standby area defined by the second cassette table mechanism 7 ′ of the second laser mechanism 1 b and the position where the second workpiece is held or unheld with respect to the second chuck table 36 ′. That is, the first and second doors 201 and 204 are used in loading/unloading the first and second cassettes 70 and 70 ′ to/from the first and second cassette tables 71 and 71 ′, respectively.
[0064] The first door 201 is provided with a first operation panel 202 for operating the first laser mechanism 1 a . Similarly, the second door 204 is provided with a second operation panel 205 for operating the second laser mechanism 1 b . These operation panels 202 and 205 are adapted to be operated by the operator to conduct various kinds of setting to the control means. That is, the first laser mechanism 1 a and the second laser mechanism 1 b can be operated independently. Accordingly, there is no possibility that when the first door 201 is in an open condition in loading the first cassette 70 to the first cassette table 71 , the operator may erroneously operate the first operation panel 202 to start the first laser mechanism 1 a . Similarly, there is no possibility that when the second door 204 is in an open condition in loading the second cassette 70 ′ to the second cassette table 71 ′, the operator may erroneously operate the second operation panel 205 to start the second laser mechanism 1 b.
[0065] The first operation panel 202 is pivotably mounted on the first door 201 so as to be opened to the left as viewed in FIG. 12 . Similarly, the second operation panel 205 is pivotably mounted on the second door 204 so as to be opened to the right as viewed in FIG. 12 . In the laser processing apparatus 1 according to this preferred embodiment, it is assumed that the operator operates the operation panels 202 and 205 as confirming the operations of the laser mechanisms 1 a and 1 b . Accordingly, the left side wall of the housing 200 is provided with a first inspection window 203 for allowing the operator to see the first laser mechanism 1 a as shown in FIG. 12 . Similarly, the right side wall of the housing 200 is provided with a second inspection window 206 for allowing the operator to see the second laser mechanism 1 b.
[0066] Accordingly, the operator can operate the first operation panel 202 in its open condition as seeing the first laser mechanism 1 a through the first inspection window 203 . Similarly, the operator can operate the second operation panel 205 in its open condition as seeing the second laser mechanism 1 b through the second inspection window 206 . By providing these inspection windows 203 and 206 and the operation panels 202 and 205 , there is no possibility that the operation panels 202 and 205 may be confusingly operated in operating the first and second laser mechanisms 1 a and 1 b.
[0067] The present invention is not limited to the details of the above described preferred embodiment. The scope of the invention is defined by the appended claims and all changes and modifications as fall within the equivalence of the scope of the claims are therefore to be embraced by the invention.
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A laser processing apparatus includes a first chuck table for holding a first workpiece, moving units for moving the first chuck table in X and Y directions, and a first focusing unit for focusing a first laser beam to the first workpiece. A second chuck table holds a second workpiece. Other moving units move the second chuck table in the X direction and Y directions, and a second focusing unit focuses a second laser beam to the second workpiece. A laser oscillator produces an original laser beam, and an optical system branches the original laser beam into the first laser beam and the second laser beam, and leads the first and second laser beams to the first and second focusing units, respectively.
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FIELD OF THE INVENTION
The present invention relates to the field of knitted fabrics, and namely it concerns a new knitting process for obtaining a so-called “pile” fabric. The invention also relates to a knitting machine aimed at operating according to the process, and a knitted fabric obtainable with such process and machine.
BACKGROUND ART
Presently, the textile industry offers a wide range of so-called “pile” fabrics, i. e. fabrics providing on one side a distribution of tufts or hairs, formed by way of a effect (or pile) yarn. The processes for manufacturing such fabrics, and consequently the machines aimed at carrying out them, are likewise various. Considering in particular the cut pile knitted fabrics obtained by means of flat or circular knitting machines—disregarding ecological furs and peluche fabrics—according to the prior art, loops are formed, like in the terry fabrics, and cut during the finishing steps, through the so-called “shearing” operation.
With this process it is not possible to obtain pile fancy patterns, because the terry fabric knitting machines do not allow to freely arrange the pile loops, as a function of the pattern one wishes to obtain on a side of the fabric.
Besides, the shearing operation involves up to 30% yarn wastes (pile loops are cut about half their length), thus causing a remarkable increase in the production costs, which are in any case burdened by the additional shearing productive step.
SUMMARY OF THE INVENTION
The main object of the present invention is to allow the manufacturing of a weft-knitted fabric so that cut pile is formed in the course of the knitting productive step.
While accomplishing the above mentioned general object, a particular object of the present invention is to permit a free arrangement of the cut pile among the normal stitches of the fabric, in order to obtain pile fancy designs and/or patterns.
Said objects are attained with the weft-knitting process having the essential features defined in appended claim 1.
An improved knitting machine operating according to the process is essentially as defined by appended claim 10.
A knitted fabric obtainable with such process and machine has the features essentially defined by appended claim 20.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller appreciation of the features and advantages afforded by the process for knitting a weft-knitted fabric so that cut pile is formed on the backside stitches, the knitting machine operating according to the process and the knitted fabric obtainable with such process and machine according to the present invention, a preferred embodiment thereof will now be described by way purely of example and implying no limitation, with reference to the accompanying drawings, in which:
FIG. 1 shows a perspective view of a slidable member for use in the process according to the invention;
FIG. 2 shows a cross section view taken along line II—II of FIG. 1;
FIGS. 3, 4 and 5 show partial and schematic perspective views of the opposite needlebeds of a flat knitting machine operating according to the invention, in respective successive steps of the pile-forming knitting process.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2, according to a preferred embodiment of the invention, a slidable member 1 is used, having an elongated shape comprising a shank 2 which is provided with an end butt 3 for allowing a reciprocating operation, according to the system commonly used for operating knitting needles. Butt 3 extends in a orthogonal direction from an edge 2 a of shank 2 , such edge being that which, in use, is placed upwards, as will be explained hereinafter.
The other end of slidable member 1 , i. e. the working end thereof—also in this case, as will be made clearer hereinafter—has a pointed foot 4 , which extends from upper edge 2 a of shank 2 , accomplishing a substantially L-shaped arrangement. A cutting rim portion 5 is formed by upper edge 2 a of shank 2 , close to foot 4 . In the depicted example cutting rim 5 slightly slopes towards foot 4 .
With reference now to FIG. 3, in a flat knitting machine, neither shown nor described as a whole since for all that is not explicitly mentioned its features are according to the prior art, two opposite knitting needlebeds cooperate in order to form a knitted fabric T. In greater detail, consecutive ranks of stitches R, R I , R II , of fabric T are visible, the latest of said ranks—that is to say rank R which is being formed in the represented step—has the relevant stitch loops engaged by the knitting needles.
Namely, needles A 1 , A 2 , A 3 and A 4 —needles A 2 to A 4 being illustrated only partially, for the sake of clarity—are loaded with the loops of newly formed rightside stitches, while needles A 5 , A 6 and A 7 of the opposite needlebed are loaded with backside stitch loops. A following needle A 8 of this same needlebed is forming the pertinent stitch of rank R, as described in detail later on. Besides, it has to be noticed that the weft of fabric T is formed by a base yarn thread F F and a effect or pile yarn thread F p , mutually coupled. Running along threads F F and F p , a rightside stitch portion formed by needles from A 1 to A 4 is followed by a backside stitch portion formed by needles from A 5 to A 7 . The threads are fed by feeders G F , for base thread F F , and G P , for pile thread F p .
According to the preferred embodiment of the invention, slidable members 1 operatively replace respective needles of the needlebed which is opposite to that creating the base of the pertinent stitches, in order to form cut pile in correspondence thereof. For instance, FIG. 3 shows two slidable members 1 1 and 1 2 , slidably housed in the grooves which, in a conventional machine, respectively between needles A 5 and A 6 and between needles A 7 and A 8 of a needlebed, support needles of the needlebed opposite thereto. The cut pile is formed according to the following working steps, described as far as needle As is concerned and referring also to FIG. 4 .
Needle A 8 , loaded with a stitch of rank R I (previous to rank R which is being formed), is operated by the machine cam system and moves forward, so that the old stitch opens the corresponding lever, indicated at L, and locates under the same. Then, needle A 8 starts moving backward and feeders G F and G p bring the respective threads F F and F p in front of the needle hook, allowing the latter to engage with them.
In the meantime, sliding member 1 2 —placed between needle As and the previous one A 7 —has moved forward, locating the tip of its foot 4 in correspondence to the theoretical intersection axis between the planes of the two needlebeds. In this condition, as the feeders G F e G p pass, foot 4 , of which the tip is slightly higher than the needle hooks, inserts between the base thread F F and the pile thread F p , so as to keep them separate. FIGS. 3 and 4 actually represent such phase, in two steps immediately following one another, and it is clearly noticeable how foot 4 retains pile thread F p as this is hooked by needle A 8 .
When needle A 8 stops its backward motion, the old stitch of rank R I has been unloaded, after closing lever L, and a new stitch of rank R has been formed. However, foot 4 of sliding member 1 2 has formed a bridle B between the beginning of the upper loop of said new stitch and the end of the previous stitch of the same rank R, i. e. the stitch that is engaged by needle A 7 . This condition is shown more clearly in FIG. 3, in respect of needles As and A 6 and the corresponding sliding member 1 1 . The latter, by retaining pile thread F p , has thereby formed a bridle B, while base thread F F has conventionally formed a normal lower loop.
The release of fabric T from the engagement with feet 4 of sliding members 1 , necessary in order to allow the drop of the fabric itself operated by the takedown system of the machine, is accomplished as bridle B is cut by cutting rim portion 5 of the sliding member, thus forming the cut pile. Such stage is shown in FIG. 5, in which three adjacent sliding members 1 5 , 1 4 and 1 3 are represented in three successive working steps. Starting from the position retaining bridle B formed by thread F p (sliding member 1 5 ) , the member forward movement according to the arrow causes bridle B to drop over cutting portion 5 (member 1 4 ) and then the cutting off of thread F p , consequently forming the cut pile (member 1 3 ). The cutting off of thread F p is made easier by the fact that bridle B is stretched over cutting portion 5 , such condition being assisted by the slight slope thereof towards foot 4 .
The result which is accomplished can be clearly seen in the same FIG. 5, wherein cut pile formations are represented also in previously knitted ranks R I , R II , R III and R IV , in correspondence to the stitches involved by the operation of sliding members 1 . In this respect, it has to be noticed that the length of the pile formed can be easily adjusted by suitably controlling the operation of sliding member 1 . In fact, a backward displacement of the latter during the stage in which bridle B is engaged by foot 4 —that is to say the stage shown in FIGS. 3 and 4 —pulls more thread F p from the corresponding feeder G p , thus causing the bridle B to become longer. In other words, the length of the pile directly responds to the extent of said backward displacement of sliding member 1 .
On the other hand, as said backward displacement of sliding member 1 increases, and the bridle B gets longer, the effectiveness of rim portion 5 when cutting pile thread F p is affected, because bridle B is less stretched. However, in this case, it is sufficient to postpone the cutting step of bridle B. Said step, instead of occurring before rank R under formation is unloaded—as in the above described example—will occur later, namely when, after rank R and possibly one or more following ranks have been unloaded, as a consequence of the pulling action exerted on the fabric by the takedown system, bridle B is suitably stretched.
It will be appreciated that with such procedure sliding member 1 , while keeping on retaining a still uncut bridle B, can create without difficulty other bridles in the following rank. In fact, when foot 4 moves again in order to separate and retain pile thread F p , according to the above described process, it keeps on retaining the one or more bridles already formed in the previous ranks. Then, each bridle will be cut by rim portion 5 as soon as a suitable stretching is reached.
It will be apparent from the above that according to the invention the cut pile is formed in the course of the knitting productive step, i. e. when the corresponding base stitches are formed, thereby avoiding the productive costs involved by an additional shearing step. Besides, the way the cut is performed is such that pile thread F p is by no means wasted, and its length entirely turns into effective length of the pile.
In the example depicted in FIG. 5, stitches associated to pile formations are followed by a portion of fabric T formed by alternate rightside and backside stitches, knitted by needles A 9 -A 12 . On the contrary, in FIG. 3 pile-associated stitches are adjacent to a series of rightside stitches, i.e. those knitted by needles A 1 -A 4 . However, it has to be stressed that the arrangements of sliding members 1 shown in the figures have simply exemplifying purposes. Actually, the arrangement/combination of needles and sliding members can be freely set, considering that, with the process according to the invention, when cut pile is formed in correspondence to a stitch, the stitches formed by the adjacent needles are by no means affected.
In other words, a single pile formation on a backside stitch, or a plurality thereof in a row, can,be placed at will between normal rightside and backside stitches, single or in a row. Moreover, sliding members 1 can operate in a rank and kept in a non-working position in the previous or following one, as clearly explained by the example of FIG. 3, in which no pile is formed in ranks R I and R II .
As a result of the above, it is possible to spread the pile on the backside stitches so as to form any fancy design one wishes, by suitably arranging the needles and the sliding members and controlling the operation thereof. Said designs can be set all over the height of the fabric, and be combined with jacquard or links-links patterns, obtainable on the rightside stitches by using known systems.
In an improved knitting machine according to the invention, sliding members 1 are operated via butts 3 , as obvious to the skilled person, by an independent system which is perfectly analogous to that commonly used for operating the needles. As an alternative, the stitch transfer system, available on the machine, can be used.
Sliding members 1 , besides replacing respective needles in the needlebed which is opposite to that forming the base of the corresponding stitches (as in the above described embodiment), can be associated to such needles, sliding side by side thereto, in the same grooves or in supplementary ones formed between the needles. In this case, obviously, when a needle operates, the adjacent sliding member shall be in a non-working condition. Conversely, when a sliding member 1 operates on the pile thread, the corresponding adjacent needle shall be in a backward displaced, non-working condition.
Such expedient allows a quick setting of the machine, as a function of the result one wishes to obtain, by simply selecting the sliding members which have to be operated. Even more advantageously, it is possible not to affect the needle-operating system. In fact, the operation of the sliding members can be carried out by the device of a known type—which is conventionally used for controlling the needles in order to obtain jacquard weaves. The device is provided with a mechanical or electronic programmable control system.
If the latter solution is chosen, changes have to be brought about to the guide track used for operating the sliding members, as obvious to a skilled person. Namely, the size of the forward movement section has to be appropriate, so as to achieve a correct operative positioning of foot 4 of sliding member 1 , a suitable synchronization with the movement of the needle which, on the opposite needlebed, forms the corresponding stitch, as well as the desired backward displacement of member 1 when retaining bridle B. The forward movement of sliding member 1 , for cutting bridle B with rim portion 5 , can also be controlled by the cams which, in the conventional machine, carry out the stitch transfer.
In this way, the range of products which can be realized is even wider. In fact, all the functional features of a conventional knitting machines can be maintained, and namely the possibility of using the needles of both needlebeds for accomplishing the start of the piece of knitted fabric, the separation of the pieces, the transfer of single stitches from a needlebed to the other, in order to form tubular fringes etc., all this in combination with pile fancy designs, such as pile jacquard patterns in two or more colors, obtainable according to the invention.
Even though in the present description reference has been made to flat knitting machines, it is apparent that according to the invention, sliding members operating as described above can be used similarly also in double-bed circular knitting machines, with adjustments that are obvious to an expert in the field. For example, as far as the shape of sliding elements 1 is concerned, the angle between foot 4 and shank 2 (more precisely, between the respective axes), has to be adjusted. In fact, in a flat machine, having needlebeds mutually angled by 80° or less, said angle can be of 140° and over, while in a circular machine, having mutually normal needlebeds, it will not overcome 135°.
Cutting rim portion 5 can be parallel to the axis of shank 2 , instead of being inclined towards foot 4 , especially in the above described working mode (for forming longer pile) in which the bridles are mainly stretched by the fabric takedown system. Even the type of yarn used can affect the shape of sliding members 1 , because when thick yarns are knitted, foot 4 need not be pointed in order to separate and retain pile thread F p .
On the other hand, the process according to the invention can be carried out even by making use of devices which are different from the above described sliding members, provided that they are able to assure an equivalent working, that is, separating and retaining the pile thread for forming a bridle on the backside stitch when the corresponding needle is hooking the yarn, and cutting said bridle so that cut pile is formed.
Variations and/or modifications can be brought to the process for knitting a weft-knitted fabric so that cut pile is formed on the backside stitches, the knitting machine operating according to the process and the knitted fabric obtainable with such process and machine without departing from the scope of the invention as set forth in the attached claims.
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In a process for knitting a weft-knitted fabric (T) by means of mutually opposite needlebeds comprising axially slidable needles, the needles being operated in correspondence to a yarn feed, said yarn consisting in a base thread (F F ) and a pile thread (F p ) mutually coupled, for stitches in correspondence with which pile has to be formed, when the needle is engaging the yarn, the pile thread (F p ) is separated from said base thread (F F ) and retained so that a bridle (B) is formed on the backside between the new stitch and the previous stitch of the same rank (R), while the base thread (F F ) forms a normal backside stitch lower loop. The bridle (B) is subsequently cut in order to obtain the cut pile, as the fabric under formation progressively moves down. The invention also relates to a knitting machine specifically designed and built for carrying out the process and to a knitted fabric obtainable with such process and machine.
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BACKGROUND OF THE INVENTION
The invention relates to a rail-cleaning locomotive for electrical toy and model trains with a cleaning unit, comprising polishing disks rotated by an electric motor and lying on the rails.
Such rail-cleaning locomotives for cleaning the rails and, with that, primarily for ensuring good electrical contact between the current-carrying rails and the current collectors of a vehicle driving thereon have already been proposed in various embodiments. Aside from arrangements, which provide clean grinding blocks dragging over the rails, constructions of the initially-described type have also already become known, for which electrically driven polishing disks or polishing rollers are driven, which must be constructed significantly wider than the rails, so that they do not lose contact with the rail even when taking curves. For one such rail-cleaning apparatus described in the German Offenlegungsschrift 26 25 582, the grinding or polishing rollers obtain their driving power from the driving motor of the locomotive. This, however, creates considerable difficulties in practice. For example, if there are variations in the driving speed of the rail-cleaning locomotive, there is also a change in the grinding performance, which is troublesome to a very high degree. In addition, especially when a high grinding performance is desired, the driving speed would also be correspondingly higher which, in turn, contributes to the fact that the power in the grinding rollers is not fully utilized since, because of the high speed, intensive cleaning of the rail surfaces cannot take place. It is equally undesirable that, due to the elastic contact between the grinding rollers and the rail surfaces, the locomotive is lifted by the impact point of the grinding rollers, which at the very least contributes to the fact that a lesser contacting pressure is available for the running wheels, which is also very burdensome.
A rail-cleaning car, which is proposed in the German Utility Patent G 86 31 074.7 and inserted in a train without its own driving mechanism, can also not provide a satisfactory remedy for the problems above. The grinding or polishing rollers are disposed together with their own driving motor in a part suspended elastically in the car between the wheel axes. Here also, the difficulty arises that, on the one hand, a high driving power for the cleaning motor is required. However, because the supply voltage is supplied over the rail, this leads in turn to a simultaneous effect on the speed of the locomotive which, when the locomotive and the cleaning unit are separated by the installation of the cleaning unit in a separate, subsequent car, causes very appreciable coordination problems.
Finally, a further rail-cleaning car has also already been proposed in the German Utility Patent G 83 14 477.3, for which the cleaning brushes, in conjunction with vacuum cleaners disposed behind them, can completely remove the dust brushed off from the rail. However, such brushing apparatuses are unsuitable for a good contact with the rail, since they cannot remove smudges such as fat and abraded rubber from the rail surfaces. In other respects, the same difficulties are associated with the arrangement of this Utility Patent as with those already described with respect to the Utility Patent G 86 31 074.7.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to configure a rail-cleaning locomotive of the initially-named type in such a way that, with a simple, robust construction, cleaning of the rails with simultaneous adjustability of the cleaning intensity is possible under all conceivable operating conditions, even in the case of weatherproof rails set down in the garden.
Pursuant to the invention, this objective is accomplished owing to the fact that the cleaning unit is disposed in a fore-part of the locomotive, coupled to the locomotive so that it can pivot about a vertical and slightly also about a horizontal axis, and is provided with a cleaning motor, which is separated from the driving motor of the locomotive, and that the polishing disks are constructed as cleaning wheels with guiding wheel flanges.
The inventive construction results in a rail-cleaning locomotive for which, in contrast to all previously described rail-cleaning vehicles, wide polishing rollers, which are shifted laterally over the rails in curves, are not provided. Instead, grinding wheels with a narrow contacting surface corresponding to the driving wheels of the locomotive are provided since, due to the provision of wheel flanges in conjunction with the mobility of the fore-part of the locomotive containing the cleaning unit, an independent swiveling of the fore-part can take place in the curves. For example, and this has proven to be particularly advantageous in practice, the whole of the driving voltage at the rails can be applied, in order to drive the cleaning motor of the cleaning unit with this high, full driving voltage, while the driving speed of the driving motor is changed by separate control elements, preferably mounted on the locomotive itself. It is self-evident that, with this type of operation, further vehicles cannot drive on the arrangement during the run of the rail-cleaning locomotive, unless it is a question of vehicles, the motor of which can be controlled by remote control even when it is supplied with a fixed, high driving voltage.
An adjusting knob, which controls the driving speed at a constantly full driving voltage for operating the cleaning motor and is disposed under a detachable covering, is therefore preferably disposed on an inventive rail-cleaning locomotive.
In a further development of the invention, a function switch with three positions can be provided. In these positions, the locomotive alternately is switched off by being currentless, drives (and, moreover, forwards or backwards depending on the polarity of the vehicle voltage) with the cleaning motor switched off in the second position, or finally, in the third function position, drives forward with the cleaning fore-part in front and the cleaning motor operating or, when the driving voltage is reversed, drives backwards with the cleaning fore-part trailing, in this case, however with the cleaning motor switched off.
As is already the case for the construction of the inventive rail-cleaning locomotive, the arrangement should in any case be such for an inventive rail-cleaning locomotive that the cleaning wheels are rotated in the opposite direction to the driving wheels, since a particularly intensive cleaning is possible in this way. Furthermore, it is avoided that the cleaning wheels act as driving wheels and intensify the drive of the driving wheels with a corresponding weakening of the cleaning effect.
In a refinement of the invention, the inventive cleaning wheels can in each case comprise a wheel flange disk with supporting ring for an exchangeable cleaning ring as well as a holding disk, which can be braced against the wheel flange disk by means of an axle bolt, thus clamping the cleaning ring. This makes it possible to dismantle the assembly very easily and to exchange the cleaning wheels easily, so that it is not necessary to exchange the whole of the cleaning roller when the polishing surface is worn away, as must be done for the rail-cleaning vehicles previously known. It is therefore only necessary to loosen the axle bolt in order to be able to remove the cleaning ring and replace it by a new cleaning ring. Because it is so easy to exchange the cleaning rings, it is also possible to use appropriate cleaning rings with different ranges of grain sizes depending on the degree of contamination of the rails.
In order to be able to utilize the rotation of the cleaning wheels effectively for the cleaning, polishing or grinding of the rail surface, a loading weight can be provided in the cleaning fore-part. This loading weight does not affect in any way the contacting force of the driving wheels of the locomotive, since the fore-part of the locomotive, containing the cleaning unit, is suspended, as it were, on gimbals on the remaining part of the locomotive. In this connection, it is self-evident that the loading weight is selected so that the cleaning unit as a whole is lighter than the actual driving part of the locomotive, as otherwise the advance against the braking force of the oppositely rotating cleaning wheels could not be guaranteed practically.
A thermal overload switch for protecting the cleaning motor can be installed, to advantage, in the cleaning locomotive.
Finally, it is also within the scope of the invention to provide flashing lights, which are coupled in their function with the operation of the cleaning motor, so that, when the inventive rail-cleaning locomotive is being run, it can be seen from the outside by the flashing of the flashing lights whether the rails are being cleaned at the same time or not whether or the locomotive is running with the cleaning unit switched off.
Further advantages, characteristics and details of the invention arise out of the following description of an embodiment, as well as from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of an inventive cleaning locomotive,
FIG. 2 shows an enlarged, partially sectional side view of the locomotive fore-part, containing the cleaning unit,
FIG. 3 shows a perspective view of the cleaning unit of the fore-part with the cleaning wheel disassembled,
FIG. 4 also shows an enlarged view from below of the cleaning unit containing the fore-part containing the cleaning unit, and
FIG. 5 is a circuit diagram of locomotive electronics which may be employed in the locomotive of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The rail-cleaning locomotive 1, shown in the Figures, comprises a rigid, shorter fore-part 2 and a longer fore-part 3, which is pivotably hinged thereto about a vertical axis and, in addition, also at least to a slight extent about a horizontal axis. The central part of the locomotive with the fore-part 2 accommodates the usual, normal locomotive driving unit with the locomotive electronics, while the movable fore-part 3 contains a cleaning unit 4 for cleaning the rails. In a housing 5 with removable cover 6, this cleaning unit comprises an electric cleaning motor 7, which is connected over a transmission 8 with an axle shaft 9, on which two rail-cleaning wheels 10 are fastened, which are driven in a rotating manner by the cleaning motor 7.
The cleaning wheels 10 comprise in each case a wheel flange disk 11 with a supporting ring 12 for a cleaning ring 13, as well as a holding disk 14, which can be braced with the help of an axle bolt 15 against the wheel flange disk 11, the cleaning ring 13 being clamped. By these means, the cleaning ring 13 can be exchanged very easily for a new one when it is worn down or contaminated more heavily. To increase the weight of the cleaning wheels on the rails, a loading weight can be provided. The cover 6 could also be constructed, for example, as such a loading weight. Under the removable cap 16 on the roof of the center part 17 of the locomotive, an adjusting knob for regulating the driving speed of the driving motor of the locomotive is disposed since, when the rail-cleaning locomotive is operating, the control console preferably is set to full driving voltage so that the cleaning motor 7 can produce the maximum output. Depending on the degree of contamination of the rails, the locomotive is run more or less slowly by means of the adjusting knob disposed below the cap 16, since a better cleaning effect is achieved if the locomotive is running more slowly. Conversely, however, for larger rail systems, one would like to conclude the cleaning procedure in a finite time; therefore the highest driving speed is selected, which will bring about the desired cleaning effect.
In the driver's cab in the center part of the locomotive, a function switch 24 with three positions, which can be activated from the outside and corresponds to three different operating states, is provided. In the first function position, the locomotive is switched off by being currentless, that is, the driving voltage, taken from the driving or running wheels 18, is not taken to the driving motor or to the cleaning motor. In the second function position of the function switch 24, only the cleaning motor is switched off, while voltage is taken to the driving motor and thus, when the control console is switched on, the locomotive runs on the rails without any cleaning action. Finally, in the third function position, the locomotive runs forwards with the cleaning fore-part in front and with the cleaning motor operating or backwards with trailing cleaning fore-part when the driving voltage is reversed at the rails. However, when the locomotive is running in the reverse direction, the cleaning motor is automatically switched off. The cleaning action thus takes place exclusively when the locomotive is moving forwards. This has the advantage that, due to the different mode of operation while driving forwards and backwards, dead-end rails, roundhouse rails, etc. can be cleaned and then left once again in the third function position.
On the roof of the center part 17 of the locomotive, flashing lights 19 can be recognized, which are coupled in their function with the operation of the cleaning motor 7. Only when the cleaning motor is running, that is, when the cleaning unit 4 is actually working, do these lights flash. It is therefore possible to see at once from the outside whether the cleaning unit is working or switched off when the locomotive is running on the rails.
In FIG. 3, connecting contact studs 20 and 21 are passed through the housing 5 of the cleaning unit 4 in order to connect the cleaning motor 7 with the electronics of the locomotive over the indicated cable 22.
The cleaning unit 4 is additionally covered (encased) against dirt and grinding dust. Independently of this, the cleaning motor 7 itself should be encased completely dust-tight.
In order to achieve an optimum grinding action, the diameter of the cleaning wheels 10 should be larger than that of the driving wheels. The optimization of the grinding action can be improved further through the use of cleaning rings of different ranges of grain sizes depending on the degree of contamination of the rails.
Finally, it has also proven to be particularly advantageous to use multiple pole motors, particularly a 7-pole motor, and not only a simple motor with 3 poles as a cleaning motor.
One example of electronic circuitry that may be employed in the locomotive of the invention is illustrated in FIG. 5, wherein suitable conventional track contacts 30, 31 are provided on the locomotive for application of current from the non-illustrated track to the locomotive. The contact 30 is connected to the movable arms 32, 32' of the switch 24. As discussed above, the switch 24 has three positions. The switch is illustrated in the OFF position, at which time neither the driving motor 35 nor the cleaning motor 7 is energized. At the central or driving position of the switch, only the driving motor 35 is energized. In the cleaning position of the switch, current is applied to the driving motor 35, as well as to the cleaning motor 7. This connection to the cleaning motor may include a thermal overload 37. Flashing lights may also be connected to be energized in the cleaning position of the switch 24, to signal that the cleaning operation is being performed. FIG. 5 also shows a pulse unit 40 for the flashing lights and also an electronic circuit 42 for constant lighting.
An electronic circuit 44 having a variable resistor is provided for controlling the speed of the driving motor. In FIG. 5, D 1 is operable to switch to non-regulated speed in a reverse direction. D 2 is operable to switch off the flashing lights while driving backwards and D 3 is operable to switch off the cleaning motor 7 while driving backwards.
While the invention has been disclosed with reference to a limited number of embodiments, it is apparent that the invention is not limited thereby. It is therefore intended, in the following claims, to cover each modification thereof that falls within the true spirit and scope of the invention.
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A rail-cleaning locomotive for electrical toy and model trains with a cleaning unit including polishing disks rotated by an electric motor and lying on the rails, wherein the cleaning unit is disposed in a fore-part, coupled to the locomotive so that it can pivot about a vertical and slightly also about a horizontal axis, and is provided with a cleaning motor, which is separated from the driving motor of the locomotive, and wherein the polishing disks are constructed as cleaning wheels with guiding wheel flanges.
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TECHNICAL FIELD
[0001] The present disclosure relates to a data processing system and method for clinical knowledge-graph enhanced clinical text natural language understanding for ICD-10-PCS computer-assisted coding of medical text.
BACKGROUND
[0002] Assigning pre-specified codes to words and phrases found in a clinical note has been attempted for various coding schemes. International Classification of Diseases version 9 (ICD-9), a coding scheme recommended by the World Health Organization and adopted in USA, is being replaced by a newer version called ICD-10. The ICD-10 coding scheme is a much more detailed coding scheme compared to ICD-9; for this reason, the coding procedure becomes more complex. For healthcare providers, there are about 69,823 diagnostic codes under the new ICD-10-CM (clinical modification) codes, five times more than its predecessor ICD-9-CM. An even more complex matrix of about 71,924 new codes for hospital-based procedures awaits in the ICD-10-PCS (Procedural Coding System), 19 times more codes than ICD-9-CM volume 3. With an increase in the number of concepts, the complexity of automating the identification of coding has also increased.
[0003] Another major difference between the ICD-9-CM Procedure and the ICD-10-PCS is structural coherence. While the ICD-9-CM Procedure is flat in its structure, ICD-10-PCS has a multi-axial seven-character alphanumeric code structure (Avril, R F et al., 2011). To address this complexity of medical coding, Computer Assisted Coding (CAC) computer software systems automatically generate a set of medical codes for review/validation and/or use based upon clinical documentation provided by healthcare practitioners.
[0004] Natural Language Processing (NLP) and machine learning has been the mainstay of earlier CAC methods such as ICD-9. The new coding scheme of ICD-10-PCS presents challenges such as highly different textual descriptions between the clinical text and the coding descriptions as well as much more fine-grained and multi-layered/multi-level coding structure. Rule-Based NLP systems utilize base dictionaries, which generally do not capture semantic and syntactic variety of entities. Over the years, different research has proven that dictionary-lookup based methods yield no better than 71.5% of F-score (Savova, Guergana K., et al. “Mayo clinical Text Analysis and Knowledge Extraction System (cTAKES): architecture, component evaluation and applications.” Journal of the American Medical Informatics Association 17.5 (2010): 507-513). Rule-based methods also depend heavily on syntactic parser accuracy, which is also insufficient for the clinical domain.
SUMMARY
[0005] It is difficult to accurately code ICD-10-PCS using only rule-based or only NLP or only machine-learning based approaches because these solutions cannot capture the multi-axial structure of ICD-10, and therefore the solutions that work for the ICD-9-CM procedure do not work for ICD-10-PCS. ICD-10-PCS CAC requires representation of concept class as well as subclasses and/or super classes, relationship between disease to anatomical site, and procedure to anatomical site and medical device. Existing procedures would require trial and error guesswork, which is a time-consuming and inefficient use of computational resources. The present disclosure, however, accomplishes ICD-10-PCS coding using a knowledge base and efficient representation of the same.
[0006] ICD-10 requires deep domain knowledge to be represented and used during the coding process. Further, the semantics of the ICD-10 code structure are harder to interpret than the ICD-9 structure. The disclosed, newly developed mapping method for generating a background knowledge base and resulting knowledge base referred to herein as “ezProcOntology” (Procedure ontology with super classes) captures this domain knowledge. Using this knowledge base, the disclosed system directly maps procedures to codes. The knowledge base is represented as a unified graph to represent all the concepts and relationships between these concepts in graphical format. Representing data in the form of a graph and storing it in a graph database enables the system to represent semantics of ICD-10-PCS at the same time it enables efficient graph traversals to support real-time querying with scalability. This increases the coverage as well as precision of the CAC process.
[0007] In one embodiment, the present disclosure is directed to a computer-controlled method for analyzing natural language clinical text describing a medical procedure, and for generating an accurate procedure code based on a procedural coding system that associates all known medical concepts to alphanumeric characters in a multi-axial coding structure that prohibits rule-based Natural Language Processing (NLP) and machine learning from generating an accurate procedure code. The procedure code comprises a set of alphanumeric characters corresponding to the described medical procedure. A background knowledge graph is created that models all known medical concepts as nodes in the graph and illustrates hierarchical relationships between the medical concepts. The background knowledge graph is then mapped to the procedural coding system to associate each of the medical concepts with at least one alphanumeric character. The medical text is analyzed to determine key words and phrases identifying medical concepts related to the described medical procedure, and each identified medical concept is mapped to the background knowledge graph to determine each character of the set of alphanumeric characters in the procedure code.
[0008] In another embodiment, the present disclosure is directed to a data processing system for analyzing natural language clinical text describing a medical procedure, and for generating an accurate procedure code based on a procedural coding system that associates all known medical concepts to alphanumeric characters in a multi-axial coding structure that prohibits rule-based NLP and machine learning from generating an accurate procedure code. The procedure code comprises a set of alphanumeric characters corresponding to the described medical procedure. The system includes at least one processor coupled to a non-transitory memory that stores computer program instructions, wherein when the at least one processor executes the instructions, the system is caused to: create a background knowledge graph that models all known medical concepts as nodes in the graph and illustrates hierarchical relationships between the medical concepts; map the background knowledge graph to the procedural coding system to associate each of the medical concepts with at least one alphanumeric character; analyze the medical text to determine key words and phrases identifying medical concepts related to the described medical procedure; and map each identified medical concept to the background knowledge graph to determine each character of the set of alphanumeric characters in the procedure code.
[0009] In another embodiment, the present disclosure is directed to a non-transitory machine-readable medium having instructions stored therein, which when executed by a processor, cause the processor to perform operations in a data processing system for analyzing natural language clinical text describing a medical procedure, and for generating an accurate procedure code based on a procedural coding system that associates all known medical concepts to alphanumeric characters in a multi-axial coding structure that prohibits rule-based NLP and machine learning from generating an accurate procedure code. The procedure code comprises a set of alphanumeric characters corresponding to the described medical procedure. The operations include: creating a background knowledge graph that models all known medical concepts as nodes in the graph and illustrates hierarchical relationships between the medical concepts; mapping the background knowledge graph to the procedural coding system to associate each of the medical concepts with at least one alphanumeric character; analyzing the medical text to determine key words and phrases identifying medical concepts related to the described medical procedure; and mapping each identified medical concept to the background knowledge graph to determine each character of the set of alphanumeric characters in the procedure code.
[0010] All of the disclosed embodiments generate the procedure code without utilizing inefficient, iterative trial-and-error techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of an exemplary embodiment of a system for Computer Assisted Coding according to the present disclosure;
[0012] FIG. 2 is an exemplary screenshot of an output of the system;
[0013] FIG. 3 is a flow chart of an exemplary method of making a knowledge graph for ICD-10-PCS;
[0014] FIG. 4 is an illustration of an exemplary ezProcontology (Procedure ontology with super classes);
[0015] FIG. 5 is an illustration of an exemplary ICD-10-PCS Ontology;
[0016] FIG. 6 is an illustration of an exemplary mapping of ezProcOntology with the ICD-10-PCS Ontology;
[0017] FIG. 7 is an illustration of an exemplary structure of core ontology;
[0018] FIG. 8 is an illustration of an exemplary structure of the ezDI Knowledge Graph;
[0019] FIG. 9 is a flow chart of an exemplary method of suggesting an ICD-10-PCS code from clinical text; and
[0020] FIG. 10 illustrates an example of the method of suggesting a particular ICD-10-PCS code.
DETAILED DESCRIPTION
[0021] FIG. 1 is a block diagram of an exemplary embodiment of a system for Computer Assisted Coding according to the present disclosure. An exemplary method of utilizing the system is shown in the numbered steps and is described in Table 1 below. The block labeled ezKG is the knowledge graph.
[0000]
TABLE 1
Steps
Details
1
Health Level-7 (HL7) Interface 11 receives HL7 Message from
client Electronic Medical Record (EMR) 12
2
HL-7 Interface parses the HL7 message and stores demographic
information into application database 13
3
HL-7 interface stores clinical text to file system 14
4
Pre-processing server 15 gets text file from file system and starts
performing pre-processing
5
After performing the pre-processing, the preprocessed file is stored
into file system 14
6
ezDI Natural Language Processing (ezNLP) server 16 gets
preprocessed file from file system and starts performing NLP
operation using associated database 17
7
After performing NLP, XML file is stored into the file system 14
8
Semantic web server 18 gets XML file from file system and starts
performing graph based computing to find ICD and Current
Procedural Terminology (CPT) codes using ezDI
knowledge graph (ezKG) 19
9
After performing graph based computing, the data is inserted into
application database 13
10
ezCAC Web Application User Interface (UI) 20 displays suggested
codes using associated application database 13 with evidences to a
coding professional.
[0022] FIG. 2 is an exemplary screen shot of an output of the system. The system output recommends an ICD-10 code and provides all the evidence for the recommended code to the coding professional.
[0023] The system provides a practical solution (via the ezCAC application) to the coding professional. The system uses a unique ezDI knowledge graph and graph-based computing, as described below, to drive better accuracy, coverage, and speed.
[0024] FIG. 3 is a flow chart of an exemplary method of making a knowledge graph for ICD-10-PCS. The knowledge graph is developed using three ontologies: “Core ontology” which covers all medical concepts and relationships between those concepts; “Procedure Ontology with all super classes” (ezProcOntology); and “ICD-10-PCS Ontology”.
[0025] FIG. 4 is an illustration of an exemplary ezProcOntology (Procedure ontology with super classes). This ontology provides standardized classification of each procedure with associated super classes, which help to identify Procedure type, body system, root operation, body part, medical device, and approach.
[0026] FIG. 5 is an illustration of an exemplary ICD-10-PCS Ontology. ICD-10-PCS Ontology maintains ICD-10-PCS characters hierarchy.
[0027] FIG. 6 is an illustration of an exemplary mapping of ezProcOntology with the ICD-10-PCS Ontology. This figure explains how ICD-10-PCS character description can be mapped to each surgical procedure description, and based on that mapping, it merges ezProcOntology with the ICD-10-PCS Ontology.
[0028] FIG. 7 is an illustration of an exemplary structure of Core ontology. This ontology covers different types of medical concepts with relationships between them such as Diseases, Procedures, Anatomical sites, and the like.
[0029] FIG. 8 is an illustration of an exemplary structure of the ezDI Knowledge Graph for procedures concerning the spleen, as an example. This is the development process of the knowledge graph shown in FIG. 3 . FIG. 4 shows how the graph looks after inserting the knowledge mapping of ICD-10-PCS.
[0030] FIG. 9 is a flow chart of an exemplary method of suggesting an ICD-10-PCS code from clinical text. The input of this method may be formatted, for example, as an XML file. After completion of all steps, the ICD-10-PCS codes may be stored in the application database shown in FIG. 1 .
[0031] FIG. 10 illustrates an example of the method of suggesting a particular ICD-10-PCS code for the following sample text of a transcribed document:
PROCEDURE PERFORMED: Fiberoptic bronchoscopy DESCRIPTION OF PROCEDURE: The procedure was performed in the endoscopy suite. The bronchoscope could not be passed easily through either nostril due to narrow nares and the patient's discomfort. No obvious trauma was caused by trying to pass the scope. A bite block was placed and the bronchoscope was inserted orally once sufficient sedation was obtained. The vocal cords were visualized. The patient appeared to have some right true vocal cord weakness. The vocal cords did approximate in the midline. Just below the vocal cords, in the subglottic area, there was scar tissue noted and some mild to moderate narrowing of the upper trachea with almost complete closure of the airway on exhalation. Pictures were taken of the upper trachea, both on inhalation and exhalation. Airways were otherwise quickly examined. The trachea; carina; right upper, middle and lower lobe bronchi; left main stem bronchus and upper and lower lobe bronchi were patent without significant mucosal abnormalities. Other than associated anxiety, the patient tolerated the procedure well maintaining good oxygen saturation during the procedure and was stable. On conclusion, no specimens were collected.
[0034] From the sample text mentioned above, the NLP system found the “Fiberoptic Bronchoscopy”, “orally”, and “endoscopy suit” as evidences from the clinical chart and identified them as primary and secondary evidences to suggest a more specific ICD-10-PCS code. From the “Fiberoptic Bronchoscopy” (Primary Procedure) and secondary evidences, the system suggests “0BJ08ZZ” ICD-10-PCS code.
[0035] FIG. 10 shows an exemplary mapping of ICD-10-PCS ontology on the left with ezProcOntology procedures on the right for the sample text mentioned above. Arrows indicate ICD-10-PCS subclasses and associated codes on the left mapped with respective procedures from the ezProcOntology on the right.
Knowledgebase Preparation
[0036] The disclosed system uses background knowledge at each level of the multi-axial ICD-10-PCS structure. This knowledge is acquired via various ontologies. The system uses NLP along with ezKG to work in unison with the ICD-10-PCS to automatically generate the relevant code(s). The disclosed solution utilizes a knowledge base comprising three ontologies: Core ontology, which covers all medical concepts and relationships between those concepts; Procedure Ontology with all super classes (ezProcOntology); and ICD-10-PCS Ontology. All these ontologies are combined to prepare a large knowledge base to increase accuracy and coverage. Semantic web technologies are used to address the data integration issue.
[0037] The disclosed system generates ICD-10-PCS codes according to the alphanumeric character identified at each level. Different procedure groups in ICD-10-PCS have a base procedure which is referred to as a “super class”. From the super classes of procedure, the system can identify top-level ICD-10-PCS layers of the multi-axial structure. For this, an ontology of procedures with all super classes (ezProcOntology) has been developed. Each procedure is represented as a node, and the semantics of each procedure are represented by connecting the procedure with base procedures by an edge in the graph. The system takes all the procedure concepts from the diagnostic, laboratory, and therapeutic procedure groups and obtains all the super classes (base procedure) for every procedure concept. Then a “subClassOf” relationship is assigned between the procedure concepts and their super classes. Finally the system stores all the data into OWL format so that a hierarchy can be maintained and utilized with the other ontologies.
[0038] FIG. 4 shows some procedure concepts and their super classes. Super classes of procedure concepts give information about the ICD-10-PCS alphanumeric characters. For example, super classes of “splenorrhaphy” are “spleen closure repair”, “surgical procedure on hemic and lymphatic system” and “surgical procedure”. Some ICD-10-PCS alphanumeric characters of “splenorrhaphy” can be obtained from the super classes such as the “body part” (in this procedure, “spleen”); “root operation” of this procedure is “repair” from “spleen closure repair” super class; and the “body system” of this procedure is “hemic and lymphatic system” from the “surgical procedure on hemic and lymphatic procedure”.
[0039] Semantics of each alphanumeric character of ICD-10-PCS codes are captured as part of the ontology, i.e., each character is associated with appropriate procedure concepts. In order to accomplish this, an ontology of ICD-10-PCS hierarchy is created, which also allows the integration of other standard ontologies such as SNOMED. Annotation Process creates relationships between concepts of this ontology and concepts of background knowledge base.
[0040] FIG. 5 shows an exemplary ICD-10-PCS ontology where ‘00’, ‘01’, ‘02’ and ‘03’ are the subclass of ‘0’. In next section the procedure of annotation is illustrated.
[0041] One of the challenges in annotation is to ensure the correctness of annotation for this large dataset. To address this, a semi-automatic annotation process has been developed to recognize the correct concept for each respective character as mentioned in the following example (Table 2).
[0000]
TABLE 2
ICD-10-
PCS Code
Label
And/or grouping
0
Medical and surgical procedure
Medical and/or surgical
09
Ear, Nose, Sinus
Ear OR Nose OR Sinus
[0042] The following steps are used to annotate ICD-10-PCS characters with procedures from ezProcOntology:
Step 1: Remove common words (surgery, procedure etc.) Step 2: Convert semantics of an ICD-10-PCS character into a logical expression (see Table 2) Step 3: Match logical expressions with procedures from ezProcOntology
[0046] Step 3a: Direct matching words( )
[0047] Example (Shown in FIG. 10 and Table 3):
[0000]
TABLE 3
ICD-10-PCS character and
Description
Procedure from ezProcOntology
0 - Medical and surgical procedure
Medical and surgical procedures,
Surgical procedures
0B - Respiratory System
Respiratory System
0BJ0 - Tracheobronchial Tree
Procedure on tracheobronchial tree
[0048] Step 3b: Direct matching synonyms( )
[0049] Example (Shown in FIG. 10 and Table 4):
[0000]
TABLE 4
ICD-10-PCS Character and
Description
Procedure from ezProcOntology
0BJ - Inspection
Examination Procedure on Bronchus
Step 4: Validate with domain expert
Step 5: Annotation
[0052] Proper “and” and “or” grouping is used in order to capture label semantics of each of the alphanumeric characters. In Table 2, to recognize that the characters should be 09, for example, the process may determine whether the procedure super class has any of the terms ‘ear’ OR ‘nose’ OR ‘sinus’. If the procedure super class has any one of these three terms, it can be mapped with the description of the alphanumeric character. Once the description is identified, the alphanumeric code can be mapped with the procedure super class. It is 09 in this example. At the end of this process, there are mappings between procedure concepts and ICD-10-PCS alphanumeric characters. These two ontologies (ICD-10-PCS and ezProcOntology) are integrated using generated mappings.
[0053] From this merged ontology, the system determines ICD-10-PCS characters from the procedure concept. Super classes of the procedure concept are checked and mapped with ICD-10-PCS alphanumeric characters. The relationships of alphanumeric characters to procedure super classes are “has_first_character”, “has_second_character”, “has_third_character” . . . and ‘has_seventh_character’. The system may determine multiple first characters using this process, which means multiple main sections are initially determined. To identify the correct main section (ICD-10-PCS first layer), the first characters are ranked. The main section with the highest ranking is considered to be the correct main section.
[0054] FIG. 6 shows some procedure concepts and their super classes mapped with the ICD-10-PCS alphanumeric characters.
[0055] From the above mapping, the system identifies ICD-10-PCS alphanumeric characters that are identified by only the procedure name. Precise ICD-10-PCS CAC requires not only procedure but also knowledge of other medical concepts like diseases, anatomical structure, symptoms, and medical devices. In addition to this, the system also requires semantics of each concept so as to increase coverage. Core Ontology represents these medical concepts and connects each of them with semantically relevant concepts. However, in order to get more specific ICD-10-PCS code, other evidences have to be considered from the clinical text. These evidences are mapped to the alpha-numeric characters. Concepts that are related to characters are identified using the grouping technique described previously. The system also identifies medical concepts that are related to specific alphanumeric characters. For this, the core ontology of medical domain has been developed.
[0056] FIG. 7 shows the structure of the core ontology of the medical domain. The core ontology of the medical domain contains the medical concepts with hierarchy and other domain relationships between:
1) ‘Disease’ to ‘Body Measurement’; 2) ‘Procedure’ to ‘Anatomical Site’; 3) ‘Disease’ to ‘Medication’; 4) ‘Disease’ to ‘Symptoms’; 5) ‘Medication’ to ‘Medication’ (for contradicted drug); 6) ‘Procedure’ to ‘Medical Device’; and 7) ‘Disease’ to ‘Anatomical Site’.
[0064] The system adds these relationships verified by domain experts and subclasses in the knowledge graph to identify more accurate and deeper level alphanumeric characters from the evidences found in the clinical text. Identifying evidence in a clinical document is a challenge because evidences are not mentioned explicitly rather they are in the form of subclass or relationships. For example, if “colon mucosa” or “colitis” is mentioned in the document, this assists the system to determine that these terms are related to colon. This is because “colon mucosa” is the subclass of ‘colon’ and ‘colon’ is a ‘body part’ of disease ‘colitis’. Subclass hierarchies and relationships of the background knowledge are used for this purpose.
[0065] This data needs to be represented in a way which allows efficient graph traversals. Data is modelled in the form of a graph for these reasons. Each medical concept, ICD-10-PCS code and procedure is represented as a node; these nodes are then connected with appropriate relationships. Thus, a graph is produced which stores procedures, direct mapping of alphanumeric characters as well as semantics, represented by ontologies discussed above. All the knowledge is combined, and a knowledge graph structure is prepared as illustrated in FIG. 8 . The process of development of the knowledge graph from the ontologies described above is shown in FIG. 3 . Thus the knowledge achieved has the following characteristics:
1) Previously found ICD-10-PCS alphanumeric characters for all procedure concepts; 2) Direct mapping between concepts and ICD-10-PCS alphanumeric characters; 3) Domain Relationship between concepts, which are mentioned in point-2 of this paragraph; and 4) Hierarchy of ICD-10-PCS alphanumeric characters.
Method Overview
[0070] First, the disclosed system finds the primary and secondary sections from the section nodes from the XML document, which is the output of the NLP module. The ‘section’ node is the main header of the documents. Different formats of procedure documents have been analyzed. From the analysis, primary and secondary sections have been identified. The primary section contains the main procedures in the procedure notes while the secondary section contains the descriptions of the main procedures mentioned in the primary sections. Examples are shown in Table 5.
[0000]
TABLE 5
Primary Sections
Procedure Performed
Procedure Title
Name of Procedure
Secondary Sections
Description of procedure
Procedure in details
[0071] There are some challenges to identify the primary and secondary sections. Procedure documents have some sections like ‘procedure’, which cannot be distinguished as a primary or secondary section. For this type of problem, the system ranks the sections. An exemplary ranking is shown in Table 6.
[0000]
TABLE 6
Rank
Section Name
1
Procedure Title
2
Procedure
3
Procedure In Details
[0072] “Procedure Title” has first rank because procedure title appears in the primary section only. “Procedure” has second rank because procedure comes sometime as primary section and sometime as a secondary section. And “Procedure In Details” has third rank because it always comes as a secondary section. Based on ranking, the problem is solved. For example, two sections may be mentioned in the procedure note such as “Procedure Title” and “Procedure”. In this example, “Procedure Title” has highest rank so it becomes a primary section. Likewise, between “Procedure” and “Procedure In Detail”, “Procedure” will be the primary section.
[0073] Another problem is sections that have the same rank and are mentioned in the same document. The system identifies the section from the content of the sections. Secondary section length is longer than the primary section. Thus sections may be identified using three approaches.
[0074] After identifying the sections, the system needs to find primary and secondary concepts using the knowledge base. There is a property named ‘primary’ in the nodes and the value of this property may be “true” or “false”. Stored mappings using ‘ezProcOntology’ have the value ‘true’ of ‘primary’ property. First the system identifies primary procedures from the primary section using a ‘primary’ property in the knowledge base. The rest of the concepts are considered as evidence of the primary procedures of the same sentence. And there may be other evidences in the secondary section. To find these evidences, the system finds paragraphs mentioned in secondary sections of the primary procedure mentioned in the primary section.
[0075] There are two types of sections: primary sections and secondary sections. Primary sections contain only primary procedures. Secondary sections contain a description of the primary procedure. Sometimes there are more paragraphs written in the secondary section, when more procedures are written in the primary section. So the system needs to identify which paragraph is for which primary procedure. Thus, related paragraphs for primary procedures need to be identified.
[0076] For document matching, TF-IDF techniques are often used for context matching. This technique, however, is not sufficient in this case. This is concept to paragraph matching that which primary procedure (concept) is related in terms of medical knowledge to which paragraph. And this matching requires domain knowledge. Thus, the system may find the paragraph of the primary procedure using TF-IDF with the background knowledge. Annotation of the procedure with background knowledge helps the system to identify paragraph(s) related to the concept of the primary procedure. Related concepts in the paragraph are considered, which are annotated to the procedure in ezKG. The system identifies the paragraph using the TF-IDF technique based on the related concepts of the primary procedure found in the paragraph. After finding the paragraph, the evidences found in the paragraph are aligned with the primary procedure and move forward for the further process.
[0077] The next step is to extract primary and secondary concepts from documents. For example, in FIG. 10 , “Fiberoptic bronchoscopy” is the primary concept while “orally” is the secondary concept, which further specifies the code for this procedure. In order to find all the characters of ICD-10-PCS, the algorithm, first finds characters that are associated with the primary concept and then traverses the knowledge graph to find a match for a secondary concept. If a match is found, further ICD-10-PCS characters are determined for this code; otherwise only characters associated with the primary concept are suggested as the final code.
[0078] The following filter process is applied to this final code. Secondary concepts can lead to multiple characters. For example, in FIG. 10 the system suggests 0BJ0 ICD-10-PCS code from the procedure name (Fiberoptic Bronchoscopy) itself. From the secondary evidences, “orally” and “endoscopy”, the system identifies “Via Natural or Artificial Opening Endoscopic” approach, which is associated with 0BJ08, 0BJ18, 0BJK8 and many more ICD-10-PCS characters. The system determines the specific code for this secondary concept and eliminates the rest of the codes by finding the intersection of the set of ICD-10-PCS characters between these codes and one found from the primary evidence.
[0079] As discussed above, to enhance coverage and assign appropriate codes, it is not sufficient to rely on direct mappings, yet direct mappings should be considered first. An object of the present disclosure is to model background knowledge of “procedures and corresponding ICD-10-PCS alphanumeric characters” and direct mappings. Moreover, this knowledge should be stored in a way that reasoning becomes easier on it at the same time it allows efficient direct matching of concepts.
[0080] To assign a proper ICD-10-PCS code for a given procedure, it requires finding corresponding ICD-10-PCS characters in the Knowledge base for the given procedure. In other words, the system needs to traverse the knowledge base, which is in the form of a graph. As described above, the system found ICD-10-PCS characters related to primary evidence. From secondary evidences, the system found more specific ICD-10-PCS characters, which are associated with characters found from the primary evidence. Moreover, this traversal should take place in a way that total time to assign the code to a given document does not exceed a threshold of 1-2 seconds. This requirement poses a challenge for using a relational database where traversal of the graph results in a query with many numbers of joins. At the same time, the mapping should be stored in a way that direct matching occurs in almost the same time as in a relational database.
[0081] For reasons stated above, the storing scheme in the present disclosure is in the form of a graph, and the system uses a graph database to store this large graph. This facilitates the traversal, and as every node in the graph is indexed, direct matching can be performed in constant time.
[0082] FIG. 4 shows an example of the graph being stored in the database. Every concept is a node while these nodes are connected with relationships. Use of the graph database allows the system to store the data in form of a graph structure. In other words, the data are stored in a way that it creates a double link with nodes and relationships to facilitate traversal.
[0083] Matching secondary concepts (last step of algorithm) to background knowledge base created, can increase the CAC coverage (recall). This step is modelled as a graph traversal. Specifically, a connectivity query in a graph. The system tries to find whether the secondary concept is connected to a concept (in its subclass hierarchy) which can suggest a code. This connection could even span more than 6-7 hops. The shortest path is considered as the path leading to a code, and paths exceeding a certain threshold value (t=7) are discarded. Since the knowledge graph contains millions of concepts, this query can be very computationally expensive. Hence, specific relationships are used to connect concepts in the graph. This enables the system to reduce the number of nodes to traverse while finding a path between two nodes. In other words, the query is performed over a subgraph consisting of relationship type “subclass”.
[0084] In summary, the method for automatically suggesting an ICD-10-PCS code for a clinical document develops a knowledge graph that captures a plurality of medical concepts encompassing ICD-10-PCS concepts as well as medical concepts expressed in clinical notes. Background knowledge is used to increase coverage and complement NLP techniques to disambiguate sections of the transcribed document. Digit-based mapping is performed between procedure super classes with ICD-10-PCS alphanumeric characters. A graph data model allows real-time response to queries. A paragraph-matching algorithm is used to execute a procedure using the knowledge base. The system identifies primary and secondary sections from clinical documents.
[0085] It is thus believed that the operation and construction of the disclosed system and method will be apparent from the foregoing description. While the system and method shown and described has been characterized as being preferred, it will be readily apparent that various changes and modifications could be made therein without departing from the scope of the invention as defined in the following claims.
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A system and method utilizing deep clinical knowledge represented as a knowledge-graph to complement and enhance Natural Language Processing (NLP) for efficient and high-quality computer assisted coding of medical text. One embodiment utilizes the International Classification of Diseases version-10 Procedural Coding System (ICD-10-PCS). The system uses multiple knowledge bases combined with direct mapping provided by the ICD-10-PCS standard to enhance the coverage of assigned code. The system identifies ICD-10-PCS code considering hierarchical mapping and identifies the code by individual ICD-10-PCS character.
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BACKGROUND OF THE INVENTION
This invention relates to production of false-twist textured yarn of polyester filaments, and is more particularly concerned with yarns of polyester filaments having a random distribution of thick and thin sections which differ in dye uptake.
Conventional processes for producing textile yarns of polyester filaments have involved melt-spinning polyethylene terephthalate into yarn at take-off speeds of 550 to 1640 yards per minute (500 to 1500 meters/minute). The take-off speed refers to the speed of the solidified yarn at windup or a roll for forwarding the yarn to subsequent processing. This as-spun yarn is usually drawn at a draw ratio of about 3.5 to 4.5× (3.5 to 4.5 times greater length) to produce the fully-drawn, uniform yarn of commerce.
Conventional as-spun yarn can be drawn to provide a random distribution of thick and thin sections along the filaments, of which the thick sections have a higher dye uptake (dye to darker shades) and provide attractive dyed fabrics.
Werner et al. U.S. Pat. No. 3,478,143 discloses such a process in which conventional as-spun yarn is incompletely drawn on a draw pin of about 1.5 to 6 cm in diameter maintained at a temperature of 60° to 105° C. (preferably 65° to 85° C.), using a draw ratio of about 60 to 80 percent, preferably 66 to 74 percent, of the draw ratio normally used for producing uniform fully drawn yarn. However, yarns produced in this way have not been suitable for producing textured (crimped) yarn by modern false-twist texturing processes because the thick sections stick or melt on contacting the texturing heater used to set twist in the yarn. Heater temperatures above 200° C. are needed to obtain satisfactory crimp properties.
Petrille U.S. Pat. No. 3,771,307 discloses that polyester yarn can be false-twist textured under conventional conditions, at heater plate temperatures of 227° C. to produce excellent textured products when using spin-oriented yarn prepared by melt-spinning at take-off speeds of 3000 to 4000 yarns per minute (2744 to 3660 meters/minute). The as-spun yarn is drawn at a draw ratio of 1.3 to 2.0 which is sufficient to provide a fully drawn, uniform yarn. The patent does not refer to production of thick and thin sections along the filaments. Schippers German OS Patent No. 2,204,397 (laid open Aug. 9, 1973) discloses melt-spinning polyester yarn at take-off speeds higher than 3000 meters/minute (3280 yards/minute) to form a spin-oriented yarn which is then drawn at a draw ratio in the range of 1.3 to 1.8× to produce a fully drawn product. The process is said to avoid denier variations caused by local instability of the draw point when yarn is spun at conventional take-off speeds of 500 to 1500 meters per minute (550-1640 yards/minute). The patent teaches that no well defined and therefore locally determined draw point forms when drawing the spin-oriented yarn, and that hot pins are not required.
SUMMARY OF THE INVENTION
The present invention provides a process for producing polyester filament yarn which has a random distribution along the filament length of thick and thin sections differing in dyeability, and which is suitable for false-twist texturing at heater temperatures greater than 200° C.
In the process of this invention, as-spun spin-oriented polyester yarn is drawn on a draw pin of about 1.3 to 6 cm in diameter maintained at 60° to 90° C., using a draw ratio which is 82 to 95 percent of a draw ratio that would fully draw the yarn. As used herein, "spin-oriented polyester yarn" refers to continuous filament yarn prepared by melt-spinning polyester and withdrawing the yarn from the spinneret at a take-off speed greater than 3000 yards/minute (2740 meters/minute).
Preferably the spin-oriented yarn is prepared by melt-spinning polyethylene terephthalate into yarn while withdrawing the yarn from the spinneret at a take-off speed of 3000 to 4000 yards/minute as disclosed in Petrille U.S. Pat. No. 3,771,307. However, take-off speeds greater than 4000 yards/minute (3660 meters/minute) can be used, and polyesters consisting essentially of linear glycol terephthalate polymer are suitable. The polyester may contain the usual delustrants, particulate matter, antistats, optical brighteners, antioxidants and copolyester components.
Preferably the spin-oriented yarn will draw to a fully-drawn, uniform yarn having a break elongation of less than 40 percent when drawn at a draw ratio within the range of 1.3 to 1.8×.
The incompletely drawn polyester yarn produced by the process of this invention can be false-twist textured by conventional processes used for fully drawn polyester yarn, with heater temperatures greater than 200° C., to produce textured yarn having good bulk. No melting of the thick sections occurs. The textured yarn provides attractive dyed fabrics due to deeper dyeing of the randomly spaced thick sections of the yarn. The drawing process is preferably combined with the false-twist texturing process in a tandem draw-texturing process in which the spin-oriented yarn is incompletely drawn in a draw zone and is then textured in a false-twist texturing zone.
DETAILED DESCRIPTION
The drawing process of this invention is performed on conventional equipment, preferably using a draw pin having a surface of "alsimag" (a ceramic composition produced by the 3M Company). The draw pin of about 1.3 to 6 cm in diameter is maintained at a temperature within the range of 60° to 90° C., the higher temperatures being used at high running speeds. At yarn speeds greater than about 500 yards/minute (457 meters/minute, the draw pin temperature is preferably about 80° to 90° C. The speeds of the draw rolls are adjusted to incompletely draw the yarn. The draw ratio should be from 82 to 95 percent of the draw ratio normally used to fully draw the yarn. The resulting incompletely drawn yarn has thick and thin sections randomly spaced along the yarn length. The thick sections of the filaments have cross-sectional areas which are less than two times that of adjacent sections along the length of the filament. The draw ratio selected depends upon the appearance desired in dyed fabric prepared from the yarn. The lower draw ratios provide very numerous deep-dyed thick sections. The frequency of thick sections decreases at higher draw ratios, and none are found in a fully drawn yarn.
The incompletely drawn yarn can be false-twist textured on a conventional machine such as the Leesona machine disclosed in Chalfant et al. U.S. Pat. No. 3,292,354. Alternatively, the drawing process and the false-twist texturing process can be performed on a single machine which has a draw zone immediately before the bottom feed roll leading to the false-twist texturing zone. The drawing process must be completed before the incompletely drawn yarn is exposed to the texturing heater. Tandem draw-texturing machines are available which can be modified to incompletely draw the spin-oriented yarn in accordance with the present invention.
Measurements indicated in the examples are determined as follows:
Break Elongation and Tenacity are measured according to the ASTM designation D-2256-69 (incorporating editorial edition of Section 2 and renumbering of subsequent sections as done in March 1971). It is defined as in Option 3.3 "Elongation at Break" of Section 3. The testing is performed on straight multifilament yarns which were conditioned by storing them at 65 percent relative humidity and 70° F. (21.1° C.) for 24 hours prior to testing. An Instron Tensile Testing Machine is used. The test sample is 5 inches (12.7 cm) long, no twist is added, the cross-head speed is 10 inches/minute (25.4 cm/min), the rate of attenuation is 200 percent/minute, and the chart speed is 5 inches/minute (12.7 cm/min). Tenacity is the maximum load in grams, before the yarn breaks, divided by the denier of the yarn.
Boil-Off Shrinkage is obtained by suspending a weight from a length of yarn to produce a 0.1 gm/denier load on the yarn and measuring its length (L o ). The weight is then removed and the yarn is immersed in boiling water for 30 minutes. The yarn is then moved, loaded again with the same weight, and its new length recorded (l f ). The percent shrinkage is calculated by using the formula:
Shrinkage (%)= (L.sub.o - L.sub.f)/L.sub.o× 100
Relative Viscosity (RV) values of the polyesters used in the examples are given as a measure of the molecular weight. Relative Viscosity (RV) is the ratio of the viscosity of a solution of 0.8 gm of polymer dissolved at room temperature in 10 ml of hexafluoroisopropanol, to the viscosity of the hexafluoroisopropanol itself, both measured at 25° C. in a capillary viscometer and expressed in the same units.
EXAMPLE I
A 245-denier polyester yarn is prepared by melt-spinning at 288° C. polyethylene terephthalate of 22 relative viscosity, using a spinneret having 34 round orifices (each orifice 9 mils diameter, 12 mils deep) and winding the filaments at 3400 yds/min. (3110 meters/min) The yarn has a tenacity of 2.35 gpd, a break elongation of 142% and a boil-off shrinkage of 55%. This yarn is drawn 1.706× in a separate step on a Whitin RK drawwinder at 454 yds/min (415 mpm) windup speed. In the draw zone the yarn takes one wrap around a 1.6-inch (4.1 cm) diameter draw pin heated to 90° C. The yarn contains filaments having thick and thin sections. Each thick section is about 1/4 inch to 1/2 inch (6 to 12 mm) long and has a cross-sectional area which is about 1.8× that of adjacent sections along the length of the filament. The drawn yarn is textured on an ARCT FTFL 440B false-twist texturing machine using the following conditions: 0% 2nd overfeed, +14% third overfeed, 0% supplementary overfeed, and -4% takeup overfeed; 60 turns per inch (2360 turns/meter); 247,323 rpm spindle speed; 210° C. 1st heater; 230° C. 2nd heater; and a cooling zone stringup. No melting occurs in the texturing zone. The yarn has good bulk. The textured yarn is knit into a circular tubing on a Lawson FAK machine and dyed with Latyl Blue FLW (Disperse Blue 27) dye. The resulting fabric showed 20-30 deep-dyed streaks per square inch (3 to 5 per cm 2 ) each streak being about 0.1 to 0.2-inch (2 to 5 mm) long. Microscopic examination of the yarns in the deep-dyed sections showed that there were both thin filament sections that dyed lighter and thick filament sections that dyed deeper. The fabric is very attractive.
EXAMPLE II
Polyethylene terephthalate is melt-spun at 285° C. using a spinneret containing 34 round orifices of 15-mil (0.38 mm) diameter and 60 mil (1.52 mm) depth. The freshly spun filaments travel in air approximately 60 inches (152 cm) before they contact a finish applying roll, after which they pass over process rolls and are wound up at 3500 yards/min (3200 meters/min) as 250-denier yarn of 22 relative viscosity polyester. The yarn has a boil-off shrinkage of greater than 60% and it is highly oriented and substantially amorphous. It has a tenacity of about 2.4 gpd and a break elongation of about 145%.
Four samples (coded A, B, C and D) of this yarn are draw-textured by the tandem process on a Leesona 570 to which a draw zone is attached immediately before the bottom feed roll. The 1.6-inch (4.1 cm) diameter draw pin is at 80° C. and the draw ratio for each sample is shown in Table I. The heater plate in the texturing zone is at the conventional temperature of 205° C. No melting of the thick sections occurs. Spindle speed is 270,000 rpm to produce in the yarn 66 turns per inch (2598 turns per meter) twist in the twist zone. Overfeeds are as follow: bottom +1%, top -4%, relaxing zone 12-1/4 %. The heater setting is at 200° C. The textured yarn contains filaments having thick and thin sections along its length. Each thick section is about 1/16 inch to 1/8 inch (about 0.16 to 0.32 cm) long and has a cross-sectional area which is less than two times that of adjacent sections. Each textured yarn is knit into a jersey stitch circular knit tube on a Lawson knitter. Sections of each knit fabric, after scouring, are dyed with Latyl Brilliant Blue BG dye. Each dyed fabric is rated as follows:
TABLE I______________________________________Sample DrawIdentification Ratio Rating______________________________________A 1.50 Very numerous thick sections; not as attractive as "B" and "C"B 1.60 Fewer thick sections than A; quite attractiveC 1.70 Very pretty fabric; thick sectionsD 1.80 No thick sections.______________________________________
EXAMPLE III
Polyethylene terephthalate is melt-spun at 283° C. using a spinneret containing 34 round orifices of 15 mil (0.38 mm) diameter and 60 mils (1.52 mm) depth. The freshly spun filaments travel in air approximately 60 inches (about 152 cm) before contacting a finish-applying roll. The yarn then passes over other process rolls and is wound up at 3420 yards/min (3127 meters/min) as 245 (approximate) denier yarn of 20 relative viscosity polyester. The yarn has a boil-off shrinkage of about 58 %, a break elongation of about 140 %, a tenacity of about 2.4 gpd and is substantially amorphous.
Three of the new yarns are prepared by drawwinding this spin-oriented supply at each of three different machine draw ratios shown in Table II on a RD drawwinder (Whitin Machine Works, Whitinsville, Mass.) using one (360° ) wrap on an 83± 2° C., 1.6 inch (4.1 cm) pin, and a draw speed of 454 ypm (415 mpm) to provide thick and thin sections along the filaments.
Each drawn yarn is knit into a jersey stitch circular knit tube on a Lawson Knitter. Sections of each tube are cut from the tube and dyed in red, blue, or yellow disperse baths. The resulting dyed tubes have attractive deep-dyed sections randomly spaced in the fabric. Ratings of each are shown in Table II.
TABLE II______________________________________Sample 1 2 3______________________________________Draw Ratio 1.483 1.593 1.706Subjective Rating* 5 4 2______________________________________ *Fabric rating: ranging from "5" representing fabric having very frequent often intense dyed sections to "1" representing fabric having no deeply-dyed sections.
Each drawn yarn is also false-twist textured on a 440 ARCT machine using the following conditions: 210° C. bottom heater; 230° C. top heater; 3 mm diameter sapphire spindle; 247,323 rpm spindle speed to produce 60 turns per inch (2362 turns/meter) in the yarn; overfeeds: bottom 0 %; second (second heater) +14 %, take up -4 %. The resulting textured yarns are knit into double knit fabrics which, after finishing, have the bulky pleasant handle associated with textured yarns. Swatches of each finished fabric are dyed with mixtures of widely used red and yellow dyes to give attractive fabrics. The dyed fabrics have exciting, unique and attractive deeply-dyed sections, randomly spaced in them. Ratings are the same as in Table II.
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Yarn of polyester filaments having a random distribution along the filament length of thick and thin sections, which differ in dye uptake, is produced by incompletely drawing a spin-oriented yarn, preferably one prepared by melt-spinning polyethylene terephthalate into yarn while withdrawing the yarn from the spinneret at a take-off speed of 3000 to 4000 yards per minute. The spin-oriented yarn is drawn on a hot draw pin of about 1.3 to 6 cm in diameter, using a draw ratio which is 82 to 95 percent of the draw ratio needed to fully draw the yarn. The incompletely drawn yarn can be false-twist textured under conditions conventionally used for fully drawn polyester yarn. The textured yarn provides attractive dyed fabrics due to darker shades of color in the thick filament sections.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional application of U.S. patent application Ser. No. 13/995,413, which is the U.S. national stage of international patent application no. PCT/EP2011/072420, filed Dec. 12, 2011, and which claims priority to French patent application no. 100 50 10, filed Dec. 21, 2010, the entire contents of each of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to a brake system master-cylinder seal having a generally annular shape, housed in a groove of the master cylinder around the piston, the seal being of a type comprising a core connecting three lips appreciably annular and concentric, respectively internal, intermediate, and concentric, each of which is equipped with a free end and an end connecting with the core, at least one portion of the free end of the intermediate lip creating an axial protrusion with respect to the free ends of the internal and external lips, the intermediate lip being interrupted along its periphery in such a way that it has several circumferentially spaced portions forming support areas and passages with the wall opposite that against which the surface of the core rests.
BACKGROUND
There exist seals, notably described in European patent document EP 2,080,939, known as resupply seals, of the type described above, but under certain conditions, it is difficult to purge the master cylinder or, at least, to purge it effectively and completely.
SUMMARY
An object of the invention is to provide a seal, e.g., a brake system master-cylinder resupply seal, that facilitates purging the brake system before it is filled with brake fluid and constitutes a supplementary sealing element for pressures on the order of 1 to 3 bars.
According to the invention the surface of the core of the seal comprises:
a peripheral platter, a raised exterior crown, externally bordering the platter and having: at least one connection zone, open and deformable from the effect of the interior pressure of the seal to recreate the continuity of the exterior crown, a heel beyond the crown and in the extension of each interruption formed by the connection zone of the crown, at least one channel realized in the platter and issuing from the interior edge that does not emerge at the exterior terminating ahead of the connection zone of the crown.
A channel that does not emerge at the exterior of the surface of the core of the seal is sufficient to constitute a passage to effectively purge the brake system when it is put in service. This also allows for the realization of a complementary sealing surface for certain pressures, notably, pressures comprised between 1 and 3 bars.
According to another advantageous characteristic, the platter terminates ahead of the exterior crown and forms, with the exterior crown, a passage constituting a supplementary sealing chamber, especially if the connection zone consists of a cavity made in the exterior crown.
According to another characteristic, the connection zone consists in the suppression of the exterior crown along a certain peripheral length. The material of the core near this connection zone can, thus, be deformed through the effect of the interior pressure of the seal to constitute a sealing zone in the extension of the exterior crown and on either side of it near the connection zone.
According to another advantageous characteristic, the peripheral platter is separated from the exterior crown by a passage near the channel and the interior edge. As indicated above, this passage, especially when the exterior crown has a connection zone consisting of a cavity, can form an intermediate chamber, promoting, on the one hand, the deformation of the connection zone from the effect of internal pressure and, on the other hand, constituting a sealing chamber.
The channel realized in the peripheral platter is preferably radially directed. This channel may be unique or several channels may be provided in the peripheral platter.
The invention also concerns a brake system master cylinder having a body with a pressure chamber receiving a piston, the bore hole of the pressure chamber having a groove receiving a seal providing a seal for the piston in the body of the master cylinder, wherein the groove separates the pressure chamber from a supply chamber connected to the hydraulic fluid supply channel, characterized in that the groove accommodates a resupply seal of generally annular shape having a core connecting three appreciably annular and concentric lips (x-x axis of the master cylinder), respectively internal, intermediate, and external, each of which is equipped with a free end and a connection end with the core, wherein at least one part of the free end of the intermediate lip protrudes axially (x-x direction) with respect to the free ends of the internal and external lips, the intermediate lip being circumferentially interrupted so as to have several spaced portions in the peripheral direction, forming support areas and passages with the wall opposite the wall against which the surface of the core rests, the surface of the core comprising:
a peripheral platter a raised exterior crown, externally bordering the platter, the exterior crown having a connection zone that can be deformed by internal pressure on the seal to recreate the continuity of the exterior crown, a heel beyond the crown and in the extension of each interruption formed in the crown by the connection zone, at least one channel issuing from the interior edge not emerging at the exterior, terminating before the connection zone of the exterior crown.
According to another advantageous characteristic of the invention, the master cylinder is a simple master cylinder with a piston and a groove receiving a resupply seal or a tandem master cylinder with a principal piston and an auxiliary piston, each of which cooperates with a resupply seal housed in a groove of the body of the master cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partial axial section of a brake system master cylinder according to the invention near a seal.
FIG. 2 shows a perspective view of the seal of FIG. 1 .
FIGS. 3A and 3B show respectively, and very schematically, illustrate the seal supports between the seal, the groove in the body of the master cylinder, and the piston, in the absence of pressure ( FIG. 3A ) and in the case of high pressure ( FIG. 3B ).
FIG. 4 shows a section of the seal according to the invention.
FIG. 5 shows a perspective view of a part of the rear face of the core of the seal of FIG. 4 with a first embodiment of the seal means.
FIG. 5A shows a straight developed view of a portion of the surface of the core of the seal.
FIG. 5B shows a side view corresponding to FIG. 5A , illustrating the different reliefs on the face of the core.
FIG. 5C shows a view similar to that of FIG. 4A , displaying the deformable zone of the face of the core,
FIG. 6 shows a partial perspective view of the rear face of the core of the seal, illustrating a second embodiment of the seal means.
FIG. 6A shows a straight developed view of a portion of the surface of the core, illustrating a second embodiment of the seal means.
FIG. 6B shows is a side view corresponding to FIG. 6A illustrating the relief of different portions of the surface of the core.
DETAILED DESCRIPTION
According to FIG. 1 , seal 22 , still referred to as a resupply seal, for brake system master cylinder 10 is shown. Body 12 of master cylinder 10 delimits pressure chamber 14 and brake fluid supply chamber 16 , itself connected to supply channel 18 . Body 12 has internal groove 20 , which is annular, with back wall 20 C and two opposed faces 20 A, 20 B. This groove 20 receives seal 22 , which cooperates with piston 24 to separate chambers 14 and 16 . Piston 24 is movable between a rest position, in which chambers 14 and 16 communicate, and an active position, when piston 24 is actuated by the brake pedal (movement to the left in FIG. 1 ) to transmit braking forces. At this moment chambers 14 and 16 are separated.
Seal 22 ( FIGS. 1 and 2 ) consists of core 25 bearing exterior lip 26 E, interior lip 26 I, and intermediate lip 26 M. Intermediate lip 26 M has raised portions separated by intervals. Intermediate lip 26 M is intended to be applied to face 20 B to hold seal 22 , applied imperviously by its interior lip 26 I, against piston 24 .
The passage of brake fluid from supply chamber 16 to pressure chamber 14 occurs by bypassing seal 22 connected imperviously to piston 24 . This bypassing occurs between core 25 and face 20 A of groove 20 , then between exterior lip 26 E and back wall 20 C of the groove, then in intervals of the raised portions 30 of intermediate lip 26 M, because neither exterior lip 26 E nor interior lip 26 I rest imperviously on groove 20 .
FIGS. 3A, 3B illustrate, respectively, the state of seal 22 in the absence of pressure ( FIG. 3A ) and when pressure is applied in pressure chamber 14 ( FIG. 3B ).
According to FIG. 3A , in the absence of pressure on seal 22 , the latter is applied against piston 24 by its interior lip 26 I, creating an impervious seal under low pressure on zone A 1 of piston 24 because of the specific, frustoconical, shape of piston 24 at this location. This low pressure allows brake fluid to flow for ESP regulation. Core 25 rests only weakly against side 20 A of groove 20 , as illustrated schematically by point A 2 . The same holds for exterior lip 26 E, which only lightly touches back wall 20 C of groove 20 (point A 3 ). As already indicated, side 20 B of groove 20 is not affected by the seal but simply serves as a support for median lip 26 M.
According to FIG. 3B , whenever pressure is generated, for example, by piston 24 , in pressure chamber 14 , this pressure is exercised in cavity 27 of seal 22 , creating a significant impervious zone B 1 with piston 24 and also an impervious zone B 2 , extending appreciably over first face 20 A of groove 20 , which accommodates the face of core 25 . A seal is also created at exterior lip 26 E, which presses against back wall 20 C of groove 20 . This seal is realized through the particular structure of the surface of core 25 according to the invention.
FIG. 4 shows the section of the shape of revolution of seal 22 when it is not housed in groove 20 , revealing the shape of core 25 , the shape of exterior branch 26 E, equipped with protrusions, the shape of intermediate lip 26 M, with its raised parts and hollows, serving as a support against wall 20 B of groove 20 and allowing brake fluid to flow.
Two embodiments of the surface of core 25 of seal 22 will be described below by means of FIGS. 5 and 6 . These surfaces are respectively assigned reference numbers 100 and 200 , and analogous or equivalent elements will be assigned similar reference numbers in the 100 and 200 series.
FIG. 5 illustrates a portion of a first embodiment of surface 100 of core 25 of the seal, which corresponds to a relief pattern and a hollow pattern distributed along the periphery of core 25 following a uniform distribution pattern, even following a unique pattern.
Surface 100 consists of platter 102 , raised with respect to interior peripheral edge 101 . Platter 102 is traversed by channel 103 , non-emergent, issuing from interior edge 102 and blocked at its externally directed end. Platter 102 is capped by discontinuous exterior crown 104 , with interruption interval 105 in the direction of channel 103 . Interruption interval 105 forms connection zone 105 , which, when deformed under pressure, as will be described below, provides a seal due to the effect of the pressure. Beyond this connection zone 105 , heel 106 appreciably occupies the width of the interval. Heel 106 is bordered by exterior edge 107 . The direction of channel 103 is preferably radial, although this direction is not imperative. It can also be inclined with respect to the radial direction of the seal.
The shape of the pattern of surface 100 is shown in the plan view of FIG. 5A , which is a straight development of the circular shape. FIG. 5B is a side view of the straight development corresponding to FIG. 5A and illustrating the various levels of the elements composing surface 100 .
FIG. 5B shows the relation between the various levels in the radial direction with respect to an unspecified origin: the height, H 0 , of interior edge 101 , the height, HI, of platter 102 , and the height, H 2 , of interrupted crown 104 . The channel has a back wall with height H 0 . In this view, heel 106 has the same height, HI, as platter 102 .
FIGS. 5 and 5A illustrate, using a dashed line, the sealing line (L) of seal 100 when it is applied to face 20 A of groove 20 ( FIG. 1 ). The seal is realized by deformation under pressure of the interior of seal 100 . The deformation involves zone ZD, drawn on FIG. 5C , which, when under pressure, is raised and flattens the surface of platter 102 in the interruption interval or connection zone 105 against face 20 A of groove 20 . Heel 106 serves to support this deformation force and constitutes a supplementary sealing surface when heel 106 is applied to side 20 A.
FIGS. 6, 6A, 6B illustrate a second embodiment of surface 200 of core 25 of seal 22 . Surface 200 consists of a pattern consisting of platter 202 beyond interior edge 201 . Platter 201 is divided by channel 203 near interior edge 201 . Channel 203 emerges beyond platter 202 in the exterior peripheral direction, in peripheral passage 208 .
Beyond the passage bordering platter 202 is exterior crown 204 , equipped with cavity 205 , which bars the extension of channel 203 and serves as a connection zone. Beyond cavity 205 is heel 206 with, on either side, exterior edge 207 . Heel 206 is also situated in the extension of channel 203 , extending on either side of this extension and there occupying a significant portion of the peripheral length of cavity 205 .
When there is pressure inside seal 22 , cavity 205 is deformed outwardly, closing the passage it forms in the absence of pressure. A seal is thereby ensured at exterior crown 204 and the surface of cavity 205 , brought to the level of the exterior surface of crown 204 , that is to say, connection zone 205 .
The invention concerns the realization of a simple or tandem master cylinder such as the one partly shown in FIG. 1 . Such a master cylinder has a single piston 24 or a primary piston and an auxiliary piston, and the impermeability between pressure chamber 14 and supply chamber 16 with supply channel 18 is provided by resupply seal 22 , whose core has a sealing surface 100 , 200 , similar to those described above.
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A master-cylinder seal housed in a groove around a piston has a core connected to three annular and concentric lips. The core rests against a side of the groove and has: a surface provided with an interior edge followed by a peripheral platter cut by at least one channel, and an exterior crown provided with a connection zone formed by an interruption in the crown and deformable due to pressure within the seal to recreate the crown's continuity and impermeability while facilitating purging the brake system when there is no pressure in the channel and the connection zone.
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CROSS REFERENCE TO RELATED APPLICATION
This application is related to copending U.S. application Ser. No. 698,396 filed 02/05/85, pending of Florian Windischbauer, entitled "Apparatus for the Constrained Actuation of the Clamping System of Filling-Yarn Insertion Devices in Shuttleless Weaving Machines", which is a continuation-in-part of Ser. No. 06/510,833, filed July 5, 1983, U.S. Pat. No. 4,515,185 and entitled "Apparatus for the Constrained Actuation of the Clamping System of Filling-Yarn Insertion Devices in Shuttleless Weaving Machines".
BACKGROUND OF THE INVENTION
The present invention broadly relates to weaving machines and, more specifically, pertains to a new and improved construction of an apparatus used in shuttleless weaving machines where the filling insertion takes place on one side by means of gripper systems provided with clamping means for the filling-yarn or weft thread and which are advanced into the shed and then retracted.
Generally speaking, the apparatus of the present invention is employed in a shuttleless weaving machine wherein filling-yarn or weft thread is inserted by gripper systems which are bilaterally advanced into the shed and then retracted and which are provided with clamping means for the filling-yarn. Control means are arranged laterally of the weaving machine for processing ends of the filling-yarn before and after insertion thereof into the shed, for constrained actuation of the clamping means by control levers controlled by cam means and entering through the warp threads of the shed from the exterior.
Such a weaving machine is known, for instance, from German Pat. No. 1,710,292, granted Aug. 30, 1973. In this patent, the filling-yarn is seized by the clamping means of a gripper system when outside of the shed and is transported by the gripper system to the approximate shed center. There, the filling is transferred to the clamping means of a gripper system advanced from the opposite side which, upon retraction, pulls the filling-yarn entirely through the shed. The yarn transfer at the center of the shed takes place while the participating clamping means are controlled in a constrained manner in such a way as to provide a brief time during which control levers pass through the shed's warp threads to open and then again close the clamping means. The actuation of the control levers is coupled to the main drive for the weaving machine and takes place not only when the filling-yarn is transferred in the shed's center, but also can be used when seizing and releasing the filling-yarn outside of the shed.
The control system is designed in such a manner that the control lever is pivotably supported on the end of arms which themselves are rigidly seated on the sley shaft and accordingly carry out a pivoting motion together with the sley during the beating-up of a filling-yarn. A pivot lever acting as a support for sensor rolls is furthermore rotatably seated on the sley shaft, where the sensor rolls rest under spring loading against a cam. The cam is mounted on a special, continuously rotating shaft side parallel to the sley shaft. The connection between the control lever and the pivot lever is provided by a connecting rod. This continuously rotating side shaft rotating at 1:1 is parallel to the main shaft ensuring the power transmission of the reed and gripper drive from one side of the weaving machine to the other and advantageously rotates, for instance, in the ratio of 3:1 or 4:1. However, the geometry of weaving machines permits only a limited space for mounting and sizing the main shaft, the side shaft with cams and the sley shaft. In particular, it is impossible to select the cams so as to possess a sufficiently large size.
When beating-up, each above-mentioned arm not only carries along the control lever, but it furthermore, by means of a stop and driver, rotates the pivot lever, whereby the sensing roll is lifted from the cam. The spacing between the stop and the driver must be precisely set in order to achieve the proper motion of the control lever during reed beat-up.
It is characteristic of this equipment that at higher operating speeds of the weaving machine, the rolls no longer intimately follow the cam profile or cam bearing surface but lift off it and tend to bounce. As a result, they will also lift off in undesired manner from the control cam profile or surface against which they are supposed to bear in relation to the desired control curve. Because the control levers follow, via the connecting rod, the motion of the rolls, i.e., the motions of the pivot lever, the clamping means at the gripper systems may be spuriously actuated. Therefore, flawless filling-yarn transfer from one gripper system to the other is no longer assured in such a case. Moreover, the bouncing and reseating of the rolls greatly stresses, and possibly damages, the cam bearing surfaces.
German Pat. No. 2,934,474, granted Jun. 11, 1981, and corresponding to the U.S. Pat. No. 4,384,598, granted May 24, 1983, describes a modified apparatus. In this apparatus, the pivot lever sensing the cam motion is rotatably supported but fixed to the machine outside the sley shaft. This design averts the above-cited difficulties and even at high operating speeds of the weaving machine, improved yarn transfer is achieved. In this design, the center of rotation of the pivot lever for driving the connecting rod and the control lever no longer is situated in the sley shaft and the roll no longer lifts off of the cam but, on the contrary, the rolls always remain on the cam's control curve. Furthermore, it is no longer necessary as previously to precisely set the costly and highly stressed bearing surface at the stop and driver. Moreover, an improved arrangement of the return spring is possible at the pivot lever, and no interfering inertial forces arise at the spring during reed beat-up.
Nevertheless, a further factor adversely affects both of the known apparatuses. This factor is that the control lever is mounted on the end of a special arm and, upon reed beat-up, is pivoted together with this arm out of the shed and back in addition to its own control motion. The number of required individual parts and bearing locations or joints results in a not insignificant amount of play. Due to the vibrations of the arms and of the control lever due to the brusque stopping motion of the reed, this play becomes noticeable at the control site, that is, at the end of the control lever, and may impair the control function.
Additionally, another problem arises. It has been noted in practice that at higher operating speeds of the weaving machine, the uncontrolled vibrations arising at the control parts due to the inertial forces exceed by far the actually required control force. Consequently, in these known designs, the springs of the cam sensor means always must be highly tightened. The high spring force results in excessive wear and furthermore constitutes an impediment when the weaving machine must be turned by hand.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved construction of an apparatus for constrained actuation of clamping means in a shuttleless weaving machine which does not exhibit the aforementioned drawbacks and shortcomings of the prior art constructions.
Another and more specific object of the present invention aims at providing a new and improved construction of an apparatus for constrained actuation of clamping means in a shuttleless weaving machine which so improves the operation of the foregoing equipment that the tendency to vibrate is further reduced and that overall there will be little play in the individual parts, whereby it is possible to achieve higher operating speeds of the weaving machine with more reliability in filling-yarn pick-up or transfer by the gripper systems, and hence improves the efficiency thereof, and moreover, the special side shaft and the therewith related and above-mentioned drawbacks are eliminated.
Yet a further significant object of the present invention aims at providing a new and improved construction of an apparatus for constrained actuation of clamping means in a shuttleless weaving machine of the character described which is relatively simple in construction and design, extremely economical to manufacture, highly reliable in operation, not readily subject to breakdown or malfunction and requires a minimum of maintenance and servicing.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the improved apparatus of the present invention is manifested by the features that it comprises: pivot means defining a pivot axis for pivotably mounting the control levers at a fixed location below a path of travel of a fabric being woven in the weaving machine; a control shaft carrying the pivot means and the control levers and extending beneath the path of travel of the fabric the pivot axis; the cam means comprising at least one mutually complementary cam wheel pair mounted on the control shaft in driven relationship thereto; actuation means comprising at least one double-lever rocker arm, sensing rolls cooperating therewith for operatively following the cam means and rocking means defining a rocking axis extending substantially parallel to the control shaft for pivotably mounting the double-lever rocker arm; the cam means and the actuating means conjointly defining a constrained-control cam system; and linkage means operatively connecting the control levers with the actuation means for pivoting the control levers out of an operative position entering the shed into an idle position beneath a path of motion of a reed stay of a reed of the weaving machine.
Advantageously, the cam means are mounted on a conventional cam or control shaft and extending substantially horizontally beneath the fabric, controlling the devices provided on both sides of the weaving machine and processing the ends of the filling-yarns or weft threads before and/or after the insertion of the filling. In this manner, the special 1:1 side shaft required in the known equipment is eliminated; hence both the main shaft and the sley shaft can be designed to meet the particular requirements without restriction. Vibrating or oscillating levers and cams are now eliminated in the vertical region between the main shaft and the sley shaft and space is available for a sufficiently large tubular reed shaft. Gearing to drive the reed is now required on only one side of the weaving machine. The one-sided reed drive with a large reed shaft provides dynamic behavior of the reed at high angular speeds which is improved in comparison to the previously conventional double drive since a double drive prevents perfect synchronization of both sides of the weaving machine, leading to reed vibrations in beating-up. Such vibrations cause additional wear in the gripper systems which are guided by the reed and may impair the transfer of the filling-yarn and cause weaving defects. These drawbacks are remedied by the present invention. Furthermore, a one-sided reed drive represents a saving in transmission components and hence an appreciable reduction in costs.
Because the special arm on the sley shaft is eliminated and because the control lever is held by a spatially fixed bearing, both the tendency to vibrate due to the reed beat-up and the special pivot levers and the long connecting rod are entirely eliminated and now the entire apparatus can be mounted compactly between the fabric and upper crossbeam connecting the two sides of the weaving machine frame. Long control bars and a substantial number of play-incurring bearings are no longer required. Because of the constrained cam control, for instance by double eccentrics or mutually complementary cam wheel pairs or disk pairs, the difficulties caused by return springs also are prevented. As a whole, the invention not only provides more reliability in the control function and a higher operating speed of the weaving machine, but also a reduction of the manufacturing costs and decreased maintenance expenses, because due to the smaller number of individual parts less wear takes place.
Since the control lever is no longer coupled to the reed and is no longer moved together with the reed out of the shed but, rather, is moved into a rest or idle position prior to beating-up and the reed is displaceable above the control lever in its rest or idle position, the control lever is advantageously bent into such a shape that, in its rest or idle position, its upper boundary or profile is substantially fitted to or conforms to the lower contour or profile of the reed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures of the drawings there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 is a schematic view of the control system mounted on a weaving machine;
FIG. 2 is a view in cross-section of the control system with the control levers and cams mounted on a common shaft;
FIG. 3 is a view in cross-section of the control system corresponding to FIG. 2 but in which the control system is mounted on a horizontal surface; and
FIG. 4 is a schematic view in cross-section corresponding to FIG. 2 but showing a modified embodiment on an enlarged scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the showing thereof only enough of the structure of the apparatus for constrained actuation of clamping means in a shuttleless weaving machine has been illustrated therein as is needed to enable one skilled in the art to readily understand the underlying principles and concepts of this invention. Turning now specifically to FIG. 1 of the drawings, this figure schematically shows the most important parts of a weaving machine as viewed from the front. This is a weaving machine with filling insertion, for instance by rigid gripper bars advanced from both sides into the shed and inserting the filling or weft from the left side, transferring it to another gripper at the center of the shed, and drawing it out toward the right side of the machine. The side walls 1 are indicated as the support components for the weaving machine; they are connected together by a lower crossbeam 2 and an upper crossbeam 3.
A main drive motor 15 with a connected electromagnetic clutch/brake device 15a is mounted on the left side wall 1. From there, the drive passes through the transmission stages 4a to the main transmission 4 from which is tapped, for instance, the gripper drive, and so forth. A main shaft 5 provides the synchronization of the main transmission 4 on the left and right sides of the machine. The main shaft 5 rotates, for instance, in the ratio of 3:1 or 4:1, depending upon the design of the two transmission stages 4a on the left and right sides of the machine in order that there be a speed ratio of 1:1.
A transmission part 7 driving the sley shaft 8 is powered from the main transmission 4 on the left side of the weaving machine. Arms, not designated further, are seated on the sley shaft 8 and support the reed stay 19 and the reed 9 mounted thereon. The main shaft 5 and the sley shaft 8 are, in this instance, designed as tubular shafts. The transmission part 7 in this illustration is required on one side only of the weaving machine because a tubular shaft 8 is used.
The overall operation of the invention will now be described. The gripper bars for inserting the filling-yarn or weft thread are indicated above the gears 4 and designated by the reference characters 6 and 6'. The filling-yarn is withdrawn from supply spools, not designated further and located on the left side of the weaving machine, and is advanced by a filling-yarn insertion means or donor device 13 of the left gripper bar 6 and seized by its clamping means to insert the filling. During insertion, the left gripper 6, in its function as the donor gripper, moves the filling-yarn approximately into the center of the shed where it transfers it to the acceptor gripper 6', which was also advanced to that location from the right side.
In the process, the control levers 14 are consecutively actuated to transfer the filling-yarn from the clamping means of the left gripper 6 to the clamping means of the right gripper 6'. When the gripper bars are retracted, the filling-yarn is pulled out of the shed toward the right and is taken off by a yarn pick-up device schematically indicated at 29.
The motions of the various components participating in filling-yarn insertion, for instance of the donor device 13, of the yarn pick-up device 29 or of other parts not shown, for instance filling-yarn shears, filling-yarn lay-in device, etc., are powered from a control shaft 11 passing above the upper crossbeam 3 from one side to the other of the weaving machine. The transmission 10 for the control shaft 11 is provided on one side only of the machine and effects a 1:1 drive. In the invention, this control shaft 11 also drives the control levers 14, and therefore also drives their control or actuating parts or cams 28.
Details of the control system are shown in FIG. 2. The control levers 14 are mounted on blocks 12 displaceable along the upper crossbeam 3. These blocks 12 also support, as likewise indicated in FIG. 1 in addition to the control levers 14, the drive means for such control levers 14, for instance cams 28. This upper crossbeam 3 is provided with a groove 3' in which the blocks 12 can be displaced and tightened, for instance by screws. The control shaft 11 is rotatably supported in the blocks 12 and provides a common shaft which supports both the control levers 14 and the cams 28. The blocks 12 and the control shaft 11 together with the control levers 14 and cams 28 are located below the fabric path or fabric 18. The control levers 14 are rotatably supported in pivot bearings 26 upon the control shaft 11. Each control lever 14 has a gooseneck shape. The free end of each control lever 14, when in the operative position shown in solid lines in FIG. 2, passes through the warp threads from beneath and in the form of a finger into the shed 17 where it comes to rest against an actuating lever 25 for the gripper clamp. The reed 9 is shown in the shed and is supported by the reed stay 19. The actuating system 16 of, for instance, the gripper 6, moves the filling-yarn as shown into the shed; the above-mentioned actuating or actuation lever 25 for the clamping means at the gripper projects sideways to the right from the illustrated one of two actuating systems 16 which are associated with the left gripper 6 and the right gripper 6'.
To open the clamping means, the end of the control lever 14 presses the actuation lever 25 by means of a slight pivoting motion from the upper position shown in dashed lines to the operational position shown in solid lines. The clamping means is thereby briefly opened for yarn transfer.
To close the clamping means, the control lever 14 rises again into the upper position shown in dashed lines. When the clamping means is actuated, each of the actuating systems 16 rest on the reed 9 and also against a guide strip 30 mounted to the reed stay 19.
After the yarn has been transferred from the donor to the acceptor gripper, both actuating systems 16 are retracted. Subsequently, the control lever 14 can be immediately moved by cam control out of the shed 17 and can be pivoted into its rest or idle position 14', shown in dash-dot lines, and downwardly to such an extent that during reed beat-up the reed stay 19 can be moved into its position 19' and the reed into the operative position 9', without being hampered by the control lever 14. The stop motion of the reed stay from the position 19 into position 19' takes place above the upper contour or profile of the control lever 14 in its idle position 14'. Due to the gooseneck shape of the control lever 14, the reed stay 19 in its position 19' conforms or fits closely without undue waste of space to the upper edge or profile of the control lever 14 in its position 14'.
While, during the simple pivoting motion of the control lever 14 into its position 14', each actuating system 16 with its actuation lever 25 is retracted out of the path of the control lever 14 so that the latter is not hampered, the guide strip 30 might nevertheless still be in the way of the pivoting motion. Therefore, clearances may be provided in the guide strip 30 allowing passage of the free end of the control lever 14. FIG. 2 shows such clearances in the guide strip 30 by the reference numeral 35. The pivoting positions of the control lever 14 are indicated in dash-dot lines and the control lever 14 passes through the clearances 35.
A constrained-control eccentric or cam system 24 is provided to control the motion of each of the control levers 14. FIG. 2 shows a mutually complementary cam wheel or disk pair 28' defining the cams 28 and mounted on the block or blocks 12. The actuating motions of the control lever 14 generated by the mutually complementary cam profiles of the cam wheel pair 28 and its pivoting motion from the operative into the rest or idle position 14' are transmitted by a rocking lever or double-lever rocker arm 23 and a driver lever arm 31 thereof via a connecting rod or link 22 to the related control lever 14. The rocking lever 23 pivots about an axis disposed substantially parallel to the surface of the crossbeam 3, that is to the base or seat of the block 12, and can be pivoted about a pin or journal 33.
Two lever arms 21 and 21' of the rocking lever 23 engage, by means of sensor or cam follower rolls 27 or the like, the mutually complementary profiles of the cam wheel pair 28', whereas the third driver lever arm 31 or equivalent means is connected in an articulated manner with the connecting rod or link 22. Each control lever 14 is provided with a lever arm 20, or at least an articulation point equivalent to such a lever arm, to connect with the connecting rod or link 22. The axes of rotation of the link points or articulations at the ends of the connecting rod or link 22, that is, on the one hand, to the lever arm 20 of the control lever 14 and, on the other hand, to the driver lever arm 31 of the rocking lever 23, extend substantially parallel.
In FIG. 2 it will be seen that the pivot bearing 26 of the control lever 14 is journalled directly on the control shaft 11. The pivot bearing 32 of the rocker arm or rocking lever 23 is journalled on rocking means or journal pin 33 stationarily mounted on the blocks 12. It will be seen in FIG. 2 that the rocking means or journal pin 33 is mounted substantially vertically below the control shaft. The mutually complementary cam wheel pair 28 and the actuation means comprising the rocking lever 23, the sensor or cam follower rolls 27 and the rocking or pivot pin 33 conjointly constitute a constrained-control cam system cooperating with the control shaft 11 conjointly carrying the control levers 14 and the cam wheel pair 28' driven by such control shaft 11. This constrained-control cam system 24 drives or actuates the control lever 14 through the linkage means or connecting rod 22 to effect the control motion defined by the mutually complementary cam profiles of the cam wheel pair 28. The control lever 14 pivots about the control shaft 11 through its pivot bearing 26.
FIG. 3 shows the control system of FIG. 2 arranged with the rocking means or pivot pin 33 laterally adjacent to the control shaft 11 instead of subjacent thereto. This permits the mounting blocks 12 to be mounted on a crossbeam 3 having a horizontal mounting surface instead of a vertical mounting surface as was depicted in FIG. 2.
FIG. 4 shows an arrangement of the control system corresponding to that of FIG. 3, but in which the lever arms 20 and 31 cooperating with the connecting rod or linkage means 22 as well as the lever arms 21 and 21' of the double-lever rocker arm 23 are more individually formed. The profiles of the cam wheel or disk pair 28' are shown more clearly and the general construction of the control system is somewhat lighter than in FIG. 3.
Two control levers 14 are provided in FIG. 1 approximately at the center of the weaving machine, each being mounted on separate and displaceable blocks 12. This makes possible precise adjustment both for the donor gripper 6 introduced from the left and for the acceptor gripper 6' introduced from the right, and a separate, finely time-stepped control of the two grippers 6 and 6'. The control levers 14 themselves are mounted in the space between two mutually adjoining arms connecting the reed stay 19 to the sley shaft 8. As already mentioned above, the control shaft 11 serves the devices needed for filling insertion, for instance for yarn tendering and yarn pick-up outside of the shed, and also to control the two control levers 14 within the shed. Where called for, further control levers and cams may be provided for the control shaft 11 and may be mounted on the side next to the shed or to the reed, to there control the pick-up of the filling-yarn tendered by the donor device 13 by means of the left donor gripper 6 or the release of the completely drawn-through filling-yarn from the right acceptor gripper 6'.
It will be obvious to those skilled in the art that many modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY,
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A shuttleless weaving machine employs filling-yarn transfer at the center of a shed from a first gripper system advanced from one side to a second gripper system approaching from the other side. The yarn transfer is implemented by opening and subsequently closing the clamping means of the gripper systems by means of control levers which are made to enter from the outside through the warp threads into the shed. The control levers are mounted at fixed locations and are so shaped and can be so pivoted from an operational position within the shed into a rest position below the shed that, when the reed beats up, the reed stay can pass unhindered over the control lever. A common shaft carries both the control levers and cam means for actuating the control levers. Actuating means transmitting actuating motion from the cam means to the control levers are mounted on pivot means arranged in spaced parallel relationship to the common shaft.
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BACKGROUND OF THE INVENTION
This invention relates to improvements in those members of a loom dobby control unit which directly cooperate with the dobby reading unit members, in order to allow complete structural separation between the two units. Such separation leads to considerable constructional advantages, and in particular improves the dobby characteristics from the operational, maintenance and repair aspects.
SUMMARY OF THE INVENTION
According to the invention, the dobby reading unit is structurally separate from the control unit, the first unit acting on the second by bearing and thrust contact between tappets of the reading unit rockers and the ends of those horizontal needles of the control unit which control the vertical lifting rods for the hooks. These rods are pivoted at their lower end to levers which rock within comb-shaped stops, and engage the hooks by means of blocks of anti-impact material. Furthermore, the vertical movements of the lifting blades for said rods are produced by the action of the same levers which control the hook lowering plates, these levers being driven by a linkage comprising levers and connecting rods which is controlled by the same shafts which control the dobby knife oscillations.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described hereinafter in greater detail by way of example, with reference to the accompanying drawings which represent one embodiment thereof and in which:
FIG. 1 is a general diagram of a dobby of known type incorporating the improvements according to the invention;
FIGS. 2 and 3 are two views at 90° apart of those parts of the dobby control unit according to the invention which directly cooperate with the reading unit, of which the rockers are shown;
FIG. 4 is a detailed view to a greatly increased scale showing the engagement between the dobby ramp lifting rods and the ramps themselves; and
FIG. 5 shows the control linkage for the hook lifting blades.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Dobbies are mechanical apparatus by means of which the shed is formed in looms starting from a predetermined fabric design which is transferred in the form of code onto a punched tape, which when read by means of needles controls rocker levers which govern the movement of the heald frames.
FIG. 1 of the accompanying drawings represents a diagram of a known Hattersley dobby. The purpose of the reading unit A is to read a punched paper tape C, and comprises reading needles 1, thrust rods 2 oscillating under the control of the needles 1, pressure bars 3 for engaging and thrusting the rods 2 selected by the needles 1, and control rockers 4 controlled by the rods 2. The purpose of the control unit B is to determine the movements of the heald frames under the control of the reading unit A, and comprises vertical control rods 5 controlled by horizontal needles 6 subjected to the actions of the rockers 4 and of return springs 7 in order to establish and remove the engagement with lifting blades 9 by way of upper end hook portions 8. It also comprises hooks 10 pivoted at 10' to the ends of rocker levers 11 which in their turn are pivoted at 11' to the centre of transmission levers 12 which operate lever systems 13 for controlling the heald frames. The vertical rods 5 engage with the hooks 10 in order to raise them and lower them in accordance with commands received from the rockers 4 of the reading unit A. The hooks 10 engage with fixed knives 14 and mobile knives 15 in order to control the rocker levers 11. Engagement with the fixed knives 14 occurs when the rods 5 raise the hooks under the control of the lifting blades 9 with which the hook portions 8 cooperate. Engagement with the mobile knives 15 occurs when the rods 5 do not exert positive force on the hooks. The movements impressed by the rocker levers 11 and transmission levers 12 on the lever systems 13 and thus on the heald frames, leading to the formation of the shed, derive from the combination of these engagements and the law governing the movement of the mobile knives 15.
It should be noted that in reality the fixed knives 14 have only their axes fixed, in the sense that they undergo oscillations about this latter for the purpose of facilitating their engagement with the hooks. In contrast, besides undergoing similar oscillation about their axes (again to facilitate engagement with the hooks), the mobile knives move such that their axes travel along trajectories in the form of circular arcs c.
It should also be noted that as a rule the hooks are lowered under the positive control of hook lowering plates 16 which ensure disengagement of the hooks from the fixed knives and facilitate their engagement with the mobile knives.
As stated, the present invention relates to improvements in those members of the control unit B which cooperate directly with the reading unit A which controls them.
The first and most important improvement according to the invention consists of having made the horizontal needles 6 which receive the command from the rockers 4 completely separate from these latter, so as to make complete physical separation possible between the reading unit A and control unit B, this being very useful both from the constructional aspect and in particular from the dobby operational and maintenance aspect. In the illustrated embodiment of the invention, the needles 6 are housed in supports 6' in which the return springs 7 act, and their end 6" which faces the reading unit A makes contact with a tappet 4' of the rocker 4. In known manner, the needles 6 comprise seats 17 in which the upper portions 5' of the lifting rods 5 for the hooks 10 slide freely.
According to the invention, the rods 5 comprise first portions 5' connected to the hook portions 8, and second portions 5" which are rigidly connected at their upper end to these latter portions but with the facility for length adjustment at 5'", and are pivoted at their lower end at 18 to transverse levers 19 which rock at 20 and are braked downwards at their free end by stops 21 having a guide comb structure (see FIG. 3).
By means of this arrangement, the rods 5 can freely carry out the small oscillations which they are required to make (in the plane of the sheet containing FIG. 1 and perpendicular to the plane of the sheet containing FIG. 3) under the control of the needles 6, in order to engage with or disengage from the hook portions 8 of the lifting blades 9. The rods 5 are also guided transversely by the comb 21 which engages the levers 19 at their free end, so as to maintain the most correct and desirable position relative to the plane of FIG. 2 during dobby operation.
The rods 5 engage the hooks 10 to lift them by way of blocks 22 (FIG. 4) of anti-impact material fixed to said rods by rivets 23. It should be noted that that side 24 of the blocks which comes into contact with the flat seat 10" provided for this purpose on the hooks 10 is in the form of a convex surface.
This arrangement is very silent and precise, and represents important progress in dobby construction.
According to a further improvement of the invention, the lifting blades 9 for the hooks 10 are carried by plates 25 slidable in vertical guides (not shown), and are controlled by levers 26 which also serve for controlling the dobby hook lowering plate (not shown) and which are driven by a linkage comprising levers 27 swivel mounted about a fixed shaft 28 and controlled by way of connecting rods 29 from levers 30 keyed onto the same pins 31, 32 (abutting and aligned on a common axis) which control the oscillations of the fixed and mobile dobby knives about their axes.
This represents a very effective, precise and convenient control system.
The invention also covers embodiments different from that described or modifications thereto which do not leave the scope of the invention idea.
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Improvements are made to members of a loom dobby control unit so as to allow structural separation between the reading unit and control unit. For this purpose, the reading unit rockers operate on the control unit by simple bearing and thrust contact with the horizontal needles which control the hook lifting rods. Moreover, the lifting blades for said rods are controlled together with the hook lowering plates by the motion of shafts which control the dobby knife oscillations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a versatile drum cap which can be utilized for various functions such as: a drum cap which protects large commercial drums from inclement weather; by inversion of the cap to use as a funnel to fill drums; and a drain pan for emptying almost empty drums or emptying of transmission or engine oil of vehicles.
2. Description of the Prior Art
The prior art of interest is discussed in the order of its perceived relevance and the disclosure of each prior art is incorporated by reference.
U.S. Pat. No. 5,018,559 issued on May 28, 1991, to Larry J. Branan describes an industrial funnel which fits on and within the top rim of a 55 gallon drum. The funnel has a circular frame with a partitioned region feeding the fluid into a spout which fits within the bung hole. The partitioned region has a hinged cover having a disk supported on a rod positioned on the inside of the lid to plug the spout when the cover is closed. The hinged cover has several supporting ribs on top. The covered funnel is suitable only for adding liquids and as a temporary cover.
German patent application No. DE 3,937,038 C1 published on Oct. 31, 1990, for Johannes Lobbert describes a drum funnel having a separate compartment with a sieved bottom leading to a spout inserted in the bung hole. The compartment has a separate rotatable cover which is rotated horizontally by means of a centrally located pivot bolt. The funnel has a sloped side supporting handle loops and the bottom fits within the top rim of the drum. This covered funnel is suitable only for adding liquids and as a temporary cover.
In U.S. Pat. No. 4,934,551 issued on Jun. 19, 1990, to Bernd Budenbender, a cover for emptying bung containing drums is described. The metal cover disk has a flange which is either folded over or welded to the drum's rim. Nipples are welded to the apertures over both bung holes but do not extend beyond the cover disk into the bung holes. There is no suggestion for utilizing the cover for a funnel.
U.S. Pat. No. 3,987,929 issued on Oct. 26, 1976, to Kinji Mineo, describes a plastic cap seal for the exposed plugs of drums. The flexible plastic seal is made of either polypropylene, polyethylene, nylon, polystyrene or polyvinyl chloride.
In U.S. Pat. No. 4,231,488 issued on Nov. 4, 1980, to William H. Ward et al., a metal closure spout is welded by either a laser beam or an electron beam method.
Lastly, U.S. Pat. No. 5,215,206 issued on Jun. 1, 1993, to Allen D. Siblik, describes a closure ring assembly for securing a cover of a storage drum container.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the versatility of the instant invention as claimed.
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of the invention to provide a multi-function drum cap for covering, filling or emptying large commercial drums.
It is another object of the invention to provide a drum cap to cover large commercial drums to protect the tops from inclement weather.
It is a further object of the invention to provide a funnel for filling large commercial drums.
Still another object of the invention is to provide a collection pan when draining fluid contents of large commercial drums.
It is another object of the invention to provide an oil drain pan for collecting transmission or engine oil from a vehicle.
It is a final object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is front view of a first embodiment of the multi-function drum cap having a partial cutaway view and positioned on a large capacity drum.
FIG. 2 is a plan view of the drum cap with an attached hose partially broken away to expose the ball valve.
FIG. 3 is a bottom view of the drum cap.
FIG. 4 is a side view of the inverted drum cap used as a funnel in a second embodiment.
FIG. 5 is a side view of a third embodiment wherein the drum cap is inverted and used as an oil drain pan collecting oil from a vehicle's oil reservoir.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a cap for commercially available 15, 30 or 55 gallon drums or the like. The drum cap has various applications due to its unique structure. The first embodiment is illustrated in FIG. 1 as a protective cap 10 for a drum 12 having four legs 14 equidistantly spaced from each other at the periphery of drum cap 10. As many as six legs 14 equidistantly spaced are contemplated. Each leg 14 has a caster or wheel 16 on its top end which is removable, if preferred, when the legs require stability as a support on a surface. Legs 14 have convenient handhold apertures 17 located proximate to the caster to enable removal of the drum cap 10. Drum cap 10 has a domed or convex wall 18 which would be a concave wall when the cap is used as a receptacle.
The sidewall or side border 20 abuts each leg 14 and has a thickened first stop portion or region 22 which does not extend to the rim 24 of bowl 26. First stop regions 22 are all the same height and will be functional when drum cap 10 is inverted for another use. Similarly, a thickened second stop portion or region 28 is formed abutting the inside surface of each leg 14 from the domed wall 18 to proximate the end of the leg 14. Second stop regions 28 are of equal height and rest on rim 30 of drum 12. Above second stop regions 28, handhold apertures 17 are located in each leg 14 to enable lifting of a filled drum cap 10. Drum cap 10 should have friction fit with drum 12; thus, different drum cap sizes are provided for each of 15, 30 and 55 gallon drums.
Domed wall 18 has a central aperture or drain hole 32 from which extends a horizontal duct 34 leading to a vertical duct 36 having a metal or plastic ball valve 38 (see also FIG. 2) and a threaded duct cover 40. Vertical duct 36 has external threading which mates with the internal threading of duct cover 40. Vertical duct 36 advantageously has internal threading 46 for attaching a hose 48 when the drum cap 10 is turned upside down to drain any of its contents in bowl 26 as illustrated in the top view of drum cap 10 in FIG. 2. The drum cap 10 thus protects the top surface of drum 10 from inclement weather, dust, sun, etc. Drum cap 10 is substantially plastic except for ball valve 38 which can be either metal or plastic. Suitable plastic compositions are polyethylene, polypropylene, nylon, polystyrene, and polyvinyl chloride. The preferred plastic composition of drum cap 10 is polyethylene.
Turning to FIG. 3, the bottom view of drum cap 10 shows the central placement of aperture 50 in bowl 26 (to permit drainage of collected liquid) and second stop regions or portions 28.
FIG. 4 is drawn to a second embodiment of the invention, wherein drum cap 10 is placed upside down over a drum 12. Second stop regions 28 on the inside of legs 14 rest advantageously on the rim 30 of drum 12 to maintain proper clearance of the domed wall 18 from the drum 12 and to permit penetration of the vertical duct 36 into the first bung hole 52 which, ordinarily, has a diameter of about 2 inches. Vertical duct 36 is positioned freely within the first bung hole 52. Vertical duct 36 is not threaded into the first bunghole 52, because it has a diameter slightly less than the inside diameter of the first bung hole 52. Located diametrically from the first bung hole 52 is a plugged second bung hole 54 having an approximate diameter of 3/4 inch. In this position, drum cap 10 is utilized as a funnel 56 for the addition of fluids to a drum 10. The funnel 56 frictionally fits the drum 12 by virtue of the legs 14 contacting the rim 30 of drum 12.
FIG. 4 is drawn to the third embodiment of the invention in that funnel 56 is utilized as a drain pan 58 to accept used oil from a vehicle's transmission pan or engine oil pan 60. The bowl 26 is large enough to handle large amounts of spent oil. Duct cover 40 is in place. Caster or wheels 16 can be removed for this operation if more stability on ground surface 70 is desired and/or when it is inclined.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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A multi-function drum cap which can be utilized as a weather protector, a drum funnel for filling or emptying the drum, and an oil drain pan for vehicles.
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This application is a continuation of application Ser. No. 08/180,477 filed Jan. 12, 1994, now abandoned, which is a continuation of application Ser. No. 07/832,996 filed Feb. 10, 1992, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording apparatus for forming an image according to an image signal or an original image, and more particularly to an ink jet recording apparatus.
2. Related Background Art
Among various recording apparatuses already known, the ink jet recording apparatus is attracting particular attention for full color image formation, because such apparatus, which forms dot records by discharging ink droplets from nozzles of a recording head, is advantageous in it's configuration and in the running cost. In this recording method, the recording is generally achieved by scanning motions of the recording head, having a nozzle array of a certain width (for example about 16 mm) in longitudinal and transversal directions relative to a recording material.
However, because of eventual fluctuations in the amount and direction of ink discharge among the nozzles of the ink jet recording head, there are formed streaks on the recorded image. For this reason, the recorded image shows cyclic streaking unevenness with a pitch corresponding to the width of the recording head, thus deteriorating the image quality. Also variation of such unevenness in time is another drawback.
Also eventual deposition of dusts or solidified ink on the nozzles of the recording head hinders proper ink discharge from the nozzles (hereinafter called discharge failure), thus causing a line-shaped defect on the recorded image and deteriorating the image quality.
In order to prevent such unevenness of the recording head, so-called head shading, there is already commercialized a recording apparatus in which a predetermined pattern is printed and said unevenness is corrected by reading the printed pattern visually or by a reader.
However, in such apparatus, since said correction is manually conducted by the operator, the correcting operation depends on the discretion of the operation and may not be executed properly. Also no sufficient measures are provided for the discharge failures.
It is desired to constantly detect such phenomena deteriorating the image quality and to effect suitable correction. Particularly in case of employing a long web-shaped recording material, the recording operation may be conducted continuously on a very long recording material of 100 meters or longer, so that the unevenness resulting from discharge failure during such recording operation poses a serious problem. In case said web-shaped recording material is composed of woven fabric, the probability of such discharge failure is significantly higher than in the ordinary recording paper, particularly coated paper, because fine fiber dusts tend to deposit on or in the vicinity of the nozzles of the recording head.
SUMMARY OF THE INVENTION
In consideration of the foregoing, an object of the present invention is to provide a recording apparatus capable of constantly providing stable recorded images with a simple structure.
Another object of the present invention is to provide a recording apparatus capable of stable recording on a web-shaped recording medium.
Still another object of the present invention is to provide a recording apparatus capable of stable recording on a recording medium with a rough surface such as woven fabric.
The above-mentioned objects can be attained, according to the present invention, by a recording apparatus capable of forming an image by scanning motions of a recording head relative to a recording medium, comprising pattern recording means for recording a predetermined pattern by said recording head at a predetermined interval, reader means for reading said predetermined pattern recorded by said pattern recording means, discrimination means for discriminating the recording state of said recording head, based on the predetermined pattern read by said reader means, and control means for controlling said recording head according to the result of discrimination by said discrimination means.
The recording apparatus of the present invention, having the above-explained configuration, is capable of preventing the deterioration of image quality by suitably checking the unevenness or discharge failure of the recording head and effecting unevenness correction or discharge recovery operation, or requesting the operator to replace the recording head.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an embodiment of the recording apparatus of the present invention;
FIG. 2 is a perspective view of a recording head and related mechanisms shown in FIG. 1;
FIG. 3 is a perspective view of a monitor shown in FIG. 2;
FIG. 4 is a chart showing the sensor output of said monitor;
FIG. 5 is a flow chart of the control sequence of said embodiment;
FIG. 6 is a perspective view of a recording head and related mechanisms in a second embodiment of the present invention;
FIG. 7 is a perspective view of a recording head and related mechanisms in a third embodiment of the present invention;
FIG. 8 is a cross-sectional view showing an ink supply system;
FIG. 9 is a flow chart of the control sequence of the third embodiment; and
FIG. 10 is a perspective view of a recording head and related mechanisms in a modification of the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now the present invention will be clarified in detail by preferred embodiments thereof shown in the attached drawings.
FIG. 1 is a cross-sectional view of a recording apparatus of the present invention, wherein shown are a main body 1; a roll 2 of web-shaped recording material (medium); a cutter 4 for cutting the recording material into a predetermined length; paired transport rollers 3, 5 for transporting the recording material in a predetermined direction; and a sub scanning roller 6 for positioning the recording material by precisely transporting the same by an amount corresponding to the recording width of a recording head to be explained later. The above-mentioned components constitute a transport path for the recording material supplied from the roll 2.
There are further provided a cassette 7 for storing sheet-shaped recording materials; guide members 8 for guiding the recording material from the cassette 7 into the transport path from said roll 2, immediately in front of the transport rollers 5; a carriage 9 bearing a recording head (not shown) and movably supported by a pair of main scanning rails 9a in a direction perpendicular to the plane of the drawing; and a platen member 10 positioned opposite to said carriage 9 across the recording material and provided with suction means that operates for example, by air suction or electrostatic suction, in order to maintain the recording material in flat state and to prevent the recording material from contacting the recording head during the recording operation.
In the following there will be explained related mechanisms, with reference to FIG. 2.
The carriage 9 is provided with recording heads 9C, 9M, 9Y, 9Bk respectively corresponding to cyan, magenta, yellow and black colors. An ink supply system 11 for supplying said recording heads with inks is provided with ink cartridges 11C, 11M, 11Y, 11Bk respectively corresponding to said colors. Inks are supplied to said recording heads, by means of unrepresented pumps, through tubes 12C, 12M, 12Y, 12Bk. A motor 13 drives the carriage 9 in the main scanning direction (lateral direction in the drawing), by means of a pulley 14 fixed to said motor 13, another pulley 15 and a belt 16. A motor 17 drives the ink supply system 11 in the main scanning direction, in synchronization with the carriage 9, by means of a pulley 18 fixed to said motor 17, another pulley 19 and a belt 20.
A recording material 22, composed for example of paper in the rolled or cut state as explained above, is transported upwards by the transport rollers 5 and the sub scanning roller 6. A cap member 23 is provided at a position for effecting an operation for eliminating the causes of image quality deterioration (hereinafter called discharge recovery operation). Said cap member 23 serves to cover the nozzle faces of the recording heads 9C, 9M, 9Y, 9Bk, and the ink is discharged or pushed out from the nozzles in such capped state, by activation or pressurization of the recording heads. At the same time high-speed air flow is directed toward the nozzle faces of the recording heads in the cap member 23, thus blowing off thus expelled ink and dusts from the nozzle faces, and eliminating the discharge failure and unevenness.
A monitor 31, for monitoring the recording state of the recording heads, reads a predetermined pattern (of uniform density), printed at a predetermined interval on the right-end margin of the recording material 22.
FIG. 3 shows the details of said monitor 31. A calibration pattern 32, containing each of cyan, magenta, yellow and black colors in uniform density and by a scanning line, is printed at a predetermined interval at an end margin of the recording material 22. There are also provided a pair of lamps 33 for illuminating said calibration pattern 32; a projection lens 34 for projecting the image of said pattern 32 illuminated by the lamps 33; and a sensor 35, such as a CCD, for photoelectrically converting the image of the calibration pattern 32 projected by said lens 34. The number of elements in said sensor is preferably at least equal to that of the recording elements in the recording head. The output of said sensor 35 is used for detecting the presence of discharge failure in the recording head and whether the unevenness of printing exceeds a predetermined level, and the aforementioned discharge recovery operation is conducted if necessary.
Now the normal recording sequence will be explained with reference to FIGS. 1 and 2. Referring to FIG. 1, when a recording material sensor (not shown) positioned in front of the transport rollers 5 detects a recording material fed from the roll 2 or the cassette 7, the transport rollers 5 and the sub scanning roller 6 advances the recording material by a predetermined amount, until the leading end thereof reaches the sub scanning roller 6.
When the leading end of the recording material 22 reaches the sub scanning roller 6 in FIG. 2, the carriage 9 and the ink supply system 11 are respectively driven by the motors 13, 17 in the scanning direction (to the right in FIG. 2). At the same time, the recording heads 9C, 9M, 9Y, 9Bk effect recording with a width I, according to image signals.
After recording of a line, the carriage 9 and the ink supply system 11 are returned to a predetermined position at the left side in FIG. 2, and the recording material 22 is simultaneously advanced by the motor 21, by an amount precisely corresponding to said printing width I.
After the above-explained sequence of recording and recording material transportation by a predetermined number of cycles, the recording material 22 is discharged from the apparatus.
In the following an explanation will be given on the monitor 31. FIG. 4 shows the output signal of the sensor 35 of said monitor 31, wherein the abscissa corresponds to the pixels of said sensor 35, while the ordinate indicates the output of each pixel. The output of the sensor 35 is subjected to so-called shading correction, utilizing the recording material before printing as the white level. Since each pixel output corresponds to each nozzle of the recording head, the amount of ink discharge from each nozzle can be determined.
A discharge failure is identified if the output signal becomes larger, even in one position, than a slice level b which is larger by a predetermined amount than the average pixel output a. Also large unevenness is identified if the output signal becomes larger than a slice level c which is larger by a predetermined amount than said average a or becomes smaller than a slice level d which is smaller by a predetermined amount than said average a. Empirically, the slice level b for detecting the discharge failure is preferably larger, by about 50%, than the average a, while the slice levels c, d for unevenness detection are preferably different, by 5 to 10%, from the average a.
However, the detection of level of unevenness is not limited to such method. There may instead be employed, for example, a method of calculating the standard deviation of the pixel outputs of the sensor and evaluating the level of unevenness from the magnitude of said standard deviation, or a method of calculating the sum A of absolute difference of adjacent pixels (A=Σ|a i -a i+1 |) and evaluating said level by the magnitude of said sum A.
For the purpose of unevenness correction, the pixel output values of the sensor 35, corresponding to the nozzles of the recording head, may be employed. However, in order to reduce the influence of noises etc., it is also possible to employ the average value of mutually adjacent pixels, for example three adjacent pixels of the sensor.
Now reference is made to FIG. 5 for explaining a calibration sequence for detecting the discharge failure and unevenness and effecting the discharge recovery operation. As explained in the foregoing, in a series of recording sequences, the calibration patterns are printed at a predetermined interval (step S1). Said calibration pattern is read by the monitor 31 (step S2), and the presence of discharge failure is discriminated by the algorithm explained above (step S3).
If a discharge failure is identified, there is discriminated whether or not to effect the recovery operation (step S4). The discrimination in the step S4 depends on whether the recovery operation is already conducted in this sequence. This is based on an empirical fact that most discharge failures are resolved if the aforementioned discharge recovery operation is properly conducted. After said discharge recovery operation (step S5), the sequence returns to the step S1 for calibration pattern printing, step S2 for pattern reading and step S3 for discrimination of the discharge failure. If the step S4 again identifies the discharge failure, the recovery operation is not conducted, but an alarm for a head trouble is given and the operation of the apparatus is interrupted (step S6).
On the other hand, if the step S3 identifies the absence of discharge failure, there is discriminated the absence of unevenness, according to the unevenness discriminating algorithm explained before (step S7). If the unevenness is identified absent, the recording operation is continued (step S12). On the other hand, if the step S7 identifies that the unevenness is equal to or larger than a predetermined level, there is discriminated whether to effect the unevenness correction operation (step S8), and there is conducted the unevenness correction (step S9). The unevenness correction in the step S9 is conducted, based on the output signal of the pattern read in the step S2, by correcting the drive signal (signal duration or voltage) of the required nozzles of the recording head. Then a pattern of uniform density, same as printed in the step S1, is printed (step S10), and the printed pattern is read by the monitor 31 (step S11).
The above-mentioned steps S7, S8, S9, S10 and S11 are repeated by a predetermined number of cycles (three times in the present embodiment), and, if the level of unevenness is still high, an alarm for a head trouble is given and the operation of the apparatus is interrupted (step S6). This is based on an empirical fact that this unevenness correcting sequence generally provides a practically sufficient effect after three cycles though the effect becomes still enhanced with a further increased number of cycles, while a significant unevenness after three correcting cycles is mostly caused by a trouble based in the recording head, such as the expired service life thereof.
The discharge state of the recording heads can be maintained in satisfactory manner, by conducting the above-explained calibration sequence for each of the cyan, magenta, yellow and black colors. Consequently the working rate of the apparatus can be improved even in the unmanned state, and such measure is particularly effective in case of using continuous web-shaped recording medium.
In the present embodiment, the recording material is assumed to be ordinary paper, but similar effects can also be obtained for other recording materials such as woven fabric.
In the following there will be explained a second embodiment of the present invention shown in FIG. 6, wherein components equivalent to those in the first embodiment shown in FIG. 2 are represented by same numbers.
This embodiment is featured by the presence of a recording material exclusive for calibration pattern printing. At an end of the platen 10, there is provided a recording material 41 exclusive for monitoring, supplied from a roll 42 and taken up, after printing, on a roll 43. The sequences of printing and calibration in the present embodiment will not be explained further, as they are same as in the first embodiment.
This embodiment, enabling recording on the entire area of the recording material without any margin therein, avoids waste of the recording material and is particularly effective for long continuous recording.
In the following there will be explained a third embodiment of the present invention. The cross-sectional structure of the apparatus of this embodiment will not be explained as it is basically the same as that of the first embodiment shown in FIG. 1. FIG. 7 is a perspective view of a recording head and related mechanisms of the present embodiment, wherein components equivalent to those in FIG. 2 are represented by same numbers.
The carriage 9 is provided with the recording heads 9C, 9M, 9Y, 9Bk respectively corresponding to cyan, magenta, yellow and black colors. The ink supply system 11, for ink supply to said recording heads, is provided with ink cartridges 11C, 11M, 11Y, 11Bk respectively corresponding to said colors. The ink supply is conducted, when the carriage is in a chain-lined position 26 (hereinafter called ink supply position), from said system 11 to sub tanks (not shown) of the carriage 9 by unrepresented pumps, as will be explained later in more detail.
A reserve carriage 25, same in structure as the carriage 9, also receives the ink supply from the ink supply system 11 at the ink supply position 26. A motor 13 drives the carriage 9 in the main scanning direction (lateral direction in the drawing) by means of a drive pulley 14 fixed to said motor, a pulley 15 and a belt 16. A motor 27 drives the reserve carriage 25 in said main scanning direction by a drive pulley 28 fixed to said motor 27, another pulley 29 and a belt 30.
Caps 24a, 24b are provided for respectively covering the nozzles of the recording heads of the carriage 9 and the reserve carriage 25 at the home positions thereof, thereby preventing viscosity increase of the inks.
Now reference is made to FIG. 8 for explaining the ink supply process.
There are shown a main tank 45 receiving ink supply from the ink cartridge 11C; a pump 46 for effecting ink pressurization for discharge recovery for the recording head 9C and ink supply to a sub tank 53 provided on the carriage; a support member 47 supporting a connector of an ink supply tube and moveable laterally by a motor 48 and a feed screw 49; a tube 50 connecting the pump 46 with the support member 47 and having a connector member 50a at an end; a tube 51 provided at an end with a connector member 51a engageable with said connector member 50a and supplying ink to the recording head 9C, said connector member 51a being provided with a valve (not shown) which is normally closed and opened only when coupled with the connector member 50a; a tube 52 connecting the recording head 9C with a sub tank 53 provided on the carriage; a tube 54 for returning the ink, overflowing at the ink supply, from the sub tank, having a connector member 54a at an end; a tube 55 connecting the support member 47 with the main tank 45 and provided at an end with a connector member 55a engageable with said connector member 54a; and a valve 56 provided in the tube 55, to be closed at the discharge recovery operation for ink pressurization.
The ink is supplied, with said connector members mutually coupled at said ink supply position, by the pump 46 to the tubes 50, 51, recording head 9C, tube 52, and sub tank 53, and, when the sub tank 53 is filled, the overflowing ink is returned to the main tank 55 through the tubes 54, 55. In this operation the valve 56 is in the open state. On the other hand, the ink pressurization at the discharge recovery operation is conducted, also at said ink supply position, with the connector members being mutually coupled, by activating the pump 46 with the valve 56 closed, whereby the ink pressure in the supply path is elevated to expel the ink from the nozzles of the recording head. The ink supply to the recording head in the course of actual recording operation is conducted from the sub tank 53 through the tube 52.
The foregoing explanation has been limited to the system for cyan color, but a similar system is provided for each of magenta, yellow and black colors. Also the reserve carriage 25 has a same structure, and the ink supply and discharge recovery are conducted in the ink supply position shown in FIG. 7.
In the following there will be explained the recording sequence of the above-explained third embodiment.
Referring to FIG. 7, when the leading end of the recording material 22 is transported to the sub scanning roller, the carriage 9 is driven in the scanning direction (to the right in FIG. 7) by the motor 13. At the same time the recording heads 9C, 9M, 9Y, 9Bk effect recording with a width I, according to image signal.
After recording of a line, the carriage 9 is returned to a predetermined position at the left side, and the recording material 22 is advanced by a distance precisely corresponding to the printing width I. The above-explained sequence of recording and transportation of recording material is repeated for a predetermined number of cycles, and then the recording material 22 is discharged from the apparatus.
Now reference is made to FIG. 9 for explaining the calibration sequence for detecting the discharge failure or unevenness and effecting the discharge recovery operation in this third embodiment. This sequence is different from that of the first embodiment in FIG. 5, in the process when a trouble in the recording head is identified. When a trouble in the recording head is identified, the step S6 in FIG. 5 provides an alarm display and terminates the function of the apparatus. In the present embodiment having a reserve recording head as explained above, a step S16 provides the alarm for the trouble in the recording head and replaces the recording head by activating the reserve carriage 25.
Thus the present embodiment monitors the unevenness and discharge failure in the recording heads, effects correction for unevenness and discharge recovery operation when required, and automatically replaces the recording heads when recovery is identified as not being possible, thereby preventing the deterioration in image quality and avoiding the interruption of recording. Thus the working rate of the apparatus can further be improved.
In the present embodiment, the calibration pattern is printed in the margin of the recording material 22, but as an alternative it is also possible, as in the second embodiment, to provide a small-sized recording material 41 for said calibration pattern, as shown in FIG. 10, and to print the calibration pattern at a predetermined interval.
Also in the present embodiment, the recording material is assumed to be composed of ordinary paper, but similar effects can be obtained on other recording materials such as woven fabric.
Also in the foregoing embodiments, the interval of detection of unevenness and discharge failure, or the timing of printing of the calibration pattern, is not particularly defined, but such calibrating operation may be conducted every line or every certain number of lines. The abnormality can be detected on real time basis if the calibration is conducted every line. On the other hand, a loss in the recording speed can be prevented by conducting the calibration at every certain number of lines.
Said interval is preferably varied according to the kind of the recording material. More specifically, said interval is preferably made shorter for a recording material with a rougher surface, such as woven cloth, since short fibers tend to adhere around the nozzles of the recording head.
As explained in the foregoing, the present invention always monitors the unevenness and discharge failure of the recording heads, whereby the correction for unevenness and the discharge recovery operation can be realized in an unmanned state and the deterioration in image quality can be prevented.
Among various ink jet recording systems, the present invention brings about a particular effect when applied to a recording head and an ink jet recording system utilizing thermal energy for ink discharge.
The principle and representative configuration of said system are disclosed, for example, in the U.S. Pat. Nos. 4,723,129 and 4,740,796. This system is applicable to so-called on-demand recording or continuous recording, but is particularly effective in the on-demand recording because, in response to the application of at least a drive signal representing the recording information to an electrothermal converter element positioned corresponding to a liquid channel or a sheet containing liquid (ink) therein, said element generates thermal energy capable of causing a rapid temperature increase exceeding the nucleate boiling point, thereby inducing film boiling on a heat action surface of the recording head and thus forming a bubble in said liquid (ink), in one-to-one correspondence with said drive signal. Said liquid (ink) is discharged through a discharge opening by the growth and contraction of said bubble, thereby forming at least a liquid droplet. Said drive signal is preferably formed as a pulse, as it realizes instantaneous growth and contraction of the bubble, thereby attaining highly responsive discharge of the liquid (ink). Such a pulse-shaped drive signal is preferably that disclosed in the U.S. Pat. Nos. 4,463,359 and 4,345,262. Also the conditions described in the U.S. Pat. No. 4,313,124 relative to the temperature increase rate of said heat action surface allows to obtain further improved recording.
The configuration of the recording head is given by the combinations of the liquid discharge openings, liquid channels and electrothermal converter elements with linear or rectangular liquid channels, disclosed in the above-mentioned patents, but a configuration disclosed in the U.S. Pat. No. 4,558,333 in which the heat action part is positioned in a flexed area, and a configuration disclosed in the U.S. Pat. No. 4,459,600 are also useable in the present invention. Furthermore the present invention is effective in a structure disclosed in the Japanese Patent Laid-open Application No. 59-123670, having a slit common to plural electrothermal converter elements as discharge opening therefor, or in a structure disclosed in the Japanese Patent Laid-open Application No. 59-138461, having an aperture for absorbing the pressure wave of thermal energy, in correspondence with each discharge opening.
A full-line type recording head, capable of simultaneous recording over the entire width of the recording sheet, may be obtained by plural recording heads so combined as to provide the required length as disclosed in the above-mentioned patents, or may be constructed as a single integrated recording head, and the present invention can more effectively exhibit its advantages in such recording head.
The present invention is further more effective in a recording head of interchangeable chip type, which can receive ink supply from the main apparatus and can be electrically connected therewith upon mounting on said main apparatus, or a recording head of cartridge type in which an ink cartridge is integrally constructed with the recording head.
Also the recording apparatus is preferably provided with the emission recovery means and other auxiliary means for the recording head, since the effects of the recording head of the present invention can be stabilized further. Examples of such means for the recording head include capping means, cleaning means, pressurizing or suction means, preliminary heating means composed of an electrothermal converter element and/or another heating device, and means for effecting an idle ink discharge independent from the recording operation, all of which are effective for achieving stable recording operation.
Furthermore, the present invention is not limited to a recording mode for recording a single main color such as black, but is extremely effective also to the recording head for recording plural different colors or full color by color mixing, wherein the recording head is either integrally constructed or is composed of plural units.
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A recording apparatus records an image by scanning a first recording head relative to a recording medium of a particular type. The apparatus includes the first recording head, a pattern recording controller, a reader, a restoring device, a second recording head, a discriminator and a control unit. The pattern recording controller controls recording of a predetermined pattern with the first recording head at a predetermined timing either on the recording medium or on a pattern recording medium different from the recording medium. The reader reads the predetermined pattern and the restoring device performs a discharge restoring operation of the recording head. The discriminator discriminates a recording state of the first recording head, based on the predetermined pattern read by the reader. The control unit enables the second recording head to record the image to be recorded by the first recording head, in a case that after the discriminator discriminates the recording state as being poor and thereafter the discharge restoring operation performed by the restoring device and a pattern recording operation by the pattern recording controller have been executed a predetermined number of times, the discriminator has discriminated the recording state as being still poor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a non-provisional of U.S. Provisional Patent Application Ser. No. 61/620,743, filed 5 Apr. 2012, and incorporated herein by reference. Priority of U.S. Provisional Patent Application Ser. No. 61/620,743, filed 5 Apr. 2012, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
FIELD OF THE INVENTION
This invention relates generally to chord playing attachments and specifically to a specially configured chord playing attachment that may be used to play a guitar or be employed as a teaching tool, and wherein a specially configured nut arrangement enables disassembly of the chord playing portion from the nut in order to play the guitar without the chord playing portion.
BACKGROUND OF THE INVENTION
Two problems present themselves when a student attempts to learn the guitar or a similar stringed instrument. The guitar strings injure the student's fingertips until the student develops calluses; and the student faces a steep learning curve prior to playing actual music. The latter problem often causes severe frustration, which in turn causes most novices to quickly abandon their learning attempts. Teaching the student a series of musical chords allows the student to play music quickly, which encourages the student to keep playing until greater understanding is gained and reduces frustration.
Various chord attachments have been developed to allow the user to play chords easily without injuring their fingers. None of these devices have ever attained widespread popularity because none of them have been designed as teaching tools. Many of the older versions were intricate, heavy, and hard to use. Some even mask the strings from the user's view, resulting in the user being unable to learn any chords while using the device. Newer versions are more usable, but do not encourage the user to play any strings directly. This forces the user to build up calluses all at once and forces the user to make the mental leap directly from playing by pressing buttons to playing by depressing complex string combinations. None of the previous chord attachments allow the user to take an intermediate step or steps to ease them into the process of playing without the aid of training devices. Also, none of the previous chord attachments were paired with a user friendly training manual to teach the user how to play chords in the right order to create songs without requiring the user be able to read standard sheet music. Additionally, many of the previous chord attachments depress all of the guitar strings at a specific point, which causes those devices to act as a capo. A capo device is undesirable because it changes the key of all of the chords played, which means that any attempts to play the guitar with the attached device will result in music that is nonstandard.
Therefore, what is needed is a chord playing attachment. The chord playing attachment should allow the user to play some chords by hand and some chords by depressing buttons. The chord playing attachment should also be used in combination with a color-coded training manual. Furthermore, other desirable features and characteristics of the present invention will become apparent when this background of the invention is read in conjunction with the subsequent detailed description of the invention, appended claims, and the accompanying drawings.
My PCT Patent Application Serial No. PCT/US11/44002, filed 14 Jul. 2011, and published on 19 Jan. 2012 under publication no. WO 2012/009533, is hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
The present invention advantageously fills the aforementioned deficiencies by providing a specially configured chord playing attachment. The chord playing attachment of the present invention includes chord members (e.g., levers) with color-coded finger pads that enable a user to depress the strings necessary to play a chord or part of a chord. The chord playing attachment is also usable in combination with a color-coded training manual for easy learning. In one embodiment, the levers and buttons are removable from a specially configured guitar “nut” so that a user can play the guitar without the chord playing portion.
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description, and any preferred and/or particular embodiments specifically discussed. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings contained herein exemplify two of the embodiments of the claimed invention. The invention is not limited to the embodiments shown. The embodiments shown are purely examples, and the invention is capable of many variations of said embodiments. In the drawings,
FIG. 1 illustrates a perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 2 illustrates a partial top view of the preferred embodiment of the apparatus of the present invention;
FIG. 3 illustrates a partial perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 4 illustrates a partial perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 5 is a partial top view of the preferred embodiment of the apparatus of the present invention;
FIG. 6 is a partial bottom view of the preferred embodiment of the apparatus of the present invention;
FIG. 7 is a partial side view of the preferred embodiment of the apparatus of the present invention;
FIG. 8 is a partial side view of the preferred embodiment of the apparatus of the present invention;
FIG. 9 is a partial end view of the preferred embodiment of the apparatus of the present invention;
FIG. 10 is a partial end view of the preferred embodiment of the apparatus of the present invention;
FIG. 11 is a partial perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 12 is a partial front elevation view of the preferred embodiment of the apparatus of the present invention;
FIG. 13 is a partial rear elevation view of the preferred embodiment of the apparatus of the present invention;
FIG. 14 is a partial top view of the preferred embodiment of the apparatus of the present invention;
FIG. 15 is a partial bottom view of the preferred embodiment of the apparatus of the present invention;
FIG. 16 is a partial side view of the preferred embodiment of the apparatus of the present invention;
FIG. 17 is a partial side view of the preferred embodiment of the apparatus of the present invention; and
FIG. 18 is a partial perspective exploded view of the preferred embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-18 show the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10 . Guitar apparatus 10 provides a body 11 , neck 12 , head 16 and strings S. The neck 12 has a first neck side 13 and a second neck side 14 . The neck 12 provides a fret board 15 . The head 16 carries a plurality of tuning pegs 17 for adjusting tension of each string S. The fret board 15 has a plurality of parallel frets 18 . The body 11 can provide a pick guard 19 . Bridge 20 is provided on body 11 . String S attach to bridge 20 .
As part of the method and apparatus of the present invention, a slot 21 can be cut or milled in neck 12 next to head 16 as seen in FIG. 3 . The slot 21 is receptive of a specially configured nut or connector or anchor 22 .
The nut or connector or anchor 22 provides a base portion 23 having a lower surface 28 that registers against the neck 12 . If a slot 21 is milled in neck 12 , the base 23 rests in the slot 21 . Spaced apart openings 29 can be provided in nut/connector/anchor 22 for attaching it to the neck 12 using fasteners 63 such as threaded wood screws (see FIG. 3 ).
Nut/connector/anchor 22 has a raised portion 30 having a plurality of string depressions 24 , each receptive of a different one of the guitar string S. A pair of spaced apart side anchors or projections 25 , 26 are provided. In between the side anchors or projections 25 , 26 there can be provided a socket or longitudinal slot 27 (see FIG. 11 ). The longitudinal slot or socket 27 can provide a generally horizontal surface 31 and a generally vertical surface 32 .
Nut/connector/anchor 22 has a front 33 and a rear 34 . Nut/connector/anchor 22 has a first side 35 and a second side 36 . Each of the side anchors or projections 25 , 26 extends away from a side 35 , 36 as shown in FIGS. 11-17 . Preferably, first side 35 and second side 36 of nut/connector/anchor 22 are aligned with first neck side 13 and second neck side 14 , respectively. When sides 35 , 36 of nut/connector/anchor 22 are aligned with neck sides 13 , 14 , nut projections 25 , 26 will extend beyond the sides of the neck 12 .
A chord playing attachment 40 (see FIGS. 2-10 ) is removably connectable to nut/connector/anchor 22 at the side anchors or projections 25 , 26 . The chord playing attachment 40 provides a frame 41 that can be of plastic (e.g., transparent plastic), metal or other material. The chord playing attachment 40 has opposed sides 42 , 43 that form an arch 62 with transverse section 48 . Diagonally extending tabs or angled flanges 44 , 45 can extend down and away from sides 42 , 43 as shown in FIGS. 9 , 10 . Each of the sides 42 , 43 provides an opening. Side 42 provides opening 46 . Side 43 provides opening 47 . Each of the openings 46 , 47 is sized and shaped to receive and connect with a side anchor or projection 25 , 26 . The distance 37 between sides 35 , 36 can be equal to or slightly greater than the distance 38 between sides 42 , 43 of frame 41 (see FIGS. 10 and 15 ). In this fashion, the sides 42 , 43 clamp the nut/connector/anchor 22 with a clamping or interference fit connection.
When a side anchor or projection 25 or 26 extends into an opening 46 or 47 , a side 35 or 36 of nut/connector/anchor 22 abuts or engages a side 42 , 43 of frame 41 as shown in FIG. 3 . In order to disconnect the chord playing attachment 40 from the nut/connector/anchor 22 , a user simply grasps each of the sides 42 , 43 or angled flanges/diagonally extending tabs 44 , 45 and moves them apart in the direction of arrows 64 in FIG. 3 . The arch 62 thus flexes to disconnect frame 41 from the nut/connector/anchor 22 .
A central post/leg/flange 49 can extend downwardly from transverse portion 48 at a position midway between sides 42 , 43 of chord playing attachment 40 . The post 49 engages and occupies the longitudinal slot or socket 27 when chord playing attachment 40 is connected to nut/anchor/connector 22 and surface 65 engages surface 31 .
Frame 41 supports a plurality of levers 50 , 51 , 52 , 53 . Each of the levers or depression members 50 - 53 can be provided with a button 54 , 55 , 56 or 57 . In this fashion a user can push on a button 54 - 57 as selected for a particular chord in order to depress a selected lever 50 , 51 , 52 or 53 . The buttons 54 - 57 can be the same as described in my prior PCT Application Serial No. PCT/US11/44002, filed 14 Jul. 2011, and published on 19 Jan. 2012 under publication no. WO 2012/009533. Each of the levers 50 - 53 is provided with a depression member 58 - 61 . The depression members 58 , 59 , 60 , 61 move down and contact and depress a string (or strings) S when a user presses on a selected lever 50 - 53 or its button 54 - 57 . The depression members 58 are a part of lever 50 . The depression members 59 are part of the lever 51 . The depression member 60 is a part of the lever 52 . The depression members 61 are a part of the lever 53 . Each lever 50 - 53 can be integrally or removably attached to frame 41 at arch 62 as seen in FIG. 5 .
The attachment apparatus of the present invention can be sized for ½ size guitars, ¾ size guitars, and full size guitars. The present invention includes both the attachment apparatus and the guitars to which the attachment apparatus is attached.
The present invention as shown in FIGS. 1-18 is commercially available from Peavey for ¾ size guitars, and full size guitars.
The inventor also plans to market a smaller attachment apparatus for ½ size guitars similar to what is shown in FIGS. 1-18 . In the prototype, the overall length is 94 mm, the width is 47 mm, and the “B” string stud was moved down the neck approximately 7 mm Optionally, the finger buttons can be built into the clear plastic mold and colored tabs (such as colored self-adhesive paper) can be added after manufacture of the clear plastic part. The main function of the present invention (to be sold by Perry's Music as ChordBuddy Jr. guitar apparatus) is to allow a student to gain the skill of strumming chords and proper timing without having to concern themselves with making the chord shapes, while building up finger dexterity and strength in the chord-making hand.
The following is a list of parts and materials suitable for use in the present invention:
PARTS LIST
Parts Number
Description
10
guitar apparatus
11
body
12
neck
13
neck side
14
neck side
15
fret board
16
head
17
tuning pegs
18
frets
19
pick guard
20
bridge
21
slot
22
nut/connector/anchor
23
base portion
24
string depression
25
side anchor/projection
26
side anchor/projection
27
socket/longitudinal slot
28
lower surface
29
opening
30
raised portion
31
horizontal surface
32
vertical surface
33
front
34
rear
35
side
36
side
37
distance
38
distance
40
chord playing attachment
41
frame
42
side
43
side
44
angled flange/diagonally extending tab
45
angled flange/diagonally extending tab
46
opening
47
opening
48
transverse portion
49
central post/leg/flange
50
lever/depression member
51
lever/depression member
52
lever/depression member
53
lever/depression member
54
button
55
button
56
button
57
button
58
depression member
59
depression member
60
depression member
61
depression member
62
arch
63
fasteners
64
arrow
65
surface
S
strings
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A removable chord playing attachment and related method is disclosed. The chord playing attachment may be attached to a guitar or similar stringed instrument, and the user may use the chord playing attachment to learn to play the instrument. The present invention discloses a design that does not function as a capo, which allows the user play chords in standard keys. The present invention includes a specially configured nut or connector or anchor that forms a removable connection with a chord playing unit. The present invention encourages novices to learn to play the instrument in stages and eventually remove the invention entirely. A companion teaching manual is also disclosed.
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TECHNICAL FIELD
[0001] The present invention relates generally to fermentation processes and apparatus and, more specifically to fermentation post-sterile additive delivery at a controlled rate through a pressurized atomizing system.
BACKGROUND OF THE INVENTION
[0002] “Fermentation” generally is defined as simply the cultivation of micro-organisms in aerobic and anaerobic, dynamic processes. Also referred to as “zymosis,” it is the enzymatic transformation of organic substrates generally accompanied by the evolution of gas. In fermentation processes, sterilized cultivation medium components are supplied at the beginning of the fermentation. While some small scale fermentations have no additional “feeds” after inoculation of the batch, in other modes of fermentation, post-sterile additives—control agents, acids, bases, fermentation inducing agents, substrate, and the like as would be known in the art—are fed into the fermentation vessel, or vat (also referred to hereinafter more simply as “the fermentor,” used synonymously for a bioreactor).
[0003] As the fermentor is generally a closed vessel, one common problem is that the evolution of gas results in the foaming of the surface of the substrates. One such post-sterile additive is an anti-foaming agent. In conventional anti-foam delivery systems, a foam detection probe senses the foam level. Upon detecting a predetermined foam level, a peristaltic pump is activated and an anti-foaming agent is pumped into the vat. Usually, the anti-foaming agent is dribbled down the interior side wall of the vat then mixed into the batch. However, at the periphery of a vat mixing is traditionally poor. Due to this sluggish method of delivery, anti-foam sits on top of the foam and swirls around the vat until it is eventually mixed and the foam level is lowered. However, by the time the foam has subsided, the pump often has delivered excess anti-foaming agent to the substrates. This excess anti-foam tends to coat the cells of the active culture, thereby interfering with cell respiration. Typically, the dissolved oxygen in the culture decreases to unacceptable levels and cell reproduction and other metabolic conditions are disturbed, even dropping to zero respiration until the cells can shed the coating. It takes a considerable amount of time for the culture to return to log-phase growth conditions.
[0004] Other known methods of dealing with surface foaming use of mechanical foam separation and removal or pneumatic foam breakers. Such systems are more expensive and generally less effective than the injection of anti-foaming agents.
[0005] Moreover, other post-sterile additives, again often introduced in the same manner as anti-foaming agents, have been found to be in need of closer controls because of their effect on the metabolic state of the batch. Ammonia is commonly used to maintain a pH of 7.0 during fermentation processes. It is common to wait until a pH of about 6.8 is monitored before adding the ammonia, mixing, and raising the pH to about 7.1. It has been found that this pH swing is also disturbing to an effective cell growth fermentation. In fact, it is desirable to keep the pH between 6.98 and 7.01 to promote a steady cell metabolism. A second additive in this category is carbon source additives, such as glucose, which are important to control to promote a steady cell growth rate.
[0006] There is a need for fermentation post-sterile additive delivery systems, controls, and processes to overcome the problems in the state of the art apparatus by creating even cell growth cycles under balanced chemical conditions.
SUMMARY OF THE INVENTION
[0007] In its basic aspects, the present invention provides a method for maintaining a chemically balanced fermentation growth cycle by introducing post-sterile additive to a fermentation batch under controlled conditions. The method includes the steps of: starting a known manner fermentation process of the batch wherein the batch has a predetermined surface area; waiting until an end to a lag phase and start of a log phase; monitoring fermentation parameters during the log phase; periodically introducing at least one post-sterile additive as a substantially homogeneous mist such that the surface area is substantially covered with the mist and mixing of the additive with the batch is optimized, wherein the operational parameters for the step of periodically introducing is determined by fermentation condition feedback information from the monitoring such that a substantially steady state metabolic condition is maintained for the batch through the log phase.
[0008] Another basic aspect of the present invention is a fermentor system, including: a fermentation vessel, having an interior chamber for containing a fermentation batch therein and a closure superjacent a surface of the batch; a controller connected to the fermentation vessel; a feedback probe associated with the batch and connected to the controller such that predetermined fermentation process parameters are monitored in real time; an additive atomizer extending through the closure into the interior chamber superjacent the surface of the batch; a post-sterile additive container, having a supply of additive therein, fluidically coupled to the additive atomizer; wherein the controller selectively activates introduction of the additive via the atomizer superjacent the surface of the batch such that a substantially homogenous spray of the additive is directed across the surface.
[0009] In another basic aspect, the present invention provides an apparatus for introducing anti-foam into a fermentation vessel to control fermentation batch surface foam, including: a monitoring probe associated with the vessel for monitoring surface foam levels of the fermentation batch within the vessel; a controllable atomizer for selectively introducing a substantially homogeneous mist of post-sterile anti-foam additive onto the surface foam during log phase foaming; a pressurized supply of anti-foam additive for fluidically coupling atomizer; a selectable valve for intermittently fluidically coupling the supply and the atomizer such that a predetermined volume of additive is introduced as the mist onto substantially all the surface foaming; and a controller, connected to the valve and the probe, for operating the selectable valve based on real time surface foaming conditions of the batch.
[0010] Some of the advantage of the present invention are:
[0011] it provides a method and apparatus for overcoming the problems of the prior art;
[0012] it can be used to add most post-sterile additives to a fermentation substrate by an automatic, controlled, and either continuous or periodic, injection;
[0013] it improves balance in the fermentation by alleviating process delays for additives that do not readily mix with the substrate;
[0014] it provides a more controlled reaction between additives and the substrate within a fermentation vessel;
[0015] its use results in a lower total volume of additives needed for a fermentor batch; and
[0016] it produces metabolic conditions in a fermentation batch that are steady-state.
[0017] The foregoing summary and list of advantages is not intended by the inventor to be an inclusive list of all the aspects, objects, advantages and features of the present invention nor should any limitation on the scope of the invention be implied therefrom. This Summary is provided in accordance with the mandate of 37 C.F.R. 1.73 and M.P.E.P. 608.01(d) merely to apprize the public, and more especially those interested in the particular art to which the invention relates, of the nature of the invention in order to be of assistance in aiding ready understanding of the patent in future searches. Other objects, features and advantages of the present invention will become apparent upon consideration of the following explanation and the accompanying drawings, in which like reference designations represent like features throughout the drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0018] [0018]FIG. 1 is a schematic drawing of the apparatus in accordance with present invention.
[0019] [0019]FIGS. 2A through 2D are post-sterile additive atomizer designs in accordance with the present invention as shown in FIG. 1.
[0020] [0020]FIG. 3 is a flow chart for the operation of the present invention as shown in FIG. 1.
[0021] [0021]FIG. 4 (Prior Art) is a graph showing typical fermentation stages.
[0022] The drawings referred to in this specification should be understood as not being drawn to scale except if specifically annotated.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Reference is made now in detail to a specific embodiment of the present invention, which illustrates the best mode presently contemplated by the inventor for practicing the invention. Alternative embodiments are also briefly described as applicable.
[0024] [0024]FIG. 1 is a schematic drawing of a fermentation system 100 in accordance with the present invention. A known manner fermentation vessel, or vat, 101 has an interior chamber 103 within which a batch 105 is cultivated. For the purpose of describing the details of the invention, an exemplary fermentation in which foaming is occurring and the need for an anti-foaming agent is required will be described. It will be recognized by a person skilled in the art that the following description also applies to other post-sterile additive manipulation. Therefore, no limitation on the scope of the invention is intended by the inventors in using this exemplary embodiment nor should any such limitation be implied therefrom.
[0025] Foaming is monitored by a known manner conductance probe 107 which reaches into the vat 101 through its closure, or lid, 109 . The probe 107 extends to an appropriate depth proximate the surface of the batch 105 to monitor foaming conditions. The probe 107 is electrically connected to a control subsystem 110 having known manner foam condition monitoring features. The continual monitoring of conditions in the batch 105 is used as feedback as to the current conditions within the chamber 103 and is used to make real-time adjustments in controlling the additive parameters.
[0026] The post-sterile additive 111 , in this exemplary embodiment, an anti-foaming agent, such as polyglycols used in the production of microbially-derived DNA products, is in a separate container 113 that is pressurized using a compressed air (or other appropriate gas) injector 115 as would be known in the art. The pressurized anti-foaming agent 111 is fed from the container 113 via an appropriate fluidic conduit 117 to a solenoid 119 . The solenoid 119 , which may be a commercially available, quick acting, DC-type, is electrically connected to and activated via the controller 110 .
[0027] The solenoid 119 acts as a valve for introducing the anti-foaming agent 111 into the chamber 103 of the vat 101 via a hygienic atomizer 121 . Turning also to FIG. 2A, a first embodiment of the atomizer 121 comprises an additive feeder tube 201 and an atomizer head, or tip, 203 , having spray nozzles 204 . The atomizer 121 is fabricated of a material that can be sterilized, such as 316L stainless steel. The atomizer head 203 can have a variety of implementations depending on the specific fermentation vessel 101 . FIG. 2A illustrates a simple, omni-directional shower type atomizer head 203 . FIG. 2B demonstrates a ball-type head 205 . FIG. 2C illustrates a capillary effect type head 207 , having additive distribution channels 208 . FIG. 2D depicts a distribution ring head 209 . As can now be recognized, a particular head can be designed to fit a particular vat 101 as needed, moving from a small tip 203 , FIG. 2A, or head type 205 , 207 for relatively small scale fermentors to a ring head 209 , FIG. 2D, for large scale fermentors. The particular atomizer design is selected to form a substantially homogeneous mist 123 of additive 111 (FIG. 1) that will coat substantially the entire surface area of the batch with the additive. As in this exemplary embodiment, the goal is to substantially simultaneously spray a heavy drop mist of anti-foam 123 over the entire foam layer 125 which is superjacent the substrate-foam interface. It is also envisioned that the atomizer 121 may be rotated to improve the homogeneity of the mist 123 .
[0028] The entire atomizer 121 should be designed such that it can be sterilized. Thus, it should be one piece. In the alternative, any joint—such as between the additive feeder tube 201 and atomizer tip 203 , 205 , 207 , 209 (see FIGS. 2 A- 2 C, phantom line)—should be a weld rather than using a screw thread attachment which could harbor by contaminants, potentially destroying the desired septic environment inside the chamber 103 .
[0029] Spray pressure should be controlled for most applications. For example, if the vessel chamber 103 is at 5-PSIG, the spray pressure will be up to about 10-PSIG, or approximately in the range of three to five PSIG higher than the vessel. By providing spray pressure controls in the controller 110 , such as by altering the compressed air injector 115 pressure to the additive container 113 , the rate of injection through the valve 119 can be automatically varied according to feedback information as to vat 101 conditions.
[0030] The operation of the post-sterile additive fermentor system 100 , FIG. 101, is controlled to optimize additive introduction into the vat chamber 103 such that a chemical balance is maintained to optimize cell growth in the batch 105 , where batch is defined as including the surface foam when the additive is an anti-foaming agent. In other words, the goal is to control metabolic conditions to achieve a steady state fermentation process.
[0031] Turning to FIGS. 3 and 4, fermentation is initiated, step 301 , for the particular batch 105 , FIG. 1, in accordance with the known chemical, bio-chemical and chemical engineering principles appropriate to the specific process. It is known that from start of fermentation—time “t 1 ”—there is a fermentation “lag” phase, e.g., about four hours, before post-sterile additive introduction is initiated. Starting thereafter (at time=t 2 ), the “log” phase occurs during which cell cultivation is active and post-sterile additive introduction happens. After the log phase, the “product” formation phase is entered (at time=t 11 ). In the exemplary embodiment, anti-foaming agent 111 will be initiated after the start of the log phase, ending at or before the start of the product formation phase.
[0032] Providing real-time monitoring of the need for the post-sterile additive to promote a steady state log phase is provided via conductance probe 107 or other monitor associated with the batch, e.g., an optical densitometer, dissolved oxygen or glucose monitors, or a spectrophotometer. In furtherance of this goal, additive timing control, step 303 , via controller 110 (FIG. 1) is provided. Note that either or both hardware and software controls can be employed in accordance with the present invention.
[0033] Three additive introduction parameters for anti-foaming agents are used:
[0034] (1) “shot” time, viz. the duration of the additive spray cycle,
[0035] (2) “working” time, viz. agitation cycle to mix the additive with the batch, and
[0036] (3) “interval” time, viz. the delay between additive introductions.
[0037] Note again however, that additive timing control 303 can either be stepped or, if appropriate to the particular fermentation process, continuously varied; that is, interval time is dropped as a factor and the additive volume is varied up and down by varying the pressure within the additive container 113 as needed or continuously in accordance with the feedback from the real-time conditions monitor.
[0038] To continue the anti-foaming additive exemplary embodiment, at the start of the log phase, t 2 , there is little foaming activity at the surface of the batch 105 . Shot time, determinative of additive volume, is set to an appropriate minimum, step 305 ; working time is set to the appropriate minimum, step 307 ; and the interval time is set to the appropriate maximum, step 309 . If the first anti-foaming agent introduction is at time=t 5 , the controller 110 is incremented, Δt=t 2 +i x , where x=an integer, to thereafter appropriately ramp the additive parameters, steps 311 - 315 , each interval until to compensate for the increase in foaming 125 at the surface of the batch 105 . Thus, after the next interval time, shot time is increased, working time is increased and interval time is decreased, in accordance with the feedback information from the probe 107 . This ramping of the injection parameters continues until the last mist injection of anti-foam agent 111 at t 10 when shot time is at a maximum value, working time is at a maximum value and the interval between t 9 and t 10 was a minimum value.
[0039] As can now be recognized, at each interval a substantially homogeneous mist of the additive has been spread across the entire surface of the batch. The mixing zone is thus optimized for working the agent into the batch.
[0040] Following the end of the log phase, t 11 , step 317 , and the start the product development phase, step 319 , the additives are no longer introduced.
[0041] The present invention thus provides an automated, post-sterile additive system and method for fermentation processes which is chemically balanced and establishes metabolic conditions at a substantially steady state. The foregoing description of the preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form or to exemplary embodiments disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in this art. Similarly, any process steps described might be interchangeable with other steps in order to achieve the same result. The embodiment was chosen and described in order to best explain the principles of the invention and its best mode practical application, thereby to enable others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use or implementation contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents. Reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather means “one or more.” Moreover, no element, component, nor method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the following claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for. . . .”
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A fermentation process post-sterile additive device and method of operation is detailed. The device is used to deliver additive as a heavy-drop mist. The mist covers the entire fermenting batch head surface of the vat broth. This improves mixing and reduces the amount of additive to appropriate introduction levels throughout log phase fermentation, preventing coating of cultivating cells and interference with cell respiration. A steady state growth rate is fostered.
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TECHNICAL FIELD
This invention relates to harmonic generation and, more particularly, to harmonic generation using insulating surfaces onto which metal particles have been deposited.
BACKGROUND OF THE INVENTION
The enhancement of surface Raman scattering due to microscopic surface roughness has been the subject of much investigation during recent years. It has been noted by those skilled in the art that surface roughness appears to be necessary in order to enhance Raman scattering on surfaces that have deposits of small metal particles. See, for example, the article entitled "Electromagnetic Theory of Enhanced Raman Scattering by Molecules Adsorbed on Rough Surfaces," by J. Gersten and A. Nitzan, J. Chem. Physics, Vol. 73, No. 7, October 1980, pp. 3023-3037. A theoretical model for Raman scattering by a molecule adsorbed at the surface of a spherical metal particle was the subject of a paper entitled "Surface Enhanced Raman Scattering (SERS) by Molecules Adsorbed at Spherical Particles: Errata," by M. Kerker et al, Applied Optics, Vol. 19, No. 24, Dec. 15, 1980, pp. 4159-4174. It was suggested in that paper that the theory presented therein for spheres could also be extended to long cylinders and to spheroids as well as to layered particles.
Theoretical investigations have also been conducted to determine the effect of constructing a grating surface of the metal which is used to provide enhanced Raman scattering from molecules that are adsorbed on that surface. See, for example, the article entitled "Intensity of Raman Scattering From Molecules Adsorbed on a Metallic Grating," by S. S. Jha et al, Physical Review B, Vol. 22, No. 8, Oct. 15, 1980, pp. 3973-3982. In the above-identified articles that relate to enhanced Raman scattering, it was recognized that one of the primary contributions is the plasmon resonances that are associated with the microscopic bumps on the metal surface. It has also been recognized in the art that this type of local field enhancement can be used to provide second harmonic generation at a silver air interface. See, for example, the article entitled "Surface-Enhanced Second-Harmonic Generation," by C. K. Chen et al, Physical Review Letters, Vol. 46, No. 2, Jan. 12, 1981, pp. 145-148. As stated in the Chen et al article, local field enhancement should also be present for all nonlinear optical processes. The Chen et al article reported measurements on second harmonic generation from smooth and roughened surfaces of bulk samples of silver, copper and gold. Large enhancements due to surface roughness were said to be observed.
The mechanism underlying both types of enhancements, harmonic generation and Raman scattering, is the modification of the local fields inside and surrounding a small dielectric particle. This resonance has been the subject of many theoretical studies. See, for example, chapter 11 of the book entitled "Theory of Electric Polarization," by C. J. F. Bottcher, Elsevier Scientific Publishing Company, 2nd Edition, 1973. As pointed out in the book by Bottcher, the field inside the particle is a function of the external electric field, the complex dielectric function of the particle and a depolarization factor that is dependent on the shape of the particle. It has been recognized in the art that resonant amplification of the internal field will occur if the particle is properly shaped. It has also been recognized in connection with surface enhanced Raman scattering that the radiation emitted may also be enhanced in view of the fact that a plasma sphere may amplify the radiation field twice. See, for example, the article entitled "Surface Enhanced Raman Scattering," by S. L. McCall et al, Physics Letters, Vol. 77A, No. 5, June 9, 1980, pp. 381-383.
SUMMARY OF THE INVENTION
A device which can provide harmonic generation is constructed in accordance with the present invention wherein metal particles having dimensions that are much less than the wavelength of light to be used as the fundamental input beam are deposited on a substrate surface such that they are insulated from each other and therefore operate as independent resonant metal particles. In accordance with the present invention these metal particles are deposited in an ordered array such that the spacing between adjacent rows is less than one-half of the wavelength of the fundamental beam and greater than one-half of the wavelength of the harmonic to be generated. Because of this spacing, the effective grating provided by the ordered array of metal particles provides a second harmonic along a path that is totally independent of the fundamental beam. As a result no additional filtering is necessary to remove energy at the fundamental wavelengths.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be more readily understood after reading the following detailed description in conjunction with the drawings wherein:
FIGS. 1-8 are cross sectional views of a silicon substrate with deposited layers that are used to construct a device in accordance with the present invention;
FIG. 9 is a cross sectional view of the device when used to provide second harmonic radiation, and
FIG. 10 is a top view of a substrate that can be used to construct a device with enhanced radiation at more than one harmonic frequency.
DETAILED DESCRIPTION
As pointed out in the above-identified text by Bottcher, the electric field E in inside a particle whose dimensions are small compared to the wavelength can be expressed by the following equation: ##EQU1## where E o is the magnitude of the external electromagnetic field, ε(ω) is the complex dielectric function of the particle and A is a depolarization factor whose values depend on the shape of the particle. This equation defines the local field enhancement factor f(ω) for particles whose dimensions are small relative to the wavelength. It can be seen from this equation that resonant amplification of the internal field will occur if the shape, packing density and frequency are such that the following condition is satisfied:
ε(ω)≈1-1/A (2)
Assuming that the particle has the shape of a general spheroid, the depolarization factor can be expressed by the following equation: ##EQU2## where the general spheroid has axes indicated by L 1 , L 2 and L 3 . The depolarization factors for the three axes will always satisfy the relationship A 1 +A 2 +A 3 =1. The values for the depolarization factor obtained for three types of general spheroids is given in the following table along with the values for the complex dielectric function that must be obtained in order to achieve a resonant amplification of the internal field.
______________________________________ A.sub.1 ε(ω.sub.o1) A.sub.2 (═A.sub.3) ε(ω.sub.o2)______________________________________sphere 1/3 -2 1/3 -23:1 ellipsoid 1/10 -9 9/20 -11/9infinitely sharp 1/∞ -∞ 1/2 -1needle______________________________________
As indicated in the table for the range of geometries from a sphere to a needle, the complex dielectric function can vary from -2 through to -∞ and produce a resonance along the major axis of the ellipsoid. If the particle is made out of silver, these dielectric values can be provided by radiation having wavelengths from 3543 Å through to the deep infrared. Similarly resonant amplification can be provided along a minor axis of the ellipsoid by dielectric functions that provide values from -2 through to -1. If the particle is silver, these values of dielectric functions can be provided by wavelengths from 3543 Å to 3369 Å.
For an n th order nonlinear process occurring in the surface layer of a particle, the polarization is given by ##EQU3## The source of the nonlinear polarizability X.sup.(n) can be either the metal particles, molecules adsorbed on the metal particles, the material of upstanding posts formed on a substrate, or the material of the substrate itself. Note that in each case the presence of a surface breaks inversion symmetry so that even centrosymmetric metals and nominally symmetric molecules will generate second harmonic radiation.
From equation 4 it can be seen that the polarization for the second harmonic (n=2) is proportional to f(2ω) and [f(ω)] 2 and therefore the second harmonic can be generated by either enhancing the f(2ω), the local field enhancement factor at the second harmonic, or by enhancing f(ω), the local field enhancement factor at the fundamental wavelength. Accordingly, the particles can be shaped in order to enlarge both local field enhancement factors and achieving a larger output at the second harmonic.
In the embodiment which was constructed in accordance with the present invention, small ellipsoidal silver particles were deposited on silicon dioxide posts with dimensions such that the second harmonic was enhanced by the major axis of the ellipsoid. The silicon dioxide posts were fabricated by starting with a silicon wafer 10 in FIG. 1 having a 500 nanometer thick thermally grown oxide layer 11. This silicon dioxide layer 11 is coated with a layer 12 consisting of 300 Å of chromium followed by a layer 13 consisting of 1000 Å of photoresist. The photoresist was then patterned by exposing it to an interference pattern having a 320 nanometer period that is formed by the interference from two 325 nanometer helium cadium laser beams. Two exposures were made with the sample rotated by 90 degrees between the exposures in order to create a crossed grating pattern. After development, an array of photoresist posts 13 is formed as shown in FIG. 2 of the drawing. This array of photoresist posts is then used as a mask for argon ion milling the chromium layer 12 thereby producing an array of photoresist and chromium posts as illustrated in FIG. 3.
The chromium makes an excellent mask for the final highly directional reactive plasma etching of the silicon dioxide layer 11. A CHF 3 plasma erosion of the chromium mask produces the slightly conically shaped posts of silicon dioxide shown in FIG. 4. The entire substrate is then chemically cleaned to remove all masking layers thereby producing a silicon substrate with silicon dioxide posts 14 as shown in FIG. 5. The substrates are quite durable and because silver can be easily removed, for example, with aqua regia, they can be reused many times.
The next step in the process is to evaporate silver onto the slightly conical silicon dioxide posts as illustrated in FIG. 6. As shown in FIG. 7 the silver is evaporated at an angle of about 82-85 degrees from a normal to the substrate thereby causing silver ellipsoids of the type illustrated in FIG. 8 to be formed on the topmost portions of the silicon dioxide posts. As a result, the array of silicon dioxide posts has the appearance of having grown metal beaks. The particles were determined to be quite uniform in size and as a first approximation can be considered to be ellipsoids with a 3:1 aspect ratio. For the embodiment constructed, each particle had dimensions of about 1000×1000×3000 Å. It should be readily apparent to those skilled in the art that ellipsoids with other aspect ratios can be obtained by varying the angle and duration of evaporation.
Since the posts that support the silver particles are arranged in a regular array and the light that is used and generated is coherent, it should not be surprising that diffraction effects can be observed. For a beam of light that is incident at an angle of θ in diffracted orders of the fundamental light at a wavelength λ 1 are determined by the following equation:
d(sin θ.sub.in -sin θ.sub.out)=m.sub.1 λ.sub.1 m.sub.1 =0,±1,±2 . . . (5)
where d is the post spacing and θ out is the exit angle. Due to the nonlinear effects on the surface, second harmonic light is created. This light will be diffracted along output rays that have discrete angles θ' out . To derive a modified equation for second harmonic generation, one has to take into account the fact that a phase lag of π along the path of an incident beam at the fundamental wavelength results in a phase change of 2π in the diffracted beam at the second harmonic. This leads to the following condition for the exit angle θ' out for the second harmonic:
d(sin θ.sub.in -sin θ'.sub.out)=m.sub.2 λ.sub.2, m.sub.2 =0,±1,±2 . . . (6)
where d is the post spacing and λ 2 is the wavelength of the second harmonic. The crucial point provided by Equations 5 and 6 is that since λ 1 =2λ 2 there are no exit angles provided by Equation 5 for the fundamental beam wavelength that are equivalent to the exit angles for the second harmonic corresponding to odd orders of m 2 . Accordingly, for odd orders of m 2 no fundamental light is diffracted along the corresponding angles θ' out , that is, Gaussian beams of second harmonic are physically separated from the fundamental beam.
To advantageously concentrate the generated second harmonic light in as few output beams as possible, the spacing d is chosen such that the following condition is satisfied
λ.sub.2 /2<d<λ.sub.1 /2. (7)
Under this condition there exists no other order than the specularly reflected beam m 1 =0 for the fundamental. For the second harmonic, however, there exists exactly one nontrivial solution for m 2 =+1. The second harmonic light is diffracted out at the angles θ' out =θ in (corresponding to the m 2 =0 specularly reflection) and at θ' out =sin -1 [sin θ in -λ 2 /d] (corresponding to the m 2 =1 reflection). There is no fundamental light along the latter output angle. The second harmonic diffraction along this direction can therefore be utilized without having to filter out the fundamental wavelength.
In the embodiment which was constructed the silicon dioxide posts were at a spacing of 3150 Å. The silver particles were exposed to a coherent beam of radiation having a wavelength of 10,640 Å thereby creating a second harmonic of 5320 Å which was resonant with the major axis of the ellipsoid particles. By directing the fundamental beam toward the silver particles at an angle of incidence equal to 75 degrees as illustrated in FIG. 9, a well defined beam of second harmonic light was back-reflected at an angle of -45±2 degrees with respect to the normal, again as illustrated in FIG. 9. No fundamental light was determined to be diffracted along this direction. The observed angle agrees quite well with the calculated value of -47 degrees.
As pointed out hereinabove, the metal particles can also be shaped so as to enhance both the fundamental and the second harmonic. By shaping the particles into ellipsoids that have a 6 to 1 aspect ratio, the depolarization factors of A 1 =0.04323 and A 2 =0.4784 can be obtained. Resonant enhancement for these values of depolarization factors will occur with a dielectric function equal to -22.13 at the fundamental wavelength and equal to -1.09 at the second harmonic. If using silver particles, these values of dielectric function can be obtained at wavelengths of 6879 Å and 3388 Å. These two plasmon frequencies are very close to the ratio of 1 to 2 which is ideal for second harmonic generation.
It should also be apparent to those skilled in the art that the particles may be shaped in even a third dimension in order to create resonant enhancement at other harmonic wavelengths. This type of shaping can be achieved by using a substrate having silicon dioxide posts with cross sectional shapes other than a circle. For example, the silicon dioxide posts illustrated in FIG. 10 would create silver particles that have three different dimensions. One dimension will be dependent on the grazing angle of the evaporated metal, a second dimension will be dependent on the duration of the evaporation, and the third dimension will be dependent on the dimension W of the posts.
It should be readily apparent to those skilled in the art that numerous departures may be made without departing from the spirit and scope of the present invention. The fundamental concept is to space the posts at a dimension which will permit the harmonic wavelength to be present along a spatial direction that is independent of the fundamental. In addition, the metal particles can be variously shaped and dimensioned in order to enhance not only the fundamental but also the harmonic wavelengths. Furthermore, the nonlinearity can be provided either by the metal particles or by molecules or materials that are placed on or near the surface that contains the metal particles. In particular, the nonlinear material may be the material used to support the metal particles, i.e., the posts. In this case, a post material such as lithium niobate with a very large intrinsic nonlinearity could be chosen.
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Metal ellipsoidal particles are deposited on an ordered array of silicon dioxide posts. Each of the particles has dimensions that are less than the wavelength of a fundamental beam to be used in the generation of second harmonic radiation. The rows of particles in the ordered array are spaced at a distance that is less than one-half of the fundamental wavelength and greater than one-half of the second harmonic wavelength.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a division of co-pending application Ser. No. 832,191 filed 2/24/86, U.S. Pat. No. 4772683.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a novel process for producing novel intermediates useful in the synthesis of 1- β-alkyl carbapenems.
2. Description of the Prior Art
A wide variety of carbapenems, such as the natural fermentation product thienamycin (Formula I), have been reported in the patent and scientific literature as having exceptional antibacterial activity. ##STR3##
However, researchers attempting to develop thienamycin have encountered two problems, namely: (1) the compound is very difficult to ferment and isolate, and (2) the product is very unstable, such that it reacts with itself and decomposes. To circumvent these problems, carbapenem derivatives have been prepared which possess excellent stability and antibacterial spectra.
One such group of derivatives currently being investigated is the 1- β-methyl carbapenems of the formula: ##STR4##
wherein R 1 is hydrogen or a conventional hydroxy-protecting group; and
R 2 and R 3 are independently selected from the group consisting of substituted and unsubstituted: alkyl, alkenyl and alkynyl, having from 1-10 carbon atoms; cycloalkyl, cycloalkylalkyl and alkylcycloalkyl, having 3-6 carbon atoms in the cycloalkyl ring and 1-6 carbon atoms in the alkyl moieties; spirocycloalkyl having 3-6 carbon atoms; phenyl; aralkyl, aralkenyl and aralkynyl wherein the aryl moiety is phenyl and the aliphatic portion has 1-6 carbon atoms; heteroaryl, heteroaralkyl, heterocyclyl and heterocyclylalkyl wherein the hetero atom or atoms in the above-named heterocyclic moieties are selected from the group consisting of 1-4 oxygen, nitrogen and sulfur atoms and the alkyl moieties associated with said heterocyclic moieties have 1-6 carbon atoms; wherein the substituent or substituents relative to the above-named radicals are selected from the group consisting of: amino, mono-, di- and trialkylamino, hydroxyl, alkoxyl, mercapto, alkylthio, phenylthio, sulfamoyl, amidino, guanidino, nitro, chloro, bromo, fluoro, cyano and carboxy; and wherein the alkyl moieties of the above-recited substituents have 1-6 carbon atoms.
Recently reported synthetic schemes for producing 1- β-methyl carbapenems of Formula II, such as those of Shih et al., Heterocycles, volume 21, no. 1, pages 29-40 (1984), proceed through intermediates of the formula ##STR5## from which the 1- β-methyl carbapenems can be formed easily and in high yield. Unfortunately, however, these schemes require numerous other intermediates and time consuming steps to produce the above intermediate, each of which increases the process time and decreases the overall yield. Furthermore, the steps required to produce β-methyl intermediate III also produce a large amount of the corresponding α-methyl product. Accordingly, there is a need for a stereoselective process which provides a high percentage β-yield (the yield of β-product/the total yield of product) of intermediates which can easily be converted to 1- β-alkyl carbapenems.
One recent process of interest described by Tajima et al, in Tetrahedron Letters, volume 26, no. 5, pp. 673-676 (1985), discloses the reaction of silyl enol ether intermediates with 4-acetoxyazetidinone to produce compounds of the formula ##STR6##
wherein R 1 is a hydroxy-protecting group, and R 2 is selected from the group consisting of ##STR7##
wherein PNZ is p-nitrobenzyloxycarbonyl, and TMS is trimethylsilyl.
This procedure has been viewed with interest because it bypasses several steps of conventional carbapenem syntheses. However the interest has been limited because practioners now wish to produce 1- β-alkyl carbapenem intermediates, and Tajima et al provides no guidance for a stereoselective process which provides a high percentage β-yield of such intermediates.
Other procedures, such as those disclosed in U.S. patent application Ser. No. 725,594 filed Apr. 22, 1985, which is a continuation-in-part of U.S. patent application Ser. No. 472,443 filed Mar. 7, 1983, use silyl enol ether precursors for preparing 1- β-alkyl carbapenem intermediates. These processes, however, do not use azetidinone thiolesters and thus provide no guidance for processes which do.
Accordingly, it would be desirable to produce azetidinone thiolester intermediates by a silyl enol ether process, which intermediates can be used to produce 1- β-alkyl carbapenems. Furthermore, it would be desirable that such process be stereoselective and provide a high percentage β-yield.
SUMMARY OF THE INVENTION
This invention is directed to novel intermediates and a novel high β-yield process for preparing intermediates useful in the synthesis of 1- β-alkyl carbapenems, which novel intermediates have the formula ##STR8## wherein R 1 is hydrogen or a conventional hydroxyprotecting group, R 2 is a lower alkyl having from 1-6 carbon atoms,
R 3 is hydrogen or a triorganosilyl group, and
R 4 represents a group of the formula ##STR9## wherein R 5 and R 6 independently, or taken together, are selected from the group consisting of hydrogen, substituted and unsubstituted: alkyl, alkenyl and alkynyl, having from 1-10 carbon atoms; cycloalkyl, cycloalkylalkyl and alkylcycloalkyl, having 3-6 carbon atoms in the cycloalkyl ring and 1-6 carbon atoms in the alkyl moieties; spirocycloalkyl having 3-6 carbon atoms; phenyl; aralkyl, aralkenyl and aralkynyl wherein the aryl moiety is phenyl and the aliphatic portion has 1-6 carbon atoms; heteroaryl, heteroaralkyl, heterocyclyl and heterocyclylalkyl wherein the hetero atom or atoms in the above-named heterocyclic moieties are selected from the group consisting of 1-4 oxygen, nitrogen and sulfur atoms, providing that when R 5 and R 6 are taken together to form said heterocyclic moiety, said moiety contains at least one hetero nitrogen atom, and the alkyl moieties associated with said heterocyclic moieties have 1-6 carbon atoms; wherein the substituent or substituents relative to the above-named radicals are selected from the group consisting of: amino, mono-, di- and trialkylamino, hydroxyl, alkoxyl, mercapto, alkylthio, phenylthio, sulfamoyl, amidino, guanidino, nitro, chloro, bromo, fluoro, cyano and carboxy; and wherein the alkyl moieties of the above-recited substituents have 1-6 carbon atoms, and which process comprises the steps of:
(A) reacting a compound of the formula ##STR10## wherein R 2 and R 4 are as defined above,
with a triorganosilyl triflate silylating agent to yield a silyl enol ether intermediate of the formula ##STR11## wherein R 2 and R 4 are as defined above, R 7 is a triorganosilyl group, and
(B) reacting Compound 8 with a compound of the formula ##STR12## wherein R 1 and R 3 are as defined above, and L is a leaving group capable of being displaced by nucleophilic substitution of Compound 8.
Saponification of Compound 12 yields the corresponding carboxylic acid, from which 1- β-alkyl carbapenems can be synthesized using well-known methods.
Normally, processes similar to the above process can be expected to yield a racemic mixture of intermediate 12, i.e., a mixture of geometric isomers wherein R 2 is in either the α- or β- configuration. Since the desired final product, i.e., the carbapenem, is of the β-configuration, a high β-yield of intermediate 12 is desireable. Unfortunately, however, previous attempts to obtain high β-yields have failed since most R 4 groups provide the α-isomer as the predominant product.
Surprisingly, it has been discovered that if R 4 is selected from a small group of moieties having the formula: ##STR13## wherein R 5 and R 6 are as defined above, an increased β-yield of up to approximately 100% can be obtained.
DETAILED DESCRIPTION OF THE INVENTION
The process for preparing the intermediates of this invention may conveniently be summarized by the following reaction sequence of Diagram 1. In this reaction, the silyl enol ether 8 of thioester 6 is generated in Step (A), and without separation is coupled, in Step (B), to azetidinone 10 by nucleophilic displacement of the 4-position leaving group "L". The resulting intermediate 12 (illustrated in the β-isomer form) can then be saponified in Step (C) to yield the corresponding carboxylic acid 14, which can be converted to a 1-β-alkyl carbapenem by reported procedures. Diagram 1 is as follows: ##STR14##
Referring now to Diagram 1, Step (A) illustrates the reaction between thioester 6 and a triorganosilyl triflate silylating agent to form the silyl enol ether 8. The reaction of Step (A) is carried out in an inert organic solvent and in the presence of an organic base. Suitable inert organic solvents which can be used include methylene chloride, tetrahydrofuran, carbon tetrachloride, cyclohexane, dioxane, dimethoxyethane, diethyl ether and chloroform. Reaction temperatures can be the range of from about -40° C. to +30° C. Most conveniently the reaction is carried out by mixing the reactants under cooling, advantageously between about -15° C. and 0° C., and the allowing them to gradually warm to room temperature.
Triorganosilyl triflate silylating agents are well known, and include trimethylsilyl trifluoromethanesulfonate, triisopropylsilyl trifluoromethanesulfonate, triethylsilyl trifluoromethanesulfonate, t-butyldimethylsilyl trifluoromethanesulfonate, t-butyldiphenylsilyl trifluoromethanesulfonate, or 2, 4, 6,-tri(t-butylphenoxy) dimethylsilyl trifluoromethanesulfonate. Advantageous results have been obtained using t-butyldimethylsilyl trifluoromethanesulfonate. Thus, R 7 will be the triorganosilyl residue of the particular triorganosilyl triflate silylating agent used.
Suitable organic amine bases include diisopropylethylamine, DBU (1,8-diazabicyclo[5.4.0]undec-7-ene), DBN (1,5-diazabicyclo[4.3.0]non-5-ene), but especially preferred are the tri(C 1 -C 4 )alkylamines such as trimethylamine, triethylamine, tributylamine and tripropylamine. It has been found, however, that in at least one instance a stronger base should be used to carry out the reaction of Step (A). When 3-methyl-2-(propionylthio-methyl)-pyridine is the thioester used, a stronger base such as lithium hexamethyl disilazane or lithium diisopropyl amide is advantageously used. (See Example 4).
Generally, the organic base and triorganosilyl triflate silylating agent are present in an approximately twofold molar excess when compared to the thioester 6, with the base being slightly in excess of the triorganosilyl triflate silylating agent. Reaction times usually vary from about one hour to about five hours, but generally a maximum yield will be obtained in about three hours. In one instance, however, a 70 hour reaction time was used to obtain maximum yield (Example 2). Advantageously, the reaction is carried out under an inert atmosphere.
As stated above, R 2 is lower alkyl having from 1-6 carbon atoms, but advantageously is methyl since 1-β-methyl carbapenems have been found to posess excellant antibiotic properties. R 3 is hydrogen or a triorganosilyl group, and R 4 is a group of the formula ##STR15##
wherein R 5 and R 6 independently, or taken together, are selected from the group consisting of hydrogen, substituted and unsubstituted: alkyl, alkenyl and alkynyl, having from 1-10 carbon atoms; cycloalkyl, cycloalkylalkyl and alkylcycloalkyl, having 3-6 carbon atoms in the cycloalkyl ring and 1-6 carbon atoms in the alkyl moieties; spirocycloalkyl having 3-6 carbon atoms; phenyl; aralkyl, aralkenyl and aralkynyl wherein the aryl moiety is phenyl and the aliphatic portion has 1-6 carbon atoms; heteroaryl, heteroaralkyl, heterocyclyl and heterocyclylalkyl wherein the hetero atom or atoms in the above-named heterocyclic moieties are selected from the group consisting of 1-4 oxygen, nitrogen and sulfur atoms, providing that when R 5 and R 6 are taken together to form said heterocyclic moiety, said moiety contains at least one hetero nitrogen atom, and the alkyl moieties associated with said heterocyclic moieties have 1-6 carbon atoms; wherein the substituent or substituents relative to the above-named radicals are selected from the group consisting of: amino, mono-, di- and trialkylamino, hydroxyl, alkoxyl, mercapto, alkylthio, phenylthio, sulfamoyl, amidino, guanidino, nitro, chloro, bromo, fluoro, cyano and carboxy; and wherein the alkyl moieties of the above-recited substituents have 1-6 carbon atoms.
Advantageously, however, R 5 and R 6 are taken together and R 4 represents a group selected from the group consisting of substituted and unsubstituted: heteroaryl, heteroaralkyl, heterocyclyl and heterocyclylalkyl wherein the hetero atom or atoms in the above-named heterocyclic moieties includes at least one nitrogen and the remaining hetero atoms, if any, are selected from the group consisting of 1-4 oxygen, nitrogen and sulfur atoms and the alkyl moieties associated with said heterocyclic moieties have 1-6 carbon atoms; wherein the substituent or substituents relative to the above-named radicals are selected from the group consisting of: amino, mono-, di- and trialkylamino, hydroxyl, alkoxyl, mercapto, alkylthio, phenylthio, sulfamoyl, amidino, guanidino, nitro, chloro, bromo, fluoro, cyano and carboxy; and wherein the alkyl moieties of the above-recited substituents have 1-6 carbon atoms.
More advantageously, R 4 is selected from the group consisting of 5 or 6 membered heterocyclic rings such as 2-picolyl (Example 1); 2-methylene-3-methylpyridine (Example 4); 3-methyleneisothiazole (Example 9); and 1-methyl-2-methyleneimidazole (Example 11). These groups have proven to be stable and to provide excellent β-yields. The most advantageous R 4 is 2-methylene-3-methylpyridine (Example 4), which yields approximately 100% of the β-isomer of intermediate 12.
In Step (B), the silyl enol ether 8 is reacted with a 4-position substituted azetidinone 10 to yield intermediate 12. The reaction is carried out in the presence of a Lewis acid catalyst and a solvent which is inert in the presence of the Lewis acid catalyst.
Suitable inert solvents, which are discussed above, are advantageously dry, and will generally comprise about 10% of the total reaction mixture volume. Dichloromethane has been found to provide satisfactory results.
Suitable Lewis acid catalysts include zinc halides, zirconium halides and boron trifluoride. Zinc chloride has been found to provide satisfactory results.
Azetidinone 10 is substituted by a leaving group "L" in the 4-position, a hydrogen or conventional hydroxy-protecting group in the 3-position, and a hydrogen or triorganosilyl group on the 1-position nitrogen.
Hydroxy-protecting groups, which are known to those skilled in the art, are desirable because they prevent side reactions and provide increased yields in later steps of the reaction sequence. Suitable hydroxy-protecting groups may be, for example, acyl groups such as benzyloxy-carbonyl, benzhydryloxycarbonyl, trityloxycarbonyl, p-nitro-benzyloxy-carbonyl and 2,2,2-trichloroethoxycarbonyl, aralkyl groups such as benzyl, benzhydryl, trityl or p-nitrobenzyl or triorganosilyl groups such as tri(C 1 -C 6 )alkylsilyl (e.g. trimethylsilyl, triethylsilyl, triisopropylsilyl, isopropyldimethylsilyl, t-butyldimethylsilyl, methyldiisopropylsilyl or methyldi-t-butylsilyl), triarylsilyl (e.g. triphenylsilyl, tri-p-xylylsilyl) or triaralkylsilyl (e.g. tribenzylsilyl). Examples of these and other suitable hydroxy-protecting groups and methods for their formation and removal are known in the art, e.g. see Protective Groups in Organic Synthesis, T. W. Greene, John Wiley & Sons, New York, 1981, Chapter 2.
The hydroxy-protecting group selected is preferably one that is removable at a later stage of the reaction process. Bulky triorganosilyl groups such as triisopropylsilyl, t-butyldiphenylsilyl or t-butyldimethylsilyl are advantageously employed because they provide for as essentially stereo-controlled reduction step. Such groups can be readily removed under mild conditions, e.g. by treatment with methanolic HCl or with fluoride ion (e.g. tetra-n-butyl ammonium fluoride/tetrahydrofuran), which preserves the sensitive β-lactam nucleus.
The 4-position substituent of Compound 10 is designated by "L", which represents a leaving group capable of being displaced by nucleophilic substitution of the silyl enol ether 8. Such leaving groups include acyloxy (e.g., acetoxy, propionyloxy or t-butyryloxy), halogen, (e.g., chloro), arylsulfonyl (e.g., phenylsulfonyl), mesyl, tosyl, etc. Advantageously, "L" is acetoxy because 4-acetoxyazetidinone is a readily available starting material.
The 1-position nitrogen substituent R 3 is normally a hydrogen, but can alternatively be a triorganosilyl group (e.g., trimethylsilyl), which is described above. Carbapenem syntheses using triorganosilyl groups on the 1-position nitrogen are well known (e.g., Merck, Drugs of the Future, volume 9, no. 5, pp 336-338, at 337, 1984).
The reaction of Step (B) is advantageously carried out under an inert atmosphere, and at a temperature of from about -30° C. to about room temperature. Advantageously, the reactants are added under cooling, about -15° C. to about +5° C. and allowed to gradually warm to room temperature. After warming, the reaction can be stirred for up to 30 hours to achieve maximum yield.
Generally, the zinc chloride and the 4-substituted azetidinone 10 are reacted in approximately equimolar amounts. The silyl enolate 8 is advantageously present in an excess of at least about 1.5 to about 3 mole equivalents per equivalent of azetidinone 10.
The α- and β-isomers of the resulting intermediate 12 can be separated by HPLC. Alternatively, the β-isomer can be separated from the α-isomer upon saponification of intermediate 12, which yields the corresponding carboxylic acid 14 because the β-isomer preferentially crystallizes when the β/α yield is about 2/1 or greater.
In Step (C), Compound 12 is saponified to yield the corresponding carboxylic acid 14. Saponification is a well known procedure of organic chemistry and can be carried out as follows. Compound 12 can first be disolved in a solvent such as 2:1 mixture of THF/water. Then, under cooling, an excess of inorganic base, such as sodium hydroxide, is added. Hydrogen peroxide may also be added. The reaction is usually complete within about 30 minutes. The carboxylic acid 14 is yielded upon subsequent acidification with an inorganic acid such as hydrochloric acid. A similar saponification is described by Shih et al, Heterocycles, volume 21, no. 1, pp 29-40, at 31 (1984).
Tables 1 and 2, and the 17 Examples which follow, illustrate the results of numerous experimental reactions carried out in accordance with the process of this invention. The results of these reactions illustrate the dramatic effect of the R 4 substituent on the β-yield of intermediate 12. In these reactions, R 1 is t-butyldimethylsilyl, R 3 is hydrogen, and t-butyldimethylsilyl trifluoromethanesulfonate is the silylating agent used.
Table 1 is a compilation of the β/α yield, and the overall yield (in percent by weight) obtained in Examples 1-15, wherein R 2 is methyl. This table facilitates comparison of the effect of various R 4 groups on the β-yield of intermediate 12. Most noticeable are Examples 4 and 5 wherein a 100% yield of the β-methyl isomer is obtained using a 2methylene-3-methylpyridine group as R 4 . Table 1 is as follows:
TABLE 1______________________________________FORMATION OF COMPOUND 12 WITH ##STR16## B/A YIELDEXAMPLE R.sup.4 RATIO (PBW)______________________________________ ##STR17## 87/13 88.6(oil) 80.0(crystal)2 ##STR18## 15/85 1003 ##STR19## 1/1 494 ##STR20## 100/0 975A ISOMER A 9/1 335B ISOMER B 100/0 556 ##STR21## 19/81 847 ##STR22## 1/9 918 t-BUTYL 8/92 749 ##STR23## 75/25 6510 ##STR24## 8/92 3711 ##STR25## 90/10 8512 ##STR26## 40/60 6613 ##STR27## 1.5/98.5 7614 ##STR28## 14/86 6715 ##STR29## 40/60 58______________________________________
Table 2 is a compilation of the β/α yield, and the overall yield (in percent by weight) obtained in Examples 16 and 17, wherein R 2 is ethyl.
TABLE 2______________________________________ ##STR30## YIELDEXAMPLE R.sup.4 B/A RATIO (PBW)______________________________________16 t-BUTYL 0/100 9217 ##STR31## 100/0 78______________________________________
The following examples illustrate the best mode for carrying out this invention.
EXAMPLE 1
A. Preparation of S-(2-picolyl)thiopropionate ##STR32##
To a cold (ice bath) aqueous (600 mL) solution of NaOH (60.0 g, 1.5 mol) previously purged with a stream of N 2 (30 minutes) was added S-(2-picolyl)thioacetate (100 g, 0.600 mol). The heterogenous mixture was stirred for 1.5 hour during which it became homogeneous. It was then washed twice with 200 mL of methylene chloride neutralized (pH 7.5, ice bath) with cold concentrated HCl and extracted with methylene chloride (2×200 mL). The methylene chloride extracts were combined, washed with water (2×500 cc), brine (1×500 mL) and dried (Na 2 SO 4 ). The volume of the organic solution was adjusted to 800 mL with CH 2 Cl 2 , cooled to 5° C. (ice bath), treated first with triethylamine (100.4 mL, 0.720 mol) and then propionyl chloride (57.4 mL, 0.660 mol) was added dropwise over a 20 minute period. The mixture was stirred for 30 minutes at 5° C., washed with cold water (2×400 mL), brine (1×400 mL), dried (Na 2 SO 4 ), and the solvent was evaporated. The residue was diluted with ether, treated with neutral activated carbon and filtered through a Celite pad. The residue upon evaporation of the solvent was distilled under high vacuum to give title compound (94.7 g, b.p. 90-98° C./0.6-0.3 mmHg).
B. Preparation of t-butyldimethylsilyl enol ether of S-(2-picolyl)thiopropionate ##STR33##
To a cold (-15° C.) methylene chloride (dried over 3A mole sieves, 500 mL) solution of S-(2-picolyl)thiopropionate (50.0 g, 0.276 mol) was added first triethylamine (69 mL, 0.495 mol) followed by the dropwise addition of TBDMS-triflate (95.3 mL, 0.415 mol). The mixture was stirred at room temperature for 3 hours after which TLC showed that no starting material was left. The solvent was evaporated at below 3° C. and the residue was taken up in petroleum ether. The cold mixture (solution-black gum) was washed with cold water (3×500 mL), cold brine (1×500 mL) dried (MgSO 4 ), treated with neutral activated carbon and filtered. Evaporation of the solvent gave title compound (68.19 g, 84% yield) as a red oil which was obtained as a mixture of 2 isomers (45:55); ir (CH 2 Cl 2 ) ν max : 1635 (double bond) and 1595 cm -1 (ar); 1 Hmr (CDCl.sub. 3) δ: 8.55-6.95 (4H, m, ar), 4.98 (1H, 5 lines, isomeric H-vinyl), 4.04 and 3.97 (2H, 2s, isomeric --CH 2 --), 1.54 and 1.55 (3H, 2d, J=6.9 Hz, J=6.7 Hz, isomeric --CH 3 ), 0.99 and 0.95 (9H, 2s, t-butyl), 0.19 and 0.23 ppm (6H, 2s, dimethyl).
C. Preparation of (3S, 4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R)-1"-(2-picolylthiocarbonyl)-ethyl]-azetidin-2-one ##STR34##
In a 1 L three neck flask, ZnCl 2 (23.8 g, 0.175 mol) was melted under N 2 , allowed to cool at room temperature and pulverized. A solution of (3S,5R)-4-acetoxy-3-[(1'R-t-butyldimethylsilyloxyethyl)]-azetidin-2-one (50.0 g, 0.174 mol) in CH 2 Cl 2 (375 mL) was added. The mixture was cooled at 5° C. (ice bath), treated with the t-butyldimethylsilyl enol ether of S-(2-picolyl)thiopropionate (77.0 g, 0.261 mol) in CH 2 Cl 2 (75 mL) and stirred at room temperature for 20 hours. It was treated again with the enol ether (12.75 g, 43 mmol) stirred for two more hours after which TLC revealed no more 4-acetoxyazetidinone. The mixture was washed with water (3×600 mL), brine, dried (Na 2 SO 4 ) and the solvent was evaporated. The crude product obtained from a reaction on 81 g of 4-acetoxyazetidinone was purified on silica gel flash (2.8 L, petroleum). The title compound was eluted with ethyl acetate (88.6% oil, 80% crystalline, heptane) m.p.: 55-58° C., and was shown to be a 87:13 mixture of β- and α-methyl isomers. β-methyl: ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1765 (β-lactam), 1682 (thioester) and 1594 cm (ar); 1 Hmr (CDCl 3 ) δ: 8.57-7.24, (4H,m, ar), 5.82 (1H, s, N-H), 4.30 (2H, s, --CH 2 ), 4.30-4.00 (1H, m, H-1), 3.88 (1H, dd, J=2.2 Hz, J=6.4 Hz, H-4), 3.15-2.7 (2H, m, H-3, --CH--C--S--), 1.25 (3H, d, J=6.9 Hz, CH 3 -2'), 1.07 (3H, d, J=6.3 Hz, --CH 3 ), 0.86 (9H, s, t-butyl) and 0.05 ppm (6H, dimethyl-Si-). α-methyl; ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1765 (β-lactam C=O) and 1780 cm -1 (thioester); 1 Hmr (80 MHz, CDCl 3 ) δ: 8.55, 8.54, 8.50, 8.49 (1H, m, H-arom) 7.75, 7.72, 7.65, 7.62, 7.55, 7.53, (1H, m, H-arom), 7.22-7.0 (2H, m, H-arom), 6.21 (1H, 6s, N-H), 4.42, 4.29, 4.25 (2H, part of ABq, J=14 Hz, CH 2 --S), 4.17, 4.09, 4.08 (1H, m, part of H'), 3.78, 3.75, 3.66, 3.63 (1H, dd, J=2.0 Hz, J=9.6 Hz, H-4), 2.95-2.55 (2H, m, H-3, H-1"), 1.31, 1.22 (3H, d, J=7.0 Hz, CH 3 ), 1.26, 1.18 (3H, d, J=6.2 Hz, CH 3 ), 0.87 (9H, s, t-butyl-Si) and 0.07 ppm [6H, (CH 3 ) 2 -Si].
EXAMPLE 2
A. Preparation of S-(2-furylmethyl)thiopropionate ##STR35##
A cold (ice bath) solution of furfuryl mercaptan (75.6 mL, 750 mmol) in CH 2 Cl 2 (750 mL) was treated with propionyl chloride (65.1 mL, 750 mmol) followed by the drop-wise addition of triethylamine (14.2 mL, 875 mmol). The mixture was stirred at room temperature (22° C.) for 1.5 hour, diluted with CH 2 Cl 2 (250 mL) and successively washed with water, 1N aqueous HCl, water 1M aqueous NaHCO 3 , water and brine. The organic solution was dried (MgSO 4 ), evaporated, diluted with ether (500 mL), and treated with neutral activated charcoal. The residue (88 g, 69%) upon evaporation of solvent was distilled to give the title compound (19.5 g, b.p. 64°-67°/0.3 mm Hg). When this reaction was repeated on a 43.8 g scale and stirred for 70 hours, it gave title material in a much better yield (48.6 g, 75%). ir (CH 2 Cl 2 ) ν max : 1690 cm -1 (C=O thioester); 1 Hmr (60 MHz, CDCl 3 ) δ: 7.32 (1H-4), 6.27 (2H, m, H-3,4), 4.17 (2H, s, CH 2 ), 2.55 (2H, q, J=7 Hz, CH 2 ) and 1.17 ppm (3H, t, J=7 Hz, CH 3 ).
B. Preparation of t-butyldimethylsilyl enol ether of S-(2-furylmethyl)thiopropionate ##STR36##
A cold (MeOH-ice bath) solution of S-(2-furylmethyl) thiopropionate (42.5 g, 250 mmol) in CH 2 Cl 2 (400 mL) was treated first with triethylamine (87.5 mL, 625 mmol), then dropwise with TBDMS-triflate (115 mL, 500 mmol). The mixture was stirred at 22° C. for 2 hours, diluted with a 1:1 mixture of cold ether-petroleum ether (1.2 L), washed with cold water (2×500 mL), cold brine, dried MgSO 4 ) and treated with activated neutral charcoal to give the title material (68.4 g, 96%), which was a mixture of geometric isomers as shown by 1 Hmr; ir (neat) ν max : 1690 cm -1 (thioester C=O); 1 Hmr (60 MHz, CDCl 3 ) δ: 7.3 (1H, bs, H-5), 6.2 (1H, m, H-4), 6.1 (1H, m, H-3), 5.0 and 4.95 (1H, 2 q, J=7 Hz, H-4), 3.87, 3.80 (2H, 2s, CH 2 ), 1.52 and 1.50 (3H, d, J=7 Hz, CH 3 ), 0.9 (9H, s, t-butyl-Si) and 0.15 ppm (6H, s, (CH 3 ) 2 -Si).
C. Preparation of (3S, 4S)-3-[1'-t-butyldimethylsilyloxyethyl]-4-[1"R and S)-1"-(2-furanylmethylthiocarbonyl)-ethyl]-azetidin-2-one ##STR37##
To freshly melted zinc chloride (6.8 g, 50 mmol) in CH 2 Cl 2 (150 mL) was added at 5° C. (ice bath) (3S, 4R)-4-acetoxy-3-[(1'-R)-1'-t-butyldimethylsilyloxyethyl]azetidin-2-one (14.37 g, 50 mmol) and the t-butyldimethylsilyl enol ether of S(2-furyl-methyl)thiopropionate (28.4 g, 100 mmol) in CH 2 Cl 2 (50 mL). The mixture was stirred at 22° C. for 18 hours, diluted with a 1:1 mixture of ether-ethyl acetate (500 mL), washed with water (2×500 mL) and brine (1×500 mL) and dried (MgSO 4 ). The solvent was evaporated and the residue was passed on a flash silica gel (250 g) pad (petroleum ether/ether: 7/3 and 1:1) to the give title material (19.49 g, 100%) as a 85:15 mixture α- and β-methyl isomers; ir (CH 2 Cl 2 ) ν max : 3410 (NH), 1765 (β-lactam C=O) and 1685 cm -1 (thioester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 7.33 (1H, m, H-arom), 6.32-6.18 (2H, m, H-arom), 5.90 (0.85 H, b.s. NH), 5.75 (0.15 H, shoulder, N-H), 4.32, 4.24, 4.10, 3.0 (1H, m, part of H-1'), 4.16(2H, s, CH 2 ), 3.87 (0.15 H, dd, H-4 β-methyl), 3.74 (0.85 H, dd, J=2.1 Hz, J=9.5 Hz, H-4 α-methyl), 3.0-2.5 (Hz, m, H-3 and H-1"), 1.26 (3H, d, J=7.0 Hz, CH 3 ), 1.22 (3H, d, J=6.3 Hz, CH 3 ), 0.87 (9H, s, t-butyl-Si) and 0.07 ppm (6H, s, (CH 3 ) 2 0Si;. Anal. calcd for C 19 H 31 NO 4 SSi: C 57.40, H 7.86, N 3.52; found: C 57.80, H 7.94, N 3.49.
EXAMPLE 3
A. Preparation of dimethylaminoethylthiopropionate ##STR38##
A cold (ice bath) solution of dimethylaminoethyl mercaptan (3.54 g, 25.0 mmol) in CH 2 Cl 2 (50 mL) was treated dropwise with triethylamine (3.5 mL, 25 mmol) and stirred for 15 minutes. The cold solution was treated dropwise with propionyl chloride (2.3 mL, 26.5 mmol) followed by the drop-wise addition of triethylamine (3.9 mL, 28 mmol). The reaction mixture was then allowed to warm up to room temperature and stirred for 1.5 hour. The mixture was washed with cold water (2×25 mL), brine and dried over MgSO 4 . The residue obtained upon solvent evaporation was distilled to give the title compound (b.p. 46°-50° C/0.5 mm Hg. Yield: 1.7 g, (42%); ir (CH 2 Cl 2 ) ν max : 1690 cm -1 (thioester C=O); 1 Hmr (60 MHz, C 3 D 6 O) δ: 2.95 (2H, q, J=7 Hz, CH 3 CH 2 ), 2.52 (4H, t, J=7 Hz, CH 2 ), 2.22 (6H, s, N-CH 3 ) and 1.1 ppm (3H, t, J=7 Hz, CH 3 CH 2 ).
B. Preparation of t-butyldimethylsilyl enol ether of dimethylaminoethylthiopropionat ##STR39##
A cold (MeOH-ice) solution of dimethylaminoethylthiopropionate (805 mg, 5 mmol) in CH 2 Cl 2 (10 mL) was treated dropwise first with triethylamine (1.4 mL, 10 mmol) and TBDMS-triflate (1.9 mL 8.3 mmol). The reaction mixture was stirred for 1.5 hour at 22° C, diluted with a 1:1 mixture of ether-petroleum ether, washed with cold water (2×25 mL), brine (1×25 mL), dried (MgSO 4 ). The solvent was evacuated in vacuo to give title compound as a 1:1 geometric mixture (1.4 g, 100%); ir (CH 2 Cl 2 ) ν max : 3040-2780 (CH) and 1682 cm -1 (olefin); 1 Hmr (60 MHz, C 3 D 6 O) δ: 5.07 and 5.0 (1H, 2 q, J=7.0 Hz, - H), 3.0-2.32 (4H, m, CH 2 ), 2.20 (6H, s, N-(CH 3 ) 2 ), 1.85, 1.75 (3H, 2d, J=7.0 Hz, CH 3 ), 0.95, 0.92 (9H, 2s, t-Bu-Si), and 0.022, 0.018 ppm (6H, 2s, (CH 3 ) 2 -Si).
C. Preparation of (3S, 4S)-3-[1'R)-1'-t-butyldimethylsilyloxyethyl-4-(1"R and S)-1"-(dimethylaminoethylthiocarbonyl)-ethyl]-azetidin-2-one ##STR40##
Zinc chloride (272.5 mg, 2 mmol) was freshly fused (under N 2 ) with a flame and allowed to cool down at room temperature. CH 2 Cl 2 (8 mL) was added and the mixture was cooled to 5° C. (ice). Then (3S, 4R)-3-[(1'-R-1'-t-butyldimethylsilyloxyethyl)]-4-acetoxyazetidin-2-one (575 mg, 2 mmol) was added followed by a solution of t-butyldimethylsilyl enol ether of dimethylaminoethylthiopropionate (1.1 g, 4.0 mmol) in CH 2 Cl 2 (2 mL). The mixture was stirred at about 22° C. for 18 hours, diluted with a 1:1 mixture of ether-ethyl-acetate (30 mL), washed with water (1×25 mL), 1M aqueous NaHCO 3 (2×25 mL) brine (1×25 mL) and dried (MgSO 4 ). The residue obtained upon solvent evaporation was poured on a flash silica gel column (20 g) and was eluted with a 50% i-propanol-ethyl acetate mixture to give the title material as a 1:1 mixture of α- and β-methyl as estimated by 1 Hmr; (0:1, 382 mg,; 49%) ν max : 3410 (N-H), 1765 (β-lactam C=O) and 1680 cm -1 (thioester C=O); 1 Hmr (80 MHz, C 3 D 6 O) δ: 7.25 (1H, b.s., N-H), 4.32-4.05 (1H, m, H-1'), 3.79 (0.5 H, dd, J=2.1 Hz, J=5.3 Hz, H-4 of 1"-β-methyl), 3.68 (0.5 H, dd, J=2.1 Hz, J=7.0 Hz, H-4 of 1"-α-methyl), 3.10-2.75 (4H, m, CH 2 -N, H-3 and H-1"), 2.51, 2.43, 2.42, 2.34, 2.33, 2H, m, CH 2 -S), 2.19 (6H, s, N-(CH 3 ) 2 ), 1.27, 1.11, 1.10 (6H, superimposed d, J= 6.8 Hz, J=7.3 Hz, CH 3 ), 0.89 and 0.88 (9H, 2s, t-bu-Si), 0.11 and 0.08 ppm (6H, 2s, (CH 3 ) 2 Si).
EXAMPLE 4
A. Preparation of t-butyldimethylsilyl enol ether of 3-methyl-2-(propionylthio-methyl)-pyridine ##STR41##
A cold (acetone dry-ice bath) solution of 3-methyl-2- (propionylthio-methyl)-pyridine (b 3.30 g, 16.9 mmol) in dry THF (50 mL) was treated dropwise with a 1M THF solution of lithium hexamethyl disilazane (18.6 mL, 18.6 mmol), and stirred for 5 minutes. The resulting enolate was treated with TBDMS-triflate (436 mL, 18.6 mmol), stirred for 30 minutes and quenched with 1M aqueous NaHCO 3 (50 mL). The mixture was diluted with ether (400 mL) and the phases were separated. The organic layer was washed with cold water (2×200 mL), brine (200 mL) and dried (MgSO 4 ). The solvent was evaporated to give the title material (5.2 g, 100%) as a 7.5/2.5 ratio of geometric isomers. Part of this mixture (1.6 g) was passed through a flash silica gel (160 g) chromatography column (25% ether, petroleum ether) to give pure isomer A (Rf. 0.75, 25% ether petroleum ether, 230 mg) and pure isomer B (Rf 0.68, 25% ether-petroleum ether, 570 mg); Isomer A, ir (CH 2 Cl 2 ) ν max : 1635 cm -1 (olefin); 1 Hmr (CDCl 3 , 80 MHz), δ: 8.40-8.34 (1H, m, H-aromatic), 7.37-7.06 (2H, m, H-aromatic), 5.03 (1H, d, J=7.0 Hz, olefinic-H), 4.10 (2H, s, CH 2 ), 2.38 (3H, s, CH 3 ), 1.56 (3H, d, J=6.8 Hz, CH 3 , 0.96 (9H, s, t-butyl-Si) and 0.20 ppm (6H, s, (CH 3 ) 2 -Si); isomer B, ir (CH 2 CL 2 ) ν max : 1635 cm -1 (olefin); "Hmr(80MHz, CDCl 3 ) δ: 8.39, 8.34 (1H, m, H-aromatic), 7.37-6.95 (2H, m, H-aromatic, 5.00 (1H, q, J=6.8, olefinic-H), 4.04 (2H, s, CH 2 ), 2.35 (3H, s, CH 3 ), 1.34 (3H, d, J=6.8 Hz, CH 3 ), 0.97 (9H, s, t-butyl-Si) and 0.21 ppm (6H, s, (CH 3 ) 2 -Si).
B. Preparation of (3s,4S)-3-[(1'R)-1"-(3-methylpyridin-2-methylthiocarbonyl)-ethyl]-azetidin-2-one ##STR42##
To freshly fused ZnCl 2 (2.90, 21.3 mmol) under N 2 was added (3S,4R)-4-acetoxy3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-azetidin-2-one (3.06 g, 10.7 mmol) in CH 2 Cl 2 (100 mL). The mixture was cooled to 0° C. and treated drops-wise with the t-butyldimethylsilyl enol ether of 3-methyl-2-(propionylthio-methyl)-pyridine (6.60 g, 21.3 mmol) in CH 2 Cl 2 (100 mL) and stirred for 20 hours at 22° C. The mixture was diluted with ethyl acetate (250 mL), washed with cold water (2×300 mL), brine (1×300 mL), dried (MgSO 4 ) and flushed down under vacuum. The residue was triturated with petroleum ether (20 mL) to give pure solid title material (3.19 g). The mother liquor was concentrated (3.5 g) to give a residue which was passed through a flash silica gel (140 g) column (20% CH 3 CN/CH 2 Cl 2 -EtOAc) to give more crystalline title material (1.18 g, combined yield: 4.37 g, 97%). Inspection of the 1 Hmr spectrum shown the presence of only the β-methyl isomer; ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1765 (β-lactam C=O) and 1680 cm -1 (thioester C=O); 1 Hmr (80 Hz, CDCl 3 ) δ: 8.48-8.40 (1H, m, H-aromatic), 7.60-7.52 (1H, m, H-aromatic), 7.27-7.07 (1H, m, Haromatic, 5.95 (1H, b.s., N-H), 4.38 (2H, s, CH 2 ), 4.15 (1H, center of dq, J=6.3 Hz, J=4.5 Hz, H-1'), 3.88 (1H, dd, J=2.2 Hz, J=5.5 Hz, H-4), 3.1-2.5 (2H, m, H-1"and H-3), 2.39 (3H, s, CH 3 ), 1.26 (3H, d, J=6.9 Hz, CH 3 ), 1.10 (3H, d, J=6.3 Hz, CH 3 ), 0.85 (9H, s, t-butyl-Si) and 0.05 (6H, s, (CH 3 ) 2 -Si); Anal. calcd for C 21 H 34 N.sub. 2 O 3 SSi: C 59.68, H 8.11, N 6.63; found: C 59.87, H 7.97, N 6.66.
When isomer A of the silyl enol ether of 3-methyl-2-(propionylthiomethyl)-pyridine was reacted with 4-acetoxy-azetidin-2-one, the β-methyl was obtained as the major isomer, contaminated with only 16% of the corresponding α-isomer (see Example 5A). With isomer B, only the β-methyl isomer was obtained (see Example 5B).
Part C of Example 4 (which follows) illustrates the saponification shown in Step (C) of Diagram 1.
C. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R)-1"-carboxyethyl]-azetidin-2-one ##STR43##
A cold (ice bath) THF (4 mL) solution of (3S,4S)3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R)-1"-(3-methylpyridin-2-methylthiocarbonyl)-ethyl]-azetidin-2-one (211 mg, 0.5 mmol) was treated first with H 2 O 2 (30% v/v, 0.0086 mL, 1 mmol) and dropwise with 1.0N aqueous NaOH (1 mL, 1 mmol). The mixture was stirred for 10 minutes (ice bath), diluted with ethyl acetate (40 mL) and acidified with 1N aqueous HCl (20 mL). The organic phase was washed with water, aqueous NaHSO 3 (1M, 20 mL), water (20 mL), brine (20 mL) and dried (MgSO 4 ). Evaporation of ethyl acetate gave the β-methyl carboxylic acid (136 mg, 90%) with i.r. and 'Hmr data identical to that reported by Merck's scientists in Heterocycles, Volume 21, no. 1, page 29 (1984).
EXAMPLE 5A
Experimental conditions with Isomer A from Example 4
To freshly fused ZnCl 2 (41 mg, 0.33 mmol) under N 2 was added at 0° C. (3S,4R)-4-acetoxy-3-[(1'R)-1't-butyldimethylsilyloxyethyl]-azetidin-2-one (86 mg, 0.33 mmol) in CH 2 Cl 2 (1 mL) and dropwise isomer A of the silyl enol ether (102 mg, 0.33 mL) in CH 2 Cl 2 (2 mL). The mixture was stirred for 20 hours at about 22° C., and then diluted with ethyl acetate (25 mL), washed with water (2×15 mL), brine (15 mL), dried (MgSO 4 ) and flashed down under vacuum to give an oil (120 mg). The oil was passed through a flash silica gel (4 g) chromatography column (20% CH 3 CH/CH 2 Cl 2 -EtOAc). A 9/1 mixture of β/α isomers (42 mg, 33%) was obtained, as observed by 1 Hmr; characteristic of the α -isomers in the 1 Hmr spectrum: (80 MHz, CDCl 3 ). δ: 6.42 (b.s., N-H), 3.67 (dd, J=2 Hz, J=9 Hz, H-4), 1.23 (d, J=6.0 Hz, CH 3 ).
EXAMPLE 5B
Experimental Conditions with Isomer B from Example 4
The experimental conditions were identical to those used for isomer A. However only the β-methyl isomer product was obtained (70 mg, 55%, 100% β-isomer).
EXAMPLE 6
A. Preparation of t-butyldimethylsilyl enol ether of 2-thiophene-methylthiopropionate ##STR44##
A cold (ice-MeOH bath) solution of 2-thiophene-methyl thiopropionate (373 mg, 2 mmol) in CH 2 Cl 2 (3 mL) was treated with triethylamine (0.7 mL, 5 mmol) and dropwise with TBDMS-triflate (0.92 mL, 4 mmol). The mixture was stirred for 3 hours at 22° C., diluted with cold ether (5 mL), washed with cold water (2×20 mL), cold brine (1×20 mL) and dried (Na 2 SO 4 ). The mixture was then evaporated under vacuum to give the title material (595 mg, 99%) as a yellow oil in a 7:3 mixture of geometric isomers, as shown by 1 Hmr. 1 Hmr (80 MHz, CDCl 3 ) δ: 7.20, 7.05 (1H, m, H-aromatic), 6.92-6.72 (2H, m, H-aromatic), 5.04 (0.7 H, q, J=6.9 Hz, olefinic-H), 4.95 (0.3 H, q, J=7 Hz, olefinic H), 4.11 (1.4 H, s, CH 2 ), 4.05 (0.6 H, s, CH 2 ), 1.6 (2.1 H, d, J=6.8 Hz, CH 3 ), 1.56 (0.9 H, d, J=7, CH 3 ), 0.96, (9H, s, t-butyl-Si) and 0.19 ppm (6H, s, (CH 3 ) 2 -Si).
B. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R and S)-1"-(2-thiophene)-methylthiocarbonylethyl)]-azetidin-2-one ##STR45##
To freshly fused ZnCl 2 (173 mg, 2 mmol) in CH 2 Cl 2 (8 mL) was added at 0° C. (ice bath) (3S,4R)-4-acetoxy-3-[-(1'R)-1'-t-butyldimethylsilyloxyethyl]-azetidin-2-one (575 mg, 2 mmol) and the t-butyldimethylsilyl enol ether of 2-thiophenmethyl thiopropionate (1.11 g, 3.7 mmol) in CH 2 Cl 2 (2 mL). The mixture was stirred at 22° C. for 18 hours, diluted with ethyl acetate (40 mL), washed with water (2×40 mL), brine (1×40 mL) and dried (Na 2 SO 4 ). The solvent was evaporated to leave a yellow oil (1.3 g) which was passed through a flash silica gel (40 g) column (50% ether-petroleum ether) to give the crystalline title material, (700 mg, 84%). HPLC determined the title material to be a 81:19 mixture of α- and β-methyl isomers; ir (CH.sub. 2 Cl 2 ) ν max : 3410 (NH), 1765 (β-lactam C=O) and 1680 cm -1 (ester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 7.25-7.1 (1H, m, aroma-tic-H), 6.95-6.8 (2H, m, aromatic-H), 5.85 (0.8 H, b.s. NH), 5.8 (0.2H, shoulder, NH), 4.32 (2H, s, CH 2 ), 4.15 (1H, center of 5 lines, H-1'), 3.87 (0.2 H, dd, J=2 Hz, J=6 Hz, H-4 β-methyl), 3.72 (0.8 H, dd, J=2 Hz, J=9 Hz, H-4 α-methyl), 3-2.5 (2H, m, H-3 and H-1"), 1.27 (3H, d, J=7 Hz, CH 3 ), 1.22 (3H, d, J=7 Hz, CH 3 ), 1.10 (0.6 H, d, J=7 Hz, CH 3 ), 0.87 (9H, s, t-butyl-Si) and 0.08 ppm (6H, s, (CH 3 ) 2 -Si); Anal. calcd for C 19 H 31 NO 3 S 2 Si: C 55.17, H 7.55, N 3.39; found: C 55.48, H 7.65, N 3.47.
EXAMPLE 7
A. Preparation of t-butyldimethylsilyl enol ether of phenyl thiopropionate ##STR46##
A cold (ice-MeOH bath) solution of phenyl thiopropionate (332 mg, 2 mmol) was treated first with triethylamine (0.70 mL, 5 mmol) and dropwise with TBDMS-triflate (0.92 mL, 4 mmol). The mixture was allowed to warm up to 22° C. and then stirred for 3 hours. The mixture was diluted with ether (15 mL), washed with cold water (2×20 mL), brine (1×20 mL), dried (Na 2 SO 4 ) and treated with neutral activated charcoal to give title material (550 mg, 98%) as a yellow oil.
Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R and S)-1"-(phenylthiocarbonyl)-ethyl]-azetidin-2-one ##STR47##
To cold (ice bath) freshly fused ZnCl 2 (136 mg, 1 mmol) in CH 2 Cl 2 (3 mL) was added (3S,4R)-4acetoxy-3-[(1'R)-1't-butyldimethylsilyloxyethyl]-azetidin-2-one (287 mg, 1 mmol) and the t-butyldimethylsilyl enol ether of phenyl thiopropionate (550 mg, 2 mmol). The mixture was stirred for 18 hours at 22° C., diluted with ethyl acetate (15 mL), washed with cold water (2×20 mL), brine (1×20 mL), dried (Na 2 SO 4 ) and passed trough a flash silica gel (20 g) column (50% ether/petroleum ether) to give the title material (349 mg, 91%) as a 9:1 mixture of α/β isomers as shown by HPLC; ir (CH 2 Cl 2 )ν max : 3410 (NH), 1765 (β-lactam C=O) and 1680 cm -1 (ester C=O); 1 Hmr (80 MHz, CDCl.sub. 3) δ: 7.41 (5H, s, H-arom), 5.96, 5.7 (1H, 2 b.s., NH), 4.18 (1H, center of 5 lines, J=5.8, H-1'), 3.80 (center of dd, H-4 β-methyl), 3.77 (1H, dd, J=2.0 Hz, J=9.5 Hz, H-4 α-methyl), 3.0-2.55 (2H, m, H-1" and H-3), 1.33 (3H, d, J=7.2 Hz, CH 3 ), 0.87 (9H, s, t-butyl-Si), and 0.07 ppm (6H, s, (CH 3 ) 2 -Si); Anal. calcd for C 20 H 31 NO 3 SSi: C 61.03, H 7.94, N 3.56; found: C 61.40, H 8.04, N 3.57.
EXAMPLE 8
A. Preparation of t-butyldimethylsilyl enol ether of t-butyl thiopropionate ##STR48##
A cold (ice-MeOH) solution of t-butyl thiopropionate (2.93 g, 20 mmol) in CH 2 Cl 2 (40 mL) was treated with triethylamine (5.0 mL, 36 mmol) and dropwise with TBDMS-triflate (6.9 mL, 30 mmol). The mixture was stirred at 22° C. for 4 hours., then evaporated, diluted with petroleum ether (50 mL), washed with cold water (2×60 mL) brine (1×60 mL), dried (MgSO 4 ) and treated with neutral activated charcoal. Evaporation of the solvent gave a colorless oil (5.1 g, 98%) as a 8:2 mixture of geometric isomers, as estimated by 1 Hmr; ir (CH 2 Cl 2 ) ν max : 1625 cm -1 (olefin); 1 Hmr (80 MHz, CDCl 3 ) δ: 5.75 (0.8 H, q, J=6.8 Hz, olefinic-H) 5.23 (0.2H, q, J=7.0 Hz, olifinic H), 1.73 (2.4 H, d, J=6.9 Hz, CH 3 ), 1.62 (0.6 H, d, J=6.9, CH 3 ), 1.36 (7.2 H, s, t-butyl-Si), 1.32 (1.8 H, s, t-butyl-Si), 0.95 and 0.93 (9H, 2s, t-butyl-Si) and 0.18 and 0.15 ppm (6H, 2s, (CH 3 ) 2 Si).
EXAMPLE 9
A. Preparation of t-butyldimethylsilyl enol ether of isothiazolyl-3-methyl thiopropionate ##STR49##
A cold (ice-MeOH bath) solution of isothiazolyl-3-methyl thiopropionate (375 mg, 2 mmol) in CH 2 Cl 2 (5 mL) was treated with triethylamine (0.71 mL, 5 mmol) and dropwise with TBDMS-triflate (0.94 mL, 4 mmol). The mixture was stirred at 22° C. for 1 hour, diluted with cold ether (25 mL), washed with cold water (2×15 mL), brine (1×10 mL); dried (MgSO 4 ) and treated with activated neutral carbon to give the title compound (532 mg, 92%) as a yellow oil. 1 Hmr revealed a 1:1 mixture of geometric isomers; ir (neat) ν max : 1635 cm -1 (olefin); 1 Hmr (80 MHz, CDCl 3 ) δ: 8.58-8.53 (1H, m, H-aromatic), 7.25-7.17 (1H, m, H aromatic), 5.03 (0.5 H, q, J=7 Hz, olefinic-H), 4.95 (0.5 H, q, J=7. Hz, olefinic H), 4.10 and 4.03 (2H, 2s, CH 2 ), 1.59 (1.5 H, d, J=6.9 Hz, CH 3 ), 1.55 (1.5 H, d, J=6.7 Hz, CH 3 ), 0.95 (9H, s, t-butyl-Si, and 0.09 ppm (6H, s, (CH 3 ) 2 -Si).
B. Preparation of (3S, 4S)-b 3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[1"R and S)-1"-(isothiazol-3-methylthiocarbonyl)-ethyl]-azetidin-2-one ##STR50##
To freshly fused ZnCl 2 (136 mg, 1 mmol) under N 2 was added (3S,4R)-4-acetoxy-3-[(1'R)-1-t-butyldimethylsilyloxyethyl]-azetidin-2-one (287 mg, 1 mmol) in CH 2 Cl 2 (3 mL). The mixture was cooled at 5° C. (ice bath) and the t-butyldimethylsilyl enol ether of 3-isothiazolyl-methyl thiopropionate (540 mg, 1.8 mmol) in CH 2 Cl 2 (3 mL) was added in. It was stirred for 19 hours at 22° C. and more ZnCl 2 (136 mg, 1 mmol) was added in. The mixture was stirred for an additional 5 hours, diluted with ethyl acetate (25 mL), washed with water (2×10 mL), brine (10 mL), dried (MgSO 4 ). The residue after evaporation of the solvent was passed through a flash silica gel (25 g) column (5%-25% CH 3 CN/--CH 2 Cl 2 ) to give the title material as an oil (270 mg, 65%) which slowly crystallized upon standing. 1 Hmr analysis of the spectrum showed a 25.75 mixture of α- (25) and β-isomer (75); ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1770 (β-lactam C=O) and 1685 cm -1 (thioester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 8.63, 8.57 (1H 2 lines, J=4.7 Hz, H-aromatic), 7.18, 7.13 (1H, 2 lines, J=4.7 Hz, H-aromatic), 6.0 (0.25 H, b.s. N-H), 5.79 (0.75 H, b.s., NH), 4.31 (2H, s, CH 2 ), 4.24, 4.18, 4.16, 4.10 (1H, 4 lines, part of H-1'), 3.89 (0.75 H, dd, J=2.1 Hz, J=Hz, H-4 β-methyl), 3.72 (0.25 H, dd, J=2 Hz, J=10, H-4 α-methyl), 3.03-2.75 (2H, m, H-3 and H-1"), 1.26 (3H, d, J=6.9 Hz, CH 3 ), 1.22 (0.75 H, d, J=6.1 Hz, CH 3 ), 1.10 (2.25 J=6.3 Hz, CH 3 ), 0.86 (9H, s, t-butyl-Si), and 0.06 ppm (6H, s, (CH 3 ) 2 -Si); Anal. calc'd for C 18 H 30 N 2 O 3 S 2 Si: C 52.14, H 7.29, N 6.76; found: C 52.51, H 7.36, N 6.56.
EXAMPLE 10
A. Preparation of t-butyldimethylsilyl enol ether of S-(3-picolyl)thiopropionate ##STR51##
A cold (ice-MeOH bath) solution of S-(3-picolyl)-thiopropionate (1.45 mg, 8 mmol) in CH 2 Cl 2 (20 mL) was treated with triethylamine (2.8 mL, 20 mmol) and dropwise with TBDMS-triflate (3.7 mL, 16 mmol). The mixture was stirred at 22° C. for 3 hours. Then more triethylamine (0.56 mL, 4 mmol) and TBDMS triflate (0.92 mL, 4 mmol) were added and the mixture was stirred for 1 hour. This process was repeated again. The mixture was diluted with cold ether (80 mL), washed with water (2×100 mL), brine (1×100 mL), dried (MgSO 4 ), treated with neutral activated charcoal. The solvent was evaporated to leave a pale yellow oil (2.34 g, 99%). The 1 Hmr showed a 45:65 ratio of geometric isomers; 1 Hmr (80 MHz, CDCl 3 ) ν: 8.45-8.3 (2H, m, aromatic-H), 7.60-7.35 (1H, m, aromatic-H), 7.2 7.0 (1H, m, aromatic H), 4.97 (0.45 H, q, J=7.0 olefinic H), 4.84 (0.55 H, q, J=7 Hz, olefinic-H), 3.78 (0.9 H, s, CH 2 ), 3.70 (1.1 H, s, CH 2 ), 1.52, 1.49, 1.84, 1.80 (6H, 6 lines of CH 3 , 2CH 3 ), 0.95-0.92 (9H, 2s, t-butyl-Si) and 0.15-0.07 ppm (6H, 2s, (CH 3 ) 2 -Si.
B. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R and S)-1"-(3-picolylthiocarbonyl)-ethyl]-azetidin-2-one ##STR52##
To freshly fused ZnCl 2 (273 mg, 2 mmol) in CH 2 CL 2 (10 mL) was added at 5° C. (ice bath) (3S,4R)-4-acetoxy-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-azetidin-2-one (575 mg, 2 mmol) and the t-butyldimethylsilyl enol ether of S-(3-picolyl)thiopropionate (1.1 g, 3.7 mol). The mixture was stirred at 22° C. for 18 hours, diluted with EtOAc, washed with water (2×50 mL), brine (1×50 mL) and dried (MgSO 4 ). Evaporation of the solvent gave a residue which was passed through a flash silica gel (50 g) column (EtOAc) to yield the title material (300 mg, 37%) as an oil. HPLC and 1 Hmr analysis revealed a 92/8 ratio of α- and β-methyl isomers: ir (neat) ν max : 3480 and 3210 (broad shoulder, NH), 1760 (β-lactam C=O) and 1682 cm -1 (ester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 8.55-8.45 (2H, m, H-aromatic), 7.64-7.52 (1H, m, H-aromatic), 7.29-7.14 (1H, m, H-aromatic), 5.95 (1H, b.s. NH), 4.23, 4.16 (part of H-1'), 4.10 (2H, s, CH 2 ), 3.94 (0.1 H, dd, J=2.3 Hz, J=7.6 Hz, H-4-β-methyl), 2.74 (0.9 H, dd, J=2.1, J=9.4, H-4-α-methyl), 3.2-2.5 (2H, m, H-3 and H-1"), 1.26 (3H, d, J=7.1 Hz, CH 3 ), 1.21 (3H, d, J=6.2 Hz, CH 3 ), 1.06 (0.3 H, d, J=6.3 Hz), CH 3 β-methyl), 0.086 (9H, s, t-butyl-Si) and 0.06 ppm (6H, s, (CH 3 ) 2 -Si); Anal. calcd for C 28 H 32 N 2 O 3 SSi: C 58.78, H 7.89, N 6.86; found: C 58.38, H 8.02, N 6.93.
EXAMPLE 11
A. Preparation of t-butyldimethylsilyl enol ether of 1-methyl-2-(propionylthio-methyl)-imidazole ##STR53##
A cold (ice-MeOH bath) solution of 1-methyl-2-(propionylthio-methyl) imidazole (370 mg, 2 mmol) in CH 2 Cl 2 (5 mL) was treated with triethylamine (0.71 mL, 5 mmol) and dropwise with TBDMS-triflate (0.94 mL, 4 mmol). The mixture was stirred for 3 hours. Then more triethylamine (0.28 mL, 2 mmol) and TBDMS-triflate (0.47 mL, 2 mmol) were added and stirring was continued for 20 more hours. TLC indicated the presence of the starting material, thiopropionate. More triethylamine (0.28 mL, 2 mmol) and TBDMS-triflate (0.47 mL, 2 mmol) were added and followed by a 2 hour stirring period. This process was repeated twice. The mixture was diluted with cold ether (25 mL), washed with cold water (2×25 mL), brine (25 mL), dried (MgSO 4 ) and treated with activated carbon to give title material (580 mg, 100%) as a yellow oil.
Analysis of the 1 Hmr spectrum indicated a 42/58 ratio of geometric isomer; ir (CH 2 Cl 2 ) ν max : 1635 cm -1 (olefin); 1 Hmr (80 MHz, CDCl 3 ) δ: 6.95 (1H, s, H-aromatic), 6.80 (1H, s, H-aroma-tic), 5.05 and 5.03 (1H, 2q, J=7 Hz, olefinic-H), 3.67 (1.74 H, s, N-Me), 3.64 (1.26 H, s, N-Me), 1.58 (1.74 H, d, J=6.9 Hz, CH 3 ), 1.55 (1.26 H, d, J=6.8 Hz, CH 3 ), 0.95-0.90 (9H, 2s, t-Butyl-Si), 0.019-0.08 ppm (6H, 2s, (CH 3 ) 2 -Si).
B. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R)-1"-(1-methylimidazol-2-yl)-methylthiocarbonylethyl]-azetidin-2-one ##STR54##
To a freshly fused ZnCl 2 (272 mg, 2 mmol) under N 2 was added (3S,4R)-4-acetoxy-3-[(1'R)-t-butyldimethylsilyl-oxyethyl]-azetidin-2-one (287 mg, 1 mmol) in CH 2 Cl 2 (3 mL). The mixture was cooled (ice bath), treated with the t-butyldimethylsilyl enol ether of 1-methyl-2-(propionylthiomethyl)-imidazole (663 mg, 2 mmol) in CH 2 Cl 2 (2 mL) and stirred for 20 hours at 22° C. The mixture was diluted with ethyl acetate (30 mL), washed with water (2×20 mL), brine (20 mL), dried (MgSO 4 ) and evaporated under vacuum to give a residue (850 mg). This residue was passed through a flash silica gel (35 g) column (1/1 acetone/ethyl acetate) to give the title material (350 mg, 85%) as a 90/10 mixture of β/α methyl*; ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1770 (β-lactam C=O) and 1690 cm -1 (thioester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 7.06 (1H, d, J=1.5 Hz, H-aromatic), 6.86 (1H, d, J=1.3 Hz, H-aromatic), 6.35 (0.1 H, b.s., NH), 6.08 ((0.9 H, bs, NH), 4.55 (2H, s, CH 2 ), 4.15 (1H, dq, J=7 Hz, J=5 Hz, H-1'), 3.83 (0.9 H, dd, J=2.1 Hz, J=5.4 Hz, H-4 β-methyl), 3.67 (3H, s, N-CH 3 ), 3.15-2.5 (2H, m, H-3 - H-1"), 1.20 (3H, d, J=7.0 Hz, CH 3 ), 0.85 (9H, s, t-butyl-Si), and 0.05 ppm 6H, s, (CH 3 ) 2 -Si); Anal. calcd for C 19 H 33 N 3 O 3 SSI: C 55.44, H 8.08, N 10.21; found: C 50.00, H 7.25, N 10.23.
EXAMPLE 12
A. Preparation of t-butyldimethylsilyl enol ether of 6-methyl-2-(propionylthio-methyl)-pyridine ##STR55##
A cold (ice-MeOH bath) solution of 6-methyl-2-(propio-nylthio-methyl)-pyridine (370 mg, 1.9 mmol) in CH 2 Cl 2 (5 mL) was treated with triethylamine (0.56 mL, 4 mmol) and dropwise with TBDMS-triflate (0.88 mL, 3.8 mmol). The mixture was stirred at 22° C. for 3 hours, diluted with cold ether (25 mL), washed with water (2×25 mL), brine (1×25 mL), dried (MgSO 4 ) and treated with neutral activated charcoal. Evaporation of the solvent gave title material (575 mg, 98%) as a yellow oil. 1 Hmr spectrum releaved a 7/3 mixture of geometric isomer; ir (CH 2 Cl 2 ) ν max : 1635 cm -1 (olefin); 1 Hmr (80 MHz CDCl 3 ) δ: 7.55-7.2 (1H, m, H-aromatic), 7.15-6.80 (2H, m, H-aromatic), 5.02 (0.3 H, q, J=6.8 Hz, olefinic-H), 4.94 (0.7 H, q, J=6.8 Hz, olefinic-H), 4.02 (0.6 H, s, CH 2 ), 3.94 (1.4 H, s, CH 2 ), 2.53 (3H, s, CH 3 ), 1.54 (3H, d, J=6.8 Hz, CH 3 ), 0.98, 0.94 (9H, 2s, t-butyl-Si), 0.18-0.09 (6H, 2s, (CH 3 ) 2 -Si).
B. Preparation of (3S,4S)-3[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R and S)-1"-(6-methylpyridin-2-yl)-methylthiocarbonylethyl]-azetidin-2-one ##STR56##
To cold (ice bath) freshly fused ZnCl 2 (136 mg, 1 mmol) in CH 2 Cl 2 (3 mL) was added (3S,4R)-4-acetoxy-3-[(1'R)-1't-butyl-dimethylsilyloxyethyl]-azetidin-2-one (287 mg, 1 mmol) and the t-butyldimethylsilyl enol ether of 6-methyl-2-(propionylthio-methyl)-pyridine (560 mg, 1.8 mmol), in CH 2 Cl 2 (3 mL). The mixture was stirred for 18 hours at 22° C., diluted with ethyl acetate (25 mL), washed with water (2×15 mL), brine (15 mL), dried (MgSO 4 ) and the solvent was evaporated. The residue (610 mg) was passed through a silica gel (25 g) column (EtOAc) to give title material (280 mg, 66%). 1 Hmr spectrum analysis revealed a 60/40 mixture of α/β methyl isomer; ir (CH 2 Cl 2 ) ν max : 3410 (NH), 1765 (β-lactam C=O) and 1680 cm -1 (thioester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 7.65-7.50 (1H, m, H-aromatic), 7.25-7.03 (2H, m, H aromatic), 6.22 (0.6H, b.s. N-H α-methyl), 5.85 (0.4 H, bs, N-H β-methyl), 4.33 (0.8 H, s, CH 2 ), 4.30 (1.2 H, s, CH 2 ), 4.24, 4.22, 4.16, 4.14, 4.09, 4.07, 4.01, 3.98 (part of dq, H-1' α- and β-methyl), 3.86 (0.4H, dd, J=2.2 Hz, J=5.6 Hz, H-4 β-methyl), 3.70 (0.6 H, dd, J=2.0 Hz, J=9.5 Hz, H-4 α-methyl), 3.06-2.5 (2H, m, H-3 and H-1"), 2.59 (3H, s, CH 3 ), 1.26 (1.8 H, J=7.1 Hz, CH 3 ), 1.24 (1.2 H, J= 6.4 Hz, CH 3 ), 0.86 (9H, s, t-butyl-Si) and 0.06-0.04 (6H, 2s, (CH 3 ) 2 --Si); Anal. calcd for C 21 H 34 N 2 O 3 SSi: C 59.68, H 8.11, N 6.63; found: C 59.84, H 8.24, N 6.66.
EXAMPLE 13
A. Preparation of methylthiomethyl thiopropionate ##STR57##
A cold (ice bath) solution of thiopropionic acid (360 mg, 4 mmol) in CH 2 Cl 2 (5.0 mL) was treated with chloromethyl methylthioether (0.33 mL, 4 mmol) and triethylamine (0.7 mL, 5 mmol) and stirred for 30 minutes at 5° C. The cold bath was removed and the mixture was stirred for 30 minutes at about 22° C., diluted with CH 2 Cl 2 , washed successively with 1N aqueous HCl, water 1M aqueous NaHCO 3 , water and brine and dried (MgSO 4 ). The title compound was obtained as a yellow oil (510 mg, 85%); ir (CH 2 Cl 2 ) ν max : 1695 cm -1 (thioester C=O); 1 Hmr (60 MHz, CDCl 3 ) δ: 4.07 (2H, s, CH 2 ), 2.62 (2H, q, J=7 Hz, CH 2 ), 2.2 (3H, s, CH 3 ) and 1.2 ppm (3H, t, J=7 Hz, CH 3 ).
B. Preparation of t-butylsilyl enol ether of methylthiomethyl thiopropionate ##STR58##
A cold (ice-MeOH) solution of methylthiomethyl thiopropionate (470 mg, 3.1 mmol) in CH 2 Cl 2 (6 mL) was treated with triethylamine (0.84 mL, 6 mmol) and dropwise with TBDMS triflate (1.06 mL, 4.6 mmol). The mixture was stirred at 22° C. for 2.5 hours, diluted with ether (20 mL), washed with cold water (2×10 mL), brine (1×20 mL) and dried (MgSO 4 ). Evaporation of solvent gave title material 850 mg, 100%) as a yellow oil; ir (CH 2 Cl 2 ) ν max : 1635 cm -1 (olefin).
C. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl)]-4-[(1"S)-1"-(methylthiomethylthiocarbonyl)-ethyl]-azetidin-2-one ##STR59##
To a cold (5° C.) suspension of ZnCl 2 freshly melted (204.4 mg, 1.5 mmol) in methylene chloride (5 mL) was added (3S,4R)-4-acetoxy-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]azetidin-2-one (431 mg, 1.5 mmol). A solution of the t-butyldimethylsilyl enol ether of methylthiomethyl thiopropionate (595 mg, 2.25 mmol) in CH 2 Cl 2 (1 mL) was then added. The mixture was stirred at 22° C. for 18 hours, diluted with ether (20 mL), washed with water (3×10 mL), brine and dried (MgSO 4 ). The residue obtained upon solvent evaporation was first purified on a flash silica gel pad (7 g, CH 2 Cl 2 -5% EtOAc/CH 2 Cl 2 ) and then on preparative silica gel plate (5% EtOAc/CH 2 Cl 2 ) to give the title material (429 mg, 76%) containing more than 98.5% of the α-methyl isomer as shown by the 1 Hmr spectrum; ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1765 (β-lactam C=O) and 1680 cm -1 (thioester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 5.92 (1H, b.s., N-H), 4.18 (1H, center of 5 lines, J=5.5 Hz, J=6.1 Hz, H-1'), 4.02 (2H, s, CH 2 ), 3.75 (1H, dd, J=2.1 Hz, J=9.5 Hz, H-4), 3.1-2.5 (2H, m, H-3 and H-1"), 2.16 (3H, s, CH 3 ), 1.29 (3H, d, J=7.0 Hz, CH 3 ), 1.23 3H, d, J=6.2 Hz, CH 3 ), 0.87 (9H, s, t-Bu-Si) and 0.07 ppm (6H, s, (CH 3 ) 2 -Si).
EXAMPLE 14
A. Preparation of methoxyethoxymethyl thiopropionate ##STR60##
A cold (5° C.) solution of triethylamine (8.0 mL, 57 mmol) in CH 2 Cl 2 (200 mL) was treated with a stream of H 2 S for 30 minutes (keeping the temperature below 10° C.). To this solution was added dropwise propionyl chloride (3.7 mL, 40 mmol) in CH 2 Cl 2 (50 mL). The mixture was stirred for 2.5 hours at 22° C., diluted with CH 2 Cl 2 (100 mL), washed with 1N aqueous HCl (2×20 mL), water (2×20 mL), brine and dried (MgSO 4 ). Evaporation of the solvent gave thiopropionic acid (1.02 g, 28%). A solution of the thiopropionic acid (450 mg), in CH 2 Cl 2 (5 mL) was cooled (5° C.) and treated with MEM-chloride (0.57 mL 5.0 mmol) and triethylamine (0.9 mL, 6.5 mmol). The mixture was stirred at 22° C. for 30 minutes, diluted with CH 2 Cl 2 , washed successively with 1N aqueous HCl, water, 1M aqueous NaHCO 3 , brine and dried (MgSO 4 ) to give title material (850 mg, 95%) as an oil; ir (CH 2 Cl 2 ) ν max : 1700 cm - 1 (thioester C=O); 1 Hmr (60 MHz, CDCl 3 ) δ: 5.2 (2H, s, SCH 2 O), 3.6 (4H, b.s. O(CH 2 ) 2 O), 3.42 (3H, s, CH 3 ), 2.65 (2H, q, J=7 Hz, CH 2 ) and 1.2 ppm (3H, t, J=7 Hz, CH 3 ).
B. Preparation of t-butyldimethylsilyl enol ether of methoxyethoxymethyl thiopropionate ##STR61##
A cold (-15° C.) solution of methoxyethoxymethyl thiopropionate (623 mg, 3.5 mmol) in CH 2 Cl 2 (7 mL) was treated with triethylamine (1 mL, 7.0 mmol) and TBDMS triflate (1.21 mL, 5.25 mmol). The mixture was stirred at 22° C. for 1.5 hour, diluted with a 1:1 mixture of ether-petroleum ether (20 mL), washed with water (2×20 mL) brine, dried (MgSO 4 ) and treated with neutral activated charcoal. Evaporation of the solvent afforded the title material (1.1 g, 100%) as an oil; ir (CH 2 Cl 2 ) ν max : 1635 cm -1 (olefin).
C. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl)]-4-[(1"S and R)-1"-(methoxyethoxymethylthiocarbonyl)-ethyl]-azetidin-2-one ##STR62##
To freshly fused ZnCl 2 (204 mg, 1.5 mmol) in CH 2 Cl 2 (5 mL), cooled to 5° C. was added (3S,4R)-4-acetoxy-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-azetidin-2-one (431 mg, 1.5 mmol) and the t-butyldimethylsilyl enol ether of methoxyethoxymethyl thiopropionate (658 mg, 2.25 mmol) in CH 2 Cl 2 (1 mL). The reaction mixture was stirred at 22° C. for 18 hours. Since TLC revealed the presence of 4-acetoxyazetidinone, more enol ether (146 mg, 0.5 mmol) was added to the mixture. It was then stirred for 1 hour, diluted with ether (20 mL), washed with water (2×20 mL), brine and dried (MgSO 4 ). The residue (990 mg) was passed on a flash silica gel (15 g) column (CH 2 Cl 2 -20% EtOAc/CH 2 Cl 2 ) to give the title material (407 mg, 67 %) as a colorless oil. HPLC analysis of the mixture showed a ratio of 86:14 of α- and β-isomers; ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1765 (β-lactam C=O), 1690 cm -1 (thioester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 6.10 and 5.75 (1H, 1 b.s., NH α and β), 5.25, 5.22, 5.17, 5.14, 5.11 and 4.92 (2H, ABq, S-CH 2 -O), 4.27-3.95 (1H, 5 lines, H-1'), 3.85 (H-4-β-methyl), 3.67 (1H, dd, J=1.7 Hz, H-4-α-methyl), 3.60-3.38 (4H,m, O(CH 2 ) 2 O),3.36 (3H, s, OCH 3 ), 3.05-2.5 (2H, m, H-3 and H-1"), 1.28 (3H, d, J=7.1 Hz, CH 3 ), 1.23 (3H, d, J=6.1 Hz, CH 3 ), 0.87 (9H, s, t-butyl-Si) and 0.07 ppm (6H, s, (CH 3 ) 2 Si).
EXAMPLE 15
A. Preparation of S-(4-picolyl)thiopropionate ##STR63##
A solution of 4-picolyl chloride 5.0 g, 30.5 mmol) and thiourea (2.6 g, 33.5 mmol) in water (15 mL) was heated (90°-95° C.) for 2 hours. The solution was cooled to 5° C. (ice bath) and NaOH (3.7 g, 91.5 mmol) was added in small portions, while keeping the reaction mixture temperature below 20° C. The mixture (suspension) was stirred for 20 hours at about 22° C. (homogeneous), cooled at 5° C., diluted with THF and treated dropwise with propionyl chloride (2.64 mL, 30.5 mmol). The solution was stirred at 5° C. for 30 minutes, neutralized at pH 7 with 10% aqueous NaHCO 3 and extracted with ethyl acetate (4×25 mL). The organic extracts were combined, washed with water and brine, dried (MgSO 4 ) and treated with neutral activated charcoal. The residue obtained upon solvent evaporation was distilled (b.p. 110°-3° C./300 mm Hg) to give the title material (4.8, g, 87%); ir (CH 2 Cl 2 ) ν max : 1695 cm -1 (thioester C=O); 1 Hmr (60 MHz, CDCl 3 ) δ: 8.55 (2H, b.d., arom.-H); 7.22 (2H, b.d., arom.-H), 4.10 (2H, s, CH 2 -ar), 2.62 (2H, q, J=7.5 Hz, CH 2 -CH 3 ) and 1.20 ppm (3H, t, J=7.5 Hz, CH 3 ).
B. Preparation of t-butyldimethylsilyl enol ether of S-(4-picolyl)thiopropionate ##STR64##
A cold (MeOH-ice) solution of S-(4-picolyl)-thiopropionate (2.71 g, 15 mmol) in CH 2 Cl 2 (30 mL) was treated dropwise with triethylamine (4.2 mL, 30 mmol) and TBDMS-triflate (5.8 mL, 25 mmol). The mixture was stirred at about 22° C. for 1.5 hour, diluted with a 1:1 mixture of ether: petroleum ether, washed with cold water 2×50 mL) brine (1×50 mL), dried (MgSO 4 ) and treated with neutral activated charcoal. The title compound was obtained upon solvent evaporation as an oil (5.0 g, 100%) and the 1 Hmr clearly showed a major geometric isomer; ir (CH 2 Cl 2 ) ν max : 1635 (olefin) and 1600 cm -1 (aromatic); 1 Hmr (60 MHz, CDCl 3 ) δ: 8.52 (2H, b.d., H arom.), 7.18 (2H, b.d., H arom.), 4.90 (1H, q, J=7 Hz, =H), 3.82 (0.1 H, s, CH 2 ), 3.75 (0.9 H, s, CH 2 ), 2.5 (3H, d, J=7 Hz, CH 3 ), 1.02 (9H, s, t-butyl-Si) and 0.25 (6H, s, (CH 3 ) 2 Si).
C. Preparation of (3s,4S)-3-[(1'-R)-1'-t-butyldimethylsilyloxyethyl)]-4-[(1"R and S)-1"-(4-picolylthiocarbonyl)-ethyl]-azetidin-2-one ##STR65##
To freshly melted zinc chloride (272.5 mg, 2 mmol) under nitrogen atmosphere was added CH 2 Cl 2 (8 mL). The mixture was cooled to 5° C., treated with (3S,4R)-4-acetoxy3-[(1'R)-1'-t-butyldimethylsilyloxyethyl)]-azetidin-2-one (5.75 mg, 2 mmol) and the t-butyldimethylsilyl enol ether of S-(4-picolyl)thiopropionate (890 mg, 3 mmol) in CH 2 Cl 2 (2 mL). The mixture was stirred for 18 hours at 22° C. Thin layer chromatography revealed the presence of 4-acetoxyazetidinone. More silyl enol ether (293 mg, 2 mmol) was added and the reaction mixture was stirred for 4 hours. It was diluted with a 1:1 mixture of ethyl acetate:ether, washed with cold water (2×25 mL), brine (1×25 mL) and dried (MgSO 4 ). The residue was purified on flash silica gel (25 g) column (ether-ethyl acetate) to give title material (471 mg, 58%) as a yellow oil. The 1 Hmr spectrum showed a 6:4 mixture of α and β methyl; ir (CH 2 Cl 2 ) ν max : 3410 (N-H), 1765 (β-lactam C=O) and 1685 cm -1 (thioester C=O); 1 Hmr (80 MHz, CDCl 3 ) δ: 8.61, 8.55, 8.53 (2H, b.d., arom. H), 7.33, 7.27, 7.25 (2H, b.d., arom. H), 5.98 (0.6 H, b.s, N-H), 5.8 (0.4 H, bs, N-H), 4.17-3.9 (1H, hidden m, H-1'), 4.09 (2H, s, CH 2 ), 3.86 (0.4 H, dd, J=1 Hz, J=5.6 Hz, H-4 β-methyl), 3.73 (0.6 H, dd, J=2.1 Hz, J=9.3 Hz, H=4 α-methyl), 2.95-2.5 (2H, m, H-3 and H-1"), 1.27 (d, J= 7.1 Hz, CH 3 ), 1.21 (d, J=6.1 Hz, CH 3 ), 1.07 (d, J=6.3 Hz, CH 3 ), 0.87 (9H, s, t-butyl-Si) and 0.06 ppm (6H, s, (CH 3 ) 2 -Si).
EXAMPLE 16
A. Preparation of t-butyldimethylsilyl enol ether of t-butyl thiobutyrate ##STR66##
A cold (ice bath) solution of t-butylthiobutyrate (1.0 g, 6.2 mmol) was treated, as described with the corresponding thiopropionate (in part A of Example 8), with triethylamine (1.6 mL, 11.2 mmol) and TBDMS triflate (2.20 mL, 9.4 mmol in CH 2 Cl 2 (15 mL) to give the title material (1.7 g, 100%) as a 9/1 α/β mixture of geometric isomers; ir (neat) ν max : 1620 cm -1 (olefin); 'Hmr (CDCl 3 , 200 MHz) δ: 5.258 (0.9 H, t, J=7.4 Hz, olefinic H), 5.149 (0.1 H, t, J=7.2 Hz, olefinic H), 2.30-2.0 (2H, m, CH 2 ) 1.342 and 1.304 (9H, 2s, S-t-butyl), 0.95 and 0.162 (3H, part of t, CH 3 ), 0.912 and 0.842 (9H, 2s, Si-t-butyl) and 0.136 (6H, s, Si(CH 3 ) 2 ).
B. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"S)-1"-t-butylthiocarbonylpropyl]-azetidin-2-one ##STR67##
To freshly fused ZnCl 2 (845 mg, 6.2 mmol) under N 2 was added (3S,4R)-4-acetoxy-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-azetidin-2-one (891 mg, 3.1 mmol) and the silyl enol ether of t-butyl thiobutyrate (1.7 g, 6.2 mmol) in CH 2 Cl 2 (10 mL) at 5° C. The mixture was stirred and worked up under the same conditions as described for the corresponding α-methyl isomer in part B of Example 8 to give the title material (1.1 g, 92%) mp 102°-104° C. (EtOAc); ir (CH 2 Cl 2 ) ν max : 3400 (NH), 1760 (C=O β-lactam) and 1670 cm -1 (C=O thioester); 1 Hmr (CDCl 3 , 80 MHz) δ: 5.81 (1H, bs, NH), 4.128 (1H, 5 lines, J=5.9 Hz, and 6.1 Hz, H-1'), 3.68 (1H, dd, J=2.0 Hz, J=9.4 Hz, H-4), 2.466 (1H, b and t, J=1.8 Hz, J=1.3 Hz and J=5.0 Hz, H-3), 2.477 and 2.454 (1H, dt, J=9.3 Hz, J=4.6 Hz, H-1"), 1.8-1.4 (2H, m, CH 2 CH 3 ), 1.448 (9H, s, t-butyl-S), 1.205 (3H, d, J=6.3 Hz, CH 3 ), 0.936 (3H, t, J=7.4, CH 3 ), 0.851 (9H, s, t-butyl-Si) and 0.050, 0.046 (6H, 2s, CH 3 Si).
Part C of this Example illustrates the saponification shown in Step (C) of Diagram 1.
C. Preparation of (3S,4S)-3[(1'R)-1-t-butyldimethylsilyloxyethyl]-4-[1"S)-1"-carboxypropyl]-azetidin-2-one ##STR68##
A cold (ice bath) THF solution of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"S)-1"-t-butylthiocarbonylpropyl]-azetidin-2-one (194 mg, 0.500 mmol) was treated with H 2 O 2 (30% v/v, 0.09 mL, 1.0 mmol) and 1N aqueous NaOH (1 mL, 1 mmol). The mixture was allowed to warm to room temperature (ca. 22° C.) and stirred for 48 hours. The reaction mixture was worked up to yield the title material (136 mg, 86%); m.p. 171-74° C.; ir (CH 2 Cl 2 ) ν max : 3480, 3380 (OH), 3400 (NH), 1760 (C=O β-lactam) and 1745 and 1710 cm -1 (C=O acid); 1 Hmr (CDCl 3 200 MHz) δ: 6.25 (1H, bs, NH), 4.18 (1H, center of 5 lines, H-1'), 3.779 (1H, dd, J=1.9 Hz, J=9.4, H-4), 2.832 (1H, bd, J=4.34 Hz, H-3), 2.480 and 2.455 (2H, dt, J=4.9 Hz, J=9.2 Hz, H-1"), 1676 (2H, m, CH 2 ), 1.244 (3H, d, J=7.2 Hz, CH 3 ), 1.014 (3H, t, J=7.4 Hz, CH 3 ), 0.875 (9H, s, t-butyl-Si) and 0.078 and 0.067 (6H, 2s, CH 3 -Si).
EXAMPLE 17
A. Preparation of t-butyldimethylsilyl enol ether of 3-methyl-2-(butyrylthiomethyl)-pyridine ##STR69##
A cold (dry ice-acetone) THF (10 mL) solution of 3-methyl-2-(butyrylthiomethyl)-pyridine (1.032 g, 4.30 mmol) was treated, under the conditions described for the preparation of the corresponding propionylthio derivative (part A of Example 4), with lithium hexamethyldisilazane (5.42 mL, 5.42 mmol, 1.0M in THF) and TBDMS-triflate 1.24 mL, 5.42 mmol) to give the title material (1.84 g, 100%) as a 54/46 mixture of geometric isomers; ir (neat) ν max : 1620 cm -1 olefin; 'Hmr (200 MHz, CDCl 3 ) δ: 8.370, 8.346, 7.412, 7.378, 7.066, 7.042, 7.029, 7.005 (3H, aromatic), 4.996 (0.46 H, t, J=7.50 Hz, olefinic H), 4.890 (0.54 H, t, J=7.18 Hz, olefinic H), 4.083 (0.96 H, s, CH 2 ), 4.017 (1.06 H, s, CH 2 ), 2.366 and 2.349 (3H, 2s, CH 3 ), 1.988 (2H, center of 5 lines, CH 2 -CH 3 ), 0.9490 (9H, s, t-butyl), 0.8453 and 0.784 (3H, 2t, J=7.50 and 7.18 Hz, CH 3 ), and 0.134 ppm (6H, s, Si--CH 3 ).
B. Preparation of (3S, 4S)-3[(1'-R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R)-1"-(3-methylpyridin-2-yl)-methylthiocarbonylpropyl]-azetidin-2-one ##STR70##
To freshly fused ZnCl 2 (674 mg, 4.93 mmol) under N 2 was added (3S,4R)-4-acetoxy-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-azetidin-2-one (710 mg, 2.47 mmol) in CH 2 Cl 2 (5 mL) and the t-butyldimethylsilyl enol ether of 3-methyl-2-(butyrylthiomethyl)-pyridine (1.6 g, 4.93 mmol) in CH 2 Cl 2 (5 mL). The mixture was treated under the conditions described for the preparation of the corresponding β-methyl isomer (part B of Example 4). The title compound (β-ethyl) was obtained in excellent yield (78%, 837 mg) mp 70°-72° C. (EtOAc) no α-ethyl isomer was present; ir (CH 2 Cl 2 ) ν max : 3400 (NH), 1755, 1680 cm -1 (C=O); 1 Hmr (CDCl 3 , 200 MHz) δ: 8.36, 8.34, 7.45, 7.41, 7.12, 7.09, 7.08, 7.05 (3H, m, aromatic H), 5.856 (1H, bs, NH), 4.31 (2H, center of ABq, J=13.87 Hz, CH 2 ), 4.150 (1H, center of 9 lines, H-1'), 3.815 (1H, dd, J=2.05 Hz, J=7.08 Hz, H-4), 3.049 (1H, bt, J=2.5 Hz, H-3), 2.705 (1H, m, H-1"), 2.344 (3H, s, CH 3 ), 1.988-1.42 (2H, m, CH 2 ), 1.0379 (3H, d, J=6.36 Hz, CH 3 ), 0.957 (3H, t, J=7.42 Hz, CH 3 ), 0.837 (9H, s, t-butyl) and 0.0292 ppm (6H, s, CH 3 Si).
C. Preparation of (3S,4S)-3-[(1'R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R)-1"-carboxypropyl]-azetidin-2-one ##STR71##
A cold (ice bath) THF (4 mL) solution of (3S,4S)-3-[(140 R)-1'-t-butyldimethylsilyloxyethyl]-4-[(1"R)-1"-(3-methylpyridin-2-yl)-methylthiocarbonylpropyl]-azetidin-2-one (437 mg, 1 mmol) was treated, as described previously for the corresponding β-methyl analog (part C of Example 4), with H 2 O 2 (30%, 0.72 mL, 2 mmol) and 1N aqueous NaOH (2 mL, 2 mmol). The mixture was stirred at about 22° C. for 90 minutes and worked up to give pure title material (280 mg, 89%) m.p. 136°-138° C. (EtOAC); ir (Nujol) ν max : 3400 (NH), 3480-2500 (OH), 1765 β-lactam C=O) and 1745 and 1710 cm -1 (C=O acid); 'Hmr (200 MHz, CDCl 3 ) δ: 6.28 (1H, 6S, NH), 4.21- 4.15 (1H, m, H-140 ), 3.86 (1H, dd, J=2.0 Hz, J=6.6 Hz, H-4), 3.10 (1H, 6t, J=2.6 Hz, H-3), 2.54 (1H, center of m, H-1"), 1.8-1.2 (2H, m, CH 2 ), 1.147 (3H, d, J=6.3 Hz, CH 3 ), 0.986 (3H, t, J=7.3 Hz, CH 3 ), 0.847 (9H, s, t-butyl) and 0.047, 0.040 (2s, 6H, CH 3 Si).
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Disclosed herein is a novel high β-yield producing novel intermediates of the formula ##STR1## where R 4 is ##STR2## useful in the synthesis of 1-β-alkyl carbapenems.
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BACKGROUND OF THE INVENTION
A. Field of the Invention
This relates to the use of an extension ladder and specifically the safe use of the extension ladder. This is an attachment piece that is attached near the bottom front of the ladder and will safely secure the extension ladder to a structure.
B. Prior Art
There are many other prior art references to ladder devices and specifically ladder devices, which seek to minimize injury as a result of a fall from a ladder. Representative examples of them are many in the prior art, and some attach to the structure and some to buildings. These types of structures can be found in the following representative patents: Bee, et al., U.S. Pat. No. 6,012,545, Boring, U.S. Pat. No. 4,974,669, Gardner, U.S. Pat. No. 5,960,905, and Griffin, U.S. Pat. No. 4,858,725.
None of the prior art references, however, use a device that attaches to the ladder and is then secured by the frame of a structure as contemplated in this device.
BRIEF SUMMARY OF THE INVENTION
Extension ladders are used, for among other purposes, to paint and repair surfaces on buildings. An extension ladder merely allows an individual to remain off the ground and closer to a piece of particular work. Extension ladders are used by, among others, painters, electricians, and carpenters in repairing and installing various fixtures in a house or building.
An extension ladder has essentially two elements. Each element has two parallel sides and a set of rungs on which the person will stand to climb the ladder. One of the elements will slide against the other and will lock in place. The primary safety concern associated with extension ladders is that, once the ladder is on the ground it needs to remain in place as the person goes up and down the ladder. If the ladder slips on the surface below, the individual on the ladder may fall. This is particularly true of the ladder surfaces placed on a tile or wood floor, which tend to be more slippery than traditional carpet or other surfaces, although the ladder can certainly slip on carpeted surfaces as well.
Most, if not all, extension ladders have a non-skid surface on the bottom portion of the ladder element that rests on the floor surface. Sometimes, because of wear, the non-skid surfaces become slick and will allow the ladder to slip backwards and possibly cause injury or death to the worker and/or parts of the house or to the contents of the house.
This is a device, which attaches to the bottom of the extension ladder near the bottom of one of the elements and secures a telescoping pull with a flat rectangular pad on one end. When the extension ladder is positioned, the telescoping pole is rotated away from the ladder. A pad, which may contain weighted material, will be secured against the baseboard or wall of the building.
A clamping mechanism to secure the position of the telescoping tube is also provided to ensure that the tube does not collapse during normal use. The telescoping tube is attached to a T-member, which is a female plug, which is attached to a U-shaped support mechanism that clamps on both legs of the ladder slightly above the non-skid surface and below the first rung of the ladder.
In another embodiment a female threaded portion will be installed on the bottom rung of the extension ladder to secure a swivel mechanism. The male end of the telescoping tube will attach to the swivel mechanism. This ability to swivel will allow the telescoping tube to be positioned in many different places.
For ease of transport, a clip on one rung of the ladder whereby a portion of the telescoping tube will clip onto the ladder to hold the tube in place.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the device secured to the extension ladder.
FIG. 2 is an exploded view of number 2 as indicated on FIG. 1 .
FIG. 3 is an isometric view of the device in use.
FIG. 3A is an isometric view of the device used against a baseboard and in the corner of the baseboard when doing corner work.
FIG. 3B is an isometric view of the device used with an archway.
FIG. 3C is an isometric view of a double base pad embodiment to prevent flipping of the ladder.
FIG. 4 is an isometric view of the device with the telescoping tube extended.
FIG. 5 is an isometric view of the clamping mechanism and support mechanism.
FIG. 6 is a top view of the device in use.
FIG. 7 is an exploded view of item 7 on FIG. 6 .
FIG. 8 is a side view of the device in use.
FIG. 9 is an exploded view of item 9 on FIG. 8 .
FIG. 10 is an isometric view of the device stowed.
FIG. 11 is an exploded view of the clamping device as shown by the area in item 11 on FIG. 10 .
FIG. 12 is an exploded view of the clip on the ladder.
FIG. 13 is an exploded view of the bearing for the clamping mechanism.
FIG. 14 is a side view of the clamping mechanism.
FIG. 15 is a view of the interior of the clamp on the ladder that holds the pole.
FIG. 16 is a front view of the alternative embodiment.
FIG. 17 is a top view of the alternative embodiment.
FIG. 18 is an isometric view of the swivel mechanism for the alternative embodiment demonstrating at least three possible positions of the pole: locked on the base, locked on the chair rail or wall and locked on the ladder.
FIG. 19 is an isometric view of an alternative swivel mechanism for the second alternative embodiment depicting the ladder rung attachment as past of the existing ladder.
REFERENCE TO NUMBERING
5
Device
8
Foot supports
10
Extension ladder
10R
Extension ladder movable member
10S
Extension ladder stationary member
15
Clip
20
Wall structure
21
Baseboard
22
Archway brace
25
Telescoping pole
27
Locking mechanism
28
Double mounting member-U shaped base member
30
Base
35
Adjustable Tee
36
Connection means for the tee
40
Adjustable width support structure
45
Clamping mechanism
50
Clamp bolt
55
Female portion of rung attachment for ladder
57
Flexible portion of rung attachment
59
Swivel for rung attachment
60
Rung attachment
DETAILED DESCRIPTION OF THE EMBODIMENTS
This device 5 is a safety device to be used with an extension ladder 10 . The extension ladder has two pieces, one section rests on the floor and has a series of foot supports 8 and remains stationary. These foot supports 8 will rest on the ground surface during normal use. The other section will move parallel to the stationary member of the extension ladder.
When the ladder is initially being positioned one section of the ladder will move up and down while the other section stays stationary. One section 10 R will go up and down relative to the stationary portion 10 S. This device will be clamped to the bottom of section 10 S slightly above the foot supports 8 and below the first ladder rung. It is secured to the ladder member with a clamping mechanism 45 , which take the general shape of a “U”. Various types of clamps may be used and the means to secure the clamping mechanism 45 to the extension ladder may include bolts as well as eye screws.
Two solid support structure 40 members will extend outward from the clamping mechanism 45 and will be joined at a tee 35 . The tee will be equipped with a female end into which the male end of a telescoping tube will be inserted. One end of a telescoping tube 25 will be inserted into the one female end of the tee 35 . This may be threaded or it may be a molded as part of the device itself.
A means to secure 27 the tube will allow the sections of the telescoping tube 25 to be locked into place. The means to secure the sections of tube may vary but a locking coupling or threaded clamp may be used as well as a tube with a series of holes into which protrusion would fit may also be contemplated.
The support structure 40 , which are secured at the tee will rotate around the clamp 45 and will allow the first end of the telescoping pole 25 to be placed against a wall as depicted in FIGS. 3 , 3 A, 3 B, 3 C and 6 . On the first end of the telescoping tube will be a base 30 , which may be weighted for additional stability, and which will be secured against the baseboard of the wall 20 . The shape of the pad 30 may be shaped to conform to the general shape of a baseboard. The base 30 may also be allowed to swivel at the end where it connects to the telescoping pole. This pad will ensure that, if the ladder slips backward, the movement of the ladder will be stopped in place.
In order to enable the device to be more versatile a swivel mechanism may be placed near the tee, which is joined to the support structure. The ability to swivel will enable the telescoping pole to be secured in many different positions.
In some environments the ladder is placed in a structure that does not provide a base board behind the ladder but instead an opening is behind the ladder. In that situation a base board member 22 can be installed in the opening and the pad rests against the base board member 22 such as depicted in FIG. 3 c.
There may also be attached to one end of the telescoping tube a U shaped base member 28 that will accommodate two pads such as depicted in FIG. 3 c . This particular arrangement will provide additional security for the device.
The tee 35 that is used to secure the support members together will likely come in two sections, which will clamp around the support structure members 40 . The means of connection for the sections of the tee 35 are likely to be a bolt and nut 36 but other means to secure the sections of the tee may also be contemplated.
The clamping mechanism on the extension ladder leg 45 can also be of many different varieties, but it should clamp securely on the respective extension ladder legs and allow the support structure 40 to rotate so that the telescoping tube is able to position the pad 30 securely against the wall. The advantage to the use of clamps is the ability to change the positions on the ladder to accommodate different working conditions.
For ease of storage, a clip 15 is provided on one rung of the extension ladder. When the device is stowed, it can be clipped as depicted in FIG. 1 . Various materials may be used in the construction of this particular device, and certain safety considerations would be paramount.
A possible choice of materials may include aluminum, PVC pipe, or any other material that would provide sufficient strength in the event that the ladder may began to slip backward.
ALTERNATIVE EMBODIMENT
One of the salient features of this device is the method by which the device is secured to the extension ladder. A plurality of clamps may be used as described above in the first embodiment. Another alternative is to incorporate a female portion into the bottom rung of the extension ladder. A swivel mechanism is placed in the female end and the male end of the telescoping tube is installed in the swivel mechanism.
The device operates the same way with regard to rotating the telescoping tube to secure the device to the wall or baseboard. The advantage of installing the female end directly into the rung of the ladder is that it eliminates the clamping mechanisms.
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This is a device that will provide additional security for individuals who work on extension ladders. It can be fit to any extension ladder and provide a support mechanism so that, if the ladder were ever to shift backward, it would stop the ladder from shifting, thereby protecting the worker. Because of the telescoping nature of the tube, it provides protection and it may be used in a variety of settings.
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CLAIM TO PRIORITY
This application claims priority to copending United Kingdom utility application entitled, “A METHOD OF SELECTIVELY STORING DIGITAL IMAGES,” having serial no. GB0103362.0, filed Feb. 10, 2001, which is entirely incorporated herein by reference.
TECHNICAL FIELD
This invention relates to a method of selectively storing digital images.
BACKGROUND
When taking still photographs, a photographer needs to select a particular instant in time in which to capture an image. Whether or not the image will be pleasing to the eye, however, will depend on the photographers ability to recognize good photographic composition and to anticipate the time when the photograph should be taken to capture such composition. The photographic composition task is not trivial and involves conscious anticipation of action and movement of the photographer in order to compare alternative viewpoints.
Generally speaking, the average person taking a photograph will not want to spend time considering composition factors, the end result being that many memorable events go un-recorded or poorly-recorded. One way in which this problem is reduced in film-based cameras is to provide a motor-drive mechanism which automatically winds-on the camera film to allow photographs to be taken at the highest rate possible. Of course, such film-based cameras (being bulky and mainly mechanical in their film-winding structure) are limited in terms of the rate at which photographs can be taken and ultimately produce a large number of photographs which are of no use or interest to the photographer. Digital cameras, which are being increasingly used, are able to capture photographic images at a faster rate than their non-digital counterparts. Thus, a user is able to select the better images, from a compositional point of view, from the large number of total images captured and stored. However, such cameras still suffer from the disadvantage that a large number of captured images will be of no use or interest to the photographer. Since such cameras have a limited memory capacity, such unwanted images take up significant amounts of storage space and so frequent ‘clearing-out’ operations have to be performed, as well as post-editing to sort out the good-photos from the bad (and thus still requiring the user to have some appreciation of composition).
SUMMARY
According to a first aspect of the present invention, there is provided a method of selectively storing digital images, the method comprising: storing, in a memory, a plurality of digital images received from a source, each image representing an event captured at a different respective time; using a processing means to perform an analysis of the image content; assigning a quality factor to each image, the quality factor being representative of the composition quality of the analyzed image content; and updating the memory to maintain images for which the assigned quality factor indicates a higher composition quality than an image captured at an earlier time.
Thus, by using the processing means to analyze and assign a quality factor to each image, based on composition quality, the memory of the device in question can be maintained so as to store only those images which are indicated as being better (from a compositional point of view) than earlier-captured images. Accordingly, memory space, be it in a computer or in a digital camera, is better utilized For example, in the method, first and second images may be stored, the second image being captured after the first image, the step of updating the memory comprising deleting the first image if its assigned quality factor indicates a lower composition quality than that assigned to the second image. The user is not required to have any real knowledge of composition considerations.
In the context of the present specification, “composition quality” relates to measures of the disposition of elements within a photographic composition, disposition covering any or all of orientation of the element itself, position or orientation relative to other elements of the composition, and position or orientation relative to the composition as a whole. It does not relate to optimization of the image, as opposed to the composition (such as, for example, by sharpening focus or removing artifacts arising from the image capture apparatus).
The step of analyzing the image content may comprise identifying groups of images having similar content by means of comparing the content of an image acquired at a time t1 with the content of images captured prior to t1, the step of updating the memory being performed separately for each identified group of images having similar content. In this way, images representing differing viewpoints of a particular scene may be grouped together, with the step of updating the memory being performed for each group. The end result, therefore, should provide a number of image groups, with an image being stored for each group having good composition compared with others in that group. In the step of analyzing the image content, the content of the image to be compared may be established by means of (i) identifying one or more area(s) of interest in the image, and (ii) tracking the motion of the area(s) of interest over subsequent images.
The step of identifying area(s) of interest may comprise segmenting the image into regions having generally consistent texture and/or color.
The step of analyzing the image content may further comprise identifying at least one subject area of interest, and wherein, in the step of assigning a quality factor to each image, the quality factor is representative of the composition quality of the subject area(s) of interest. In this sense, the subject area of interest will usually be the intended subject of the photograph, e.g., a person, animal, or object. In the step of identifying the subject area(s) of interest, the subject area(s) of interest might be assumed to be generally located in the center of the image.
In the step of identifying the subject area(s) of interest, human facial features may be identified as comprising the subject area(s) of interest.
The quality factor may be determined according to the size of the subject area(s) of interest, the composition quality increasing with the size of the subject area(s) of interest. Alternatively, the quality factor can be determined according to the spatial separation of the subject area(s) of interest with respect to other parts of the image having a high relative motion, the composition quality increasing with the amount of spatial separation. As a further option, the quality factor may be determined according to the presence of area(s) of interest at the edges of the image, the composition quality decreasing in the presence of such area(s) of interest at the image edges.
In the case where the subject area(s) of interest are facial features, the quality factor may be determined according to the presence of area(s) of interest obscuring the identified facial subject area(s) of interest, the composition quality decreasing according to the degree that the facial subject area(s) is/are obscured. Further, the quality factor may be determined according to the orientation of the identified facial subject area(s) of interest, the composition quality increasing if (a) there is at least one identified facial subject area where most or all of the face is visible in the image and/or (b) there are two identified facial subject areas whose orientations face one another. Taking this a stage further, the quality factor might be determined according to recognition of facial subject area(s) of interest, the composition quality increasing if there is a facial subject area in the image which is identified as being present in a database of previously-stored facial features.
The above-described methods of determining the quality factor of an image are by no means exclusive to one another. Indeed, more sophisticated algorithms may be devised to judge the composition quality of an image based on a combination of the above methods or by using further methods.
In one embodiment of the invention, in the step of storing images received from a source, the images are divided into first and second groups, the first group comprising images received at a first data rate and a first resolution, and the second group comprising images received at a second data rate and a second resolution, the second data rate being greater than that of the first data rate, and the second resolution being less than that of the first resolution, and wherein, in the step of analyzing the image content, the content of the image to be compared is established by means of tracking the motion of the area(s) of interest using images of the second group, the resulting quality factor being assigned to a preceding image of the first group. This effectively provides a situation where so-called “key-frames” (forming the first group of images and having a relatively high-resolution) are acquired. Preferably, between each acquired key-frame, images in the second group are acquired at a higher data rate and with a lower resolution. Motion tracking may therefore be performed more efficiently and effectively on the high data rate images to produce a quality factor which can be assigned to the preceding high resolution image. Thus, the low resolution images may be discarded and the updating step performed on the high resolution images only.
The processing operation may be performed in-situ e.g., within a camera, or as a post-processing operation by means of downloading the contents of a camera memory to a computer system, the analysis and/or updating operations being performed by the computer system.
In accordance with a second aspect of the present invention, there is provided a computer program stored on a computer usable medium, the program comprising computer readable instructions for causing a computer to execute the steps of: storing, in a memory, a plurality of digital images received from a source, each image representing an event captured at a different respective time; using a processing means to perform an analysis of the image content; assigning a quality factor to each image, the quality factor being representative of the composition quality of the analyzed image content; and updating the memory to maintain images for which the assigned quality factor indicates a higher composition quality than an image captured at an earlier time.
In accordance with a third aspect of the present invention, there is provided a system for selectively storing digital images, the system comprising: a processor; a memory; and a video input port, the processor being arranged to store, in the memory, a plurality of digital images received from a source by means of the video input port, each image representing an event captured at a different respective time, the processing means being arranged to perform an analysis of the image content and to assign a quality factor to each image, the quality factor being representative of the composition quality of the analyzed image content, the processor being further arranged to update the memory to maintain images for which the assigned quality factor indicates a higher composition quality than an image captured at an earlier time.
The system may comprise a computer system.
The system could be provided as an integral part of a digital camera, be it a still camera or a combined still/video camera. Accordingly, in a fourth aspect of the present invention, there is provided a camera system for selectively storing digital images, the camera system comprising: a processor; a memory; and an image capture system, the processor being arranged to store, in the memory, a plurality of digital images received from the image capture system, each image representing an event captured at a different respective time, the processing means being arranged to perform an analysis of the image content and to assign a quality factor to each image, the quality factor being representative of the composition quality of the analyzed image content, the processor being further arranged to update the memory to maintain images for which the assigned quality factor indicates a higher composition quality than an image captured at an earlier time.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram representing the elements of a camera system;
FIG. 2 illustrates the arrangement of a number of frames captured by the camera system shown in FIG. 1 ;
FIG. 3 is a flowchart showing the different stages of analysis and image updating of the captured frames; and
FIG. 4 is a flowchart showing the different stages of assigning a quality factor to a captured frame.
DETAILED DESCRIPTION
Referring to the drawings, FIG. 1 shows a camera 1 which effectively comprises two separate camera systems 3 , 5 . The first camera system 3 is a high resolution camera which captures images at a rate of approximately one frame per second. The second camera system 5 is able to capture images at a faster rate, but at a lower resolution. The two camera systems 3 , 5 capture images via a single lens system (not shown). Data representing the captured image frames is passed to a processor 7 and stored in a memory 9 , which may be in the form of a microchip storage device, or a removable device such as a memory card or floppy disk. A data port 11 is also provided for transferring the image data to a personal computer (PC) 13 .
In use, the camera may be operated in first or second modes. In the first mode, the camera operates as a conventional still camera. In the second mode, the camera operates in a so-called ‘continuous capture’ mode. In this latter mode, the two camera systems operate together to produce two different sets of frames, i.e., a set of high resolution frames (hereinafter referred to as ‘key frames’) from the first camera, interleaved by a number of low resolution frames (hereinafter referred to as ‘video frames’) from the second camera. The number of video frames being captured between each key frame will obviously depend on the relative capture rate of the two camera systems.
FIG. 2 represents an example set of frames captured in the continuous capture mode. In this example, ten video frames (represented by reference numeral 14 ) are captured between every adjacent pair of key frames (represented by reference numeral 15 ). The image data representing the 14 , 15 frames illustrated in FIG. 2 are transferred to the PC by means of the video port 11 .
The PC 13 includes an application program for performing an analysis and memory update operation of the image data received from the camera 1 . The operation of this application program will be described in detail below. However, it should be understood that the operation of the application program need not be performed remotely from the camera 1 . Indeed, the program could be stored and executed in a non-volatile memory within the camera 1 .
The main purpose of the application program is to decide which of the captured key frames 15 should be stored, and which should be discarded (i.e., by a deletion or replacement operation) thereby freeing-up memory. This is performed by means of the application program performing an analysis of the image content, assigning a quality factor to the image content based on the composition quality of the image content, and updating the memory to remove key frames 15 which have a quality factor indicating a lower composition quality than a subsequently captured key frame. Thus, only those key frames 15 having ‘interesting’ content will be saved, and those key frames which are poor in terms of their content or composition will not occupy memory if a better key frame is identified.
As will be understood from the above, in this example, the selection process is performed only for the high-resolution key frames 15 . The video frames 14 are used for identifying so-called ‘regions of interest’ in each image by tracking the relative motion of different regions having consistent color and texture. It will be appreciated that motion tracking can be performed particularly efficiently with frames captured at a higher rate. It should also be appreciated that there are other conventional techniques for identifying regions of interest.
As will be discussed below, the application program is further configured to recognize different ‘groups’ of images having similar or comparable content. The updating operation may thereafter be performed in respect of each identified group, rather than on the whole set of key frames 15 acquired. Thus, if the user is pointing the camera 1 at a particular subject, then turns away to look at something completely different, then the update operation will be performed separately for the two different ‘scenes’ or groups. If the user points the camera 1 back to the original scene, the program should recognize that the new image key frame 15 is related to the original group of image key frames 15 , and so the update operation will continue for that group.
The overall process by which the application program operates is illustrated by the flowchart of FIG. 3 .
Initially, a key frame 15 is examined by the application program in step 3 a . In step 3 b , an analysis is performed to determine whether the key frame 15 differs significantly from the previously captured key frame. This is performed using the video frames 14 , and the abovementioned tracking operation for the areas of interest within the video frames. Other techniques for achieving motion tracking are known in the art. If it is determined that there are no significant differences between the image content, then the next frame is analyzed and the process repeats at step 3 a . If the analysis determines that there is significant difference, then in the next step (step 3 c ) the program determines whether there is an identifiable ‘subject area of interest’. The subject area of interest will usually be the subject (e.g., a person) which the user is trying to capture, and will generally comprise one of the areas of interest. Many methods are possible for identifying such areas which are likely to be of particular interest. As an example, one technique is to identify foreground areas from background areas. One way of achieving this is to cluster the colors of particular regions to find a set of regions occupying a large proportion of the image, yet containing relatively few colors. Typically, such regions represent the sky or ground. Non-background regions can then be grouped into subject area(s) of interest, by locating groups of non-background regions which are separated from other such groups by background regions. These groupings can be refined by the use of motion tracking. If a particular grouping of foreground regions later splits into two groups, clearly two objects are involved and this knowledge can be used to revise the earlier analysis. A more refined approach to this aspect is to predispose the system to favor some subjects as more interesting than others. Typically, this will be done by enabling the system to recognize people of interest.
If no subject area is identified, then the process will go back to step 3 a . If a subject area is identified, then the process goes to the next step, step 3 d.
In step 3 d , a comparison is made with previously stored key frames 15 relating to that subject area of interest. The easiest method of establishing whether a subject area of interest has been seen previously is by determining how its regions have been tracked from one frame to the next. This is suitable providing the object does not go out of view. If the object does go out of view and later reappears it is sometimes possible to detect this using one of the following methods, namely a) color matching followed by shape and feature matching, b) detecting identifier tags on the object, (for example, visible badges or infrared detected badges pinned to people of interest), or c) by tracking the motion of the camera 1 , so that when the camera returns to a particular line of sight, views of static objects can be easily matched to previous views of the same objects. In this last method, motion sensors (e.g., gyros) are incorporated in the camera 1 such that the position of the camera is known. By keeping track of what the camera 1 has looked at previously, the application program will be able to determine whether or not a particular image has been seen before, i.e., by detecting that the camera is looking in the same direction as was previously the case.
To elaborate on b) mentioned above, the camera system can be configured to identify subject areas of interest by means of ‘identifying’ so-called identifier tags which have been placed on particular subjects. In this way, it is possible to predispose the camera to identify and capture particular classes, or types, of subject. For example, the user might wish to capture images which only include a particular member or members of his family. Thus, by tagging members of his family, e.g. using a pin badge, the camera will detect such tags and classify such identified regions as the subject areas of interest. The camera will not identify other areas of interest (e.g., simply because they exhibit a particular color or interesting movement pattern). Such a method of identifying a subject area of interest is particularly useful where ‘interesting’ subjects are mingling amongst similar ‘uninteresting’ subjects, say, in a theme park or zoo.
To take this a step further, different tags can be used for different classes of subject. Different tag types can indicate the user's preference to what is captured. The user might predispose the camera to capture a person of prime importance, for example, a person at their own party, while at the same time configuring the camera to capture members of that persons family when the person of prime importance is not in view. The family members would have to wear different tag types to those worn by the person of prime importance.
Of course, predisposing the camera system to identify tags not only requires the actual tag to be identified as a subject area of interest. The region ‘attached’ to that tag will, of course, form the overall subject and so detecting the regions around the tag will have to be performed, e.g., by identifying particular colors and/or textures and/or tracking the relative motion of those regions with respect to the tag.
If the subject area has not been seen before, e.g., because the user has quickly turned away from the subject and has pointed the camera 1 at a completely different scene, then the current key frame 15 is saved as the best frame for this particular ‘group’ of frames, and the process repeats from stage 3 a again. If the subject area has been seen, e.g., the previous key frame was of the same subject area, but at a slightly different orientation, or because the camera 1 has been moved back to a previously captured scene, then the process moves on to step 3 f . This step evaluates the composition quality of the subject area of interest and assigns a quality factor to the key frame 15 as a result. This process is described in more detail below.
Referring to FIG. 4 , which shows step 3 f in detail, at the start of the composition quality evaluation stage, a composition quality index, or factor, is set to zero. Analysis of the subject area of interest thereafter follows to assess the quality of composition of that subject area with respect to the stored ‘best frame’ for this group. In a first test, at step 4 a , the size of the subject area of interest is compared with the best frame. If it is larger than in the best frame, then the quality factor remains at zero. If it is smaller, then the quality factor is incremented. At step 4 b , the image is analyzed to determine whether the subject area is closer to the center of the overall image compared with the best frame. If not, the quality factor is incremented. In step 4 c , the image is further analyzed to determine whether there are distracting regions close to the edges of the frame. If so, the quality factor is incremented. These tests could prove particularly useful where the user is walking past a subject, keeping it roughly in the center of the camera view. As the user approaches and passes the object, it will appear larger, occluding objects will move out of the way, and then the object will appear smaller or become occluded again. These three tests should provide a lower numerical quality factor (indicating a higher composition quality) for the closest frame with the subject being closest to the center.
While only three analysis steps 4 a–c , or tests, are shown, it will be appreciated that more could be included. For example, the quality factor could be increased if there are large regions of boring detail, or where the subject area is more obscured by some other region than in the previous best frame.
In the case where the key frames 15 include facial features, conventional image recognition techniques could be employed to identify this special subject area. The analysis tests could be customised to deal with faces. For example, since it is particularly preferred that faces not be obscured, this test might be included. Images where the face appears to be looking towards another face, or looking in the same direction as another face might also be preferred, these characteristics being relevant to photographic composition techniques. Taking this a step further, images where the face is known to the user might be preferred. By keeping a database of facial features, a comparison could be made with the subject area of the captured key frame 15 . The fact that there are a greater number of faces looking into the camera's view might also be a preferred characteristic.
At the end of step 3 f , the key frame in question will be assigned the resultant quality factor. The higher the number, the lower the quality of composure and vice-versa.
Referring back to FIG. 3 , in step 3 g , the assigned quality factor for the current key frame 15 is compared with that previously assigned to the best frame. If it is lower, then this indicates a higher composition quality, and so the best frame is deleted and replaced with the current key frame 15 . The next key frame 15 is then analysed at step 3 a , and so on, with the key frame previously analysed being considered the best frame for this next analysis. If the quality factor is higher, this indicates a poorer composition quality and so the current key frame 15 is discarded and the process repeats from step 3 a.
In following the above described steps, the application program selectively and automatically stores only that key frame 15 (for each separate image group) which is considered the best composed version.
In this embodiment, the application program is executed in the PC 13 . This means that the camera 1 is operated over the course of a session until the in-situ memory 9 becomes full, at which time the image data is downloaded for processing, the camera memory becomes erased, and a new session initiated. Alternatively, however, the software could be executed within the camera 1 itself so that the frame selection is performed whilst the continuous capture mode is in operation. Thus, the in-situ memory 9 of the camera will become full less frequently.
With the recent increase in use of ‘non-viewfinder’ cameras, such as those worn on a part of the body, the use of this method is particularly advantageous since the wearer will not have any perceivable idea of the composition which is being captured by the camera. The method will allow images having the best composition to be captured and stored.
As a further point, it will be appreciated that the system described above finds useful application in mounted-camera situations. For example, in theme parks, mounted cameras are commonly used to capture people on particular attractions, e.g., rollercoasters. However, such cameras do not capture images based on composition factors, but rather require some switching operation based on the position of the ride. The system described above does not require such switching, and can be used in any mounted environment to capture images where composition is important. Photographs involving groups of people can also be identified and sorted using the above-mentioned tagging procedure.
Finally, whilst the above-described embodiment utilises two camera systems 3 , 5 (producing two groups of frames as shown in FIG. 2 ) it will be appreciated that the method is not limited to such an arrangement. Frames acquired at one capture rate and at the same resolution can be used, although where motion tracking is used to identify regions of interest in a frame, a high capture rate is preferable.
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Briefly described, one embodiment is a method comprising storing, in the memory, a plurality of digital images received from the source, each image representing an event captured at a different respective time, using the processor to perform an analysis of the images, assigning a quality factor to each image, the quality factor being representative of the composition quality of the analysed images, and updating the memory to maintain images for which the assigned quality factor indicates a higher composition quality than an image captured at an earlier time.
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BRIEF DESCRIPTION OF DRAWINGS
[0001] FIG. 1 shows a GUI representation of an object within a class.
[0002] FIG. 2 shows an exemplary property-value pair table for an object as described in FIG. 1 .
[0003] FIG. 3 shows updates incorporated into the table of FIG. 2 .
[0004] FIG. 4 shows an error message indicating invalid, unacceptable or incompatible input to the table of FIG. 3 .
[0005] FIG. 5 shows object instantiation code generated according to the values shown in FIG. 3 .
[0006] FIG. 6 shows an exemplary computer system for implementing the embodiments described herein.
[0007] FIG. 7 illustrates one example of a System Object Dialog generated from a MATLAB system object class.
DETAILED DESCRIPTION
[0008] A software object may have an associated set of properties. Each of the properties may take on a particular value. The properties, along with the corresponding values, serve to define the characteristics of the object. The properties and their corresponding values may be organized in a list of property-value pairs.
[0009] In order to establish particular values for a set of object properties, a software developer may manually enter property-value pair lists, in order to instantiate an object in the code. But writing code to set up property-value pairs at construction time of an object can be cumbersome and time-consuming when the object has a large number of properties.
[0010] Some design tools and/or coding environments include inherent features that can help streamline the process of establishing object property values. For example, some developers have discovered that they can instantiate an object of a given class in the command line workspace, to be able to use tab completion for that class in the MATLAB editor. Doing so allows the developer to fill up the property value pairs of an object faster than manual typing, but it is still a tedious procedure.
[0011] The embodiments described herein may speed up the process of instantiating objects in code by utilizing a graphical user interface (GUI) to establish property-value pairs, and automatically generate code in the editor or command window. The GUI, an example of which is shown in FIG. 1 , provides a visual representation the object-related concepts describe herein, as well as unrelated tools and effects such as split window editing, cursor effects, selectable windows, among others.
[0012] Many of the embodiments described herein may be used in a Technical Computing Environment (TCE), for example MATLAB. A TCE facilitates high-performance numeric computation and visualization. A TCE integrates numerical analysis, matrix computation, signal processing, and graphics into an easy-to-use environment where problems and solutions are expressed just as they are written mathematically, without much traditional programming.
[0013] The described embodiments may perform validity checks on property values prior to running the code. When used in, for example, the MATLAB Editor, run-time errors are replaced with code-time errors, thereby reducing the time a software developer spends debugging code.
[0014] The described embodiments may be implemented on a particular machine such as a workstation, a personal computer, a mobile computing device, or any other particular machine a software developer deems necessary or desired for carrying out a particular programming task. Further details of such implementation are included herein.
[0015] In one embodiment, a software developer (or other user; hereinafter referred to generally as “user”) types, enters or otherwise submits a class name in the editor. In this exemplary embodiment, a MATLAB editor is used for illustrative purposes, although the concepts described herein also apply generally to other editors. Further, other embodiments may include a command window GUI rather than an editor GUI for implementing the embodiments described herein.
[0016] Once the editor recognizes the class name, the user can cause the editor to launch a property-value pair table dialog by selecting (e.g., by highlighting and/or double clicking with a mouse or other selection tool) the object within the class name text, as show in FIG. 1 .
[0017] Upon clicking or otherwise selecting the object, a table with property names and default property values associated with the object is presented to the user through the GUI, as shown in FIG. 2 . In one embodiment, all property names and values can be presented to the user. The exemplary object shown in FIG. 2 relates to a digital up-converter.
[0018] For this digital up-converter example, only the relevant properties are visible and hidden properties may appear as they become relevant. The determination of which properties are relevant may be based on the particular object, other object(s), the environment or other factors. For example, one property may only be defined when another property exceeds a certain value. Consider an exemplary object “automobile_brake_system,” for which the property “emergency_deceleration” could be defined only when the property “speed” exceeds 100 mph.
[0019] In other embodiments, all properties are available to the user regardless of their relevance. Properties that have numerical values may be represented in a field within the GUI. The user can enter an initial value into the field, or select and edit an existing value within the field.
[0020] Properties may be characterized by a set of limited, predefined values. For example, properties that have ENUM options (i.e., enumerated alternative options) may have drop-down menus from which a selection from an enumerated group can be made. In at least one embodiment, user input fields and the presented enumerations are automatically generated for any object whose class definition code has been developed following a predetermined API or template. In another example, properties that are characterized by Boolean values may be associated with check boxes of which a selection of one or more may be made. In yet another example, properties characterized by mutually-exclusive settings may be associated with “radio buttons” that only one of a set of such radio buttons can be selected at a time.
[0021] Once the object-property pair table is displayed, the user has the opportunity to set some or all of the property values, as shown in FIG. 3 . In some embodiments, this entails manually entering a number into a predefined field within the property-value pair table. In other embodiments, the user makes selections by manipulating drop-down menus. In other embodiments, the user uses both techniques to enter property information.
[0022] In the exemplary up-converter object shown in FIG. 3 , the user enters a value of “50” to replace the default value of 100 for the property “InterpolationFactor.” As the user changes the property “MinimumOrder” from TRUE to FALSE, the previously non-relevant and undisplayed properties of “FirstFilterOrder,” “SecondFilterOrder” and “NumCICSections” become relevant and displayed. The user then enters particular values for those properties in the table. The selection of TRUE or FALSE as described above can be accomplished in a number of ways—for example by providing the user with check boxes or radio buttons, or any other appropriate selection mechanism known in the art.
[0023] Once all property value entries have been made, the user may click an OK button or field, or otherwise acknowledges that the selections are complete.
[0024] In one embodiment, the selections are screened against a range of valid or otherwise acceptable values. The screening may occur prior to the acknowledgement described above, or upon such acknowledgement. One reason for waiting until the acknowledgement is to allow sufficient time for all inputs to be entered for associated properties, i.e., when one or more property values depend on other property values. For example, if the value of property A must be twice the value of property B, properties A and B are associated properties. In the case of associated properties, it may be preferred to not indicate an error until both property values have been entered.
[0025] If any of the properties were set to an invalid or unacceptable value, an error message such as the one illustrated in FIG. 4 is presented to the user through the editor GUI. In one embodiment, the property values are evaluated to determine whether or not they are within the range of allowed values for the corresponding property. For example, a particular property may require an integer property value, so that a property value in floating point format with a fractional portion would not be in the range of allowed values for that property.
[0026] For the example shown in FIG. 4 , the value associated with the property “FirstFilterOrder” must be an even number. Since the user entered a “25” for the FirstFilterOrder property, the GUI presented an error message telling the user that the property value must be even. If other invalid or otherwise unacceptable values are detected, error messages similar to the one shown in FIG. 4 are presented to the user through the GUI.
[0027] In this example, the user corrects the FirstFilterOrder error and any other errors that were indicated. When the user is satisfied that all of the errors have been corrected, the user once again acknowledges that the selections are complete. If the editor determines that all of the property values are acceptable, the editor generates code for instantiating the object, as shown in FIG. 5 . The code corresponds to the property settings established in the property-value pair table. In at least one embodiment, the code is not generated until the user corrects all errors, incompatibilities or unacceptable property values. In other embodiments, the code is generated whenever the user inputs new property values into the table.
[0028] If the editor detects that a property has retained its default value, the editor in one embodiment omits that property setting in the code since the default value already exists and does not need to be reestablished. In other embodiments all property values are included in the code regardless of whether the user changes the default value.
[0029] One embodiment includes automatic dialog construction performed with System objects. System object dialogs are property dialogs that are automatically generated from (for example) MATLAB System object class files. These dialogs are available for any MATLAB System object class without any additional coding necessary on than the class definition; however, easy-to-use markup is available for further customization. Automatic dialogs based on System object class definition are available from MATLAB or from Simulink blocks. FIG. 7 illustrates one example of a System Object Dialog generated from a MATLAB system object class.
[0030] Embodiments described herein can be implemented on various types of computer systems (e.g., desktop, laptop or notebook PC, mobile handheld computing system, workstation or other particular machine). Described embodiments may be implemented in a computer program product that may be non-transitory and may be tangibly embodied in a machine-readable storage medium for execution by the computer system. Methods of described embodiments may be performed by a computer system executing a program to perform functions, described herein, by for example, operating on input data and/or generating output.
[0031] An exemplary computer system 602 is shown in FIG. 6 . Referring to FIG. 6 , computer system 602 may include a processor 604 , an information storage medium 606 , and a user interface 608 . These components may be contained within a typical desktop, laptop or mobile form factor housing, or they may be integrated into a single component such as a multi-chip module or ASIC (application specific integrated circuit).
[0032] Suitable processors 604 may include, for example, both general and special purpose microprocessors. Generally, the processor 604 receives instructions and data from a read-only memory (ROM) and/or a random access memory (RAM) through a CPU bus. The processor 604 may also receive programs and data from a storage medium 606 , such as, for example, an internal disk operating through a mass storage interface, or a removable disk operating through an I/O interface. Instructions for executing the described embodiments may be stored on the storage medium.
[0033] Information storage media 606 suitable for tangibly embodying computer program instructions for implementing the described embodiments may include various forms of volatile memory and/or non-volatile memory, including but not limited to, semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices, and magnetic disks, such as internal hard disks and removable disks, magneto-optical disks, and CD-ROM disks. The information storage medium 606 may also store an operating system (“OS”), such as Windows or Linux, which the processor may execute to provide, for example, a supervisory working environment for the user to execute and control, for example, one or more embodiments of the invention.
[0034] The user interface 608 may include a keyboard, mouse, stylus, microphone, trackball, touch-sensitive screen, or other input device. These elements are typically found in a conventional desktop computer as well as other computers and workstations suitable for executing computer programs implementing methods described herein. The computer system 602 may also be used in conjunction with a display device for providing a GUI. The display device may include an output device that may be capable of producing color or gray scale pixels on paper, film, display screen, or other output medium.
[0035] The touch-sensitive screen described above may be used to effect a multi-point input interface. For example, the user may sequentially or simultaneously select items in the GUI using two or more fingers.
[0036] The described embodiments are not limited to an implementation that is contained within a single platform. The described embodiments may also be suitable for use in a distributed computing environment or in an environment of computing devices communicating through a network or other linked architecture. For example, a user may utilize functionality in a mobile device that enables the mobile device to communicate and cooperate wirelessly with a workstation. The user may employ the concepts of the described embodiments to bind an entity displayed on the mobile device (e.g., an HMI element) with an entity displayed on the workstation (e.g., an expression from a piece of code) by selecting those entities as displayed on their respective output devices (e.g., screens). For example, the selection may be accomplished by touching the respective screens with a finger from each of the user's hands.
[0037] The foregoing description of embodiments is intended to provide illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from a practice of the invention. Further, non-dependent acts may be performed in parallel. Also, the term “user”, as used herein, is intended to be broadly interpreted to include, for example, a computing device (e.g., a workstation) or a user of a computing device, unless otherwise stated.
[0038] It will be apparent that one or more embodiments, described herein, may be implemented in many different forms of software and hardware. Software code and/or specialized hardware used to implement embodiments described herein is not limiting of the invention. Thus, the operation and behavior of embodiments were described without reference to the specific software code and/or specialized hardware—it being understood that one would be able to design software and/or hardware to implement the embodiments based on the description herein.
[0039] Further, certain embodiments of the invention may be implemented as logic that performs one or more functions. This logic may be hardware-based, software-based, or a combination of hardware-based and software-based. Some or all of the logic may be stored on one or more tangible computer-readable storage media and may include computer-executable instructions that may be executed by a processor, such as processor 1204 . The computer-executable instructions may include instructions that implement one or more embodiments of the invention. The tangible computer-readable storage media may be volatile or non-volatile and may include, for example, flash memories, dynamic memories, removable disks, and non-removable disks.
[0040] No element, act, or instruction used herein should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
[0041] It is intended that the invention not be limited to the particular embodiments disclosed above, but that the invention will include any and all particular embodiments and equivalents falling within the scope of the following appended claims.
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A method of populating object property values includes receiving an instruction on behalf of a user. The instruction represents an input indicating selection of the object. The method includes presenting, in response to the input, a list of property names and corresponding default values associated with the selected object, and presenting, for each of one or more default values, a user input field. The method includes presenting, for each of the one or more default values, an enumeration of alternative property values when the enumeration is compatible with the corresponding property. The method includes receiving from the user, for zero or more of the property names, an updated property value that is a selection from a value entered in the user input field or the enumeration of alternative property values, and generating code operative to instantiate the object. The updated property values are associated with the properties of the object.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a medium support member, especially for print media, and a method of forming a medium support member.
[0003] 2. Description of the Background Art
[0004] In the field of printing, it is known to use medium support members for holding and flattening of print media during a print process in which the print media are scanned with a printhead. It is known to use a suction box as medium support member. Such a suction box usually has a perforated top surface, and the inner volume of the suction box is maintained at an underpressure by means of a vacuum pump.
[0005] It is a disadvantage of this kind of medium supports that the suction box must have a very complex structure in order to be able to evenly distribute the underpressure from the suction device over the surface of the print medium.
[0006] As the distance between the printhead and the print medium must be very well defined and preferably constant over the whole print area, the support surface should be very perfectly flat.
[0007] US 2008/0055382 A1 discloses a medium support member comprising:
[0008] a table having a top surface;
[0009] an overlay placed on the top surface of the table, the overlay having a top surface and a bottom surface and a plurality of through-holes;
[0010] a spacer array provided between the top surface of the table and the bottom surface of the overlay to define a gap between the table and the overlay, and
[0011] at least one vacuum passage communicating with said gap for creating an underpressure in the gap.
[0012] The spacers of the spacer array are formed by punching the overlay, which may be formed by a sheet metal, so that depressions or recesses are formed in the top surface of the overlay and projections corresponding to these recesses are formed in the bottom surface of the overlay. The spacers define a gap with a well-defined width between the overlay and the top surface of the table. Further, since the spacers are arranged in the form of separate islands, the hollow space surrounding the spacers forms a distribution manifold for evenly distributing the suction pressure over the through-holes in the overlay.
[0013] When a sheet of a print medium is placed on the top surface of the overlay, the underpressure results in a force that will firmly draw the sheet against the overlay. Since the size of the print media may sometimes be smaller than the area of the medium support member, there may be a case where not all of the through-holes in the overlay are covered by the print medium sheet, but through-holes in a marginal area of the overlay are left open. In these areas, the overlay is held on the surface of the table only by gravity, assisted by a certain flow resistance which the through-holes will provide for the air that is being drawn in. The overlay, which may be relatively thin and flexible, should be safely prevented from forming warps which, in view of the very small distance between the printhead and the surface of the print medium, might lead to collisions between the printhead and upwardly bulged surface areas of the print medium or the support surface.
[0014] Medium support members according to the preambles of claim 1 are disclosed in JP 2008 238674 A and US 2008/174652 A1.
SUMMARY OF THE INVENTION
[0015] It is an object of the invention to provide a medium support member wherein the overlay is reliably secured on the top surface of the table.
[0016] In the medium support member according to the invention, magnetic strips are secured to the overlay, and the the table is made of a magnetically attractable material, and in that the spacer array comprises spacers that are formed by the magnetic strips.
[0017] Thus, the overlay will safely be attracted towards the surface of the table regardless of whether or not air is drawn-in through the through-holes, and the magnetic strips forming the spacers can be arranged such that they do not close-off the through-holes that are needed for applying underpressure to the media.
[0018] In a preferred embodiment, it will be, at least among others, the marginal or outer peripheral portions of the overlay that are magnetically drawn against the table. Then, when the print media have a format that is smaller than the size of the support member, the area where underpressure is applied may be limited to the actual area of the print media, so as to avoid leakage of air through the open through-holes in the marginal portion of the overlay, thereby reducing the energy consumption of the vacuum pump. Nevertheless, the magnetic attraction will prevent the overlay from forming warps.
[0019] The spacers provided in the peripheral portions of the overlay may be configured as seals for sealing the distribution manifold formed in the gap between the top surface of the table and the bottom surface of the overlay.
[0020] The spacers that are distributed over the central part of the overlay may also be formed by magnetic strips. When all spacers are formed by magnetic strips that have exactly the same thickness, the width of the gap between the table and the manifold will be defined with high precision.
[0021] When the spacers, i.e. magnetic strips, are detachably secured at the bottom surface of the overlay, the configuration of the spacer array may easily be modified and may thus be adapted to varying sizes of the print media.
[0022] Since it is not necessary to punch the overlay and to form recesses in the top surface thereof, in order to provide the spacers at the bottom surface, the top surface of the overlay will be an almost continuous flat surface that is perforated only by the through-holes which may have relatively small diameters so as to prevent the portions of the print media covering these through-holes from being bent.
[0023] According to the invention, a method of forming a medium support member of the type that has been described above comprises a step of providing a jig formed with cavities adapted to the contours of the magnetic strips and located in predetermined relative positions, placing magnetic strips in the cavities of the jig, and superposing the overlay and the jig with the magnetic strips contained therein so as to mount the magnetic strips at the predetermined positions on the bottom surface of the overlay.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only and are thus not limitative of the invention, and wherein:
[0025] FIG. 1 is a schematic view showing a medium support member according to an embodiment of the present invention;
[0026] FIG. 2 is a cross-sectional view (not to scale) of the support member showing in FIG. 1 ;
[0027] FIG. 3 is a bottom view of one half of an overlay of the support member shown in FIGS. 1 and 2 ; and
[0028] FIG. 4 is a perspective view of a jag that is used in a method according to the invention for forming the medium support member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] FIG. 1 shows a schematic view of a printing system comprising a medium support member 10 according to an embodiment of the present invention. The support member 10 comprises a table 12 and an overlay 14 positioned on top of the table 12 .
[0030] The overlay 14 is perforated by a plurality of through-holes 16 that are regularly distributed over the top surface of the overlay 14 . The through-holes 16 connect the top surface of the overlay 14 to the bottom surface thereof (not visible in FIG. 1 ), where a distribution manifold 18 ( FIG. 2 ) is formed to which an underpressure as applied by means of a vacuum pump 20 (acting as a suction device) and a suction duct 22 .
[0031] The underpressure causes ambient air to be drawn-in through the through-holes 16 . As a consequence, when a sheet of a print medium 24 is supported on the support member 10 , the sheet will be firmly sucked against the top surface of the overlay 14 . In this way, the medium 24 will be kept stationary and flat. A carriage (not shown) comprising one or more printheads 26 is controlled to move across the print medium 24 to scan the same with high speed in a main scanning direction (fast direction) X and a sub-scanning direction (slow direction) Y, while ink droplets are jetted out from the printhead 26 and onto the medium 24 to form an image thereon. In this embodiment, the printhead 26 ejects droplets of UV-curable ink, but it will be clear for the skilled person that other types of marking material such as solvent ink, water based inks or hot melt inks may be used instead.
[0032] In a modified embodiment, the printhead 26 may be moved only in the main scanning direction X to print a swath of the image while the medium 24 is held stationary, and the medium 24 is intermittently advanced in the sub-scanning direction Y so as to print successive swathes.
[0033] The dimensions of the overlay 14 and the table 12 may be 3 by 4 meters, for example, and the overlay 12 may be foamed by an aluminum sheet having a thickness of not more than 100 to 150 μm, for example. The through-holes 16 are arranged in rows and columns with a row-to-row distance of 20 mm and may have a diameter of 1.5 mm.
[0034] In the cross-sectional view shown in FIG. 2 , the dimensions in thickness direction of the overlay 14 have been exaggerated. A spacer array 28 is provided on the bottom surface of the overlay 14 , so that a gap with a predetermined height of, e.g., 1.1 mm is formed between the bottom surface of the overlay 14 and the top surface of the table 12 .
[0035] As can be seen in a bottom plan view in FIG. 3 , the spacers of the array 28 are arranged in the form of separated islands, so that the hollow part of the gap not filled by the spacers forms a contiguous distribution manifold 18 capable of evenly applying the underpressure to all of the through-holes 16 . As shown in FIG. 2 , the manifold 18 is connected to the vacuum duct 22 ( FIG. 1 ) via internal suction passages 30 of the table 12 .
[0036] FIG. 3 shows only one half of the bottom surface of the overlay 14 , the rest of the overlay being symmetric thereto relative to a symmetry axis A. The locations of the mouths of the suction passages 30 have been indicated in the phantom lines.
[0037] The individual spacers forming the spacer array 28 are formed by magnetic strips 32 - 36 that are bonded to the bottom surface of the overlay 14 by means of an adhesive. Some of these strips, designated as 32 and 34 , extend along the periphery of the overlay 14 as a kind of frame structure. An innermost frame formed by the strips 34 has the function of a seal that limits and seals the manifold 18 . Other, shorter, strips 36 are arranged inside the manifold 18 in parallel lines separated by aisles 38 . Thus, the underpressure applied via the suction passages 30 is distributed over the entire surface of the manifold 18 while the overlay 14 is supported in both, the edge portion and the interior portion by the various strips of the spacer array 28 . In the example shown, the strips 36 extend in the main scanning direction X. They are arranged in the intervals between every second pair of rows of the through-holes 16 , so that, on the one hand, the through-holes 16 are not covered by the strips and, on the other hand, the overlay 14 is particularly supported against the suction force acting in the vicinity of the through-holes 16 . Thus, the strips 36 have mutual spacings of 40 mm.
[0038] The marginal portions of the overlay 14 which are not perforated by the through-holes 16 are safely attached to the table 12 by means of the frames formed by the magnetic strips 32 and 34 , so that the thin overlay 14 is held in a perfectly flat condition even in the marginal areas where no suction pressure is present or where the suction pressure is reduced because the through-holes 16 are not closed-off by the medium 24 .
[0039] When print media 24 of a different format are to be used, the spacer array 28 may be modified so as to limit and concentrate the suction pressure to the area that is actually covered by the print medium. In this way, it is possible to reduce the number of through-holes 16 that are not covered by the print medium 24 and thereby to reduce the amount of leakage of air through these through-holes.
[0040] A method of forming the medium support member 10 with a spacer array adapted to a specific format of the print media will now be explained by reference to FIG. 4 .
[0041] As is shown in FIG. 4 , jig 40 is used for positioning the magnetic strips 16 , 32 in the correct positions. The jig 40 is formed by a rigid plate 42 forming a mold 44 with cavities 32 ′, 36 ′ into which the magnetic strips 36 , 32 may be inserted. The cavities 36 ′, 32 ′ are adapted to the contours of the respective strips and define the target positions thereof. The depth of the cavities is slightly smaller than the thickness of the strips 36 , 32 so that the strips will slightly project out of the cavities, as has been shown for the strip 36 in FIG. 4 . The surfaces of the strips 36 , 32 that form the top surfaces in FIG. 4 are coated with an adhesive 46 . When all strips have been inserted in their respective cavities, the overlay 14 is placed onto the jig 40 and its bottom face is pressed against the projecting strips 16 , 32 , so that these strips are bonded to the overlay 14 . Positioning pins 48 formed on the plate 42 will engage into corresponding positioning holes (not shown) that may be formed in the overlay so as to assure that the strips forming the spacer array 28 will be positioned relative to the pattern of the through-holes 16 with high precision.
[0042] Preferably, the butting edges of the strips 32 forming the outer frame of the spacer array will be sealed by means of a curable sealing liquid or the like so as to form an air-tight seal.
[0043] Finally the overlay with the strips 32 , 36 adhering thereto will be lifted off from the jig 40 and will be placed on the top surface of the table 12 . The table 12 is formed of a magnetically attractable steel so that the overlay with the spacer array will be held in place by magnetic attraction between the strips 32 , 36 and the table 12 .
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A medium support member includes a table having a top surface; an overlay placed on the top surface of the table, the overlay having a top surface and a bottom surface and a plurality of through-holes; a spacer array provided between the top surface of the table and the bottom surface of the overlay to define a gap between the table and the overlay, and at least one vacuum passage communicating with said gap for creating an underpressure in the gap, wherein at least portions of the overlay and corresponding portions of the table are held together by magnetic attraction.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an alarm driving signal generator for generating a signal to drive a voltage actuated alarm device such as electronic chime (piezoelectric buzzer) in response to an alarm signal.
2. Description of the Prior Art
As alarm sound producing devices, recently electronic chimes such as piezoelectric buzzers have been widely used. The piezoelectric buzzer can be actuated by voltage without passing drive current therethrough. Further, since the resonant frequency of a piezoelectric element is relatively high, a high frequency driving (voltage) signal (clock) is applied to the element to produce alarm sound. On the other hand, the buzzer is usually driven intermittently to produce a warning sound. Therefore, the high frequency driving signal is usually amplitude modulated by a low-frequency signal obtained by a CR circuit.
In the conventional alarm driving signal generator as described above, the circuit configuration is relatively complicated, and therefore there exists a problem in that the number of parts is large and the cost is high.
A more detailed description of the prior-art-alarm driving signal generator will be made with reference to the attached drawings under DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS.
SUMMARY OF THE INVENTION
With these problems in mined, therefore, it is the primary object of the present invention to provide an alarm driving signal generator of relatively simple circuit configuration.
To achieve the above-mentioned object, an alarm driving signal generator for driving a voltage actuated buzzer in response to an alarm signal, according to the present invention, comprises: (a) a capacitor having a first terminal connected to a supply voltage via a resistor and a second terminal connected to the alarm buzzer; (b) a first switching element connected to the first terminal of said capacitor, for intermittently discharging said capacitor in response to the alarm signal; and (c) a second switching element connected to the second terminal of said capacitor, for intermittently charging said capacitor in accordance with a time constant in response to a clock signal having a frequency higher than that of the alarm signal, after said capacitor has been discharged by said first switching elements, to activate the alarm buzzer in response to voltage intermittently charged at the second terminal of said capacitor.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the alarm driving signal generator according to the present invention will be more clearly appreciated from the following description of the preferred embodiments of the invention taken in conjunction with the accompanying drawings in which:
FIG. 1A is a circuit diagram showing a conventional alarm driving signal generator;
FIG. 1B is a timing chart showing various waveforms of the generator shown in FIG. 1A;
FIG. 2A is a circuit diagram showing first embodiment of the alarm driving signal generator according to the present invention;
FIG. 2B is a timing chart showing various waveforms of the generator shown in FIG. 2A;
FIG. 3A is a circuit diagram showing a second embodiment of the alarm signal generator according to the present invention; and
FIG. 3B is a timing chart showing waveforms of the generator shown in FIG. 3A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
To facilitate understanding of the present invention, a brief reference will be made to an example of prior-art alarm signal generator with reference to the attached drawings.
In FIG. 1A, the prior-art generator is composed of three, first, second and third, transistors Tr 1 , Tr 2 , and Tr 3 and a CR circuit. An alarm pulse signal as shown by a in FIG. 1B is applied to a first input terminal IN 1 of the first transistor Tr 1 . A reference clock signal with a period shorter than that of the alarm pulse signal as shown by c in FIG. 1B is applied to a second input terminal IN 2 of the third transistor Tr 3 . Further, the symbol Vcc denotes a supply voltage; and OUT denotes an output terminal from which an alarm driving signal for driving an electronic chime such as piezoelectric buzzer is outputted.
In operation, when an alarm pulse a is applied to the base of the first (NPN) transistor Tr 1 , the Tr 1 is turned on, so that the second (PNP) transistor Tr 2 is turned on to charge a capacitor C via a registor R 1 in accordance with a time constant CR 1 . Therefore, a point b in FIG. 1A rises relatively sharply as shown by b in FIG. 1B, as long as the alarm pulse a is kept at a high voltage level.
When the alarm pulse a falls to a low voltage level, two transistors Tr 1 and Tr 2 are both turned off, so that the capacitor is no longer charged up but discharged gradually via a resister R 2 (higher than R 1 ) in accordance with a time constant CR 2 as shown by b in FIG. 1B. The capacitor voltage is applied to the output terminal OUT via a resister R 3 . However, since the third (NPN) transistor Tr 3 connected to a capacitor C is turned on or off by a clock signal as shown by c in FIG. 1B, an alarm driving signal as shown by d in Fib. 1B can be outputted from the output terminal OUT. In other words, an alarm driving signal is obtained from the output terminal OUT in such a way that the clock signal is modulated by the capacitor charging/discharging voltage waveform in amplitude.
In the above circuit shown in FIG. 1A, since the capacitor C is charged by the second (PNP) transistor Tr 2 , it has been necessary to additionally provide another (NPN) transistor Tr 1 of opposite conduction type to turn on or off the Tr 2 in response to the alarm pulse a. Therefore, three transistors are required in total, thus resulting in a problem in that the number of parts is large and therefore the manufacturing cost is high.
In view of the above description, reference is now made of a first embodiment of the alarm driving signal generator according to the present invention.
In FIG. 2A, the generator comprises a first transistor 1, a second transistor 2, a capacitor 3, and a diode 4.
A base of the first (NPN) transistor 1 is connected to a first input terminal IN 1 via a resistor r 1 ; an emitter thereof is grounded; and a collector thereof is connected to a supply voltage Vcc via a resister r 2 and to a positive polarity of the capacitor 3 directly. On the other hand, a base of the second (NPN) transistor 2 is connected to a second input terminal IN 2 ; an emitter thereof is grounded; and a collector thereof is connected to a negative polarity of the capacitor 3. Further, a cathode of the diode 4 is connected to the negative polarity of the capacitor 3 or an output terminal OUT. A piezoelectric buzzer BZ used as an electronic chime is connected between the output terminal OUT and the ground.
An alarm pulse a indicative of an alarm as shown by a in FIG. 2B is applied to the first input terminal IN 1 , and a reference clock signal b as shown by b in FIG. 2B is applied to the second input terminal IN 2 .
In operation, the alarm pulse signal a and the reference clock signal b are both applied to the first and second input terminals IN 1 and IN 2 , respectively.
When the alarm pulse signal a rises to a high voltage level, since the transistor 1 is turned on, the positive terminal of the capacitor 3 drops down to the ground level, because an electric charge stored in the capacitor 3 is discharged via the diode 4. On the other hand, when the alarm pulse a falls, since the transistor 1 is turned off, a supply voltage Vcc is supplied to the positive terminal of the capacitor 3 via a resister r 2 to start charging up the capacitor 3.
Under these conditions, while the second transistor 2 is turned off, no current flows through the capacitor 3, so that a supply voltage difference Vcc develops across the capacitor 3. However, when the second transistor 2 is turned on, since the negative terminal of the capacitor 3 is grounded, a charge current flows through the resister r 2 and the capacitor 3, so that the capacitor 3 is charged up in accordance with a time constant τ o =R o C o determined by the resistance R o of the resistor r 2 and the capacitance C o of the capacitor 3. That is, only when the reference clock b is at a high voltage level, the capacitor 3 is charged up and therefore a voltage waveform c as shown in FIG. 2B is obtained at the positive terminal of the capacitor 3. In this case, the time constant τ of the voltage waveform can be expressed as
τ=R.sub.o ·C.sub.o /d
where d denotes a duty ratio of the reference clock.
In other words, when the second transistor 2 is turned off, since the capacitor 3 is not charged up, Vcc develops at point d. However, when the second transistor 2 is turned on, since capacitor 3 is charged up, a voltage obtained by subtracting a charged-up voltage from the supply voltage Vcc develops at point d. That is, a voltage waveform d as shown in FIG. 2B develop at the negative terminal of the capacitor 3 or at the output terminal OUT. This voltage waveform d is applied to the piezoelectric buzzer BZ. The voltage waveform d shown in FIG. 2B at the output terminal OUT is roughly the same as that d shown in FIG. 1B, so that it is possible to generate an alarm (buzzer) driving signal in the same way as in the prior art circuit shown in FIG. 1A.
FIG. 3A shows a second embodiment of the alarm driving signal generator according to the present invention, in which two diodes 5 and 6 are additionally connected between the collector of the second transistor 2 and the output terminal OUT in opposite-directional parallel-connection relationship to each other.
The function of these diodes will be described with reference to FIG. 3B.
In case the supply voltage Vcc is interrupted while the circuit is in operation, the supply voltage Vcc and therefore the collector voltage of the transistor 1 drops sharply in accordance with a time constant as shown by Vcc in FIG. 3B. Further, the reference clock may drop as shown by b in FIG. 3B. At this moment, if an electric charge remains in the capacitor 3, this electric charge is discharged quickly across the capacitor 3 by way of the first transistor 1, ground and the diode 4, so that a negative voltage corresponding to a forward voltage V D (about 0.7V) of the diode 4 is generated at the negative terminal of the capacitor 3. Under these conditions, in case the second transistor 2 is still turned on by the remaining reference clock, the voltage level at the negative terminal of the capacitor 3 drops down to the ground, so that a negative pulse signal turned on or off on the negative side as shown by d in FIG. 3B develops at the cathode of the diode 4. This reverse alarm driving signal is not preferable because an abnormal sound may be produced when applied to the piezoelectric buzzer BZ.
In the circuit shown in FIG. 3A, however, since a pair of opposite-direction parallel-connected diodes 5 and 6 are connected between the capacitor 3 and the output terminal OUT, although the normal alarm driving signal is applied from the output terminal OUT to the buzzer BZ via the diode 5, the abnormal alarm driving signal (negative alarm driving signal) will not be applied to buzzer BZ, because the voltage level of the abnormal alarm driving signal is below the forward voltage V D of the diode 6.
In the alarm driving signal generator of the present invention, since the circuit can be configured by only two NPN transistors of the same conduction type without use of a PNP transistor, it is possible to reduce the number of parts and the cost thereof.
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To activate a buzzer of voltage driven type in response to an alarm signal, the alarm driving signal generator comprises a capacitor connected between a supply voltage and the buzzer; a first transistor for intermittently discharging the capacitor in response to the alarm signal; and a second transistor for intermittently charging the capacitor in accordance with a time constant in response to a clock signal higher than the alarm signal in frequency, after the capacitor has once been discharged. The alarm buzzer can be actuated on the basis of the intermittently charged capacitor voltage. The above generator is simple in circuit configuration as compared with the conventional circuit.
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BACKGROUND OF THE INVENTION
The present invention relates to vehicle parts, and particularly to an engaging device for a starter and a starter including the engaging device.
A starter is also referred to as a motor, in which power is generated by a DC motor and then is transmitted to a flywheel gear via a starter gear. A flywheel is driven, rotating a crankshaft to start an engine.
After the starter is activated, a pinion is moved axially along a main shaft. The teeth of the pinion are elastically pressed against the teeth of a ring gear. Then, the pinion is rotated along with the main shaft, such that the teeth of the pinion slide into tooth spaces of the ring gear, and thus engaging of the pinion and the ring gear is achieved.
In most cases, the pinion of the starter may not engage with the ring gear directly. The engaging motion will not begin until the pinion is driven by the electric motor to turn a certain angle. The engaging process of the pinion requires some time and the engagement depth increases with time. Since there is a very high torque when the electric motor just starts to rotate (when the speed is low), generally, at the time when the pinion is driven by the electric motor to turn a certain angle to find the tooth space of the gear ring, the pinion still cannot engage with the ring gear completely, to put it more precisely, the engagement depth in the ring gear (initial engagement depth) is very small (typically 0.5-1.5 mm). Under high torque, there is a possibility that the ring gear will be scratched by the pinion if the engagement depth of the pinion is too small (typically, the strength of the material of the pinion is much higher than that of the ring gear, and so is the rigidity). This phenomenon is similar to the process of machining a part with a milling cutter and thus is commonly known as “teeth milling”. Therefore, the initial engagement depth of the pinion with the ring gear is an important factor to judge the engagement performance of a starter.
Currently, there are a few solutions to improve the engagement performance. One of them is to produce a tip chamfer for the pinion and a flank chamfer for the ring gear at the opposing end surfaces of the pinion and the ring gear, to facilitate guiding the teeth of the pinion to slide along the teeth of the ring gear. However, a large relative rotating angle is still needed for the pinion to engage with the ring gear, and the need to rely on motor drive to implement the process of finding tooth spaces cannot be avoided completely. Another solution is, by using a two-stage circuit, to allow an enhanced first stage circuit to drive the pinion to fulfill the process of finding tooth spaces and engaging, a second stage current to actually drive an engine is not switched on until the engagement depth of the pinion reaches a relatively high value (over 5 mm), thereby reducing teeth milling phenomenon during the engaging process caused by driving a pinion under high torque. However, another circuit design is needed to achieve this function and thus increases the cost of the product. Further, such a circuit is prone to failure in poor working conditions, causing dissatisfaction from a user.
SUMMARY OF THE INVENTION
The technical problem to be solved by the present invention is to provide an engaging device for a starter, which enables the pinion of the starter to engage with the flywheel ring gear of an engine quickly and reliably.
The engaging device according to one aspect of the present invention comprises a main shaft and a pinion sleeved on the main shaft, an external spline is provided on the main shaft and the main shaft defines a limit position of the pinion, the external spline has teeth comprising a first active tooth flank; an internal spline mating with the external spline of the main shaft is provided inside the pinion, the internal spline has teeth comprising a first passive tooth flank; the acting force applied on the pinion by the first active tooth flank of the external spline when the first active tooth flank of the external spline is in contact with the first passive tooth flank of the internal spline has a circumferential component and an axial component toward the limit position; the teeth of the internal spline comprise a second active tooth flank and the teeth of the external spline comprise a second passive tooth flank, the acting force applied on the pinion by the second passive tooth flank of the external spline when the second active tooth flank of the internal spline is in contact with the second passive tooth flank of the external spline has no axial component away from the limit position.
Optionally, in the engaging device described above, the external spline of the main shaft and the internal spline of the pinion forms a clearance fit therebetween, an elastically pre-deformed elastic element is mounted between the main shaft and the pinion, the pre-deformed elastic element applies an elastic force in a direction toward the limit position to the pinion.
Optionally, in the engaging device described above, the first active tooth flank extends in a helical form in a first direction; the second active tooth flank extends axially and/or in a helical form in a second direction, the helical in the second direction is opposite to the helical in the first direction.
Optionally, in the engaging device described above, the external spline of the main shaft comprises a first external spline and a second spline, the first active tooth flank is provided on the first external spline, the first external spline is a helical spline, the second external spline is a straight spline; the internal spline of the pinion comprises a first internal spline, the first internal spline is a helical spline, the second active tooth flank is provided on the teeth of the first internal spline located corresponding to the second external spline.
Optionally, in the engaging device described above, the second active tooth flank is a chamfer on the first internal spline, the surface where the chamfer lies is parallel to the surface of the tooth flank of the second external spline.
Optionally, in the engaging device described above, the first external spline and the second external spline are made integrally or arranged separately.
Optionally, in the engaging device described above, a clearance exists between the second external spline and the first internal spline when the first active tooth flank contacts the tooth flank of the first internal spline; a clearance exists between the first internal spline and the first external spline when the second active tooth flank contacts the second external spline.
Optionally, in the engaging device described above, the main shaft comprises a snap ring mounted thereon, which snap ring abuts the pinion to define the limit position of the pinion.
Optionally, in the engaging device described above, the snap ring is mounted on the external spline of the main shaft.
The pinion is able to find clearance of tooth spaces of the ring gear immediately and fulfill engaging due to the fact that the pinion may turn a certain angle relative to the main shaft by itself while making an axial movement therebetween. The pinion is capable of engaging with the ring gear rapidly all the time, but not only in the circumstance that the main shaft is rotating, even it is not rotating. At least one of the main shaft and the pinion is provided with combined splines, respectively a helical spline and a straight spline, wherein the helical spline and the straight spline may be arranged and manufactured separately.
The starter according to a second aspect of the present invention comprises an electric motor, a speed reducer connected with the electric motor, an overrunning clutch comprising a driving piece connected with the speed reducer and a driven piece, and the above described engaging device, the main shaft of the engaging device is connected with the driven piece of the overrunning clutch.
The starter of the present invention is capable of quickly engaging and ensures a certain initial engagement depth. During the engagement, the pinion may engage with a ring gear in its own initiative, reducing the effect of teeth milling phenomenon on the ring gear to a maximum extent. Compared with the prior art, the present starter only adds combined splines, which can easily made in construction and manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects and characters of the present invention will become apparent from the following description in detail with reference to accompanying drawings. However, as will be understood, the figures are designed only for illustration, and should not be construed as limitation of the scope of the present invention, for which reference should be made to the appended claims. It should also be noted that the figures are merely intended to conceptually illustrate the structures and processes described herein and are not necessarily drawn to scale, unless indicated otherwise.
The present invention will be understood more fully with reference to the detailed description of the specific embodiments below in conjunction with the drawings. Similar or identical elements are indicated by the same reference signs throughout the drawings, in which:
FIG. 1 is a structural schematic view of a specific embodiment of a starter of the present invention;
FIG. 2 is a perspective view of a specific embodiment of the main shaft in the starter of the present invention;
FIG. 3 a is a partial perspective view with the pinion and the main shaft in the starter of the present invention being assembled, FIG. 3 b is a partial sectional view of the assembled pinion and main shaft in FIG. 3 a;
FIG. 4 is another partial sectional view with the pinion and the main shaft in the starter of the present invention being assembled;
FIG. 5 shows schematic views (a) and (b) of two specific embodiments of the combined splines in the starter of the present invention; and
FIGS. 6-9 are schematic views of the engaging process of the starter of the present invention with a flywheel of an engine.
DETAILED DESCRIPTION
Hereinafter, specific embodiments of the present invention will be described in detail with reference to the drawings, in order to help persons skilled in the art to understand exactly the subject claimed in the present invention.
Spatial relationship expressions, such as “front side”, “front end”, “rear end”, “left”, “right”, “downward” and the like, will be used herein for convenience to describe the relationship of one element or feature and another element or feature shown in the drawings. As will be appreciated, in addition to the orientations described in the drawings, those spatial relationship expressions are intended to encompass different directions and orientations of the device in use or in operation.
Referring to FIG. 1 , a structural schematic view of a specific embodiment of a starter of the present invention is shown. The starter includes an electric motor, a drive mechanism and a control portion. The electric motor is a DC electric motor 10 , which functions to transfer DC electric power input by a battery into mechanical energy, generating electromagnetic torque. The drive mechanism is responsible for transmitting the electromagnetic torque and motivating the electric motor to engage with a ring gear 80 on an engine.
The drive mechanism includes a speed reducer, an overrunning clutch and an engaging device. Here, the engaging device refers to the part in the starter engaging with the ring gear 80 of the engine, which includes a main shaft 50 and a pinion 60 . The speed reducer may be a speed reducer of any kind known by persons skilled in the art, for example, a gear speed reducer. As shown in FIG. 1 , the speed reducer is a planet gear speed reducer 20 . In particular, the planet gear speed reducer 20 includes a sun gear 21 , and an outer ring gear 22 that is mounted concentrically with the sun gear 21 , a planet gear 23 and a planet carrier 24 . The outer ring gear 22 may rotate about the sun gear 21 , with the planet gear 23 located between the sun gear 21 and the outer ring gear 22 and engaging with the sun gear 21 and the outer ring gear 22 , respectively. Meanwhile, an output shaft of the planet gear 23 is connected to the planet carrier 24 . An output shaft of the electric motor is connected to the sun gear 21 . When the electric motor rotates and drives the sun gear 21 , the output movement of the planet carrier 24 is a rotary movement with reduced speed.
The overrunning clutch 3 includes a driving piece 31 and a driven piece 32 . The driving piece 31 is disposed inside the overrunning clutch 3 and is connected with the planet carrier 24 . The driven piece 32 is disposed outside the overrunning clutch 3 . In particular, the driven piece 32 has one end sleeved outside the drive piece 31 and another end connected with the main shaft 50 . A roller 33 is arranged between the driving piece 31 and the driven piece 32 , and through the roller 33 , the output torque in the planet carrier 24 is transmitted from the driving piece 31 to the main shaft 50 via the driven piece 32 . The construction of the overrunning clutch 3 is not limited to the above described form, and the roller 33 may be other transmitting element known by persons skilled in the art.
The overrunning clutch 3 is connected to one end of the main shaft 50 through a spline means 4 . The pinion 60 is installed on the other end of the main shaft 50 . The spline means 4 includes an interior spline provided on the inside of the driven piece 32 of the overrunning clutch 3 and an exterior spline provided on the main shaft 50 . The interior spline and the exterior spline mate with each other. That is, the respective teeth of the interior and exterior splines fit into tooth spaces of the counterpart. The tooth profile of the spline can adopt any form known by persons skilled in the art, for example, a rectangular tooth or a involute tooth. The interior and exterior spline may be a straight spline with its teeth extending straightly along an axis of the main shaft 50 or a helical spline with its teeth extending helically. FIG. 1 shows an example of a helical spline.
When the overrunning clutch 3 is engaged, the driven piece 32 rotates and drives the main shaft 50 . Between the interior spline and the exterior spline, a rotary movement is performed. Meanwhile, due to the effect of the helical spline, the exterior spline (i.e., the main shaft 50 ) is moved in an axial direction relative to the interior spline (i.e., the driven piece 32 ). As shown in FIG. 1 , the axial movement of the main shaft 50 is further controlled by a control device 70 . A front end 73 of a shift lever 71 of the control device 70 is fixed on the main shaft 50 , a middle portion of the shift lever 71 is disposed on a pivot and is rotatable about the pivot, and a rear end 74 of the shift lever 71 is connected with an actuating mechanism (not shown) of the control device 70 . When the actuating mechanism pulls the rear end 74 of the shift lever 71 , the front end 73 of the shift lever 71 enables the exterior spline of the main shaft 50 to move relative to the interior spline of the driven piece 32 of the overrunning clutch 3 . In addition, an axial limiting means is further provided for the main shaft 50 . A stopper 34 is arranged in the overrunning clutch 3 at an end surface of the interior spline of the driven piece 32 . The main shaft 50 is prevented from moving further away from the driven piece 32 in the axial direction when the interior spline comes into contact with the stopper 34 .
When the electric motor is started, the torque is in turn transmitted through the speed reducer, the overrunning clutch 3 , the spline means 4 , the main shaft 50 to the pinion 60 . Then, the pinion 60 is rotated.
Referring to FIG. 2 , a structural schematic view of the main shaft 50 of the engaging device of the present invention is shown. The main shaft 50 is a stepped shaft, which includes a middle section 53 , and a first section 51 and a second section 52 arranged on both ends of the middle section 53 . The middle section 53 is used for connection with the shift lever 71 . The first section 51 has a diameter smaller than that of the middle section 53 . The first section 51 includes thereon a spline portion 501 where a spline is provided and a smooth spring mounting portion 502 where no spline is provided. A spring 516 is sleeved on the spring mounting portion 502 , how the spring 516 is arranged will be described below. A first external spline 511 is provided on the spline portion 501 . The first external spline 511 is a helical spline and begins at one end (a front side, as shown in FIG. 2 ) of the spline portion 501 . A second external spline 512 is further provided on the spline portion 501 . The second external spline 512 is a straight spline and terminates at the other end of the spline portion 501 , as shown in the Figure. The first external spline 511 and the second external spline 512 have the same tooth profile, which may be a rectangular tooth profile or a involute tooth profile. In the present embodiment, an external spline with an easily manufactured rectangular tooth profile is preferable. The teeth of the first external spline 511 extends spirally on the spline portion 501 toward the middle section 53 , and the teeth of the second external spline 512 extend axially and straightly along an axis of the main shaft 50 toward the middle section 53 . The first external spline 511 and the second external spline 512 may separate, or may be made integrally. In the present embodiment, it is preferable that the first external spline 511 and the second external spline 512 are arranged separately with a certain space therebetween, technically, which can be done more easily, and the first external spline 511 has a length much larger than that of the second external spline 512 .
It should be understood, it is also possible that the first external spline 511 is a straight spine and the second external spline 512 is a helical spline, so as to constitute the combined splines on the spline portion 501 .
The second section 52 (its external spline is not shown) of the main shaft 50 mates with the internal spline of the driven piece 32 of the overrunning clutch 3 .
Referring to FIGS. 3-4 , a structural schematic view of the engaging device of the present invention including the pinion 60 is shown. The pinion 60 includes a pinion body 61 , on which an inner hole 62 is provided and exterior teeth 63 for engaging with the flywheel ring gear 80 of the engine are circumferentially disposed. The inner hole 62 is a step hole and includes at least a spline portion 602 for providing a spline. A first internal spline 621 is provided on the spline portion 602 . The first internal spline 621 is the spline that mates with the helical external spline on the spline portion 501 of the first section 51 of the main shaft 50 . That is, parameters, such as the profile, the number and the helical angle, etc., of the teeth of the first internal spline 621 coincide with those of the helical external spline of the first section 51 of the main shaft 50 , such that the respective teeth of the internal and external splines may be inserted into the tooth spaces of the counterpart. When the first external spline 511 or the second external spline 512 of the first section 51 of the main shaft 50 has its tooth profile in rectangular shape, the tooth profile of the first internal spline 621 of the pinion 60 will also be rectangular.
The spaces of the first internal spline 621 of the pinion 60 and the teeth of the external spline (which includes the teeth of the first external spline 511 and the teeth of the second external spline 512 ) of the first section 51 of the main shaft 50 are clearance fit with each other. That is, the teeth of the external spline are received in the spaces of the internal spline with a gap therebetween, so as to ensure that a relative rotation movement can be made between the internal and external splines. In addition, an axial movement is made by the internal and external splines relative to each other. The dimension in width of the space of the first internal spline 621 may also receive the second external spline 512 in a straight spline form making relative axial movement.
Referring to FIG. 5 , a schematic view of the mating between the teeth of combined external splines and the spaces of an internal spline is shown. No matter whether the first external spline 511 and the second external spline 512 are formed integrally or they are arranged separately, in a rotating direction of the main shaft 50 , the first external spline 511 and the second external spline 512 are in flush arrangement or in staggered arrangement. When the both are in flush arrangement, the first external spline 511 and the second external spline 512 are synchronous; when they are in staggered arrangement, as shown in Figures, the second external spline 512 is arranged in a lagging position with respect to the first external spline 511 . Here, the so-called synchronous mainly means that the first internal spline 621 contacts the first external spline 511 and the second external spline 512 at the same time when the pinion 60 drives the main shaft 50 to rotate. Under this circumstance, the two ends in the width direction of the teeth of the second external spline 512 have to be in the extended lines of the flanks at both sides of the teeth of the first external spline 511 . The so-called lagging means that when the main shaft 50 drives the pinion 60 to rotate (a relative rotation between the external and internal splines), the first external spline 511 contacts the first internal spline 621 first (while the second external spline 512 is at a distance from the first interior spline 621 ); and that when the pinion 60 drives the main shaft 50 to rotate, the first internal spline 621 contacts the second external spline 512 first (while the first internal spline 621 is at a distance from the first external spline 511 ).
Therefore, according to the mating between the internal and external splines, the teeth of the first external spline 511 includes at least a first active tooth flank 514 , and the first internal spline 621 includes at least a second active tooth flank 622 . The first internal spline 621 includes at least a first passive tooth flank 623 , and the second external spline 512 includes at least a second passive tooth flank 517 . The first active tooth flank 514 is located corresponding to the first passive tooth flank 623 of the first internal spline 621 , and the second active tooth flank 622 is located corresponding to the flank of the second external spline 512 in a straight spline form. When the second active tooth flank 622 is a chamfer on the first internal spline 621 , the surface where the chamfer lies is parallel to the second passive tooth flank 517 of the second external spline 512 . In the direction in which the main shaft 50 drives the pinion 60 to rotate together, the first passive tooth flank 623 (i.e., the first interior spline 621 ) may be driven by the first active tooth flank 514 ; and in the direction in which the pinion 60 drives the main shaft 50 to rotate together, the second passive tooth flank 517 (i.e., the second external spline 512 ) may be driven by the second active tooth flank 622 . The above description applies to the case where the first external spline 511 is a helical spline and the second external spline 512 is a straight spline. As could be understood by persons skilled in the art, when the first external spline is a straight spline and the second external spline is a helical spline, it also applies as long as the condition that, in the direction where the pinion 60 is an active piece and the main shaft 50 is a passive piece, the first external spline may be driven by the second active tooth flank of the first internal spline is met.
Although the second external spline is a straight spline, persons skilled in the art should understand that, in addition that, the second external spline may also be an oblique spline with its inclined direction opposite to the turning direction of the first external spline, and/or be a helical spline with its turning direction opposite to that of the first external spline. Then, the form of the first internal spline also needs to be adjusted accordingly, that is, as an oblique spline and/or a helical spline.
As could also be understood by persons skilled in the art, apart from the integrally formed internal spline as shown in the present example, the internal spline could be divided into a first internal spline and a second internal spline, which respectively correspond to the first external spline 511 in a form of a helical spline and a second external spline 512 in a form of a straight spline (or an oblique spline and/or a helical spline). Alternatively, the external spline is integrally formed and corresponds to a first internal spline in a form of a helical spline, and a second internal spline in a form of a straight spline (or an oblique spline and/or a helical spline).
The spiral direction of the helical spline depends on the rotating direction of the main shaft 50 . Therefore, the spiral direction of the helical spline shown in the Figures is for illustration only by way of example. When the rotating direction of the main shaft 50 reverses, the spiral direction of the helical spline follows to reverse.
Turning back to FIGS. 3-4 , a structural schematic view of the main shaft 50 and a pinion 60 after assembling is shown. A circle of ring groove 513 is opened on the first external spline 511 , and a snap ring 515 is disposed within the ring groove 513 to prevent the pinion 60 from moving out of the main shaft 50 axially relative to the main shaft 50 . The pinion 60 is located at a limit position relative to the main shaft 50 when the pinion 60 touches the snap ring 515 . The spring 516 is sleeved on the spring mounting portion 502 with its one end abutting against and within a stepped hole and the other end abutting against an end surface of the middle section 53 . The spring is compressed when the pinion 60 is located at the limit position contacting the snap ring 515 .
Referring now to the FIGS. 6-9 , the engaging process of the pinion 60 of the starter and the flywheel ring gear 80 of the engine is shown. In an initial state, the shift lever 71 is pushed by an action switch of a control section to move the main shaft 50 axially to the left. The electric motor rotates and the torque is transmitted to the main shaft 50 through the planet gear speed reducer 20 and the overrunning clutch 3 . At that time, the pinion 60 abuts against the snap ring 515 due to the preload applied by the spring 516 . Since the pinion 60 is fixed relative to the first section 51 of the main shaft 50 , the pinion 60 is rotated together with the main shaft 50 , as shown in FIG. 6 .
The pinion 60 will just mesh into the ring gear 80 when the main shaft 50 is moved axially to the left if the teeth of the pinion 60 do not interfere with the teeth of the ring gear 80 . As shown in FIG. 7 a , however, in the case that the teeth of the pinion 60 happen to interfere with the teeth of the ring gear 80 , the end surface of the pinion 60 will run into the end surface of the ring gear 80 without meshing into the ring gear 80 . As the main shaft 50 continues to move axially to the left, since the pinion 60 has not yet meshed into the ring gear 80 at this moment, with the block of the ring gear 80 , the pinion 60 will make an axial linear movement in the direction indicated by a dotted arrow in FIG. 7 a (to the right) with respect to the main shaft 50 . The shift lever 71 stops when controlling the main shaft 50 to advance to a predetermined position.
Then, turning to the FIG. 7 b , it is an enlarged schematic view of the internal and external splines in FIG. 7 a . When the first internal spline 621 (the pinion 60 ) moves downward relative to the first external spline 511 (the main shaft 50 ) as indicated by a dotted arrow in the Figure (which equals to the pinion 60 moves to the right with respect to the main shaft 50 ), the first active tooth flank 514 of the first external spline 511 will soon come into contact with the first passive tooth flank 623 of the first internal spline 621 . Through this mutual contact, an acting force is produced between the first active tooth flank 514 of the first external spline 511 and the first passive tooth flank 623 of the first internal spline 621 . Due to the function of the helical spline, the acting force applied on the pinion 60 by the first active tooth flank 514 of the first external spline 511 has a circumferential component (in a left direction as shown in FIG. 7 b ) and an axial component toward the limit position (in a forward direction as shown in FIG. 7 b ). On one hand, a blocking force applied by the ring gear 80 to the pinion 60 drives the pinion 60 to move axially and linearly away from the limit position relative to the main shaft 50 (in a downward direction as shown in FIG. 7 b ) against the axial component of the acting force applied to the pinion 60 by the first active tooth flank 514 and a frictional force between the first active tooth flank 514 of the first external spline 511 and the first passive tooth flank 623 of the first internal spline 621 . On the other hand, the circumferential component of the acting force applied by the first external spline 511 pushes the first internal spline 621 to make a leftward rotation movement as shown in the Figure. In this way, the pinion 60 is rotated relative to the main shaft 50 and the teeth on the ring gear 80 find the spaces of the pinion 60 quickly and enter into the spaces.
Under the reaction force of the spring 516 , the pinion 60 springs back and moves axially toward the direction as shown in FIG. 8 until it touches the snap ring 515 . At this moment, the pinion 60 is completely engaged with the ring gear 80 .
Once the pinion 60 is meshed into the flywheel ring gear 80 , it means that the torque is further transmitted to a crankshaft of the engine by the fly wheel, thereby the engine is started.
Referring to FIG. 9 , after the engine is started and ignited, the ring gear 80 rapidly speeds up, overruns the pinion 60 and then reversely transmits the overrunning torque to the main shaft 50 . In the overrunning state, the second active tooth flank 622 of the first internal spline 621 contacts the second passive tooth flank 517 of the second external spline 512 . Through this contact, a mutual acting force is produced between the second active tooth flank 622 of the first internal spline 621 and the second passive tooth flank 517 of the second external spline 512 . In one specific embodiment according to the present invention, both the second active tooth flank 622 of the first internal spline 621 and the second passive tooth flank 517 of the second external spline 512 are axially extending surfaces, therefore, there is only circumferential acting force and no axial acting force therebetween.
In another specification embodiment according to the present invention, the second active tooth flank 622 of the first internal spline 621 and the second passive tooth flank 517 of the second external spline 512 may also be surfaces extending in an opposite spiral direction to that of the first active tooth flank 514 and the first passive tooth flank 623 . That is, if the first active tooth flank 514 and the first passive tooth flank 623 are left spirals in spiral direction, the second active tooth flank 622 and the second passive tooth flank 517 are right spirals, and vice versa. In this case, the acting force applied to the pinion 60 by the second passive tooth flank 517 of the second external spline 512 has a circumferential component and an axial component toward the limit position, but has no axial component away from the limit position, thereby an axial return movement (toward the right direction of FIG. 9 a ) by the pinion 60 can be avoided. By that time, the power transmission between the crankshaft of the engine and the electric motor is immediately cut off by the overrunning clutch 3 , preventing the electric motor from being damaged due to reverse dragging by the engine operating with high speed.
The above embodiment is merely intended to illustrate but not limit the present invention, and various changes and modifications may be made by persons skilled in the art without departing the scope of the present invention. Therefore, all the equivalent technical solutions belong to the scope of the present invention, which should be defined by the appended claims.
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An engaging device and a starter comprising the engaging device, the starter comprises an electric motor, a speed reducer connected with the electric motor, an overrunning clutch comprising a driving piece connected with the speed reducer and a driven piece, and an engaging device with a main shaft connected with the driven piece of the overrunning clutch. A quick engagement may be achieved and a certain initial engagement depth is guaranteed. During the engaging process, the pinion may mesh into a ring gear in its own initiative, reducing the effect of teeth milling phenomenon on the ring gear to a maximum extent.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to certain pyrazolo 4,3-d!pyrimidine derivatives which selectively bind to corticotropin-releasing factor (CRF) receptors. More specifically, the invention relates to 3-aryl substituted pyrazolo 4,3-d!pyrimidine derivatives. The invention further relates to pharmaceutical compositions comprising such compounds. It also relates to the use of such compounds in treating stress related disorders such as post traumatic stress disorder (PTSD) as well as depression, headache and anxiety.
2. Description of the Related Art
International Application PCT/US93/11333 describes pyrazolo 3,4-d!pyrimidines said to be CRF antagonists. Bull. Chem. Soc. Japan. 52(1), 208-11, (1979) describes the synthesis of 3-phenyl-pyrazolo 4,3-d!pyrimidines.
SUMMARY OF THE INVENTION
This invention provides novel compounds of Formula I which interact with CRF receptors.
The invention provides pharmaceutical compositions comprising compounds of Formula I. It further relates to the use of such compounds in treating stress related disorders such as post traumatic stress disorder (PTSD) as well as depression, headache and anxiety. Accordingly, a broad embodiment of the invention is directed to a compound of Formula I: ##STR2## wherein Ar is phenyl, 1- or 2-naphthyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl, 4- or 5-pyrimidinyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, provided that at least one of the positions on Ar ortho to the point of attachment to the pyrazole ring is substituted;
R 1 is lower alkyl;
R 2 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy having 1-6 carbon atoms;
R 3 and R 4 are the same or different and represent
hydrogen, lower alkyl, alkoxy lower alkyl, hydroxy lower alkyl, or alkenyl;
phenyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl or 2-, 4- or 5-pyrimidinyl, each of which is optionally mono- or disubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy;
phenyl-, 2-, 3-, or 4-pyridinyl-, 2- or 3-thienyl-, or 2-, 4- or 5-pyrimidinyl-lower alkyl, each of which is optionally mono- or disubstituted with lower alkyl;
cycloalkyl or cycloalkyl lower alkyl, each of which is optionally mono- or disubstituted with lower alkyl; or
2-hydroxyethyl or 3-hydroxypropyl, each of which is optionally monosubstituted with lower alkyl;
provided that not both R 3 and R 4 are hydrogen; or
R 3 and R 4 taken together represent --(CH 2 ) n --A--(CH 2 ) m -- where
n is 2, or 3;
A is methylene, 1,2-phenylene, oxygen, sulfur or NR 6 , wherein R 6 is lower alkyl, phenyl, 2-, 3-, or 4-pyridinyl, 2-or 3-thienyl or 2-, 4- or 5-pyrimidinyl, or phenyl-, 2-, 3-or 4-pyridinyl-, 2-or 3-thienyl-, or 2-, 4- or 5-pyrimidinylalkyl; and
m is 1, 2 or 3.
These compounds are highly selective partial agonists or antagonists at CRF receptors and are useful in the diagnosis and treatment of stress related disorders such as post traumatic stress disorder (PTSD) as well as depression and anxiety.
DETAILED DESCRIPTION OF THE INVENTION
In addition to the compounds of Formula I above, the invention encompasses of Formula II: ##STR3## wherein R a represents halogen, hydroxy, lower alkyl, or lower alkoxy;
R b , and R c independently represent hydrogen, halogen, hydroxy, lower alkyl, or lower alkoxy;
R 1 is lower alkyl;
R 2 is hydrogen or lower alkyl; and
R 3 and R 4 are the same or different and represent hydrogen, lower alkyl, lower alkenyl, cycloalkyl, cycloalkyl lower alkyl, 2-hydroxyethyl or 3-hydroxypropyl;
provided that not both R 3 and R 4 are hydrogen.
Preferred compounds of Formula II are those where R 3 and R 4 independently represent C 1 -C 6 alkyl (i.e., lower alkyl) optionally substituted with halogen, hydroxy, or C 1 -C 6 alkoxy, Ar is phenyl that is mono-, di-, or trisubstituted with halogen, hydroxy, C 1 -C 6 alkyl, or C 1 -C 6 alkoxy, with the proviso that at least one of the positions on the phenyl group ortho to the point of attachment to the pyrazole ring is substituted. More preferred compounds of Formula II are those where Ar is phenyl that is trisubstituted with C 1 -C 6 alkyl, with the proviso that at least one of the positions on the phenyl group ortho to the point of attachment to the pyrazole ring is substituted. Most preferred compounds of Formula II are those where Ar is phenyl that is trisubstituted in the 2, 4, and 6 positions (para and both ortho positions relative to the point of attachment to the pyrazole ring) with C 1 -C 3 alkyl, most preferably methyl. Particularly preferred compounds of Formula II are those where R 3 and R 4 are independently hydrogen or C 1 -C 4 alkyl, e.g., methyl, ethyl, propyl, butyl, or cyclopropylmethyl, provided not both R 3 and R 4 are hydrogen.
The invention further encompasses compounds of Formula III: ##STR4## wherein R a represents halogen, hydroxy, lower alkyl, or lower alkoxy;
R b , and R c independently represent hydrogen, halogen, hydroxy, lower alkyl, or lower alkoxy;
R 1 is lower alkyl;
R 2 is hydrogen or lower alkyl; and
R 3 and R 4 are the same or different and represent
hydrogen, lower alkyl, cycloalkyl, cycloalkyl lower alkyl, or alkenyl;
phenyl, 2-, 3-, or 4-pyridinyl, or 2-, 4- or 5-pyrimidinyl, each of which is optionally mono- or disubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy; or
phenyl-, 2-, 3-, or 4-pyridinyl-, or 2-, 4- or 5-pyrimidinyl-lower alkyl, each of which is optionally mono- or disubstituted with lower alkyl;
provided that not both R 3 and R 4 are hydrogen.
Further, the invention encompasses compounds of Formula IV: ##STR5## wherein R a represents halogen, hydroxy, lower alkyl, or lower alkoxy;
R b , and R c independently represent hydrogen, halogen, hydroxy, lower alkyl, or lower alkoxy;
R 1 is lower alkyl;
R 2 is hydrogen or lower alkyl; and
R 3 and R 4 taken together represent with the nitrogen atom to which they are attached represent --(CH 2 ) n --A--(CH 2 ) m -- where
n is 2, or 3;
A is methylene, 1,2-phenylene, oxygen, sulfur or NR 6 , wherein R 6 is lower alkyl, phenyl, 2-, 3-, or 4-pyridinyl, 2-or 3-thienyl or 2-, 4- or 5-pyrimidinyl, or phenyl-, 2-, 3-or 4-pyridinyl-, 2-or 3-thienyl-, or 2-, 4- or 5-pyrimidinylalkyl; and
m is 1, 2 or 3.
Preferred compounds of the invention have Formula V: ##STR6## wherein R a , R b , and R c independently represent hydrogen, halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that not both R a and R c are hydrogen;
R 1 is lower alkyl;
R 2 is hydrogen or lower alkyl; and
R 3 and R 4 are the same or different and represent hydrogen, lower alkyl, cycloalkyl, cycloalkyl lower alkyl, alkenyl, 2-hydroxyethyl or 3-hydroxypropyl, provided that not both R 3 and R 4 are hydrogen.
Other preferred compounds of Formula V are those where R 3 and R 4 independently represent C 1 -C 6 alkyl (i.e., lower alkyl) optionally substituted with halogen, hydroxy, or C 1 -C 6 alkoxy.
More preferred compounds of Formula V are those where R a , R b , and R c are methyl. Particularly preferred compounds of Formula V are those where R a , R b , and R c are methyl, R 1 and R 2 independently represent lower alkyl, and R 3 and R 4 are independently hydrogen or C 1 -C 4 alkyl, e.g., methyl, ethyl, propyl, butyl, or cyclopropylmethyl, provided not both R 3 and R 4 are hydrogen.
Other preferred compounds of the invention have Formula VI: ##STR7## wherein R a , R b , and R c independently represent hydrogen, halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that not both R a and R c are hydrogen;
R 1 is lower
R 2 is hydrogen or lower alkyl; and
R 3 and R 4 are the same or different and represent hydrogen, lower alkyl, cycloalkyl, cycloalkyl lower alkyl, alkenyl, 2-hydroxyethyl or 3-hydroxypropyl, provided that not both R 3 and R 4 are hydrogen.
Other preferred compounds of Formula VI are those where R 3 and R 4 independently represent C 1 -C 6 alkyl (i.e., lower alkyl) optionally substituted with halogen, hydroxy, or C 1 -C 6 alkoxy.
More preferred compounds of Formula VI are those where R a , R b , and R c are methyl. Particularly preferred compounds of Formula VI are those where R a , R b , and R c are methyl, R 1 and R 2 independently represent lower alkyl, and R 3 and R 4 are independently hydrogen or C 1 -C 4 alkyl, e.g., methyl, ethyl, propyl, butyl, or cyclopropylmethyl, provided not both R 3 and R 4 are hydrogen.
The invention also encompasses intermediates for preparing compounds of Formula I. Among these intermediates are compounds of Formula VII: ##STR8## wherein R s is hydrogen or lower alkyl;
R 1 and R 2 are as defined above for Formula I;
R a is hydrogen or R b O 2 C-- where R b represents C 1 -C 6 alkyl; and
Ar is phenyl, 1- or 2-naphthyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl, 4- or 5-pyrimidinyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, provided that at least one of the positions on Ar ortho to the point of attachment to the pyrazole ring is substituted.
Preferred Ar groups are 2,4,6-tri(C 1 -C 6 )alkylphenyl groups, most preferably 2,4,6-trimethylphenyl groups. Preferred R s groups are hydrogen and methyl.
The invention further encompasses intermediates of Formula VIII: ##STR9## wherein R 1 and R 2 are as defined above for Formula I;
R a is hydrogen or R b O 2 C-- where R b represents C 1 -C 6 alkyl; and
Ar is phenyl, 1- or 2-naphthyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl, 4- or 5-pyrimidinyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, provided that at least one of the positions on Ar ortho to the point of attachment to the pyrazole ring is substituted.
Preferred Ar groups are 2,4,6-tri(C 1 -C 6 )alkylphenyl groups, most preferably 2,4,6-trimethylphenyl groups.
The invention further encompasses intermediates of Formula IX: ##STR10## wherein R o is hydrogen or lower alkyl;
R 1 and R 2 are as defined above for Formula I; and
Ar is phenyl, 1- or 2-naphthyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl, 4- or 5-pyrimidinyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, provided that at least one of the positions on Ar ortho to the point of attachment to the pyrazole ring is substituted.
Preferred Ar groups are 2,4,6-tri(C 1 -C 6 )alkylphenyl groups, most preferably 2,4,6-trimethylphenyl groups. Preferred R o groups are methyl and ethyl.
Also, intermediates of Formula X are within the invention: ##STR11## wherein R o is hydrogen or lower alkyl;
R 1 and R 2 are as defined above for Formula I; and
Ar is phenyl, 1- or 2-naphthyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl, 4- or 5-pyrimidinyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, provided that at least one of the positions on Ar ortho to the point of attachment to the alkyl 2,4-dioxo-3-oximinobutanoate moiety is substituted.
Preferred Ar groups are 2,4,6-tri(C 1 -C 6 )alkylphenyl groups, most preferably 2,4,6-trimethylphenyl groups. Preferred R o groups are methyl and ethyl.
The invention also encompasses compounds of Formula XI: ##STR12## where R o is hydrogen or lower alkyl;
R 1 and R 2 are as defined above for Formula I; and
Ar is phenyl, 1- or 2-naphthyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl, 4- or 5-pyrimidinyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, provided that at least one of the positions on Ar ortho to the point of attachment to the alkyl-2,4-dioxobutanoate moiety is substituted.
Preferred Ar groups are 2,4,6-tri(C 1 -C 6 )alkylphenyl groups, most preferably 2,4,6-trimethylphenyl groups. Preferred R o groups are methyl and ethyl.
Representative compounds of the present invention, which are encompassed by Formula I, include, but are not limited to the compounds in Table I and their pharmaceutically acceptable salts. Non-toxic pharmaceutically acceptable salts include salts of acids such as hydrochloric, phosphoric, hydrobromic, sulfuric, sulfinic, formic, toluenesulfonic, methanesulfonic, nitric, benzoic, citric, tartaric, maleic, hydroiodic, alkanoic such as acetic, HOOC--(CH 2 ) n --COOH where n is 0-4, and the like. Those skilled in the art will recognize a wide variety of non-toxic pharmaceutically acceptable addition salts.
The present invention also encompasses the acylated prodrugs of the compounds of Formula I. Those skilled in the art will recognize various synthetic methodologies which may be employed to prepare non-toxic pharmaceutically acceptable addition salts and acylated prodrugs of the compounds encompassed by Formula I.
When a compound of formula I is obtained as a mixture of enantiomers these may be separated by conventional methods such as crystallization in the presence of a resolving agent, or chromatography, for example, using a chiral HPLC column.
In the compounds of the invention, the Ar group is preferably a phenyl group that is mono-, di-, or trisubstituted with halogen, hydroxy, C 1 -C 6 alkyl, or C 1 -C 6 alkoxy, with the proviso that at least one of the positions on the phenyl group ortho to the point of attachment to the isoquinolinamine or phthalazinamine ring is substituted. Where Ar is phenyl, the carbon atom by which the phenyl group is attached to the pyrazole ring is defined as the 1-position. Thus, the positions ortho to the point of attachment are the 2 and 6 positions, and the para position is the 4-position of the phenyl group.
By the terms (C 1 -C 6 )alkyl and lower alkyl is meant straight and branched chain alkyl groups having from 1-6 carbon atoms as well as cyclic alkyl groups such as, for example, cyclopropyl, cyclobutyl, or cyclohexyl. Specific examples of such alkyl groups are methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, tert-butyl, sec-butyl, neopentyl and n-pentyl. Preferred C 1 -C 6 alkyl groups are methyl, ethyl, propyl, butyl or cyclopropylmethyl.
By the terms (C 1 -C 6 )alkoxy and lower alkoxy is meant straight and branched chain alkoxy groups having from 1-6 carbon atoms.
By hydroxy C 1 -C 6 alkyl or hydroxyalkyl is meant a C 1 -C 6 alkyl group carrying a terminal hydroxy moiety.
By C 1 -C 6 alkoxy C 1 -C 6 alkyl (alkoxy lower alkyl) is meant a group of the formula --(CH 2 ) x O(CH 2 ) y CH 3 , where x and y independently represent integers of from 1-6.
By the term C 1 -C 6 alkenyl or lower alkenyl is meant straight or branched chain hydrocarbon groups having from 1-6 carbon atoms and at least one double bond.
By halogen, halo, or halide is meant fluorine, chlorine, bromine and iodine substituents.
By aryl(C 1 -C 6 )alkyl, e.g., phenylalkyl, pyridinylalkyl, pyrimidinylalkyl, and thienylalkyl, is meant aryl groups attached to the parent group by a straight or branched chain alkyl group having 1-6 carbon atoms. Thus, the aryl groups include phenyl, 1- or 2-naphthyl, 2-, 3-, or 4-pyridinyl, 2- or 3-thienyl or 2-, 4-, or 5-pyrimidinyl. These aryl groups are optionally substituted with up to two groups selected from halogen, hydroxy, (C 1 -C 6 )alkyl, and (C 1 -C 6 )alkoxy.
Representative examples of compounds according to the invention are shown in Table 1 below. ##STR13##
The pharmaceutical utility of compounds of this invention is indicated by the following assay for CRF receptor activity.
Assay for CRF receptor binding activity
CRF receptor binding is performed using a modified version of the assay described by Grigoriadis and De Souza (Biochemical, Pharmacological, and Autoradiographic Methods to Study Corticotropin-Releasing Factor Receptors. Methods in Neurosciences, Vol. 5, 1991). Membrane pellets containing CRF receptors are resuspended in 50 mM Tris buffer pH 7.7 containing 10 mM MgCl 2 and 2 mM EGTA and centrifuged for 10 minutes at 48000 g. Membranes are washed again and brought to a final concentration of 1500 μg/ml in binding buffer (Tris buffer described above with 0.1% BSA, 0.15 mM bacitracin and 0.01 mg/ml aprotinin.). For the binding assay, 100 μl of the membrane preparation is added to 96-well microtube plates containing 100 μl of 125 I-CRF (SA 2200 Ci/mmol, final concentration of 100 pM) and 50 μl of drug. Binding is carried out at room temperature for 2 hours. Plates are then harvested on a Brandel 96 well cell harvester and filters are counted for gamma emissions on a Wallac 1205 Betaplate liquid scintillation counter. Non specific binding is defined by 1 uM cold CRF. IC 50 values are calculated with the non-linear curve fitting program RS/1 (BBN Software Products Corp., Cambridge, Mass.). The compounds of the invention typically have binding affinities, expressed as IC 50 values, of from about 0.5 nanomolar (nM) to about 10 micromolar (μM). The binding characteristics for representative examples of the invention are shown in Table 1.
TABLE I______________________________________Compound Number IC.sub.50 (nM)______________________________________1 1.43 1.8______________________________________
Compound numbers relate to compounds described in the examples below:
The compounds of general formula I 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. One or more compounds of general formula I 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 compounds of general formula I 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 ingredient 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 materials 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 ingredients 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 monooleate, and condensation products of the said partial esters with ethylene oxide, for example polyoxyethylene sorbitan monooleate. The emulsions may also contain sweetening and flavoring agents.
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 1,3-butanediol. 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 compounds of general formula I 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.
Compounds of general formula I 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 140 mg per kilogram of body weight per day are useful in the treatment of the above-indicated conditions (about 0.5 mg to about 7 g per patient per day). The amount of active ingredient 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 ingredient.
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.
A representative illustration of methods suitable for the preparation of compounds of the present invention is shown in Scheme I. Those having skill in the art will recognize that the starting materials may be varied and additional steps employed to produce compounds encompassed by the present invention. For example, in certain situations, protection of reactive moieties such as amino groups will be required. ##STR14##
In the above scheme, R 1 -R 4 , and Ar carry the definitions set forth above for Formula I.
The disclosures in this application of all articles and references, including patents, are incorporated herein by reference.
The invention is illustrated further by the following examples which are not to be construed as limiting the invention in scope or spirit to the specific procedures and compounds described in them.
EXAMPLE 1
A. Ethyl 2,4-dioxo-4-(2,4,6-trimethylphenyl)butanoate ##STR15##
To a solution of 2', 4', 6'-trimethylacetophenone (15 g, 92.6 mmol) and diethyl oxalate (20 g, 139 mmol) in 500 mL of anhydrous toluene was cautiously added 7.4 g of NaH (60% dispersion in mineral oil). The reaction mixture was slowly heated to reflux under N 2 . It was refluxed for about 20 minutes, then cooled, poured into ice-cold aqueous HCl solution, and extracted with ether. The extracts were washed with brine, dried over Na 2 SO 4 , filtered through a short silica gel pad and concentrated to give 16.2 g of a red oil which was used in the next reaction without further purification.
B. Ethyl 2,4-dioxo-3-oximino-4-(2,4,6-trimethylphenyl)butanoate ##STR16##
N 2 O 3 gas was slowly passed into a stirred solution of the product of step A (16.2 g) in 300 mL of ethanol until the disappearance of starting material was confirmed by TLC. N 2 O 3 gas was generated by the dropwise addition of 12N aqueous HCl solution into an aqueous slurry of NaNO 2 . The solvent was removed from the mixture and 200 mL of water was added to the residue. The product was then extracted into ether. The ether extract was dried over Na 2 SO 4 and evaporated to give 16.1 g of a semi-solid.
C. Ethyl 4-amino-1-methyl-5-(2,4,6-trimethylphenyl)pyrazole-3-carboxylate ##STR17##
To a solution of the product of step B (4.0 g, 13.8 mmol) and 1.6 mL of 12N hydrochloric acid in 100 mL of methanol was added dropwise 0.63 g of methyl hydrazine at 0° C. The reaction mixture was stirred at room temperature 4 hours, and then concentrated. The resulting residue was partitioned between water and ethyl acetate. The organic phase was separated and washed once with brine. The ethyl acetate solution was then mixed with 100 mL of water. Solid Na 2 S 2 O 4 in excess was added in small portion until TLC showed completion of the reduction. The organic phase was separated, washed with water and brine, and dried over Na 2 SO 4 . Evaporation gave 3.1 g of the title compound as a foam.
D. 2,5-Dimethyl-3-(2,4,6-trimethylphenyl)-2,6-dihydro-2H-pyrazolo 4,3-d!pyrimidin-7-one ##STR18##
A solution of the product of step C (3.1 g) in 100 mL of anhydrous CH 3 CN was saturated with HCl gas, stirred at room temperature overnight, and then concentrated. The residue was partitioned between aqueous NaHCO 3 solution and ethyl acetate. The organic layer was separated, washed with brine, dried over Na 2 SO 4 and concentrated. The residue was triturated with ether. The solid was collected by filtration to give 1.0 g of the title compound as a white solid, m.p. 264°-66° C.
E. 2,5-Dimethyl-3-(2,4,6-trimethylphenyl)-2,4-dihydro-2H-pyrazolo 4,3-d!pyrimidin-7-thione ##STR19##
A mixture of the product of step D (0.6 g, 2.2 mmol) and P 2 S 5 (1.0 g, 2.2 mmol) in 50 mL of dioxane was heated to reflux for 2 hours. The solvent was evaporated. The residue was partitioned between water and ethyl acetate. The organic layer was separated, washed with brine, dried over Na 2 SO 4 and concentrated to give 0.60 g of the title compound as a yellow foam.
F. N-Propyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine ##STR20##
A solution of the product of step E (0.6 g) and 1 mL of propylamine in 10 mL of ethanol was heated to reflux for 3 hours. Evaporation of the volatile gave 550 mg of the title compound as a foam.
G. N,N-Dipropyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine (Compound 1) ##STR21##
A mixture of the product of step F (400 mg, 1.2 mmol), powder KOH (1.0 g) and 1-bromopropane (1 mL) in 2 mL of DMSO was heated at 60° C. for 8 hours. The excess bromopropane was then evaporated. The mixture was partitioned between water and ether. The aqueous layer was separated and extracted with ether. The combined ether extracts were washed with water and brine, dried over Na 2 SO 4 and concentrated to an oil. The oil was purified through silica gel column chromatography to give 260 mg of the title compound as an oil. 1 H NMR (CDCl 3 ): d 0.97 (t, 6H), 1.76 (m, 4H), 1.96 (s, 6H), 2.32 (s, 3H), 2.45 (s, 3H), 3.77 (s, 3H), 3.40-4.30 (br, 4H), 6.95 (s, 2H)ppm. The hydrochloride salt prepared in Ether/HCl melted at 210°-13° C.
EXAMPLE 2 AND EXAMPLE 3
A. N-Ethyl-5-methyl-3-(2,4,6-trimethylphenyl)-1H-pyrazolo 4,3-d!pyrimidin-7-amine ##STR22##
A solution of 5-Methyl-3-(2,4,6-trimethylphenyl)-1H-pyrazolo 4,3-d!pyrimidin-7-thione (250 mg, prepared in a manner similar to the compound of step E in Example 1) and 25 mL of ethylamine (2M in methanol) was heated to reflux for 3 hours. Evaporation of the volatile gave 255 mg of the title compound as a foam.
B. 1. N,N-Diethyl-1-ethyl-5-methyl-3-(2,4,6-trimethylphenyl)-1H-pyrazolo 4,3-d!pyrimidin-7-amine (Example 2) (Compound 2) ##STR23##
2. N,N-Diethyl-2-ethyl-5-methyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pydmidin-7-amine (Example 3) ##STR24##
A mixture of the product of step A (250 mg, 0.85 mmol), powdered KOH (0.5 mg) and 1-bromopropane (0.5 mL) in 2 mL of DMSO was heated at 60° C. for 2 hours. The excess bromopropane was then evaporated. The mixture was partitioned between water and ether. The aqueous layer was separated and extracted with ether. The combined ether extracts were washed with water and brine, dried over Na 2 SO 4 and concentrated to an oil. The oil was purified through silica gel column chromatography using Hexane/EtOAc (100/30, v/v). The faster moving fraction, comprising the titled compound (example 2) was collected. Evaporation of the solvents gave 26 mg of the title compound (example 2) as an oil. 1 H NMR (CDCl 3 ): d 1.24 (t, 6H), 1.37 (t, 3H), 2.08 (s, 6H), 2.31 (s, 3H), 2.60 (s, 3H), 3.58 (q, 4H), 4.44 (q, 2H), 6.94 (s, 2H)ppm. The slower moving fraction, comprising the titled compound (example 3) was collected. Evaporation of the solvents gave 80 mg of the title compound (example 3) as an oil. 1 H NMR (CDCl 3 ): d 1.32 (t, 6H), 1.36 (t, 3H), 1.98 (s, 6H), 2.33 (s, 3H), 2.47 (s, 3H), 4.03 (q, 2H), 3.60-4.40 (br, 4H), 6.97 (s, 2H)ppm.
The following compounds are prepared essentially according to procedures set forth above in Examples 1, 2, and 3.
EXAMPLE 4
N-Cyclopropylmethyl-N-propyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H -pyrazolo 4,3-d!pyrimidin-7-amine (Compound 3).
EXAMPLE 5
N-Ethyl-N-propyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine.
EXAMPLE 6
N-Butyl-N-ethyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine.
EXAMPLE 7
N,N-Diethyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine.
EXAMPLE 8
N,N-Diallyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine.
EXAMPLE 9
N-Ethyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine.
EXAMPLE 10
7-(1-Morpholino)-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidine.
EXAMPLE 11
N-Benzyl-N-ethyl-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine.
EXAMPLE 12
N,N-Di 1-(2-methoxy)ethyl!-2,5-dimethyl-3-(2,4,6-trimethylphenyl)-2H-pyrazolo 4,3-d!pyrimidin-7-amine.
The invention and the manner and process of making and using it, are now described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains, to make and use the same. It is to be understood that the foregoing describes preferred embodiments of the present invention and that modifications may be made therein without departing from the spirit or scope of the present invention as set forth in the claims. To particularly point out and distinctly claim the subject matter regarded as invention, the following claims conclude this specification.
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This invention encompasses compounds of the formula ##STR1## wherein Ar represents a mono-, di- or trisubstituted aryl group where at least one position on Ar ortho to the point of attachment to the pyrazole ring is substituted; and
R 1 represents lower alkyl;
R 2 is hydrogen or lower alkyl; and
R 3 and R 4 independently represent organic and inorganic substituents,
which compounds are highly selective partial agonists or antagonists at human CRF 1 receptors and are useful in the diagnosis and treatment of treating stress related disorders such as post traumatic stress disorder (PTSD) as well as depression, headache and anxiety.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of manufacturing a molded wooden product composed of a wooden body and a skin by compression molding of a collected body of wooden material containing a binder. More specifically, it relates to simultaneous integral molding of a molded wooden product which is used for manufacturing door trim for automobiles and the like.
2. Description of the Prior Art
A molded wooden product of the type to which this invention pertains has a less weight than plywood and is superior in resistance to heat, water and moisture. Moreover, it is strong for its thickness. It is typically known as hardboard and is used for a wide range of applications including the decoration of the interior of automobiles, and the manufacture of furniture and television or stereo cabinets.
This kind of product has hitherto been manufactured by, for example, treating woodchips with steam having a temperature of 160° C. to 180° C. in a steaming tank to loosen them; splitting the loosened chips by means of a splitting machine and the like to produce a wooden fiber; admixing to said wooden fiber a binder such as a synthetic resin, followed by compression molding thereof into a wooden body; and adhering a skin to said wooden body with an adhesive. For manufacturing a wooden body, one method known as the dry mat molding method which includes the steps of forming a mat for molding and compression molding said mat has been carried out. However, this method had problems in that it involves complex procedures, poor workability, high cost of production and the like.
In order to solve the above problems, JP-A 62-90203 disclosed a method of direct compression molding which does not require the step of preparing the mat. The disclosed method comprises stacking a wooden fiber having added binder to form a mass of wooden materials of low density, and delivering said mass of low density into the mold wherein it is compression molded.
As described above, molded wooden products have been manufactured by applying an adhesive onto a wooden body or skin and adhering said skin to said body by means of vacuum molding and the like. The method, however, requires a lot of labor and steps for adhering the skin, thus offsetting the economical merits of employing a new method of manufacturing a wooden body. This led to a study of new methods which comprise delivering the wooden body for molding into the mold to which the skin has been provided previously, and performing simultaneously the formation of the wooden body and the adhesion of the skin.
For example, an R-RIM method has been proposed which comprises injecting urethane to which single glass fibers are admixed while subjecting it to impingement mixing, after mounting the skin into the mold, and then carrying out the molding of the body and adhering with skin at the same time. However, the materials employed in the method are costly, and the strength of the resulting molded product is insufficient.
In addition, the binders used in the above-described manufacturing method of wooden bodies are thermosetting resins such as phenol resins, the hardening process of which requires heating to the high temperatures of 200° to 250° C. Such high temperatures melt and decompose the skin material, since it is made from thermoplastic resins such as PVC and TPO. Therefore, simultaneous integral molding with the above-described wooden bodies was almost impossible.
In order to overcome such problems, JP-A 3-92301 has proposed the method of manufacturing a molded wooden product using polyisocyanate as the binder. This method permits reduction in molding temperature by using a catalyst in hardening of polyisocyanate, so that it is possible to avoid the above problem and permit simultaneous integral molding of the wooden body and the skin.
However, the wooden bodies manufactured using a polyisocyanate as the binder have very low strength as compared to those manufactured with a phenol resin as the binder, and they have a problem of high restitution after compression molding under heat. Use of polyisocyanates also gives rise to the problem of a short of working life due to its high reactivity.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method of manufacturing molded wooden products which employs materials having long working life, enables simultaneous integral molding of the wooden body and the skin, and provides excellent characteristics.
In order to achieve the objects and in accordance with the purpose of the invention, the method of manufacturing a molded wooden product composed of a wooden body and a skin comprising stacking wooden fibrous mixture in which the binder, selected from an anaerobic adhesive, an unsaturated polyester, or a combination of a phenol and a polyisocyanate, has been added to wooden fibers to form a collected body of the wooden materials, delivering said collected body of wooden material into a compression mold, to which a skin material has been provided previously, and compressing said collected body of wooden material and a skin material to carry out simultaneously the molding of said collected body of wooden material to form a wooden body and the adhesion of said wooden body and the skin.
According to this invention, a simultaneous integral molding of the wooden body and the skin can be performed without melting or deforming the skin material. In addition, according this invention, it is possible to lengthen the usable period of time during which the collected body of wooden material can be used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view showing by way of example as apparatus which can be used for preparing a material for molding in accordance with the method of this invention.
FIG. 2 is a view showing by way of example a molding process which can be employed for manufacturing a molded wooden product in accordance with the method of this invention.
FIG. 3 is a vertical sectional view of the device for forming a collected body of wooden material.
FIGS. 4 and 5 are vertical sectional views showing a mold.
FIG. 6 is a vertical sectional view of the device for spraying a polyisocyanate onto the fibrous mixture containing a phenol resin.
FIG. 7 shows different ways of adding a polyisocyanate onto the fibrous mixture containing a phenol resin.
FIG. 8 is a graph showing the distribution of the binder within the molded wooden product obtained in Example 6.
FIGS. 9 and 10 show different ways of adding a polyisocyanate to the fibrous mixture containing a phenol resin.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An outline of the method of this invention is described by referring to FIGS. 1 and 2. Wood chips W1 are carried from a storage tank 1 to a chip washing machine 2 in which they are washed. Then, they are carried to a splitting machine 3 in which they are treated with steam and split into fibers while a water-repelling agent is supplied from a pump 4 to the splitting machine 3. The wooden fibers W2 are carried to a drier 5. They are carried on a stream of hot air from a blower 5b through a hot air tube 5a to a cyclone 5c, whereby they are dried. They are then carried to a hopper 6a in a mixer 6 and are allowed to drop from the hopper 6a into the main body 6b of the mixer 6 in which they are mixed with a binder, and other additive, whereby a fibrous mixture M is prepared.
The mixture M is transferred from the mixer 6 to a collecting device 10 and is caused to float down and gather to form collected body W of wooden material having a particular shape. The collected body W of the wooden material is transferred to a holding vessel 20 and conveyed to a mold 30 having a lower mold half 31 in which the collected body W of the wooden material is placed. A skin material was previously provided on the lower mold half 31. An upper mold half 32 is lowered to compress the collected body W of the wooden material, whereby molding of the wooden body and adhesion of the wooden body and the skin material S are carried out and a molded wooden product P is manufactured.
The wooden fibers used in the practice of this invention can be obtained, for example, by splitting wood chips. There is no particular limitation to the wood employed. It is possible to use, for example, Japanese cypress, Japanese red pine, Japanese cedar, lauan, Japanese beech and the like. There is no particular limitation to the wood splitting method, which includes any method known to those skilled in the art. An exemplary method involves heat boiling the wood chips followed by splitting them at ambient pressure, or mechanically splitting the wood chips after boiling.
The binder to be added to the wooden fiber is one selected from an anaerobic adhesive, an unsaturated polyester, or a mixture of a phenol and a polyisocyanate.
When using a mixture of a phenol and a polyisocyanate as the binder, the ratio of the phenol resin and a polyisocyanate is preferably 1:3 to 3:1 by weight, and more preferably 1:1 by weight. The use of the phenol resin alone as the binder requires a molding temperature of higher than 200° C., while the use of a polyisocyanate along cannot yield sufficient strength required for the molded product. The combinated use of a phenol resin and a polyisocyanate permits molding at reduced temperatures at which the skin material does not melt, so that the molded wooden product having more satisfactory strength can be obtained. This effect is further secured by employing the above ratio of the mixture.
The phenol resin may be any one of those which are generally used in the art for adhering wood. Polyisocyanates are also known, and tolylenediisocyanate (TDI), diphenylmethane diisocyanate (MDI), or isocynate prepolymer and the like may be used. The polyisocyanate are so reactive that they form strong primary bonds with, for example, wood, fiber, paper, synthetic resin and the like at relatively reduced temperature. The phenol resin and the polyisocyanate can be added to the wooden fiber, either in combination or alone. Because the undiluted phenol resin or the polyisocyanate is too sticky to be mixed well, the phenol resin may be diluted with water, acetone and the like to facilitate mixing, the polyisocyanate may be diluted with acetone and the like to facilitate mixing.
The phenol resin and the polyisocyanate are added preferably in the range of 6 to 20% by weight of the mixture. When the amount added is lower than the range, sufficient strong bonding may not be obtained, whereas when it is higher than the range, the manufacturing cost will be too high and the molded product obtained may be too rigid, which can cause brittle fracture.
Thus, the wooden mixture into which the wooden fiber and the binder are added is stacked to form the collected body of the wooden material, which then is delivered into the mold into which the skin material has been provided previously, followed by the simultaneous compression molding and adhesion of the above collected body of the wooden material and the skin material. By carrying out the molding at 90° to 130° C., sufficiently strong bonding will be obtained without melting the skin material. A variety of skin materials can be used, including PVC, PVC with PVC foam layer, TPO with PP foam layer, PVC with PP foam layer and the like.
While a mixture of a phenol resin and a polyisocyanate fully hardens at temperature of 90° to 130° C., the curtailment of hardening time may be desirable in some cases. Although higher temperatures can shorten the hardening time, it may result in the problem of deformation of the skin material. In order to overcome the problem, the temperature of one of the mold half with which the skin material comes into contact is reduced, whereas the other one of the mold half with which the collected body of the wooden material comes into contact is elevated. That is, the temperature of the mold half at the side of the skin is maintained in the range of 80° to 110° C., whereas the temperature of the mold half at the side of the collected body of the wooden material is maintained in the range of 100° to 150° C. Because the coefficient of linear expansion of the skin material is greater than that of the collected body of wooden material, molding using the same mold temperature may cause warp of the resulting wooden product when it returned to room temperature due to a larger constriction of the skin material. However, this warp which occurs when the collected body of wooden material returned to room temperature can be minimized by adopting a higher temperature at the side of the collected body of the wooden material.
In order to shorten the hardening time, a catalyst for hardening of polyisocyanate may also be used. A variety of such catalyst are known, including, for example, N,N,N',N'-tetramethylhexamethylenediamine, N,N,N',N'-tetramethylpropylenediamine, N,N,N',N'-tetramethylethylenediamine, N,N,N',N',N'-pentamethyldiethylenetriamine, N,N-dimethylbenzylamine, N-methylmorpholine, N-ethylmorpholine, 1,4-diazobicyclo 2,2,2!octane, 1,8-diazabicyclo 5,4,0!-7-undecene, 1,5-diazabicyclo 4,3,0!non-5-ene, dimethylethanolamine, N-methyl-N-(dimethylaminopropyl)aminoethanol, dimethylaminopropylamine, N,N,N',N'-tetramethyldiethylenetriamine, 2,4,6-tris(dimethylaminomethyl)phenol.
Thus these catalysts may be added at the time of mixing the binder, wherein the hardening of the binder proceeds even at reduced temperatures, leading to the unfavorable result of a short period of time during which the collected body of wooden material can be used. In order to lengthen the time, above catalysts can be used as follows:
In one method, the above catalyst is precoated on the surface of the skin material with which the collected body of the wooden material comes into contact at the time of delivery of the collected body of the wooden material. The catalyst evaporates at the time of compression molding of the molded wooden product and spreads into the interior of the collected body of the wooden material. As a result, the hardening of the binder is promoted, so that the hardening time can be shortened. In another method, the catalyst is admixed with the collected body of wooden material at the time of its molding of the collected body of the wooden material after it was introduced into the mold. The mold for molding is, usually, perforated for degassing. Using these holes in the mold, the catalyst can be spread within the collected body of the wooden material. According to this method, the catalyst can be homogeneously dispersed and the hardening time of the binder can be further shortened. Thus, use of the catalyst enables the curtailment of the hardening time of the binder, and the molding can proceed at lower temperatures than when no catalyst is used.
As described above, polyisocyanates are highly reactive and slowly react with water or phenol even at ambient temperature. Therefore, when the collected body of the wooden material containing the binder is allowed to stand for a prolonged period of time, it becomes useless due to the hardening of the binder. In order to lengthen the time during which the collected body of the wooden material can be used, the delayed addition or addition immediately before the hardening of the binder is desired.
According to one method, the wooden fiber is first mixed with the phenol resin. Since the phenol resin has a low reactivity, it can be stored for a prolonged period of time provided it is stored under desired conditions. Subsequently, and immediately before molding, the mixture of the wooden fiber and the phenol resin may be stacked into the stacking case of a collecting device while spraying a polyisocyanate to the mixture as the mixture is allowed to drop, whereby the collected body of the wooden material is formed. The spraying serves to homogeneously disperse the polyisocyanate into the collected body of the wooden material. Subsequently the collected body of the wooden material is delivered into the mold for molding.
According to second method, the wooden fiber and the phenol resin is mixed and stacked to form the collected body of the wooden material. As described above, the collected body of the wooden material can be stored for a prolonged period of time. Polyisocyanate is then sprayed onto the collected body of the wooden material on the side with which the skin will come into contact while it is being transferred to be delivered into the mold. The collected body of the wooden material has such a low density that the polyisocyanate can penetrate deep into the inside of the collected body of the wooden material. As can be expected, the concentration of the polyisocyanate is higher at the side the polyisocyanate is sprayed, i.e. the side with which the skin comes into contact. Since the adhering strength of the polyisocyanate and the skin material is greater than that of the phenol resin and the skin material, the molded wooden product with a greater bonding strength can be obtained. Although the mold side of the collected body of the wooden material is richer in the phenol resin and poorer in the isocyanate, the elongation of the hardening time can be prevented by elevating the temperature of the mold.
According to a third method, the wooden fiber and the phenol resin is mixed as described above, whereafter a polyisocyanate is sprayed onto the mixture of the wooden fiber and the phenol resin thus obtained while the mixture is allowed to fall, and is stacked into the stacking case of collecting device. Thereupon the polyisocyanate is sprayed to a portion and not the entire collected body of the wooden material required for manufacturing the molded product, so that the upper part of the above stack does not contain the polyisocyanate. The collected body of the wooden material is then weighed, and the amount that is not necessary for manufacturing the collected body of the wooden material is discarded. The discarded portion of the collected body of the wooden material contains little or no, polyisocyanate, so that it can be stored for a prolonged period of time and can be recycled. Subsequently, the polyisocyanate is sprayed onto the collected body of the wooden material, and the collected body of the wooden material is delivered into the mold.
The object of the invention can also be attained by using an anaerobic adhesive as the binder. The anaerobic adhesive remains as liquid while it is in contact with oxygen, but when contact with oxygen is blocked, it starts to polymerize to become a polymeric compound having a strong three-dimensional structure. In the air, the wooden fiber and the anaerobic adhesive are mixed to form the collect body of the wooden material. The collected body of the wooden material can be stored for a prolonged period of time since the anaerobic adhesive does not harden in the air. For molding, the collected body of the wooden material is delivered to the mold which is preset with a skin material, and subsequent compression molding serves to eliminate a large portion of the air within the collected body of the wooden material. Degassing causes the anaerobic adhesive to harden, thus enabling integral molding. A non-limiting example of known anaerobic adhesive is the reactive acrylic adhesive. Molding can be performed even at ordinary temperature, but heating the collected body of the wooden material to, for example, approximately 130° C. will promote the hardening. At this temperature, 130° C., the skin will not change its shape. Further the molded product manufactured by using the anaerobic adhesive as the binder has a sufficient strength.
The object of the present invention may also be attained by using an unsaturated polyester resin in powder form as a binder. Since unsaturated polyester in powder form hardens at a temperature between 80° to 130° C., such a high temperature as is needed when using the phenol resin is not required. It can be hardened even at 50° to 80° C. when the catalyst is used. In addition, the molded wooden product thus obtained has a sufficient strength.
The following examples are submitted to illustrate but not to limit this invention. Unless otherwise indicated, all parts and percentages in the specification and claims are based on weight.
EXAMPLE 1
A phenol resin (Gunei Kagaku K.K., PL4630 (trade mark)) was diluted with water to make a 50% aqueous solution, to which was mixed a wooden fiber in solid form in a ratio of 5% by weight followed by agitation by air. MDI (Nihon Polyurethane, MR-100 (trade mark)) was diluted with acetone to 50% by weight solution. To this solution was added the above mixture of a phenol resin and a wooden fiber in 5% by weight. The mixture thus obtained was stirred to prepare a fibrous mixture M, wherein the ratio of the phenol resin and MDI was 1:1, and MDI was present in the mixture at 10% by weight.
The fibrous mixture M was then transferred to a stacking case 11 of the collecting device 10. As shown in FIG. 3, the fibrous mixture M was stirred by the air supplied from a compressor outside of the case 11 through a plurality of air hole 12 in the perforated bottom plate 13 to make the fibrous mixture M homogeneous.
Then, the bottom plate 13 of the case 11 in which the fibrous mixture M was floating was lifted by actuation of a cylinder 14, while performing vacuum cleaning (V/C) from a holding vessel 20 provided above the case 11 to form the collected body W of wooden material. A molding member 21 for extrusion composed of metal net or punching metal and the like hung from a ceiling plate 22 having a vent hole 23 was attached in a shape that suits the shape of a finished molded product of above fibrous mixture M, for example, in a curved form, so that the collected body W of wooden material after vacuum drawing had a shape that corresponds to that of the molded product and a fixed density. The collected body W of wooden material thus obtained was transferred to the molding device shown in FIG. 4 by moving the holding vessel 20 using a cylinder 24.
The molding device comprises an upper mold half 32, a lower mold half 31, a holding frame 33 encircling the lower mold half 31, and a hot plate 34 for physically supporting and maintaining the desired temperatures of the upper mold half 32 and the lower mold half 31. Onto the lower mold half 31 was placed a skin material S which was formed by vacuum molding a skin material having a 0.45 mm thick PVC sheet and a 1.5 mm thick PVC foam layer by opening the electromagnetic valve 35 through the vent holes 36. By releasing the vacuum drawing of the holding vessel 20 for transfer, the collected body W of wooden material falls, due to its own weight, onto the skin material S. Thereafter, the upper mold half 32 was lowered, whereupon molding was conducted at the mold temperature of 100° C., a compressing time of 30 seconds, and a molding pressure of 30 kgf/cm 2 to obtain sample 1 of a molded wooden product. Further the collected body W of wooden material was formed using 8% by weight of the phenol resin as the binder, which then was compression molded at 200° C., followed by its adhesion using a urethane adhesive to obtain a comparative sample 1. In addition, a comparative sample 2 was obtained using 23% by weight of the polyisocyanate as a binder in the same manner as above. A comparative sample 3 was obtained employing the R-RIM method described above. On each of these, the adhesion strength and the bending strength of the skin and the body were measured, results of which are shown in Table 1 and 2. Hereupon, the adhesion strength was measured in the peeling test wherein the skin is peeled halfway from the body and the weight required for the peeling is determined. The bending strength was measured as the three-point bending strength.
TABLE 1______________________________________ Adhesion Strength______________________________________Sample 1 2.6 kgf/25 mmComparative Sample 1 2.0 kgf/25 mm______________________________________
TABLE 2______________________________________ Bending Strength______________________________________Sample 1 250 kgf/25 mmComparative Sample 1 380 kfg/25 mmComparative Sample 2 180 kgf/25 mmComparative Sample 3 170 kgf/25 mm______________________________________
As shown in Table 1 and 2, by using the mixture of a phenol resin and a polyisocyanate as the binder, the hardening temperature can be reduced so that the integral molding of the skin and the wooden body can be conducted at lower temperatures than when phenol alone is used, and molded wooden products having a higher strength than those obtained using a polyisocyanate alone can be obtained.
EXAMPLE 2
In a manner as described in Example 1, the collected body W of wooden material was formed, and this was placed in the molding device. Molding was conducted at the molding pressure of 30 kg/cm 2 , and a compression time of 30 seconds as in Example 1, employing different temperatures at the upper mold half 32 (the side of the collected body W of wooden material) and the lower mold half (the side of the skin material S) at the time of molding as shown in Table 3. The outer appearance of the skin, irreversible deformation of the foam layer, and the warp of the obtained molded wooden products (500 mm×500 mm) were determined, and results are shown in Table 3.
TABLE 3______________________________________Temp. of Upper Mold Half 110° C. 140° C. 140° C.Temp. of Lower Mold Half 110° C. 90° C. 140° C.Quality of Skin good good NGAppearanceIrreversible Deformation <0.1 mm 0.1-0.15 mm 0.1-0.2 mmin the FoamWarp 3-5 mm 1-3 mm 2-4 mm______________________________________
As shown in Table 3, by using different temperatures at the side of the skin and at the side of collected body of the wooden material, with the temperature at the side of the skin being lower, the change of the shape of the skin was reduced. On the other hand, higher temperatures are employed at the side of the wooden body in order to shorten the hardening time of the skin, thus enabling the reduction in the cycle time.
EXAMPLE 3
N,N,N',N'-tetramethylethylenediamine catalyst (Kao K.K., Kaolyzer No. 11 (trade mark)) was sprayed onto the skin material S at the side at which the collected body W of the wooden material comes into contact at a concentration of 0.5 g/m 2 , whereafter this skin material S was placed in the lower mold half which was kept at a temperature of 100° C. The collected body W of the wooden material was formed in a manner of Example 1, and placed in the molded device. Then molding was carried out at a temperature of the upper mold half of 125° C., a temperature of lower mold half of 110° C., the compression time of 20 seconds, and the molding pressure of 30 kgf/cm 2 . The bending strength of the resulting molded product was 250 kgf/cm 2 , which was almost equal to Sample 1 in Example 1 despite the short compression time of 20 seconds.
By applying a catalyst for binder hardening the body on the side of the skin prior to molding, said catalyst can be evaporated and diffused into the body during the molding, resulting in the reduction of the hardening time. In addition, due to the pressure of a greater amount of the catalyst in the adhesion surface between the skin and the wooden body, the hardening at this portion is faster than other portions, so that the bonding between the skin and the wooden body is ensured.
EXAMPLE 4
As described in Example 1, the collected body W of the wooden material was formed. As shown in FIG. 5, this was then placed onto the skin material S in the mold device, whereafter the upper mold half 32 was allowed to descend so that the holding frame 33 and the upper mold half 32 come into contact with each other to form a closed chamber. Immediately after this, the electromagnetic valve 37 was switched to cause the catalyst gas to flow through the vent hole 38. The catalyst gas was allowed to flow for up to half of the total compression time at the most, whereafter the electromagnetic valve 37 was switched to the side of the V/C pump through the vent hole 38. Thereafter, the upper mold half was allowed to descend to obtain a sample of the molded product.
In this example, the catalyst can be homogeneously dispersed into the collected body W of wooden material, so that a reduction in the hardening time is attained.
EXAMPLE 5
A phenol resin (Gunei Kagaku K.K., PL4630 (trade mark)) was distilled with water to prepare a 50% aqueous solution. This solution was mixed with 5% by weight of wooden material in the solid form and stirred, by air, to homogeneity to obtain the fibrous mixture M'. Using an apparatus such as shown in FIG. 6, this fibrous mixture M' was allowed to pass through a fluffer roller 41 and to fall vertically. At the bottom end of the vertical falling path 42, a 50% solution of MDI (Nihon Polyurethane K.K., MR-100 (trade mark)) in acetone was sprayed through a nozzle 43 to form the fibrous mixture M. The fibrous mixture M thus formed was allowed to spread and fall, whereby it is supplied to the stacking case 11 of the collecting device 10 shown in FIG. 3. After formation of the collected body W of the wooden material, a sample of the molded wooden product was obtained in a manner as described in the above Example 1.
In this example, the addition of the polyisocyanate which reacts with water or phenol resin even at room temperature is delayed by adding it immediately before the forming of the collected body W of the wooden material, so that the curtailment of the period during which the body is usable can be prevented.
EXAMPLE 6
Using the same method as described in Example 5, the fibrous mixture M' containing only the phenol resin, was formed and, fed into the stacking case 11, whereby the collected body W' of wooden material was formed. When this collected body W' of wooden material was being carried in the holding vessel 20, the polyisocyanate was sprayed from below as shown in FIG. 7 using the air gun 51 (Iwata Tosouki K.K., W88-10E2P) with air pressure of 3.5 kg/cm 2 . Then this collected body W' was placed into the molding device, wherein a sample of the molded wooden product was obtained using the same method as described in Example 1. The content of the binder in the molded wooden product sample obtained was measured along the direction of the thickness of the molded wooden product to determine its distribution. As a result, as shown in FIG. 8, the phenol resin was distributed evenly since this was originally contained in the sample, whereas more polyisocyanate was present at the lower portion. With this method, the distribution of the polyisocyanate can be changed, so that more polyisocyanate can be distributed near the interface with the skin material S where a stronger adhesion is required. By mixing the polyisocyanate immediately before delivering into the mold, the collected body of the wooden material can be stored for a prolonged period of time, and the period during which the collected body of the wooden material is usable can be prolonged.
EXAMPLE 7
As shown in FIG. 9, using the same method as shown in Example 5, the fibrous mixture M' containing only the phenol resin was formed. This fibrous mixture M' was then allowed to fall from the nozzle 61 whereupon the polyisocyanate was sprayed thereto. The fibrous mixture M thus formed was supplied to the stacking case 63. In the inside of the stacking case 63 is provided a shape-forming member 64 composed of punched metal or the like, below which is provided a discharge tube 65 connected to a suction means. The fibrous mixture M is scattered from above the stacking case 63 by means of a scatterer 62, and is allowed to float and descend in the flow of the air suctioned through the discharge tube 65, whereby the fibrous mixture stacks onto the shape-forming member 64 to form the collected body W of the wooden material. The amount of the stacked collected body W of the wooden material is kept at about 80% of that required for the finished molded product. After thus stacking the fibrous mixture M, the spraying of the polyisocyanate is discontinued to stack the fibrous mixture M' which only contain the phenol resin but not the polyisocyanate. Thereafter, the surface of the stack is shaved and the extra amount of stack is discarded to obtain a given weight of the product. In this process, only the material which does not contain the polyisocyanate is discarded. Because the discarded material does not contain the polyisocyanate, no hardening proceeds in the material, so that it can be stored for a prolonged period of time and recycled as needed. After shaving is completed, as shown in FIG. 10, the stacking case 63 is reversed and the polyisocyanate is sprayed with air gun 51 from below. The collected body W of wooden material is then carried and the molded wooden product is formed using the same method as described in Example 1.
EXAMPLE 8
An anaerobic adhesive (Nihon Rokkutaito K.K., PMS-10E (trade mark)) at a concentration of 10% by weight was sprayed to the wooden fiber and this was stirred and mixed homogeneously by air. Though the adhesive can be used undiluted due to its low viscosity, it may be diluted with, for example, acetone to effect homogenous dispersion. The fibrous mixture thus prepared may be introduced into the stacking case in the same method as described in Example 1 to form the collected body W of wooden material, which then is carried to the molding device, wherein molding is performed at the mold temperature of 110° C., the compression time of 60 seconds, and the molding pressure of 30 kg/cm 2 . At the start of the molding, the valve of the upper mold half was opened for suction for 60 seconds. The molded wooden products thus formed had a bending strength of 285 kgf/cm 2 and an adhesion strength of 2.1 kgf/cm 2 which were satisfactory.
EXAMPLE 9
To the wooden fiber having a water content of 6 to 9% by weight was admixed 10% by weight of an unsaturated polyester in powder form (Matsushita Denko K.K., CE5100 (trade mark)), and the mixture was stirred by hot air at about 80° C. to form a fibrous mixture M. The fibrous mixture M was introduced into the stacking case as described in Example 1 to form the collected body W of the wooden material. This was then carried to the molding device, wherein it was subjected to molding under the condition of the mold temperature of 130° C., the compression time of 40 seconds, and a molding pressure of 30 kg/cm 2 . The molded wooden products thus formed had a bending strength of 290 kgf/cm 2 and an adhesion strength of 1.9 kgf/cm 2 which were satisfactory.
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This invention relates to a method of manufacturing molded wooden products composed of a wooden body and a skin material. This method employs materials having long working life and enables simultaneous integral molding of the wooden body and the skin. The obtained molded wooden product has excellent characteristics.
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FIELD OF THE INVENTION
[0001] This invention relates to the field of computers, and more specifically, to a computer mouse pad or mouse incorporating a recorder upon wherein paperless notes can be temporarily stored.
BACKGROUND OF THE INVENTION
[0002] The advent of desktop computers would appear to provide the ultimate in desktop organization. Desktop computers are capable of preparing simple letters or calculating complex algorithms making desktop computers an indispensable tools. The development of the mouse, which provides translational movement of a cursor in response to the rotational movement of a trackball, has further simplified computers making them usable by most any individual.
[0003] One of the most common uses of computers today is for accessing the Internet. The Internet is a network of computers based on standard protocols that allow computers to communicate with each other even if using different software vendors, thus allowing anyone with a computer has accessibility to anything else connected to the Internet worldwide. Interconnected computers may exchange information using various services, for example, the worldwide web (WWW). The WWW is a structure which allows users seeking information on the Internet to switch from server to server. The WWW structure allows a server computer system (web server or web site) to send graphical web pages of information to a remote client computer system. A program known as a web browser running on a client computer allows the client computer to communicate with the WWW. The remote clients' computer system can then display the web pages.
[0004] A problem with computer usage, to which the invention addresses, is the need to remember items on a very temporary basis. For instance, Internet browsing may include the need for an individual to temporarily remember a website location or address. By way of example, an Internet search may reveal a number of addresses for locations that provide patent related items (e.g. www.uspto.gov ). An individual may wish to view the PTO site after checking out some other sites, however, the individual must remember the address or retrace their steps if a viewing of the site is to occur. So as not to lose the website address, the individual may make a note of the address on scrape paper or a note pad. In this scenario, the individual must pause during the search to write down the address and make note of reason for the address. This is a time consuming process and makes it a disadvantage for business people who need only make note of an address for a few minutes. Non-business people also find a lack of need to record every address. The use of paper for the temporary recording of such address adds to, if not creates, the clutter of a work space thereby defeating one of the objectives of a computer, that is, to achieve a paperless office.
[0005] U.S. Pat. No. 5,405,168 discloses a mouse pad that also operates as a note pad. While this patent discloses the basic need for temporary storage of matters in relation to a mouse pad, it is well known that an writing on a mouse pad can quickly cause problems with the operation of the mouse trackball.
[0006] Thus, what is lacking in the art is a means for note taking particularly directed to the use of address note taking while browsing the Internet.
SUMMARY OF THE INVENTION
[0007] The instant invention is a mouse or a mouse pad having an integrated digital recorder which allows an individual to leave a brief message such as to the details of a website address. The recording mechanism has an audio controller with an audio data memory connected to and under the control of the audio controller. A speaker is connected to and coupled to the audio controller, a switch connected to the audio controller such that when an operation switch is activated the audio controller retrieves audio data from the audio data memory and outputs audio data to the speaker.
[0008] Thus, an objective of an instant invention is to eliminate the need for hand written notes for the temporarily recording of Internet website addresses.
[0009] Yet another objective of the instant invention is to provide a recording device that allows an individual to record a message such as that found on a computer without taking the individuals eyes away from the computer during the recording of the message, thereby lessening the chance for inaccuracies.
[0010] Yet still another objective of the instant invention is to eliminate the need for handwritten notes used for temporary storage.
[0011] Still another objective of the invention is to integrate a recording device into a computer mouse pad that is further used as a platform for a computer mouse.
[0012] Yet still another objective of the invention is to integrate a recording device into a computer mouse.
[0013] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a pictorial view of a computer mouse pad with an integrated digital recorder;
[0015] [0015]FIG. 2 is a diagrammatic representation of a digital recorder; and
[0016] [0016]FIG. 3 is a perspective view of a computer mouse having an integrated digital recorder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Although the invention will be described in terms of a specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by the claims appended hereto.
[0018] Referring now to FIG. 1, set forth is a computer mouse pad 10 formed from a sheet of material having a top face 12 , a bottom face, not shown, and opposing side edges 14 . Said top face 12 having a texture for engaging of a mouse 16 track ball. The mouse 16 is moveable along the top face 12 of the pad 10 wherein rotation of the track ball results provides the appropriate signal carried by coupling cord 18 for translation movement of a display cursor. The pad 10 may also include a wrist rest 20 that is raised a height above the top face 12 .
[0019] Mounted or formed integral to the pad 10 is a recorder 22 having an on/off switch 24 for providing power to the recorder. A speaker grill 26 shields a speaker cone and a microphone grill 28 shields a microphone. A manual/voice activation switch 30 allows the recordation to be performed automatically upon receipt of voice commands or manually by depressing a record/playback face plate 32 . The face plate 32 further allows playback of a previously made recording by activation of a playback cycle. An optional display screen 34 provides visual indication of battery life, recording action, and audio data memory remaining.
[0020] Referring to FIG. 2 the recorder 22 includes the power switch 24 which is coupled to the manual/voice activation switch 30 an audio controller 40 . Audio controller 40 controls data memory 42 , speaker 44 and microphone 46 . The audio controller 40 includes circuitry necessary to receive analog audio data from microphone 46 , an analog to digital (A/D) converter and associated circuitry to convert and store data into data memory 42 , a digital to analog (D/A) converter and associated circuitry to retrieve digital data and converter it to audio data, and an amplifier to amplify the audio data and play it on speaker 44 A/D converters, D/A converters, and amplifiers are well known in the art. Battery 50 is attached to audio controller 40 and provides power for operation of the device.
[0021] Data memory 42 is a digital audio memory device. Digital audio memory is well known in the art and commercially available from numerous vendors. Those skilled in the art will recognize that alternative memory technologies, such as magnetic tape, can be implemented. However, these technologies have the disadvantages associated with any device that has moving parts.
[0022] In the preferred embodiment, when an individual depresses switch 24 , audio controller 40 activates microphone 46 . Audio data from microphone 46 is input into audio controller 40 where it is converted to digital data and stored in data memory 42 , converts it to analog audio data and outputs it to speaker 44 . If the mouse pad is a disposable device, then battery 50 would not be replaceable. For reusable embodiments, battery 50 would be replaceable.
[0023] Referring to FIG. 3, set forth is a second embodiment of the invention wherein a mouse 60 includes the recordation device. In this embodiment, the mouse has a speaker grill 62 and a microphone grill 64 . A manual/voice activation switch can be programmed into the toggle button 66 for left handed individuals, or into toggle button 68 for right handed individuals. In this manner, the mouse can be used in its typical manner with recordation can be performed automatically upon receipt of voice commands or manually by double clicking the same toggle button.
[0024] As with the first embodiment, the recordation mouse will include an audio controller which controls data memory, speaker and a microphone. The audio controller includes circuitry necessary to receive analog audio data from microphone, an analog to digital (A/D) converter and associated circuitry to convert and store data into data memory, a digital to analog (D/A) converter and associated circuitry to retrieve digital data and converter it to audio data, and an amplifier to amplify the audio data and play it on the speaker, A/D converters, D/A converters, and amplifiers are well known in the art. Power is obtained from the power cord that controls the mouse.
[0025] It is to be understood that while I have illustrated and described certain forms of my invention, it is not to be limited to the specific forms or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification.
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The instant invention is a mouse or a mouse pad having an integrated digital recorder which allows an individual to leave a brief message such as a website address location. The message can be recorded automatically, by voice activation, or manually by an on/off switch.
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TECHNICAL FIELD
[0001] The invention generally relates to wall panels and systems.
BACKGROUND
[0002] A typical basement has perimeter walls of poured concrete or blocks which line a hole or cavity excavated into a ground surface and which acts as a foundation for a home or other structure supported thereby.
[0003] Typical perimeter walls are built with load bearing rather than aesthetic aspects in mind and accordingly tend to be somewhat irregular and are generally uninsulated. In order to finish a basement, the foregoing aspects must be dealt with.
[0004] The typical way to finish a basement is to erect “studs” (vertical wooden members) typically spaced 16 inches apart along the interior face of the perimeter walls. Insulation of some form (e.g. Styrofoam™ or fibreglass) is inserted in the channels defined by the wall and the adjacent studs. A suitable vapour barrier is placed over the insulation if required and “drywall” (gypsum wallboard) sheets are secured to the studs over the insulation and vapour barrier.
[0005] The “finishing” of a typical basement using the prior system is labour and time intensive. Typically upper and lower framing members would be installed adjacent respectively the ceiling joist and a floor. Studs would be mounted between the upper and lower members. The insulation would be cut and installed. The drywall sheets would be cut and secured and finally joints between the drywall sheets would be taped and filled with drywall compound for subsequent sanding and final finishing.
[0006] In addition to the above steps, accommodation must be made for electrical sockets and switches. Such would typically be mounted in boxes secured to the studs and serviced by wiring also secured to the studs. Once the boxes have been installed, a challenge is presented to one installing drywall sheets over the boxes in that the location of the boxes has to be carefully measured and translated to the drywall sheet in order to cut suitable openings to accommodate the boxes.
SUMMARY
[0007] In one or more embodiments, the present invention relates to wall systems which provide a means for finishing interior walls; such as basement walls. In certain embodiments of the present invention, wall panels offer several options for light switches, plug outlets, cable outlets and communication box outlets. In other embodiments of the present invention, wall panels are provided with a means for eliminating or reducing the need for taping and filling that is used in conventional drywall finishing.
[0008] Wall systems according to the present invention are modular.
[0009] In one or more embodiments, the present invention relates to a modular wall panel including a sheet of material suitable for forming at least part of an interior wall, the sheet having an outer face and an inner face; a layer of insulation secured to the sheet on the inner face; and connectors for connecting the panel to one or two other panels. In certain embodiments, the panel may further include at least two framing members. In certain embodiments, connectors may be provided in the framing members. Suitable connectors include but are not limited to tongue and groove and click lock connectors. In certain embodiments, one or more conduits for wiring may be provided in the panel. Suitable conduits include tubes such as PVC tubes. In certain embodiments, the conduits may be located in the insulation of the panel. In certain embodiments, the conduits are housed in channels in the insulation. In certain embodiments, channels formed in the insulation may serve as conduits. In certain embodiments, the panel may further comprise an electrical or communications outlet. In certain embodiments, the panel may comprise one or more bevels formed in one or more edges of the panel. In certain embodiments, the panel includes one or more level bubbles in one or more directions. In certain embodiments, the panel may be a door header panel, a light switch panel, an outlet or cable panel or a plain wall panel. In certain embodiments, two or more panels can be connected together to form a interior wall or part thereof. In certain embodiments, two or more panels are connected together to form a modular wall system.
[0010] In another embodiment, the present invention relates to a template comprising a plate including an opening in the plate for tracing the outline of an opening for a well in a modular wall panel; and a flange at one end of the plate and in a plane perpendicular to the plane of the plate.
DESCRIPTION OF DRAWINGS
[0011] Embodiments of the present invention are described below with reference to the accompanying illustrations in which:
[0012] FIG. 1 is a front view of a panel according to an embodiment of the present invention;
[0013] FIG. 2 is a cross section taken along line A-A of FIG. 1 ;
[0014] FIG. 3 is a rear view of the panel of FIG. 1 with insulation not shown;
[0015] FIG. 4 is a cross section taken along line B-B of FIG. 3 ;
[0016] FIG. 5 is front view of a panel according to another embodiment of the present invention;
[0017] FIG. 6 is a cross section taken along line A-A of FIG. 5 ;
[0018] FIG. 7 is a rear view of the panel of FIG. 5 with insulation not shown;
[0019] FIG. 8 is a cross section taken along line B-B of FIG. 7 ;
[0020] FIG. 9 is front view of a panel according to another embodiment of the present invention;
[0021] FIG. 10 is a cross section taken along line A-A of FIG. 9 ;
[0022] FIG. 11 is a rear view of the panel of FIG. 9 with insulation not shown;
[0023] FIG. 12 is a cross section taken along line B-B of FIG. 11 ;
[0024] FIG. 13 is front view of a panel according to another embodiment of the present invention;
[0025] FIG. 14 is a cross section taken along line A-A of FIG. 13 ;
[0026] FIG. 15 is a rear view of the panel of FIG. 13 with insulation not shown;
[0027] FIG. 16 is a cross section taken along line B-B of FIG. 15 ;
[0028] FIG. 17 is front view of a panel according to another embodiment of the present invention;
[0029] FIG. 18 is a cross section taken along line A-A of FIG. 17 ;
[0030] FIG. 19 is a rear view of the panel of FIG. 17 with insulation not shown;
[0031] FIG. 20 is a cross section taken along line B-B of FIG. 19 ;
[0032] FIG. 21 is front view of a panel according to another embodiment of the present invention;
[0033] FIG. 22 is a cross section taken along line A-A of FIG. 21 ;
[0034] FIG. 23 is a rear view of the panel of FIG. 21 ;
[0035] FIG. 24 is a cross section taken along line B-B of FIG. 23 ;
[0036] FIG. 25 is a side view of a sheet of material suitable for forming an interior wall according to an embodiment of the present invention;
[0037] FIG. 26 is a side view of part of two sheets of wall finishing material according to an embodiment of the present invention jointed together;
[0038] FIG. 27 is a side view of a template according to an embodiment of the present invention;
[0039] FIG. 28 is a top view of the template of FIG. 27 ;
[0040] FIG. 29 is a front view of a panel according to the present invention showing the template of FIG. 27 in use;
[0041] FIG. 30 is a front view of a wall installation of panels according to one or more embodiments of the present invention;
[0042] FIG. 31 is a side view of the installation of FIG. 30 ;
[0043] FIG. 32 is a side view of a panel according to the present invention;
[0044] FIG. 33 is a side view of a panel according to the present invention;
[0045] FIG. 34 is a side view of a panel according to the present invention; and
[0046] FIG. 35 is a top view of a panel according to the present invention.
DETAILED DESCRIPTION
[0047] A modular wall panel according to one embodiment of the present invention is generally illustrated by reference 2 .
[0048] The panel 2 , also referred to as a “light switch panel” if a light switch installed in the panel, is comprised of a sheet 4 of medium-density fiberboard (“MDF”) having an outer wall finishing surface 6 and an interior surface 8 . The sheet 4 is 14 inches wide and 96 inches high but may be of other dimensions depending upon the application. The sheet 4 may be made of other material suitable for forming an interior wall, such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board and drywall. The wall finishing surface 6 is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface 6 may be pre-primed such that once installed, it can be painted without further priming.
[0049] Two framing members 10 and 12 are secured to the panel on the interior surface 8 side of the sheet 4 . The framing members 10 and 12 may be secured to the sheet 4 by suitable adhesives or fasteners. The framing members 10 and 12 are at or near the edges of the sheet 4 but may be located at other locations on the sheet 4 provided that the sheet 4 is provided with a sufficient amount of structural integrity. The framing members 10 and 12 are 2′×3′ wood lumber and extend from the top 26 of the sheet 4 to near the bottom edge 27 of the sheet 4 . Recesses 29 are provided between the end of the framing members 10 and 12 and the bottom edge 27 to receive a cleat when the panel 2 is installed on joists provided with a cleat. Recesses 29 are optional and the framing members 10 and 12 may extend to the bottom edge 27 . The framing members 10 and 12 may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the sheet 4 . The framing member 10 is provided with a groove 14 while the framing member 12 is provided with a tongue 16 . The groove 14 is for receiving a tongue from another panel while the tongue 16 is designed to be received by a groove in another panel when more than one panel 2 is joined together to form an interior wall or part of an interior wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the panel 2 for connecting panel 2 to one or more other panels.
[0050] In order to provide electrical or communications service to the panel 2 , a box 18 is provided for housing an electrical or communications outlet (not shown). The electrical or communications outlet includes an electrical outlet, electrical switch, cable box, telephone jack, internet jack, and the like. An opening 20 in the sheet 4 provides access to the box 18 . The box 18 is located in the panel 2 such that upon installation of the panel 2 , the box 18 is at approximately the standard height from the floor that is typical for that type of box. The box 18 , in other embodiments, may be located elsewhere in the panel 2 such that when panel 2 is installed, the box 18 is located at a non-standard height above the floor. In other embodiments the horizontal position of the box 18 in the panel 2 may vary. A tube conduit 22 extends from an opening 24 in the box 18 to the top edge 26 of the panel 2 . The conduit 22 allows for the installation of wiring for wiring an electrical or communications outlet housed in the box 18 . The conduit 22 can be made of PVC or other suitable material.
[0051] Insulation can be placed in the area between the framing members 10 and 12 and around the box 18 and conduit 22 and secured to the sheet 4 and/or the members 10 and 12 by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction to insulate. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet 4 and/or to the members 10 and 12 and/or retained in place by other suitable means such as by a sheet of plastic vapour barrier material, (not shown) or other suitable material secured to the back side of the panel.
[0052] In another embodiment, in the panel 2 , the box 18 and the conduit 22 can be housed in sheet foam insulation 30 . FIG. 2 is a cross section taken along line A-A of FIG. 1 of another embodiment (with insulation 30 ) of the panel 2 of FIG. 1 (panel 2 in FIGS. 1 , 3 and 4 is shown without insulation). The insulation 30 may cover all or part of the area of the sheet 4 . In such an embodiment, a well (not shown) is provided in the sheet insulation to house the box 18 . A channel (not shown) is provided in the foam insulation to house the conduit 22 . In a further embodiment, the tube conduit 22 can be omitted and a channel in the insulation 30 can serve as a conduit for wiring. In a still further embodiment, the well in the sheet of insulation is omitted. In such an embodiment, an opening in the sheet 4 and a well in the insulation 30 may be cut such that the cut well is in communication with the conduit 22 . An electrical or communications box may then be inserted into the well. In a still further embodiment, the sheet 4 may be omitted
[0053] The incorporation of an electrical outlet box 18 with an electrical conduit 22 in panel 2 facilitates the installation of electrical or communication services in a finishing operation such as in a basement. Previously, electrical outlet and cable would have been secured to studs prior to placement of drywall over the studs. This proved challenging in guessing with any degree of accuracy where to place a hole in the overlying drywall sheet so as to correspond with the electrical or communications outlet.
[0054] A wall panel according to another embodiment of the present invention is illustrated by reference 40 . The panel 40 is also referred to as an “outlet or cable panel” if an outlet or cable box is installed in the panel. The panel 40 is comprised of a sheet 44 of MDF having an outer wall finishing surface 46 and an interior surface 48 . The sheet 44 is 24″ wide and 96″ high but may be of other dimensions depending upon the application. The sheet 44 may be made of other material suitable for forming an interior wall, such as gypsum but not limited to wallboard, shiplap, HDF, OSB, fibre cement board and drywall. The wall finishing surface 46 is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface 46 may be pre-primed such that once installed, it can be painted without further priming.
[0055] Two framing members 50 and 52 are secured to the panel on the interior surface 8 . The framing members 50 and 52 may be secured to the sheet 40 by suitable adhesives or fasteners. The framing members 50 and 52 are at or near the edges of the sheet 44 but may be located at other locations on the sheet 44 provided that the sheet 44 is provided with a sufficient amount of structural integrity. The framing members 50 and 52 are 2′×3′ wood lumber and extend from the top 53 of the sheet 44 to near the bottom edge 55 of the sheet 44 . Recesses 57 are provided between the end of the framing members 50 and 52 and the bottom edge 55 to receive a cleat when the panel 40 is installed on joists provided with a cleat. Recesses 57 are optional and the framing members 50 and 52 may extend to the bottom edge 55 . The framing members 50 and 52 may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the panel 40 . The framing member 50 is provided with a groove 54 while the framing member 52 is provided with a tongue 56 . The groove 54 is for receiving a tongue from another panel while the tongue 56 is designed to be received by a groove in another panel when more than one panel 40 is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the framing members 50 and 52 for connecting panel 40 to one or more other panels.
[0056] In order to provide electrical or communications service to the panel 40 , a box 58 is provided for housing an electrical or communications outlet (not shown). The electrical or communications outlet includes an electrical outlet, electrical switch, cable box, telephone jack, Internet jack, and the like. An opening 60 in the sheet 50 provides access to the box 58 . The box 58 is located in the panel 40 such that upon installation of the panel 40 , the box 58 is at approximately the standard height from the floor that is typical for that type of box. The box 58 in other embodiments may be located elsewhere in the panel 40 such that when the panel 40 is installed, the box 58 is located at a non-standard height above the floor. In other embodiments, the horizontal position of the box 58 in the panel 40 may vary. A tube conduit 62 extends from an opening 64 in the box 58 to the top 66 of the panel 40 . A second conduit 63 extends horizontally from the box 58 and through the member 50 . A third conduit 65 extends horizontally from the box 28 and through the member 52 . The conduits 62 , 63 and 65 allow for the installation of wiring for wiring an electrical or communications outlet housed in the box 58 . The conduits 62 , 63 and 65 may be made of PVC or other suitable material.
[0057] Insulation can be placed in the area between the framing members 50 and 52 and around the box 58 and conduits 62 , 63 and 65 and secured to the sheet 40 and/or the members 50 and 52 by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet 44 and/or to the members 50 and 52 and/or retained in place by other suitable means such as a sheet of plastic vapour barrier material secured to the back side of the panel 40 .
[0058] In another embodiment, in the panel 40 , the box 58 and the conduits 62 , 63 and 65 can be housed in a sheet of foam insulation 66 . FIG. 6 is a cross section taken along line A-A of FIG. 5 but with insulation 66 included. Panel 40 is shown in FIGS. 5 , 7 and 8 without insulation 66 . The insulation 66 may cover all or part of the area of the sheet 44 . In such an embodiment, a well (not shown) is provided in the sheet insulation 66 to house the box 18 . Channels are provided in the sheet insulation 66 to house conduits 62 , 63 and 65 . In a further embodiment, the conduits 62 , 63 and 65 can be omitted and the channels themselves can serve as the conduits for wiring. In a still further embodiment, the well in the sheet of insulation 66 is omitted. In such an embodiment, an opening in the sheet 44 and a well in the insulation 66 may be cut such that the cut well is in communication with one or more of the conduits 62 , 63 and 65 . An electrical or communications box may then be inserted into the well. In a still further embodiment, the sheet 44 may be omitted.
[0059] A modular wall panel according to another embodiment of the present invention is generally illustrated by reference 80 . The panel 80 is also referred to as a “plain wall panel”. The panel 80 is comprised of a sheet MDF having an outer wall finishing surface 86 and an interior surface 88 . The sheet 84 is 14 inches wide and 96 inches high but may be of other dimensions depending upon the application. The sheet 84 may be made of other suitable material for forming an interior wall such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. The wall finishing surface 86 is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface 86 may be pre-primed such that once installed, it can be painted without further priming.
[0060] Two framing members 90 and 92 are secured to the panel on the interior surface 88 . The framing members 90 and 92 are secured to the panel 40 on the interior surface 88 side of sheet 84 by suitable adhesives or fasteners. The framing members 90 and 92 are at or near the edges of the sheet 84 but may be located at other locations on the sheet 84 provided that the sheet 84 is provided with sufficient amount of structural integrity. The framing members 90 and 92 are 2′×3′ wood lumber and extend from the top 91 of the sheet 84 to near the bottom 93 of the sheet 84 . Recesses 95 are provided between the end of the framing members 90 and 92 and the bottom edge 93 to receive a cleat when the panel 80 is installed on joists provided with a cleat. Recesses 95 are optional and the framing members 90 and 92 may extend to the bottom edge 93 . The framing members may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the panel 80 . The framing member 90 is provided with a groove 94 while the framing member 92 is provided with a tongue 96 . The groove 94 is for receiving a tongue from another panel while the tongue 96 is designed to be received by a groove in another panel when more than one panel 80 is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors., such as a click-lock system, may be provided in the framing members 80 and 82 for connecting panel 80 to one or more other panels.
[0061] In order to allow wiring to pass through the panel, the panel 80 is provided with a conduit tube 98 which extends through the members 90 and 92 . The conduit 98 can be made of PVC or other suitable material.
[0062] Insulation can be placed in the area between the framing members 90 and 92 and around the conduit 98 and secured to the sheet 84 and/or the members 90 and 92 by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet 84 and/or to the members 90 and 92 and/or retained in place by a sheet of plastic vapour barrior material or other suitable material secured to the back side of the panel.
[0063] In another embodiment, in the panel 80 , the conduit 98 can be housed in a sheet of foam insulation 100 . FIG. 10 is a cross section taken along line A-A of FIG. 9 but with insulation 100 included. Panel 80 is shown in FIGS. 9 , 11 and 12 without insulation 100 . The insulation 100 may cover all or part of the area of the sheet 84 . In such an embodiment, a channel is provided in the foam insulation to house the conduit 98 . In a further embodiment, the conduit 98 can be omitted and a channel in the insulation 100 may serve as a conduit for wiring.
[0064] The incorporation of a conduit 98 in panel 80 facilitates the installation of electrical or communication services in a finishing operation such as in a basement.
[0065] A modular wall panel according to another embodiment of the present invention is generally illustrated by reference 120 .
[0066] The panel 120 is comprised of a sheet 124 of MDF having an outer wall finishing surface 126 and an interior surface 128 . The sheet 124 is 24 inches wide and 96 inches high but may be of other dimensions depending upon the application. The sheet 124 may be made of other suitable material for forming an interior wall such as such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. gypsum wallboard and drywall. The wall finishing surface 126 is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface 126 may be pre-primed such that once installed, it can be painted without further priming.
[0067] Two framing members 130 and 132 are secured to the panel on the interior surface 128 side of the sheet 124 . The framing members 130 and 132 may be secured to the sheet 124 by suitable adhesives or fasteners. The framing members 130 and 132 are at or near the edges of the sheet 124 but may be located at other locations on the sheet 124 provided that the sheet 124 is provided with sufficient amount of structural integrity. The framing members 130 and 132 are 2′×3′ wood lumber and extend from the top edge 125 of the sheet 124 to near the bottom edge 127 . Recesses 129 are provided between the framing members 130 and 132 and the bottom edge 127 to receive a cleat when the panel 120 is installed on joists provided with a cleat. Recesses 129 are optional and framing members 130 and 132 may extend to the bottom edge 127 . The framing members 130 and 132 may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the panel 120 . The framing member 130 is provided with a groove 134 while the framing member 132 is provided with a tongue 136 . The groove 134 is for receiving a tongue from another panel while the tongue 136 is designed to be received by a groove in another panel when one or more panel 120 (or other panels according to the present invention) is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the framing members 130 and 132 for connecting panel 120 to one or more other panels.
[0068] In order to provide electrical or communications service to or through the panel 122 , two horizontal conduits 142 and 144 and two vertical conduits 146 and 148 are provided. The conduits 146 and 148 are PVC tubes but may be made of other suitable materials.
[0069] Insulation can be placed in the area between the framing members 130 and 132 and around the conduits 146 and 148 and secured to the sheet 124 and/or the members 130 and 132 by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet 124 and/or to the members 130 and 132 and/or retained in place by a sheet of plastic vapour barrier material or other suitable material secured to the back side of the panel.
[0070] In another embodiment, in the panel 120 , the conduits 142 , 144 , 146 , and 148 are housed in a sheet of foam insulation 150 . FIG. 14 is a cross section taken along line A-A of FIG. 13 but with insulation 150 included. Panel 120 is shown in FIGS. 13 , 15 and 16 without insulation 150 . The insulation 150 may cover all or part of the area of sheet 124 . In a further embodiment, the conduits 142 , 144 , 146 and 148 can be omitted and the channels formed in the insulation 150 can themselves serve as conduits.
[0071] An electrical or communications box can be located at points along any of the conduits 142 , 144 , 146 and 148 . In order to locate a box, a suitably sized and shaped opening 160 is cut in the sheet 124 and a suitably sized and shaped well (not shown) is cut in the sheet insulation 150 to house box 162 . The conduits passing through the well are also cut. For example, if box 162 is located at intersection 156 , conduit 142 is severed to form two conduits 164 and 166 and conduit 148 is severed to form two conduits 168 and 170 . Conduit 164 extends from an opening 172 in the box 162 to the top 174 of the panel 120 . Conduit 166 extends from an opening 174 in the box 162 to near the bottom 176 of the sheet 124 . Conduit 168 extends from an opening 178 in the box 162 and through the framing member 130 . A conduit 170 extends from an opening 180 in the box 162 and through the faming member 132 .
[0072] Once the well is cut, an electrical or communications box may then be inserted into the well. The electrical or communications outlet includes an electrical outlet, electrical switch, cable box, telephone jack, internet jack, and the like.
[0073] The conduits 164 , 166 , 168 , and 170 allow for the installation of wiring for wiring an electrical or communications outlet housed in the box 162 .
[0074] A modular wall panel according to another embodiment of the present invention is generally illustrated by reference 180 . The wall panel 180 is referred to as a “door header panel” when the panel is installed above a door in an interior wall. The panel 180 comprises a sheet 182 of MDF having an outer wall finishing surface 186 and an interior surface 188 . The sheet 184 is 38 inches wide and 16 inches tall but may be of other dimensions depending upon the application. The sheet 184 may be made of other material suitable for forming an interior wall, such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. gypsum wallboard and drywall. The wall finishing surface 186 is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface 186 may be pre-primed such that once installed, it can be painted without further priming.
[0075] Two framing members 190 and 192 are secured to the panel 180 on the interior surface 188 side of the sheet 182 . The framing members 190 and 192 may be secured to the sheet 182 by suitable adhesives and fasteners. The framing member 190 is at one end of the sheet 182 . The framing member 192 is located at an interior location of the sheet 182 but may be placed at another location where it can impart sufficient structural integrity to the sheet 182 . The framing members 190 and 192 are 2′×3′ wood lumber and extend from the width of the sheet 182 . The framing members in certain embodiments can extend less than the width of the sheet 182 . The faming members 190 and 192 may be made from other materials such as metals, alloys, composites and plastics that provide sufficient structural integrity to the panel 180 . The framing member 190 is provided with a groove 194 while the framing member 192 is optionally provided with a tongue 196 . The groove 194 is for receiving a tongue from another panel while the tongue 196 is designed to be received by a groove in another panel when more than one panel according to the present invention is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the framing members 190 and 192 for connecting panel 180 to one or more other panels.
[0076] A third framing member 198 is provided. The third member 198 is not initially attached to the sheet 182 and may be provided with the sheet 182 as a kit. If the full width of the panel 180 is to be used, the third member 198 is affixed at the end of the sheet 182 opposite to the end where framing member 190 is located. If the panel 180 is to be less than the full width of the sheet 182 , (for example a width less than full 38″ width in the embodiment shown in FIGS. 22 and 24 ), the third member 198 is affixed at a location on the sheet 182 closer to the member 190 . Cut lines 200 may be provided on the interior surface 188 , such as at 26″, 28″, 30″ and 32″ along the width of the sheet 182 (as measured from the end of the sheet 182 where the framing member 190 is located). The sheet 182 can be cut along one of the cut lines 200 according to the width of the panel desired. The third member 198 is then affixed along the cut line where the sheet 182 has been cut. The member 198 is provided with a tongue 202 designed to be received by a groove in another panel when the panel 180 is to be joined to another panel on the end where third member 198 is located.
[0077] The panel 180 may be provided with insulation 204 . The insulation can be any insulation suitable for residential or commercial construction to insulate. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet 182 and/or to the members 190 and 192 and/or retained in place by other suitable means such as by a sheet of plastic vapour barrier material or other suitable material secured to the back of the panel 180 .
[0078] Insulation can be omitted from modular wall panels according to certain embodiments of the present invention.
[0079] Framing members can be omitted from modular wall panels according to certain embodiments of the invention if the sheet used in the panel has sufficient structural integrity to be installed without the need for framing members to provide additional structural integrity. In such embodiments, the modular wall panels have connector means associated with the panels that are attached to the sheets by means other than framing members.
[0080] Sheets of wall finishing material according to certain embodiments of the present invention may optionally have a bevel on one or both side edges of the sheet. A sheet 210 of material suitable for forming an interior wall 210 is 3 mm in thickness and 24″ in width and 96 inches in height. A first bevel 212 is located at an edge of the sheet 210 of the outer wall finishing surface 214 . The bevel is formed at a 45 degree angle but bevels at other suitable angles are possible. A second bevel 216 is located at the edge of the sheet 210 opposite the edge in which the bevel 212 is formed. Once sheets 210 are joined together to connect the two sheets (such as for installation), the small groove 218 created by two abutting bevelled edges can be caulked with silicone, or similar type of paintable caulking, and then troweled smooth as an alternative to the taping, filling and sanding of seems between panels of traditional gypsum wall sheet installations.
[0081] Panels according to certain embodiments of the present invention may include one or more level bubbles. One level bubble may be located in a side edge of the panel for vertical positioning (see for example 219 in FIG. 1 ). A level bubble may be located on the front face of the panel for horizontal positioning (see for example 221 in FIG. 1 ). Level bubbles may be embedded in the panel as long as they are still visible for reading.
[0082] As discussed above, wall panels according to certain embodiments of the present invention, have conduits pre-installed but do not have a well for an electrical or communications box. In order to cut an opening in sheets of wall material, a template may be used such as the template indicate by reference 220 . The template 220 is made of a material that is resistant to wear from a saw blade running inside or along side the template. The template has a plate 222 and a flange 224 at right angles to the plate 222 . The plate 222 includes an H-shaped opening 226 which is dimensioned to correspond to size of an opening for a standard electrical or communications box. The template 222 and the opening 226 may be of other shapes and sizes depending upon the application.
[0083] In use, in order to cut an opening in a sheet of material suitable for forming an interior wall 228 , having conduit 230 , the template 222 is positioned such that the flange 224 abuts the side 232 of the sheet 228 . A saw such as a jig saw is used to cut out an opening in the sheet 228 by cutting along the inside edges of the H-shaped opening 226 .
[0084] A series of wall panels according to certain embodiments of the present invention may be joined together to form an interior wall of a basement. The interior wall could equally be in another area of a dwelling or commercial building. The panels are installed against 2×3 cleats 250 and 260 that are fastened to the bottom of floor joists 270 at the top of the wall and to a subfloor system 265 of the basement. The top cleat 250 may be installed first against floor joists 270 and the bottom cleat 260 is then installed offset from the top cleat to accommodate the notch 280 at the bottom of each floor panel. Once the cleats 250 and 260 are installed, one determines which type of panel is required and where, and installation can proceed beginning in a corner of the basement. For walls that require plumbing installation as well, the cavity 272 created behind the wall 273 formed by the panel system and the exterior wall 274 of a dwelling or commercial building, allows for the pre-installation of all plumbing required. Once the plumbing is installed, the wall panels 290 , 300 , 310 , 320 and 330 may be installed. The wall panels 290 , 300 , 310 , 320 and 330 are preferably installed before the ceiling is installed enabling electrical installation to be completed after installation of the wall panels but prior to the installation of the ceiling.
[0085] Typically the wall panels 290 , 300 , 310 , 320 and 330 would be installed before the ceiling enabling electrical installation to be completed after installation of the wall panels and before the ceiling.
[0086] Wall panel 290 is a light switch panel with light switch 291 installed, panel 300 is a door header panel, panel 310 is an outlet or cable panel with outlet 311 installed, panel 320 is a plain wall panel and panel 330 is a second outlet panel with outlet 331 installed, all according to certain embodiments of the present invention. The panels 290 , 200 , 310 , 320 and 330 are joined together using the tongues and grooves (not shown) provided with the panels 290 , 200 , 310 , 320 and 330 .
[0087] Panels according to embodiments of the present invention can also be configured to be installed with and to accept vertical cleats.
[0088] In further embodiments, panels according to the present invention may include rigid foam with channels and optionally conduits.
[0089] In other embodiments, in place of a rigid or solid foam, such as used for foam sheets 30 , 66 , 100 , 150 , 204 , can be replaced with a non-solid structure such as a corrugated structure, a honeycomb structure and the like, or a combination of such structures. An exemplary embodiment of such a structure is shown in FIG. 32 which depicts a panel indicated generally at 400 which includes a first sheet of outer wall finishing material 410 having an outer finishing surface 412 and an inner surface 414 and a second sheet of outer wall finishing material 416 having an outer finishing surface 418 and an inner surface 420 . The sheets 410 and 416 may be made of wall board, but may be made of other material suitable for forming an interior wall, such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. The interior of the panel 400 includes a corrugated structure 430 . The corrugated structure 430 is secured to the sheets 410 and 416 . A channel 440 is located in the panel 400 and passes through the corrugated structure 430 . Additional channels can be included in the panel 400 . The channel 440 can be lined with a conduit (not shown). The panel 400 includes tongue 450 and groove 460 connectors but other connectors may be substituted therefore or the connectors omitted altogether. Such a wall panel may be used for example as an inner interior wall panel, i.e one which is not used for finishing the inside of an exterior wall.
[0090] In panels according to certain embodiments of the present invention, the framing members can be omitted. The tongue and groove or other type of connectors can be integrated into the foam sheet of the panel. For example a wall panel according to another embodiment of the present invention is illustrated by reference to FIG. 33 . The panel indicated generally at 500 includes a first sheet 510 of MDF having an outer wall finishing surface 512 and an interior surface 514 and a second sheet 516 of MDF having an outer wall finishing surface 518 and an interior surface 520 . The sheets 510 and 516 are 24″ wide and 96″ high but may be of other dimensions depending upon the application. The sheets 510 and 516 may be made of other material suitable for forming an interior wall, such as gypsum, wallboard, shiplap, HDF, OSB, fibre cement and drywall. The wall finishing surfaces 512 and 518 are ones which are suitable for accepting wall finishes such as wallpaper and paint. The surfaces 512 and 518 may be pre-primed such that once installed, it can be painted without further priming. Between the sheets 510 and 516 is sheet foam 580 or other suitable material.
[0091] The panel 500 includes tongue 550 and groove 560 connectors but other connectors may be substituted therefore or the connectors omitted altogether. A channel 570 may be included in the panel 500 . Such a wall panel may be used for example as an inner interior wall panel, i.e one which is not used for finishing the inside of an exterior wall.
[0092] In other embodiments, sheet foam material used in certain embodiments of the present invention can have a dimpled outer surface. For example a wall panel according to another embodiment of the present invention is illustrated by reference to FIG. 34 . The panel indicated by reference 600 includes a sheet 610 of MDF having an outer wall finishing surface 612 and an interior surface 614 . The sheet is 24″ wide and 96″ high but may be of other dimensions depending upon the application. The sheet 610 may be made of other material suitable for forming an interior wall, such as gypsum, wallboard, shiplap, HDF, OSB, fibre cement and drywall. The wall finishing surface 612 is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface may be pre-primed such that once installed, it can be painted without further priming. A rigid foam 630 is attached to the interior surface 614 and includes dimples 616 .
[0093] In other embodiments of the present invention, the position of channels or conduits as the case may be in the panels may be marked on finishing surfaces according to the present invention by for example chalk lines, such as dashed lines. Chalk is preferred because it can be easily erased or painted over. Alternatively, the lines may be sprayed on or applied as a peel coat.
[0094] A panel according to another embodiment of the present invention may be used as a corner piece in a wall. For example, a wall panel indicated by reference numeral 700 according to another embodiment of the present invention is illustrated by reference to FIG. 35 . The panel 700 includes outer sheets 702 and 704 of MDF having an outer wall finishing surfaces 706 and 708 and interior surfaces 710 and 712 . The sheets 702 and 704 may be made of other material suitable for forming an interior wall, such as gypsum, wallboard, shiplap, HDF, OSB, fibre cement and drywall. The wall finishing surfaces 706 and 708 are suitable for accepting wall finishes such as wallpaper and paint. The surface may be pre-primed such that once installed, it can be painted without further priming. Groove 714 is formed in the sheet 716 of foam material or the like attached to the sheets 702 and 704 and tongue 718 is formed of the sheet 716 . Alternatively, a member with a groove and a member with a tongue way be recessed within the sheet 716 . One or more channels (not shown) may be formed in the sheet. The channels may be lined with conduits.
[0095] The above invention is described in an illustrative rather than a restrictive sense. Deviation from the exact arrangements and dimensions described may be apparent to persons skilled in the art in adapting the above invention to specific applications. Accordingly, the scope of the invention is defined by the claims set out below.
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Wall systems according to certain embodiments of the present invention provide a means for finishing interior walls such as basement walls. In certain embodiments of the present invention, wall panels offer several options for light switches, plug outlets, cable outlets, communication box outlets and the like. In other embodiments of the present invention, wall panels are provided with a means for eliminating or reducing the need for taping and filling that is used in conventional drywall finishing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the polymerization of lactide (either S or R) using a bismuth, scandium, yttrium or lanthanide series rare earth metal based catalyst.
2. Description of the Related Art
Lactides are presently polymerized to high molecular weight plastics using tin, titanium, zinc and other metal based catalysts by ring opening polymerization of the cyclic ester: ##STR1## The resulting polymers of lactide are useful in medical applications such as wound closure devices, orthopedic implants, controlled release drug carriers, as well as degradable paper coatings and plastic packaging films.
A. J. Nijenhuis et. al., disclosed lactide could be polymerized using Sn(acetylacetonate) 2 and substituted Zn(II) acetylacetonate complexes as catalyst. They claimed the very high crystallinity polymer was produced because the polymerization rate was lower than the crystallization rate, thus allowing polymeriation directly onto the p-lactide crystal (Polymer Bull. (1991), 25, pp. 71-77).
U.S. Pat. No. 4,853,459 discloses ring-opening polymerization of cyclic carbonates at 200°-350° C. using coordination compounds of lanthanides such as Cerium tris(acetylacetonate).
Shen, Z.; Sun, J. and Wu, L., Huaxue Xuebao, 48(7), pp. 686-689(1990), disclose solution polymerization of DL-lactide using a mixture of aluminum alkyls, rare earth compounds, and water.
U.S. Pat. No. 5,028,667 discloses the polymerization of various lactones including lactide using yttrium and lanthanide series rare earth based catalysts. In a commonly assigned U.S. application serial number CH-1883, concurrently filed herewith, preferred catalysts within U.S. Pat. No. 5,028,667 for use in melt polymerizations of lactide are disclosed.
SUMMARY OF THE INVENTION
The present process relates to a process for the polymerization of lactide and optionally up to 20 mole % based on lactide of one or more lactones selected from ##STR2## by contacting a melt of lactide and the optional lactone with one or more catalysts having the formula MZ 3 , wherein n is 4 or 5, h, i, k, and m are independently 1 or 2, each R is independently selected from hydrogen or hydrocarbyl containing up to 20 carbon atoms or substituted hydrocarbyl containing up to 20 carbon atoms, M is chosen from scandium, yttrium, bismuth, or a lanthanide series rare earth metal, and Z can be the same or different and are selected from certain highly coordinating ligands such as beta-diketonates such as 2,2,6,6-tetramethylheptan-3,5-dionate and acetylacetonate, fluoride, chloride, bromide, iodide, carboxylate, tetrasubstituted porphyrinato (-2), phthalcyanato (-2), beta-ketoester anions such as methylacetoacetate, dialkylmalonate anion, cyclopentadienide, pentamethylcyclopentadienide, and aryloxide such as phenoxide, where at least one of the Z groups is selected from beta-diketonates, beta-ketoesters and malonate anions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a process for the ring opening polymerization of molten lactide and up to 20 mole % based on lactide of another lactone using as catalysts certain compounds of scandium, yttrium, bismuth or lanthanide series rare earth metal.
The lactones which can used as comonomers in the process of the present invention include: ##STR3## wherein n is 4 or 5, h, i, k, and m are independently 1 or 2 and each R is independently chosen from H or hydrocarbyl containing up to 12 carbon atoms. Preferred lactones are those in which R is hydrogen or methyl, and especially preferred lactones are e-caprolactone, d-valerolactone, glycolide (1,4-dioxan-2,5-dione), 1,5-dioxepan-2-one and 1,4-dioxan-2-one.
The catalysts for this polymerization are compounds of scandium, yttrium, bismuth and the rare earth metals. Rare earth metals include those elements with atomic numbers 57 thru 71, namely lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium. Preferred metals are lanthanum, cerium, praseodymium, and neodymium. In all of the catalysts the metal is trivalent. The catalyst preferably is at least slightly soluble in the molten lactide or lactone mixture.
Whereas lactide can be polymerized according to U.S. Pat. No. 5,028,667, some of the catalysts disclosed therein were found subsequently not to be stable at the temperatures used for melt polymerization of lactide. See U.S. Ser. No. (Ch-18830) concurrently filed herewith and incorporated by reference. Those catalysts of U.S. Pat. No. 5,028,667, bearing up to two highly coordinating ligands such as 1,3-diketonate ligands such as 2,2,6,6-tetramethylheptan-3,5-dionate and acetylacetonate, fluoride, chloride, bromide, iodide, carboxylate, tetrasubstituted porphyrinato (-2), phthalcyanato (-2), beta-ketoester anions such as methylacetoacetate, dialkylmalonate anion, cyclopentadienide, pentamethylcyclopentadienide, and aryloxide such as phenoxide stabilized the complex, allowing high yields of polylactides via melt polymerization.
Quite surprisingly, it has now been found that transferrable alkoxide groups are not necessary for catalytic activity in lactide polymerizations. Thus, complexes of scandium, yttrium, bismuth and the rare earth metals where all the ligands are highly coordinating ligands (such as those cited immediately above) are not only quite active as catalysts for high yield and rapid lactide polymerizations, but they have the following added important features:
1. They are easily synthesized from inexpensive metal salts
2. They are air and moisture stable
3. They give lower color in the produced polymers
It is to be further appreciated that many of the compounds that are catalysts often do not exist in simple monomeric form, but are more highly coordinated and exist as "cluster compounds" or as "nonstoichiometric compounds". A review of yttrium and rare earth chemistry applicable to catalysts of the present invention is R. C. Mehotra, P. N. Kapoor, and J. M. Batwara, Coordination Chemical Reviews, Vol. 31, (1980), pp 67-91. It is understood that even if such compounds do not exist as simple MZ 3 species, such compounds where the metal is trivalent are included within the meaning of active catalysts, and are included in the meaning of structure MZ 3 in this specification. An example of such a cluster compound is Nd 4 (OH) 2 (acetylacetonate) 10 in F. Hart, Comprehensive Coordination Chemistry, Vol. 3, pp. 1077-1081.
It will also be understood by those skilled in the art that if more than one type of Z group is present in a catalyst or mixture of two catalysts containing different Z groups is used, "redistribution" reactions may take place. By redistribution reactions is meant exchange of Z groups between metal atoms, so that it is possible, in theory, to obtain any combination of Z groups present on any particular metal atom.
By hydrocarbyl is meant any monovalent radical that contains only carbon and hydrogen. By substituted hydrocarbyl is meant any monovalent hydrocarbyl radical that contains other functional groups that do not substantially interfere with the reaction or react with any of the reactants or products. Suitable functional groups include halo, ester, ether, amino, thioether, silyl, hydroxy, carbon-carbon unsaturation (i.e., double or triple bonds) and aldehyde. Trivalent scandium, yttrium, bismuth and rare earth compounds will not be stable if they contain a functional group whose pKa is less than that of the pKa of the conjugate acid of the functional group bonded to the metal. A special case may arise where the two pKas are approximately equal. Then, an equilibrium may exist as to which group is bound to the metal, and if such groups fit the definition of Z above, then both will initiate polymerization.
The polymerization of the present invention is carried out in the absence of any solvent in the molten lactide or lactide mixture at from 100° to 220° C., preferably from 110° to 200° C. and most preferably from 165° to 180° C.
It is preferred to use a dry inert gas such as nitrogen or argon to blanket the reaction. Moisture is deleterious to the activity of the catalyst due to hydration, and can limit the molecular weight of the polymer produced. The starting materials should be dry. Drying methods are known to those skilled in the art, and include distillation from calcium hydride, passage over activated molecular sieves, or crystallization.
Preferred catalysts are those wherein at least one ligand Z is a betaketonate, betaketonate ester or malonate ion. Even more preferred are those catalysts wherein all three ligands z are a betaketonate, betaketonate ester or mallenate ion. The particularly preferred catalysts are materials where all three of the ligands are 1,3-diketonate, and where the metal is lanthanum. An example of this class is lanthanum tris(2,2,6,6-tetramethylheptan-3,5-dionate): ##STR4##
The advantages of the process of the present invention are that it is fast, provides a product with better thermal stability as determined by weight loss at 200° C. and involves fewer side reactions as observed by color formation than many of the highly active catalysts in the literature. It has advantages over previous yttrium and rare earth based processes in that the catalysts are less expensive to produce, are stable to moisture and give even lower levels of color in polylactides and lactide copolymers.
Several of the catalysts utilized in the process of the present invention are new materials. General experimental procedures for the preparation of these compounds is described as follows:
All preparations were done under an atmosphere of dry nitrogen or argon, either in a drybox or in Schlenk type glassware. Tetrahydrofuran (THF) was dried by distillation from sodium benzophenone ketyl. Toluene was dried by distillation from metallic sodium argon. Acetone was sparged with argon and dried over activated 4A molecular sieves. Commercial lanthanum isopropoxide (Strem Chemicals) was purified by dissolving in dry toluene, filtering the solution to remove insolubles, and then removing the toluene in vacuo to give a white solid which was dried under high vacuum at room temperature. Acetylacetone was distilled under nitrogen. Solvents and liquid reagents were stored over activated 4A molecular sieves in a drybox. 1 H NMR spectra were recorded at 300 MHz and are reported in ppm downfield of Me 4 Si.
Lanthanum isopropoxide was used as a starting material in several of the preparations. The lanthanide isopropoxides were originally reported to have the stoichiometry La(OCHMe 2 ) 3 by K. S. Mazdiyasni, C. T. Lynch, and J. S. Smith, Inorg. Chem., Vol. 5, (1966), pp. 342-346, and L. M. Brown and K. S. Mazdiyasni, Inorg. Chem., Vol. 9, (1970), pp 2783-2786. Reactions of the lanthanide isopropoxides with ligands such as acetylacetone and beta-ketoesters were portrayed as reactions of tris alkoxides to give tris ligand complexes by B. S. Sankhla and R. N. Kapoor, Aust. J. Chem., Vol. 20, (1967), pp. 685-688 and S. N. Misra, T. N. Misra, and R. C. Mehrotra, Indian J. Chem., Vol. 5, (1967), pp. 372-374, as follows:
La(OCHMe.sub.2).sub.3 +3LH→LaL.sub.3 +3HOCHMe.sub.2
A recent X-ray crystal structure by O. Poncelet et. al., Inorg. Chem., Vol. 28, (1989), pp. 263-267 shows that the true stoichiometry of yttrium isopropoxide is Y 5 (O)(OCHMe 2 ) 13 . Based upon elemental analysis, O. Poncelet and L. G. Hubert-Pfalzgraf, Polyhedron, Vol. 8, (1989), pp. 2183-2188, concluded that neodymium isopropoxide is also an oxo alkoxide, but with the stoichiometry Nd 6 O 5 (OCHMe 2 ) 8 . Thus it appears that the stoichiometries and structures of the lanthanum isopropoxides may vary across the lanthanide series. Although yttrium is not a member of the lanthanide series, it occurs naturally with the lanthanides and has chemical properties similar to the heavier lanthanides. Two recent reports of reactions with acetylacetone reported by O. Poncelet et. al., Polyhedron, Vol. 8, (1989), pp. 2183=14 2188, and Polyhedron, Vol. 9, (1990), pp. 1305-1310, establish that different metal isopropoxides may give different products. Both of the products were characterized by X-ray crystallography, as:
Y.sub.5 (O)(OCHMe.sub.2).sub.13 +CH.sub.3 C(O)CH.sub.2 C(O)CH.sub.3 →[Y(acac).sub.2 (OC(O)CH.sub.3)].sub.2
Nd.sub.6 O.sub.5 (OCHMe.sub.2).sub.8 +CH.sub.3 C(O)CH.sub.2 C(O)CH.sub.3 →Nd.sub.4 (OH).sub.2 (acac).sub.10
where acac is the acetylacetonate ligand.
In the catalyst syntheses given below, the products of lanthanum isopropoxide plus acetylacetone or beta-ketoesters are depicted as simple trisligand complexes, but it is understood that this may not be their true stoichiometries.
Simple tris ligand complexes of beta-diketones, Ln(betadiketonate) 3 are well known, and are usually prepared from LnCl 3 or Ln(NO 3 ) 3 . These compounds have been reviewed by F. Hart, Comprehensive Coordination Chemistry, Vol. 3, pp. 1077-1081.
EXAMPLE 1
Preparation of La[CH 3 C(O)CHC(O)OCMe 3 ] 3 (Lanthanum tris (t-butyl-acetoacetate)
Tert-Butylacetoacetate (7.267 g) was added dropwise to a stirring solution of lanthanum isopropoxide (5.225 g) in 100 ml of toluene over a period of 45 min. At the end of the addition, the mixture was stirred an additional 15 min, and then refluxed in an open flask in the drybox for 15 min. About half of the toluene evaporated. The remainder of the toluene was removed on a rotary evaporator, and the resulting solid was recrystallized from minimal pentane at -20° C. The first crop of white solid had a complex 1 H NMR spectrum. The pentane filtrates from this recrystallization were concentrated to give a solid which was tested for lactide polymerization. 1 H NMR (C 6 D 6 ): 1.44 (s, 9H, --OCMe 3 ); 2.0 (s, 3H, CH 3 C(O)--); 5.10, 5.13 (s, s, 1H, --C(O)CHC(O)--).
EXAMPLE 2
Preparation of Anhydrous Lanthanum tris(acetylacetonate)
Acetylacetone (3 ml) was added dropwise to a solution of lanthanum isopropoxide (0.80 g) in 4 ml of toluene. A white precipitate began to form partway through the addition. Additional toluene was added (4 ml) and the mixture was stirred overnight. The solvent was removed in vacuo and the residue was extracted with acetone. Filtration gave 0.363 g of acetone insoluble solid. The acetone filtrate was concentrated to a pale yellow oil. The oil was extracted with pentane. The pentane solution was filtered and the pentane was removed in vacuo to give a light yellow solid (0.771 g) which was tested for polymerization activity.
EXAMPLE 3
Preparation of La[Me 3 CC(O)CHC(O)CMe 3 ] 2 (2-ethylhexanoate)
2-Ethylhexanoic acid (0.209 g) dissolved in 1 ml of toluene was added dropwise to a stirring suspension of La[Me 3 C(O)CHC(O)CMe 3 ] 3 in 50 ml of toluene. By the end of the addition, the mixture was homogeneous. After stirring for 10 hours, the solvent was removed in vacuo. The product was partially dissolved by the addition of 5.5 ml of toluene. This mixture was filtered through a medium fritted glass filter to remove 0.182 g of white solid. The filtrate was concentrated to give a thick yellow oil (0.739 g). The 1 H NMR spectrum of this material suggests that it might be a mixture of compounds but it does not appear to contain any of the La starting material. 1 H NMR(C 6 D 6 ): 0.5-2.5 (multiple peaks including two sharp --CMe 3 peaks at about 1.25, 50H); 2.62 (m, 1H, --CHCO 2 --); 5.89, 5.91 (s, s, 2H, --C(O)CHC(O)--).
EXAMPLE 4
Preparation of La[MeC(O)CHC(O)Me](2-ethylhexanoate) 2
2-Ethylhexanoic acid (0.907 ml, 1 equivalent/La) was added to a stirring suspension of commercial lanthanum acetylacetonate (Strem Chemical, 2.0 g). The mixture was heated to reflux for 5 minutes and there was still undissolved solid remaining. The addition and heating sequence was repeated with a second equivalent of acid. The mixture was filtered through a fine fritted glass filter to remove 0.085 g of insoluble material. The solvent was removed in vacuo and the resulting solid was dried at high vacuum/room temperature for 4 hours. The product was recrystallized from minimal pentane at -30° C. to give a white solid. Concentrated solutions of this compound have high viscosity and are fiber-forming.
EXAMPLE 5
Preparation of La[MeC(O)CHC(O)Me] 2 (2-ethylbutyrate)
2-Ethylbutyric acid (0.533 g, 1 equivalent/La) was added dropwise to a stirring suspension of 2.00 g of commercial lanthanum acetylacetonate (Strem Chemicals). The mixture was stirred for 12 hours and then filtered through a fine fritted glass filter to remove 1.147 g of insoluble solid. The filtrate was concentrated in vacuo to give 0.800 g of solid. This material was fractionated by extraction with pentane and filtration to give a pentane insoluble solid (0.207 g). The pentane filtrates were concentrated in vacuo to give a light yellow solid (0.312 g). Both fractions were tested for polymerization activity. The 1 H NMR spectra of the two fractions were complex and difficult to interpret. The pentane insoluble fraction had integrals consistent with the product stoichiometry as written, the pentane soluble fraction did not. 1 H NMR (pentane insoluble fraction, C 6 D 6 ): 1.10 (broad singlet, 5.4H, (CH 3 CH 2 ) 2 CH--); 1.4-2.5 (m with large peaks at 1.94, 1.97, 17.8H, (CH 3 CH 2 ) 2 CH--, CH 3 C(O)--); 5.2-5.6 (m, 1.9H, --C(O)CHC(O)--). (pentane soluble fraction, C 6 D 6 ): 0.8-1.3 (m, 4.7H, (CH 3 CH 2 ) 2 CH--); 1.5-2.2 (m with large peaks at 1.91, 1.96, 1.99, 17.6H, (CH 3 CH 2 ) 2 CH--, CH 3 C(O)--); 5.2-5.4 (m, 2.7H, --C(O)CHC(O)--).
EXAMPLE 6
Preparation of La[MeC(O)CHC(O)Me] 3 (H2 O) 3
Commercial lanthanum acetylacetonate (Strem Chemicals) was recrystallized from 60% EtOH/water with a small amount of acetylacetone according to the procedure of G. W. Pope et. al., J. Inorg. Nucl. Chem., Vol. 20, (1961), pp. 304-313. This material is insoluble in toluene and moderately soluble in THF. A small portion of the material did not dissolve in THF, so solutions used for polymerizations were filtered through 0.5 mm PTFE syringe filters to remove insoluble material.
EXAMPLE 7
Preparation of La[MeC(O)CHC(O)Me] 3 (H 2 O) x (x less than 1)
Commercial lanthanum acetylacetonate (Strem Chemical) was recrystallized from refluxing 100% EtOH. The crystals were dried for 10 hours at room temperature under high vacuum. This procedure is similar to the one for preparing "anhydrous" rare earth acetylacetonates reported by M. F. Richardson et. al., Inorg. Chem., Vol. 7, (1968), pp. 2495-2500. The product is insoluble in toluene and moderately soluble in THF. A small portion of the material did not dissolve in THF, so solutions used for polymerizations were filtered through 0.5 mm PTFE syringe filters to remove insoluble material.
EXAMPLE 8
Properties of Lanthanum tris (2,2,6,6-tetramethylheptane dionate)
Commercial material (Strem Chemicals) has the expected simple 1 H NMR spectrum (C 6 D 6 ) with sharp peaks at 1.244 (--CMe 3 ) and 5.893 (--C(O)CHC(O)--). There is also a small impurity peak at 5.840. The commercial material can be purified by sublimation at 200° C. in high vacuum with a typical recovery of 94%. After sublimation the NMR shifts are 1.264 and 5.909. Lanthanide complexes of this diketone ligand have been shown to form hydrates by J. S. Ghotra et. al. J. Chem. Soc., Chemical Communications, (1973), pp. 113-114. The change in the NMR spectrum is attributed to dehydration that occurs when the hydrated commercial material is sublimed. The solubility of the sublimed complex in toluene is 17 mg/ml. Solubility in THF is considerably higher, and solubility in toluene containing 3% THF by volume is more than 10X greater than toluene alone.
EXAMPLE 9
Preparation of Tris (tert-Butylhydroxymethylene-d,l-camphorato) lanthanum ##STR5##
The beta-diketone ligand was prepared by the reaction of racemic camphor with NaH and methyl trimethylacetate in dimethoxyethane using the general procedure reported by H. L. Goering et. al., J. Am. Chem. Soc., Vol. 96, (1974), p. 1493. The crude product was purified by Kugelrohr distillation at high vacuum. The desired fraction was collected at 60°-80° C. It was further purified according to the copper chelate procedure for purification of beta-diketones by M. D. McCreary et. al., J. Am. Chem. Soc., Vol. 96, (1974), pp. 1038-1054. The lanthanum complex was prepared by reaction of the ligand with LaCl 3 (H 2 O) 7 and NaOMe in MeOH according to the M. D. McCreary reference. (This paper reports the preparation of Tris[tert-Butylhydroxymethylene-d-camphorato]europium). The lanthanum complex as prepared had high solubility in pentane. After drying at 100° C. at high vacuum for several hours, its solubility in pentane and toluene decreased. High solubility could be restored by addition of a few % THF to the solutions. 1 H NMR (After drying, C 6 D 6 ): 0.81(s,3H,Me); 0.95(s,3H,Me); 1.11(s,3H,Me); 1.32(s,9H,--CMe 3 ); 1.59(bs,3H,--CH 2 CH 2 --); 1.96(s,1H,--CH 2 CH 2 --); 2.84(s,1H,bridgehead CH)
EXAMPLE 10
Preparation of Lanthanum tris (2,2,6-trimethyloctan-3,5-dionate)
(±)-2,2,6-trimethyloctan-3,5-dione ligand was prepared by the reaction of pinacolone with NaH and racemic methyl-2-methylbutyrate in dimethoxyethane using the general procedure reported by H. L. Goering et. al., J. Am. Chem. Soc., Vol. 96, (1974), p.1493. The synthesis of stereochemically pure (+)-(S)-2,2,6-trimethyloctan-3,5-dione and its Eu complex have been reported by D. Seebach et. al., Liebigs Ann. Chem., (1976), pp. 1357-1369.
A solution of LaCl 3 (H 2 O)7 (5.0 g) in 50 ml of MeOH was added to a solution of (±)-2,2,6-trimethyloctan-3,5-dione (7.39 g) and NaOMe (2.17 g) in 290 ml of MeOH. The mixture became cloudy and was stirred for 2 hours. The mixture was filtered to remove insolubles, and an equal volume of water was added to the MeOH filtrate. This caused precipitation of the product, however the mixture could not be readily filtered so the bulk of the MeOH was removed in vacuo on a rotary evaporator. The product separated from the aqueous mixture as a yellow oil. The mixture was extracted with 4×200 ml of hexane. The combined hexane extracts were dried over MgSO4 and concentrated to give 1.46 g of crude product as a yellow oil. Sublimation at 200° C./high vacuum gave 0.678 g of waxy yellow solid. The product is highly soluble in organic solvents, being practically miscible with pentane. 1 H NMR (C 6 D 6 ): 0.99 (t, 3H,--CH 2 CH 3 ); 1.24 (s, 12H, --CMe 3 and --CH(Me)--); 1.44 (m, 1H, --CH A H B CH 3 ); 1.80 (m, 1H, --CH A H B CH 3 ); 2.30 (bs, 1H, --CH(Me)CH 2 CH 3 ); 5.67 (s, 1H, --C(O)CHC(O)--).
EXAMPLE 11
Polymerization Using Lanthanum tris (2,2,6,6-tetramethylheptane dionate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 110° C. vapor bath. 70 microliters of 0.25M tetrahydrofuran solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, colorless mixture exhibits no flow behavior after 5 minutes. After an additional 3 minutes the tube is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 83%.
EXAMPLE 12
Polymerization Using Lanthanum tris (2,2,6,6-tetramethylheptane dionate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. Immediately upon melting, 70 microliters of 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, pale yellow mixture exhibits no flow behavior after 1 minute. After an additional 1 minute a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 95%.
EXAMPLE 13
Polymerization Using Lanthanum tris (2,2,6,6-tetramethylheptane dionate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. After 5 minutes at 165° C., a stream of Argon is introduced at the bottom of the tube to enhance mixing while 70 microliters of a 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, colorless mixture exhibits no flow behavior after 20 seconds. After an additional 10 seconds a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 91%.
EXAMPLE 14
Polymerization Using Lanthanum tris (2,2,6,6-tetramethylheptane dionate) catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. After 5 minutes at 165° C., a stream of Argon is introduced at the bottom of the tube to enhance mixing while 17.5 microliters of a 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 8000/1. The clear, colorless mixture becomes viscous almost immediately, and after 1 minute a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 66%.
EXAMPLE 15
Polymerization Using tris [tert-Butylhydroxymethylene-d,l-camphorato]lanthanu m Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. After 5 minutes at 165° C., a stream of Argon is introduced at the bottom of the tube to enhance mixing while 70 microliters of a 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, colorless mixture becomes viscous and pale yellow immediately, and after 15 seconds a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 91%.
EXAMPLE 16
Polymerization Using Lanthanum tris (acetylacetonate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. After 5 minutes at 165° C., 70 microliters of a 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, colorless mixture becomes viscous and pale yellow immediately, and after 35 seconds a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 90%.
EXAMPLE 17
Polymerization Using Lanthanum tris (acetylacetonate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 110° C. vapor bath. After 5 minutes at 110° C., 70 microliters of a 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, colorless mixture becomes viscous after 3 minutes, and after a total of 7 minutes a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 48%.
EXAMPLE 18
Polymerization Using Lanthanum bis (2,2,6,6-tetramethylheptane dionate) (2-ethylhexanoate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. After 5 minutes at 165° C., 70 microliters of a 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, colorless mixture becomes viscous after 1 minute, and after a total of 5 minutes a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 90%.
EXAMPLE 19
Polymerization Using Lanthanum tris (2,2,6-trimethyloctan-3,5-dionate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. After 5 minutes at 165° C., 70 microliters of a 0.25M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear, yellow mixture exhibits no flow after 45 seconds, and after an additional 15 seconds a sample is quenched in cold water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 95%.
EXAMPLE 20
Polymerization Using Bismuth tris (2,2,6,6-tetramethylheptane dionate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of 0.1M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The cloudy gray mixture exhibits no flow behavior after 5 minutes. A small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 83%.
EXAMPLE 21
Polymerization Using Scandium tris (2,2,6,6-tetramethylheptane dionate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of a 0.1M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The mixture becomes viscous after 10 minutes and exhibits no flow behavior after 20 minutes. After a total of 25 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 79%.
EXAMPLE 22
Polymerization Using Lanthanum tris (t-butyl-acetoacetate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 35 microliters of a 0.5M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The mixture becomes viscous after 1 minute, and after a total of 2 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 64%.
EXAMPLE 23
Polymerization Using Yttrium tris (acetylacetonate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 6.7 mg of the catalyst is added to give a monomer to catalyst molar ratio of 2000/1. The clear yellow mixture is viscous after 20 minutes, and after an additional 25 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 55%.
EXAMPLE 24
Polymerization Using Yttrium tris (2,2,6,6-tetramethylheptane dionate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 35 microliters of a 0.5M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear colorless mixture is viscous after 2 minutes, and after a total of 6 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 84%.
EXAMPLE 25
Polymerization Using Tris(d,d-dicampholylmethanato)Europium Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of a 0.1M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The cloudy yellow mixture becomes clear after 30 seconds, viscous after 1 minute, and after a total of 4 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 87%.
EXAMPLE 26
Polymerization Using Yttrium octoate Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 9 mg of the catalyst is added to give a monomer to catalyst molar ratio of 2000/1. The catalyst does not dissolve, and after a total of 29 minutes no reaction had occurred.
EXAMPLE 27
Polymerization Using Cerium tris(trifluoroacetyl acetonate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of a 0.1M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear mixture becomes viscous after 30 minutes, and after a total of 60 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 80%.
EXAMPLE 28
Polymerization using Scandium tris(hexafluoroacac) catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of a 0.1 M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear mixture becomes viscous after 18 minutes, and a total of 30 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 42%.
EXAMPLE 29
Polymerization Using Praseodymium tris(hexafluoroacac) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of a 0.1 M toluene solution of the catalyst in injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. After a total of 10 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 14%.
EXAMPLE 30
Polymerization Using Lanthanum tris(acac).xH 2 O (x less than 1) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 87 microliters of a 0.2 M THF solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear mixture becomes viscous after 60 seconds, and after a total of 5 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 82%.
EXAMPLE 31
Polymerization Using Lanthanum tris(acac).3H 2 O Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 87 microliters of a 0.2 M THF solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear mixture becomes viscous after 15 minutes, and a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 34%. (E68868-105).
EXAMPLE 32
Polymerization Using Anhydrous Lanthanum tris(acac) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 87 microlites of a 0.2 M THF solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The clear mixture becomes viscous after 15 seconds, and after a total of 35 seconds a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 90%.
EXAMPLE 33
Polymerization Using La[Me 3 CC(O)CHC(O)CMe 3 ] 2 (2-ethylhexanoate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 58 microliters of a 0.3 M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The catalyst precipitates immediately, but redissolves after 45 seconds. The clear mixture becomes viscous after 1.5 minutes, and after a total of 5 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 76%.
EXAMPLE 34
Polymerization Using La[Me 3 CC(O)CHC(O)CMe 3 ](2-ethylhexanoate) 2 Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of a 0.1 M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The catalyst precipitates immediately to give a cloudy solution, but redissolves after 14 minutes. The clear mixture becomes only slightly viscous after 20 minutes, when a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 32%.
EXAMPLE 35
Polymerization Using La[MeC(O)CHC(O)Me] 2 (2-ethylbutyrate) Catalyst
5 g L-lactide, polymer grade, is melted in a flame-dried, nitrogen-flushed glass test tube suspended in a 165° C. vapor bath. 175 microliters of a 0.1 M toluene solution of the catalyst is injected via hypodermic syringe to give a monomer to catalyst molar ratio of 2000/1. The yellow mixture becomes viscous after 30 seconds, and after a total of 2 minutes a small sample is quenched in ice water to stop the reaction. Monomer conversion as measured by thermogravimetric analysis is 92%.
Having thus described and exemplified the invention with a certain degree of particularity, it should be appreciated that the following claims are not to be so limited but are to be afforded a scope commensurate with the wording of each element of the claim and equivalents thereof.
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A process for polymerizing lactide and up to 20 mole percent of another lactone is disclosed. The cayalysts used have the formula MZ 3 wherein M is scandium, yttrium, bismuth, a lanthanide series rare earth metal or a mixture thereof and the Zs are independantly the same or different highly coordinating ligands. The preferred metals M are lanthanum, cerium, praseodymium and neodymium with lanthanum being especially preferred. The preferred ligands are betadiketones, betaketoesters and malonate anions with the beta diketones such as 2,2,6,6-tetramethyl-3,5-heptanedionates being especially preferred.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to safety monitors and appliances for a wood pulping mill environmental control system. More particularly, the present invention relates to the method of and apparatus for monitoring the combustibility of non-condensible digester blow gas.
2. Description of the Prior Art
The kraft process of delignifying wood chips for the purpose of cellulose fiber liberation releases small quantities of highly volatile turpentine and mercaptan compounds in the form of substantially non-condensible vapors. Although the quantity of such gases produced by the process is extremely small in relation to the useable mass of the wood, nevertheless, such compounds are substantially responsible for the characteristic odor generally associated with pulp mills.
In the interest of reducing this environmental irritation, pulp mills have, in recent years, eliminated the atmospheric venting of all digester blow gases. According to the best of practice, these gases are isolated from the liquid and solid constituents of a digester discharge at the blow tank to be processed separately to, first, recover steam heat value and, secondly, strip the water soluble compounds.
Those gases remaining in the vapor stream following condensation and water stripping are, substantially, the volatile, odoriferous compounds first described. Due to the combustibility thereof, these gases are burned in the firebox of a convenient heating appliance such as a lime kiln or recovery furnace. It is in the final transport of these isolated flammables that significant hazards arise.
Ideally, such gases should be volumetrically concentrated under increased pressure and delivered to the heating appliance in a controlled manner as a fuel. However, the absolute quantity and specific heating value thereof is normally insufficient to justify the capital cost of compressors and accessory equipment required. Nevertheless, the total vapor pressure of the gas must be sufficient to permit a flow transfer into a normally negative pressure firebox. This circumstance is resolved by discharging the odor control draft induction fan required by the non-condensible gas stream stripper unit directly into the suction flow of the heating appliance primary draft fan. However, the odor control fan includes a fresh air source on the draft side thereof which mixes with the noncondensible gas flow stream. Normally, the resulting mixture is too fuel-lean to be combustible. It is only when the noncondensible gas stream is particularly rich that a combustible mixture may be created which fills the duct work between the fresh draft air confluence and the non-condensible gas stream. If this combustible mixture is subjected to a convenient ignition source, considerable equipment destruction will occur.
Although numerous electrolytic sensory devices are available to continuously measure the combustibility of the critical gas flow stream, long term reliability of such devices in the corrosive atmosphere of a pulp mill is less than satisfactory.
It is the object of the present invention, therefore, to teach a method of reliability monitoring the combustibility of blow gases prior to the firebox of a major heating appliance.
Another object of the invention is to provide fabrication details of a reliable apparatus for monitoring the combustibility of a digester flow gas disposal system.
SUMMARY OF THE INVENTION
The method and apparatus by which these and other objects of the invention are accomplished comprises a small sample flow line connected to the primary condensible gas duct between the odor control fan and the chosen heating applicance primary draft fan. This sample flow line is laid to a convenient location where it is connected to a small combustion chamber of heavy pipe section.
The combustion chamber pipe is capped at one axial end with a heavy plate section and at the other with a thin frangible disc clamped between flanges. Preferably, the frangible disc is calibrated to fail at a pressure comfortably below the failure pressure of the remaining combustion chamber structure. Through the cylindrical wall of the combustion chamber is provided a sparking electrode of the automotive type. A small gas exit flow conduit penetrates the combustion chamber wall at a location opposite the electrode from the gas sample supply line to require a sweep of the gas from entrance to exit past the electrode. Also penetrating the combustion chamber wall is a high/low pressure switch connection tube. Appropriate alarms and valve signal converters are connected to the respective pressure switch terminals.
In operation, a sample flow of the potentially hazardous gas is induced by the odor control fan discharge pressure. Such sample flow sweeps past the sparking electrode in transit from the inlet and exit conduit ports. The electrode is connected to discharge intermittently on a continuous duty cycle.
Should a segment of the normally inert gas sample become combustible, an ignition will occur resulting in a pressure surge. A surge in excess of limits prescribed by the pressure switch high-limit setting actuates a signal relay system to operate appropriate valves in the primary gas stream duct and vent the dangerous flow segment away.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE of the drawing illustrates a flow schematic of a pulp mill odoriferous gas stream having the present invention connected therewith.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Following the relevant portion of a wood pulp flow stream, a completed pulp charge is expelled from a cooking digester, not shown, through a blow pipe 10 into an atmospheric blow tank 11 for an initial, gross separation of the solid, liquid and vaporous constituents. The gaseous portion of the digester charge is withdrawn from the top of the blow tank vessel through a large diameter pipe 12 and ducted into an accumulator vessel 13 for preservation of a major portion of the heat values present in the resulting condensate. Remaining vapors are drawn from the accumulator through pipe 14 and ducted to a condenser 15 for further heat removal and subsequently, through pipe 16, to a scrubber 17 for reactive removal of remaining particulates and water soluble compounds.
The gaseous residue from the scrubber 17, drawn through pipe 18 by the draft induction of odor control fan 19, predominately comprises an odorous, non-condensible mixture of hydrogen sulfide, methyl mercaptan, methyl disulfide and turpentine gases which, when combined with appropriate portions of oxygen, are combustible. Damper regulated draft pipe 20 normally provides sufficient dilution air to exceed the combustible mixture range for the resulting gas/air stream discharged from the odor control fan 19 through pipe 21 as auxiliary draft for a primary air supply fan 22 supporting a large heating appliance such as a lime kiln, recovery furnace, etc. not shown. Within the firebox of such a large appliance, the odorous gases are consumed harmlessly without consequence.
Under unusual circumstances, however, such as when two or more digesters are blown simultaneously, the quantity of such non-condensible gas effluent increases sufficiently to result in a combustible mixture when combined with the relatively constant influx of dilution air drawn through draft pipe 20. If ignited, this combustible mixture is capable of destroying the equipment line between the draft pipe 20 and the primary appliance fan 22, inclusive. Moreover, experience has proven that such ignition is highly probable.
According to the present invention, gas discharged from the odor control fan 19 is continuously tested for combustibility. If the test responds positively, valves 24 and 25 are operated simultaneously to close the auxiliary draft pipe 21 to the primary fan 22 and open an atmospheric vent 26 for harmlessly dumping the dangerous mixture.
The continuous test apparatus comprises a small pipe conduit 30 connected into that section 21 of the main gas stream pipe between the odor control fan 19 and the primary appliance fan 22. The small positive pressure from the odor control fan 19 discharge is sufficient to induce a gas sample flow through the conduit 30 and a test cell 35. Within the flow line 30 between pipe section 21 and the test cell 35, a flame arrester 34 is provided.
The test cell 35 comprises a cylindrical pipe section 36 of approximately 2 inches diameter and 12 inches length, for example. One axial end of the pipe section is securely sealed by a welded base portion 37. The other axial end of the pipe section 36 is provided with a flange connector 38. A cooperative flange section 39 is used to seal a thin frangible disc 40 of a stainless steel sheet between gaskets 41. Flange section 39 is preferably secured to a relief pipe section 42.
The frangible disc 40 is a commercially available piping component which is scribed or otherwise fabricated to fail under a calibrated pressure stress load. A rupture or failure pressure characteristic of the disc 40 is selected on the basis of the remaining test cell 35 enclosure structure load capacity: the failure pressure of the disc 40 being comfortably less than the failure pressure of the test cell.
The volumetric space internally of the pipe wall 36 and between the base 37 and frangible disc 40 constitutes a combustion chamber 43.
Gas flow introduced to the combustion chamber 43 by conduit 30 is normally discharged through small diameter exhaust conduit 44. Between the pipe wall 36 ports for inlet and exhaust conduits 30 and 44, respectfully, is provided a sparking electrode such as an automotive spark plug 45 energized by a conduit 46 from the secondary winding of a transformer 47. The transformer primary circuit is intermittently charged by an appropriate timed switching mechanism such as a clock driven cam switch 48. An appropriate sparking cycle may include 3 seconds of sparking in a 15 second cycle.
Also connected to the combustion chamber 43 by means of conduit 50 is a high/low pressure limit switch 51. Electrical conduits 52 and 53 connect the respective pressure switch circuits 52 and 53 to appropriate signal converting equipment shown generally and collectively by unit 54. Signal outputs from the converting unit 54 may include electrical circuits 55 for audio and visual alarms 56 and 57, respectively. Other output signals from the converting unit 54 may include pneumatic signals 58 and 59 for operating valves 24 and 25, respectively.
A useful accessory to the aforedescribed test system may include a source 60 of propane or other combustible gas having known properties for selective connection to the test sample pipe 30 by means of a valved conduit 61.
In operation, a small volumetric flow rate sample of the gas discharged from odor control fan 19 continuously flows through and fills the combustion chamber 43 where it is exposed to an intermittent ignition source 45. Normally, there will be little or no combustion response and the sample stream flows harmlessly from the chamber 43 through exhaust conduit 44.
Occasionally, however, a significant ignition of the sample flow stream may be attained to create a pressure wave sufficient to set off the high limit of pressure switch 51. Responsively, high limit signals from the pressure switch 51 are converted by unit 54 to set off alarms 56 and 57 and operate the valves 24 and 25 to atmospherically vent the main flow stream of the dangerous gas to the atmosphere.
In an extreme case, the flow sample may become sufficiently explosive to rupture the frangible disc 40. This event will harmlessly relieve otherwise distructive pressures within the chamber 43. Only the inexpensive frangible disc 40 designed for expeditious replacement will be destroyed.
The low pressure limit switch 51 serves to monitor the continued operation of the system with regard to a cessation of the sample flow stream due to plugging of the conduit 30.
Having fully described my invention obvious alternatives and mechanical equivalents will readily occur to those of ordinary skill in the art. As an invention, therefore,
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The flammability of non-condensible blow gases from a wood pulping digester is continuously monitored by venting a low volume sample flow stream of such gases through a small combustion chamber where the stream is subjected to an intermittent ignition source. Unusually high pressures in the combustion chamber resulting from ignition of a flammable mixture are detected by pressure measuring means providing the operative result of automatically venting a dangerous flow increment of the gas.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of optical imaging and more particularly to reduction of the peak power and speckle contrast for bright field and dark field inspection applications.
2. Description of the Related Art
Many optical systems are designed to produce images such as an inspection system for a partially fabricated integrated circuit or a photomask. Techniques and apparatus for inspecting circuits or photomasks are well known in the art and are embodied in various commercial products such as many of those available from KLA-Tencor Corporation of San Jose, Calif. Most optical imaging systems use a continuous illumination source. However, many times pulsed illumination sources are preferred or are the only sources available. This is especially true in the DUV spectral region below 250 nm where very few high brightness illumination sources exist that are not pulsed. Common examples are excimer lasers used in the photolithography process for manufacturing semiconductor devices.
If a pulsed illumination source is used, the optical imaging system must contend with the nature of pulsed illumination. This is especially true when inspecting integrated circuits or photomasks. Pulsed illumination typically suffers from two major problems. First, the peak power of the illumination transmitted from the illumination source can be very high and potentially damage elements in the optical system or the object being inspected. Second, the light energy can suffer from “speckle” or random intensity distribution of light due to interference effects. This is especially true for laser light sources.
Further, instances occur wherein a higher repetition rate source is not available. A system or device for turning a high repetition rate laser, such as a mode locked laser, into a virtually continuous source would be very useful in these situations.
One prior apparatus for reducing the peak power of a pulsed laser is U.S. Pat. No. 5,309,456 by Horton. The Horton design uses one mirror and one beamsplitter to split a single laser pulse into multiple pulses. The multiple pulses are then delayed with respect to each other using reflective optical delay schemes. Several drawbacks exist for this approach. First, the pulse-to-pulse uniformity is highly dependent on the quality of the mirror and beamsplitter used to form the multiple pulses as well as losses in the optical delay schemes. To maintain uniform pulses this system requires 100% reflective mirrors, 50% reflective and 50% transmissive beam splitters with no absorption, and perfect AR coatings with 100% transmission. Any deviations from this will cause an energy variation between the pulses. For example, consider the effects of imperfect optics on a system that generates 16 pulses. If the beamsplitter transmission is 49% and the reflectivity is 51%, the energy variation between the pulses will be 16%. In addition, if the mirror has a reflectivity of 99% it will cause an additional energy variation between the pulses of 3%. Another limitation of the Horton design is that it is not well suited for the DUV-VUV spectral range. Reflective coatings are much less efficient in this range and can cause large losses. These losses will contribute to pulse-to-pulse nonuniformity and a reduction in the efficiency of the peak power reduction scheme. For example, a reflective optical delay scheme with a 1 m long cavity, using mirrors with 99% reflectivity, and an optical delay of 10 meters will have a loss of 10%. Similarily, a reflective optical delay scheme with an optical delay of 20 m, 40 m, and 80 m will have losses of 18%, 33%, and 55% respectively. If these delay paths are used in a system to generate 16 pulses, assuming perfect 50% beam splitters and a perfectly reflecting mirror, the lowest energy pulse will be only 22% of the highest energy pulse. An additional limitation of the Horton design is that it uses a single mirror and beamsplitter to generate the multiple pulses. This optical setup is not flexible and inhibits compensation of different losses for each delay path. In addition, this scheme offers no solution for dealing with the effects of speckle.
With respect to speckle problems, two primary techniques have been used in the past to reduce the contrast of speckle in a single laser pulse. The first technique employs two rotating diffusers to create multiple speckle patterns during a single pulse. This technique relies on the relative motion of the two rotating diffusers to produce uncorrrelated speckle patterns. This technique has several major disadvantages. First, the diffusers must rotate at a high at a high rate of speed to produce smoothing within a pulse. For a typical pulse of 20 ns, only a limited number of uncorrelated speckle patterns can be produced. Also, losses from diffusers are typically very high. A typical transmission for such a diffuser is 40%. The diffusers in combination then have a transmission of only 16%. In addition, rotating diffusers can be a source of vibration that can effect the image quality of the system. The second technique uses two diffraction gratings and an electro-optic modulator to produce speckle smoothing within a single pulse. This scheme was developed to minimize speckle problems for laser fusion systems. This technique has several limitations including large size and very high cost. In addition, electro optic modulators operating at high bandwidths in the DUV and VUV ranges are not available.
It is therefore an object of the current invention to provide a system or arrangement that can reduce the peak power of a laser pulse emanating from an energy source.
It is another object of the current invention to provide an illumination solution that does not suffer excessive losses due to mirrors, beamsplitters, and optical delay lines but that can produce substantially uniform pulses.
It is a further object of the current invention to provide an illumination solution that can be readily reconfigured while producing optical delays with minimum optical losses, particularly in the DUV-VUV spectral region.
It is still a further object of the current invention to provide an illumination solution, having reduced speckle contrast for a single energy pulse.
It is yet a further object of the current invention to provide for speckle contrast reduction in an illumination system preferably employing a pulsed illumination source wherein said speckle contrast reduction may be employed in combination with other speckle reduction schemes to further reduce the speckle contrast of a single pulse.
It is yet another object of the current invention to effectively increase the repetition rate of a pulsed source and further to achieve quasi-continuous operation from a high repetition rate source.
SUMMARY OF THE INVENTION
The present invention is a system and method for reducing the peak power of a laser pulse. The system and method disclosed herein utilize multiple paths using a unique design to divide a pulse received from a light generating device, such as a laser, into multiple lower energy pulses, and delay those pulses such that they may strike the target surface at different times. The design provided herein comprises a plurality of beamsplitters combined with a plurality of delay elements to delay a pulse or pulses transmitted from the light emitting device in an advantageous manner. The design provides the ability to readily divide the pulse into two, four, eight, or conceivably any number of components with components delayed relative to one another. The energy in each pulse can be adjusted using a variety of optical attenuation schemes to produce pulses with substantially uniform energies. Energy received from the light generating device may be split into components using beamsplitters and directed through different paths toward the target, such as a semiconductor wafer surface. Certain optical delay arrangements using prisms, Brewster's angle surfaces, and reflecting devices employing mirrors or Total Internal Reflection (TIR) surfaces provide delay compensation for the optical paths. These delay schemes can be in classical arrangements such as a White Cell or Herriott Cell or other novel delay schemes described herein.
The system and method further include a design for reducing speckle contrast, wherein a similar arrangement to that presented for the peak power reduction is employed, using beamsplitters, mirrors, and optical delay arrangements, to reduce the contrast of speckle in a single laser pulse. The reduction in contrast is performed based on the fact that laser beams entering a diffuser at a different angle or position produces a changed speckle pattern leaving the diffuser. Multiple speckle patterns may therefore be generated by multiple beams operating at multiple angles or positions through a diffuser, and the speckle patterns may be integrated together to reduce contrast. However, the speckle pattern must arrive at the detector at slightly different times. Thus the design presented herein to reduce peak power may be used with altered angles between the optical paths such that the split or divided light energy components strike the diffuser at suitably different angles.
An alternate embodiment for reducing speckle contrast is disclosed wherein a single pulse is passed in an angular orientation through a grating to create a delayed portion of the pulse relative to the leading edge of the pulse. One side of the pulse is delayed with respect to the other side of the pulse. If this time delay is suitably longer than the coherence length of the laser pulse, multiple zones are created across the pulse that will not interfere. Each of these zones can then pass through a diffuser at different angles and the speckle contrast can be reduced. A second grating can also be used in combination with the first grating to remove the spectral dispersion while maintaining the optical delay from one side of the pulse to the other.
In addition, these techniques to reduce the speckle contrast can be used in combination with other speckle reduction techniques to further reduce the speckle. Two examples of such techniques are a light pipe and a lens array. A light pipe or lens array spatially divides an input beam into multiple beamlets. Each of these beamlets then overlaps at the output of the light pipe or lens array. If the spatial or temporal coherence of the input pulse is sufficient so that one beamlet does not interfere with another, speckle contrast can be reduced.
Further, the method described herein for creating multiple pulses from a single pulse effectively increases the repetition rate of a repetitively pulsed source. The method described herein for reducing the speckle contrast from a single pulse using a grating to delay one side of a pulse with respect to the other side effectively increases the pulse length in time. Using both of these techniques in combination may produce a continuous or nearly continuous source from a high repetition rate source.
These and other objects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description of the invention and the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of the design used to reduce the peak power of a laser pulse, and one that can be altered by varying the angles of the components to reduce speckle contrast for a single laser pulse;
FIG. 2 a shows a plot of the intensity of a single pulse;
FIG. 2 b is a plot of the intensity of multiple pulses, specifically eight pulses, resulting from the use of the system and method similar to the one illustrated in FIG. 1;
FIG. 3 is a delay arrangement using two prisms, each prism including a TIR surface and an AR surface;
FIG. 4 illustrates two prisms rotated such that light energy entering makes a total of six round trips between prisms, thereby increasing overall delay time;
FIG. 5 a is a delay arrangement employing a single image relay lens;
FIG. 5 b illustrates a delay arrangement having two image relay lenses;
FIG. 6 presents a delay arrangement wherein three prisms are used each having a TIR surface and incorporating a Brewster's angle surface;
FIG. 7 is a preferred angular arrangement of pulses to apply to ground glass to reduce speckle contrast in accordance with the invention herein and the design of FIG. 1;
FIG. 8 shows the results of a standard laser pulse, the use of two DUV pulses, and four DUV pulses and the associated speckle contrasts;
FIG. 9 is an alternate embodiment of the method and apparatus for reducing speckle contrast employing a diffraction grating;
FIG. 10 is the resultant speckle contrast of the grating arrangement used in FIG. 9; and
FIG. 11 illustrates a functional diagram of the elements used in a device that reduces peak power and speckle contrast.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a system and method for reducing peak power and speckle contrast in an imaging system employing a pulsed illumination source. The system uses multiple beam splitters in an arrangement that has the ability in many environments to minimize the energy variation between pulses. This system allows for a flexible setup where various combinations of plate beamsplitters and cube beamsplitters in different arrangements and geometries may be used while still within the scope of the teachings of the current invention.
In typical pulsed illumination source inspection systems, optical delay lines can be a major source of losses. The losses in the delay arms result from imperfect optics such as mirrors having less than 100% reflectivity, beamsplitters with loss and unequal beamsplit ratios, absorption of light energy in glass materials and coatings, and light energy scattering effects. These optical delay line losses adversely contribute to variations in the pulse-to-pulse energy unless a method of compensation is used. In the present invention, components are introduced between the beamsplitters to compensate for losses in the beamsplitters, mirrors, and optical delay lines. The net result is that the pulse energies are much more uniform. High efficiency within the system minimizes the required introduction of compensating losses.
A schematic of an embodiment of a scheme to generate four pulses is shown in FIG. 1 . From FIG. 1, light energy is initially generated by light emission source 101 . The light energy is shown as four separate beams to more clearly illustrate the formation of four separate pulses. In most real situations only a single light beam would originate from the light source. The light energy from light emission source 101 is a pulsed light source. Light is transmitted toward beamsplitter 102 , which splits the light energy. The pulse that is reflected by beamsplitter 101 is directed to the 10 ns optical delay 103 , and beamsplitter 104 . Beamsplitter 104 may again either split the beam or permit the beam to pass through. If it passes through, it is directed to the 20 ns optical delay 105 , mirror 106 , and to the specimen. In the case of the pulsed light energy passing through beamsplitter 102 , said light energy contacts loss compensator 107 and subsequently passes to beamsplitter 104 . Loss compensator 107 compensates for imperfect optical components such as the beamsplitter 102 or loss in optical delay 103 . In this manner, light energy reflected by beamsplitter 102 contacts beamsplitter 104 at the same or nearly the same energy as light energy passing through beamsplitter 102 and loss compensator 107 . Similarly, light energy from beamsplitter 104 that passes through loss compensator 108 strikes the sample surface at approximately the same energy as light passing the 20 ns optical delay 105 and mirror 106 . If the light from source 101 is polarized, mirror 106 could be replaced by a waveplate and polarizing beamsplitter. In this manner the beams can be easily co-aligned. This mechanization provides for varying delays of the pulsed light energy such that light energy strikes the specimen surface at a desired time with relatively uniform energies.
The design presented in FIG. 1 generates four pulses each delayed by a different amount of time. The pulse passing directly through both beamsplitters has no delay introduced, while deflecting off both beamsplitters introduces a 10 nanosecond delay. 20 and 30 nanosecond delays can also be introduced in this arrangement as shown. This introduction of delay reduces the peak power of the pulses contacting the specimen surface.
The effects of using a design similar to the one illustrated in FIG. 1 are illustrated in FIGS. 2 a and 2 b . The system used to generate the pulses in FIG. 2 b is capable of producing eight pulses delayed by varying amounts of time. In FIG. 2 a , a 532 nm laser pulse is delivered to the specimen surface. The magnitude of the energy striking the surface is 100 percent. FIG. 2 b shows the multiple pulses delivered to the surface, wherein the spacing between pulses is 14.2 nanoseconds, and eight pulses are delivered in 100 nanoseconds. The magnitude of the pulses delivered is on the order of 12.5 percent. Thus rather than exposing the surface with a single large energy pulse, the surface is contacted by multiple smaller pulses.
A scheme to create multiple pulses from a single pulse poses problems with producing a uniform energy for the multiple pulses. This is especially true when a large number of pulses or long delays are required. In addition,maintaining uniform pulse amplitudes is further complicated in the UV-DUV portion of the spectrum. Optical losses tend to be very high because of increased absorption, less efficient AR and HR coatings, and increased scattering. However, even efficient optical systems can still suffer significant differences in pulse energies. In this scheme, compensators are used to add additional losses, similar to those produced by the beamsplitters, mirrors, optical delay lines, and so forth, in order to make the pulse energy uniform.
Many different schemes can be used for compensation. A common technique is to use attenuation in the form of reflective or absorbing filters. The appropriate filters can be used to compensate for the losses and make the pulse energies uniform. Continuously variable filters are available that allow exact matching. In addition, other techniques can be used, such as employing a polarization based attenuator when using polarized light.
The optical delay line is an important component of the present system. Imaging relays or stable optical cavities are preferred because they maintain the beam profile and stability over long optical delay paths. Many of these schemes are commonly known in the industry. Reflective cavities such as White cells, Herriott cells, or other reflective multipass cells are typical examples. One major problem with these type of multipass cells is they can be very inefficient. If long optical delays are necessary, many cavity round trips will be required with many mirror reflections. In the DUV-VUV spectral range, where mirror coatings may not be highly reflective, the efficiency of an all reflective optical delay line may be unacceptable. For this reason it is desirable to employ optical delay schemes that minimize losses.
In the DUV-VUV spectral region, antireflection coatings are typically more efficient than HR coatings. In addition, interfaces at Brewster's angle and TIR surfaces can have extremely low loss. The present design allows the use of novel optical delay schemes that can utilize Brewsters angle surfaces, TIR surfaces and transmissive surfaces that can be AR coated to greatly enhance the efficiency of the optical delay scheme. One such novel optical delay scheme utilizing these types of surfaces is illustrated in FIG. 3 . The system of FIG. 3 utilizes two prisms, left prism 301 right prism 302 , having total internal reflections and an AR coated surface as an optical delay mechanism. This arrangement has the additional advantage that the optical delay can be tuned simply by rotating the prisms about their common axis. From FIG. 3, the light beam is introduced into the arrangement and is deflected by a mirror 306 to left prism 301 , which directs light outward toward right prism 302 . Right prism 302 has two TIR (total internal reflection) surfaces 303 and an AR (anti-reflective) surface 304 for directing the beam back toward left prism 301 . After a single pass through the arrangement, light energy exits the arrangement, shown as the output beam in FIG. 3, using mirror 305 to direct the light energy outward. Additional methods can be used to direct the input and output beams. Examples of these methods include a single mirror using the front surface for the input and the rear surface for the output, or a prism using TIR and AR surfaces in much the same manner as prism 301 and 302 . In addition, the input and output beams can be located in a variety of positions within the cavity to suit the particular application. This produces the necessary delay for the system in an efficient manner. As may be appreciated, the desired time of the delay directly affects the spacing between the various components.
Further delays may be obtained by creating multiple trips between the reflecting surfaces prior to passing the light energy out of the arrangement. The increase in delay by rotation of the left prism 301 and right prism 302 are shown in FIG. 4 . The arrangement shown in FIG. 4 has the limitation that the beam is not re-imaged as it passes back and forth between the prisms. An image relay can be added to the arrangement of FIG. 4 by placing a lens or lenses between the prisms. Addition of a lens or lenses provides for re-imaging such that an image may be retrieved and processed at varying points in the design, thus providing increased control over the quality of the image received. An imaging relay can be inserted in the optical delay arrangement as shown in FIG. 5 a . This optical delay improves the stability and maintain the beam size for long optical delays. An image relay example using two lenses in an afocal telescope arrangement is shown in FIG. 5 b . Alternately, one or more prism surface can be curved to act as a lens, in the case of an AR surface, or a curved mirror, in the case of a TIR surface, for purposes of re-imaging the light.
Novel optical delay schemes utilizing TIR and Brewster's angle surfaces are also possible. One such optical delay geometry is shown in FIG. 6 . From FIG. 6, input beam 601 is directed into the arrangement and redirected using a mirror 602 toward first prism 603 . First prism 603 directs the received beam toward second prism 604 , which directs the beam toward third prism 605 . Each prism has a TIR surface and two Brewster angle surfaces to efficiently deflect and transmit the light energy. Once light energy is reflected by third prism 605 , it is output as output beam 607 from the arrangement using a mirror 606 . A lens or lenses can also be added to this geometry to re-image the light, either in the path of the light or at the entrance or exit of one of the prisms. Multiple round trips can be achieved by providing a small angle of the beam out of the plane of the drawing in FIG. 6 . This will cause the beam to walk down the surfaces of the prisms with each round trip.
The system further includes the ability to reduce speckle effects in transmitted and received light. It can be shown that when a laser beam enters a diffuser at a different angle, the speckle pattern of the light energy leaving the diffuser also changes. This change in speckle pattern for different angles enables generation of multiple speckle patterns by multiple beams at multiple angles when light energy passes through a diffuser. These speckle patterns can be integrated together to reduce the speckle contrast. However, in order for integration to function properly, each speckle pattern must arrive at the detector at slightly different times. Varying arrival times of speckle patterns can be achieved by using the same optical apparatus previously described to reduce the peak power of a laser pulse. The optical apparatus, such as that illustrated in FIG. 1, generates multiple pulses separated in time from a single input pulse.
The difference between using the system illustrated in FIG. 1 for reducing peak power and using the system to reduce speckle contrast is the alignment of the optical apparatus. Typically, when multiple pulses are generated to reduce the peak power of a single pulse, all the optical paths are co-aligned to have the same optical axis and the same beam position at the exit of the optical apparatus. However, for reducing the speckle contrast, it is desirable to have different angles between the different optical paths. Different angles are achieved by slightly changing the angles of the mirrors and beamsplitters in the optical apparatus. This angular change produces different angles between each output pulse as the pulse exits the optical apparatus and enters the diffuser as shown in FIG. 7 . The result of using two and four pulses to reduce the contrast of a speckle pattern is shown in FIG. 8 . From FIG. 8, a typical DUV laser arrangement without the implementation of FIG. 1 having varying angles between optical paths produces a speckle contrast of 80 percent. Use of the implementation of FIG. 1 may entail, for example in a 2 DUV beam arrangement, light energy being directed through the beamsplitters and loss compensators for one channel, i.e. the 0 ns loss leg of FIG. 1, as well as the 10 ns path. Such an implementation requires redirecting at least one path of light energy, such as the energy emitting from the 10 ns delay path, so as to contact the surface at an angle different from the 0 ns energy path in a manner as demonstrated in FIG. 7, i.e. at an offset angle from the 0 ns path. Using this type of implementation, speckle contrast may be reduced to on the order of 56 percent. Use of four separate and summed DUV beams, such as all four paths illustrated in FIG. 1, reduces the speckle contrast to on the order of 40 percent.
One problem with this scheme is that diffusers are not efficient. In the arrangement illustrated in FIG. 1, a phase plate may be inserted in the system instead of a diffuser to increase efficiencies. Phase plates with multiple levels or continuous profiles can provide efficiencies approaching 100%.
The second method for reducing speckle contrast using a single pulse employs a grating to produce an optical delay from one side of the pulse to the other. The use of a grating to delay a portion of the pulse is illustrated in FIG. 9 . Grating 901 causes one side of the laser wavefront to be delayed in time. This delay caused by grating 901 changes across the beam making the wavefront tilt in time. In FIG. 9, the wave emanates from the light generating device (not shown) at the bottom of the illustration. The pulse has a diameter D and in the arrangement shown the left portion of the beam strikes the grating 901 and is redirected by the grating 901 before the right half of the pulse strikes the grating. The distance covered in a fixed period of time is the same for the right and left side of the pulse, and thus by the time the right side of the pulse reaches location 902 , the left side of the pulse has reached location 903 . From the illustration, the right side of the pulse covers an additional distance L before striking grating 901 . The illustration shows an approximate 45 degree angle between the pulse and grating 901 , but in practice other angles could be employed while still within the scope of the invention. In the illustrated 45 degree angle case, the right side of the pulse covers a distance that is ultimately 2L shorter than the distance covered by the left side of the pulse. This differential in time or in distance covered produces a differential akin to the delay produced by the implementation of FIG. 1 . The resultant tilted wavefront can be used in combination with a diffuser or phase plate to reduce the speckle contrast.
From FIG. 9, the initial laser pulse will have a well defined coherence length. After the pulse passes through grating 901 one side of the pulse is delayed and the coherence length remains the same. The right side of the pulse is delayed with respect to the left side by:
Delay=2L=2D tan θ i
where D is the diameter of the input beam and θ i is the diffraction angle. This mechanization effectively breaks up the pulse into many independent sections that do not interfere with each other. These independent sections combine in intensity to reduce the speckle contrast. The number of independent sections is equal to: Sections = 2 L l c
where 2L is the maximum delay and l c is the coherence length. The result of the use of a grating such as that presented in FIG. 9 to reduce the contrast of a speckle pattern in shown in FIG. 10 . From FIG. 10, speckle contrast may be reduced from 80 percent for a single pulse to 29 percent using a grating as shown in FIG. 9 .
Speckle reduction techniques using the implementation of FIG. 1 and that of FIG. 8 may be used in combination to further reduce speckle contrast. In addition, the use of optical delays and gratings or other redirectional or delaying elements can be used in combination with a light pipe or lens array to produce an ideal uniform illumination source with low peak power and low speckle contrast. FIG. 11 illustrates the operation and elements in a system for reducing speckle contrast. Step 1101 involves generating the initial laser pulse. Step 1102 provides for tilting the pulse using a grating such as the grating 901 presented in FIG. 9 . Step 1103 comprises splitting the pulse received from the grating and delaying the pulse using multiple exit angles. Step 1104 indicates passage of the varying angle and delayed pulses through ground glass or phase plates and subsequently passing the received light energy to a light pipe or lens array in step 1105 . Other combinations of the pulse delay or dividing and combining techniques disclosed herein are possible while still within the course and scope of the invention.
The system and method described for creating multiple pulses from a single pulse effectively increases the repetition rate of a repetitively pulsed source. For example, if a 2 kHz excimer laser is used in combination with the system designed to create four pulses as described in FIG. 1, the repetition rate is increased to 8 kHz. In addition, the system and method described for reducing the speckle contrast from a single pulse using a grating to delay one side of a pulse with respect to the other side effectively increases the pulse length in time. It is therefore conceivable that by using both of these techniques in combination, a continuous or nearly continuous source can be produced from a high repetition rate source. To illustrate this, assume a laser operating at 80 MHz with a 100 ps pulse width is used in combination with a system, similar to that described in FIG. 1, designed to create 32 pulses with the appropriate delays, the repetition rate is effectively increased to 2.6 GHz. The pulse separation of the 2.6 GHz source is around 400 ps. Now if the 100 ps pulse can be stretched to 400 ps, the source can be considered continuous. Using a grating at a symmetric 45 degree angle, the 100 ps pulse can be stretched to 400 ps using a beam 2.4 inches in diameter. One potential problem with this approach is the spectral dispersion created by the grating. This can be eliminated by adding a second grating. This second grating eliminates the spectral dispersion while maintaining the optical delay from one side of the pulse to the other.
While the invention has been described in connection with specific embodiments thereof, it will be understood that the invention is capable of further modifications. This application is intended to cover any variations, uses or adaptations of the invention following, in general, the principles of the invention, and including such departures from the present disclosure as come within known and customary practice within the art to which the invention pertains.
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A system and method for reducing peak power of a laser pulse and reducing speckle contrast of a single pulse comprises a plurality of beamsplitters, mirrors and delay elements oriented to split and delay a pulse or pulses transmitted from a light emitting device. The design provides the ability to readily divide the pulse into multiple pulses by delaying the components relative to one another. Reduction of speckle contrast entails using the same or similar components to the power reduction design, reoriented to orient received energy such that the angles between the optical paths are altered such that the split or divided light energy components strike the target at different angles or different positions. An alternate embodiment for reducing speckle contrast is disclosed wherein a single pulse is passed in an angular orientation through a grating to create a delayed portion of the pulse relative to the leading edge of the pulse.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a multi-band antenna and a notebook computer with a built-in multi-band antenna and, more particularly, to a notebook computer in which a multi-band antenna is installed at the inner side of a corner portion of a display device, not being damaged by an external impact or not causing an inconvenience in use, and several transmitting and receiving parts are formed at the antenna to correspond to multi-band radio frequency transmission and reception.
[0003] 2. Description of the Background Art
[0004] A mobile electronic equipment is operated by power supplied from a small portable battery, includes a portable computer, a laptop computer, a palmtop computer, a notebook computer, etc. Research has been ongoing to make the mobile electronic equipment more compact and lighter in weight and to have a multifunctional capacity, and also for making it possible to communicate by radio with an external instrument. Especially, there have been introduced devices which can communicate with an external instrument wirelessly without using cable to access a network with a LAN card or a modem card inserted in a main body.
[0005] In order to adopt the radio communication to the mobile electronic equipment, it is requisite to adopt a high efficiency antenna. But, notably, there are inconvenient aspects and restrictions in designing such an antenna and in its adaptation to the mobile electronic equipment due to the special requirement that it be mounted for use in a compact mobile electronic equipment.
[0006] For one example of a known antenna for the notebook computer, Korean Patent Laid Open No. 1998-41789 discloses an antenna bendably installed at one side of an upper surface of a main body of a notebook computer. The antenna in Korean Patent Laid Open No. 1998-41789 is bent and received in a recess portion formed in the vicinity of the antenna when the computer is not in use, while, when the computer is in use, the part of the display device of the computer is stood and the antenna bent at the recess portion is stood vertically for use. This type of antenna has a high risk that it could be easily damaged as a user inadvertently covers the display device after the antenna is stood vertically for use.
[0007] For another example, Korean Patent Laid Open No. 1997-28939 and Korean Patent Laid Open No. 1997-62858 disclose a whip antenna which is installed inside of one side of a display device of a notebook computer. In order to maximize efficiency in its use, the antenna is drawn out to be extended from the display device and drawn back for a firmness and convenience in non-use. This antenna also has such a problem that it can be damaged by being caught by human or an object since it is used in a state of being drawn out.
[0008] In consideration of those problems, recently, built-in antennas which are installed inside an electronic equipment are being developed. These built-in antennas can show an advanced technique with its resolving of the damage or the inconvenience in use caused by the externally protruded antennas. But operated only in the general frequency band of 2.4 GHz, it does not work in the frequency band of 5.2 GHz, a fresh frequency band.
[0009] That is, since the built-in antennas under the development is designed to be operable for only one frequency band, a radio communication of an electronic equipment with the built-in antenna is not possible in an area where the designed frequency band is not provided.
SUMMARY OF THE INVENTION
[0010] Therefore, an object of the present invention is to provide a multi-band antenna and notebook computer with a built-in multi-band antenna.
[0011] Another object of the present invention is to provide a notebook computer with a built-in multi-band antenna that is capable of preventing an antenna from damaging by being caught by a human or an object by installing the antenna inside a display device so that the antenna is stood when the display device of a notebook computer is stood.
[0012] Still another object of the present invention is to provide a multi-band antenna suitable to transmit and receive an electromagnetic wave in at least two or more frequency bands.
[0013] Yet another object of the present invention is to provide a multi-band antenna suitable not to increase a size of an overall product by providing the same or the smaller antenna in size such as thickness or height by comparing the size of the antenna with the thickness of liquid crystal installed inside the display device or parts of a display device such as a bracket for fixing liquid crystal to the display device.
[0014] Another object of the present invention is to provide a multi-band antenna suitable to improvement of an efficiency of a radio frequency communication by obtaining a sufficient grounding area.
[0015] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a multi-band antenna of a notebook computer in which a display device is coupled to cover a main body and has a liquid crystal frame fixing liquid crystal and a bracket fixed at an outer side of the liquid crystal frame, which includes: a grounding unit installed at both inner sides of the display device and vertically inserted between the liquid crystal frame and the bracket; a grounding connection unit extended outwardly from a lower end portion of the grounding unit and disposed in a horizontal direction at a lower side of the bracket; an antenna line fixing unit formed vertically at an outer end portion of the grounding connection unit; and at least two or more transmitting and receiving units formed upwardly by being extended from the antenna line fixing unit and transmitting and receiving an electromagnetic wave.
[0016] To achieve the above objects, there is also provided a notebook computer with a built-in multi-band antenna which includes: a down-case; a PCB installed at the down-case and connected to a radio communication device; a main body coupled to the down-case, the main body including an up-case with a keyboard positioned at an upper surface thereof; a display device rotatably installed to the main body; a lower case constituting the display device and having a bottom and a side wall; a liquid crystal mounted at the lower case and having a liquid crystal frame installed at an outer circumference; and a multi-band antenna having a grounding unit and at least two or more transmitting and receiving units with different lengths, and being installed between the liquid crystal frame and the side wall of the lower case as the grounding unit is fixed to the liquid crystal frame in contacting state.
[0017] With the multi-band antenna and the notebook computer with a built-in multi-band antenna of the present invention, the antenna is installed at both inner sides of the display device so that when a user stands the display device to use the notebook computer the antenna is stood together with the display device, comparatively high, and thus, radio frequency communication is easy and the antenna is prevented from being damaged by being caught by a human or an object.
[0018] With the notebook computer with a built-in antenna in the present invention, since the grounding unit is inserted between the liquid crystal frame and the bracket to extend the grounding over a comparatively wide area, so as to make a stable radio communication. And with the two or more transmitting and receiving units with different lengths, a multi-band radio frequency transmission and reception can be made. In addition, an electronic equipment with the multi-band antenna can be freely used without restriction to frequency band in areas with different radio frequency bands.
[0019] With the notebook computer with a built-in antenna of the present invention, since the antenna transmitting unit and the liquid crystal frame are isolated as wide as the grounding connection unit, so that radio wave can be transmitted and received without being interrupted by the liquid crystal panel or the liquid crystal frame, ensuring a favorable transmission and reception.
[0020] The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0022] In the drawings:
[0023] [0023]FIG. 1 is a perspective view showing a notebook computer with a multi-band antenna in accordance with the present invention;
[0024] [0024]FIG. 2 is a perspective view showing a partially cut-out portion where the multi-band antenna is installed;
[0025] [0025]FIG. 3 is an exploded perspective view of FIG. 2;
[0026] [0026]FIG. 4 is a perspective view showing the first embodiment of a transmitting unit of the multi-band antenna in accordance with the present invention;
[0027] [0027]FIG. 5 is a front view of FIG. 4;
[0028] [0028]FIG. 6 is a rear view of FIG. 4;
[0029] [0029]FIG. 7 is an enlarged view showing how an antenna line is connected to the multi-band antenna in accordance with the present invention;
[0030] [0030]FIG. 8 is a sectional view showing how the antenna line is installed in a bracket in accordance with the present invention;
[0031] [0031]FIG. 9 is a front view showing the second embodiment of a transmitting unit of the multi-band antenna in accordance with the present invention;
[0032] [0032]FIG. 10 is a front view showing the third embodiment of a transmitting unit of the multi-band antenna in accordance with the present invention; and
[0033] [0033]FIG. 11 is a front view showing the fourth embodiment of a transmitting unit of the multi-band antenna in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0035] [0035]FIG. 1 is a perspective view showing a notebook computer with a multi-band antenna in accordance with the present invention.
[0036] A mobile electronic equipment 1 with an antenna 6 includes a notebook computer, a laptop computer, a palmtop computer, or the like. A main body 3 is formed as an up-case 3 a and a down-case 3 b are coupled. A keyboard 4 having a plurality of keys for inputting data is installed at an upper surface of the up-case 3 a. A PCB is installed inside the down-case 3 b, which various modules such as an optical disk drive, a hard disk drive or the like are connected to and mounted on. A LAN card (not shown) enabling a radio frequency communication is provided at one side of the PCB.
[0037] At a rear end portion of the upper surface of the main body 3 , there is provided a display device 2 is rotatably installed with a hinge mechanism 5 between a user's keyboard visible position and a user's keyboard invisible (closed) position. The display device 2 includes a liquid crystal 7 , and two multi-band antennas 6 inserted respectively at left and right sides of liquid crystal 7 . In the display device 2 , an upper case 11 is coupled at an outer circumference of a lower case 12 , and the middle portion of the upper case 11 is opened so that the user can view the liquid crystal 7 .
[0038] [0038]FIGS. 2 and 3 show the inside of the display device 2 , For the convenience's sake, only the right portion of the display device 2 is shown, which is symmetrically same with the left portion.
[0039] The multi-band antenna 6 may be installed only at the left side or only at the right side according to a user's intention. The lower case 12 of the display device 2 includes a bottom 12 a and a side wall 12 b integrally extended by being bent from the end of the bottom 12 a. The liquid crystal 7 is positioned inside the lower case 12 , on which various information is displayed.
[0040] The liquid crystal frame 8 made of a metal is integrally connected with the liquid crystal 7 along the outer circumference of the liquid crystal 7 , and a screw fixing hole 8 b is formed at upper and lower portion at the side 8 a of the liquid crystal frame 8 . A bracket 9 fixed to the lower hinge mechanism 5 at its lower portion is positioned at both sides 8 a of the liquid crystal 7 to which the liquid crystal frame 8 is fixed, and holes 9 a and 9 b are formed at the bracket 9 , corresponding to the screw fixing hole 8 b.
[0041] The liquid crystal 7 , the antenna 6 and the bracket 9 are connected and fixed by a screw.
[0042] That is, in a state that the screw fixing hole 8 b of the upper portion of left and right sides of the liquid crystal frame 8 , the hole 25 of the grounding unit 21 formed at the antenna 6 and the hole 9 a of the bracket 9 are sequentially conformed, the screw 26 penetrates the hole 9 a of the bracket 9 and the hole 25 of the multi-band antenna 6 to fix the bracket 9 and the multi-band antenna 6 to the screw fixing hole 8 b of the liquid crystal frame 8 . Then, the bracket 9 and the grounding unit 21 of the multi-band antenna 6 are tightly attached and fixed to the upper side 8 a of the liquid crystal frame 8 .
[0043] Next, in a state that the screw fixing hole 8 b at the lower portion of the left and right sides of the liquid crystal frame 8 and the hole 9 b of the bracket 9 are conformed, the screw 26 penetrates the hole 9 a of the bracket 9 to fix the bracket 9 to the lower screw fixing hole 8 b of the liquid crystal frame 8 . Then, the lower portion of the side 8 a of the liquid crystal frame 8 and the bracket 9 are tightly attached and fixed to each other.
[0044] The bracket 9 is formed about as long as the side 8 a of the liquid crystal frame 8 , and connection portions 10 are formed to be respectively bent and extended from the upper end and from the about middle portion. The connection portions 10 have a screw fixing hole 10 a. The connection portions 10 are connected to the both walls 12 b of the lower case 12 and fixed to the side wall 12 b of the lower case 12 as a screw (not shown).
[0045] Thereafter, the upper case 11 is fixed to an upper portion of the liquid crystal 7 fixed to the lower case 12 . The upper case 11 is fixed such that its outer circumferential portion is connected to the side wall 12 b of the lower case 12 . Accordingly, the liquid crystal frame 8 , the multi-band antenna 6 and the bracket 9 are invisibly positioned inside the display device 2 .
[0046] [0046]FIGS. 4, 5 and 6 show details of the shape of the multi-band antenna in accordance with a first embodiment of the present invention.
[0047] As shown, the multi-band antenna 6 is manufactured by pressing a plate body made of phosphor bronze such that a grounding unit 21 , a grounding connection unit 22 , an antenna line fixing unit 23 and a transmitting and receiving unit 24 integrally make a ‘U’ shape. A hole 25 is formed at one end of the grounding unit 21 .
[0048] The grounding unit 21 , the connection unit 22 , the antenna line fixing unit 23 and the transmitting and receiving unit 24 are integrally formed with entirely made of a metallic conductor, and a removed portion 32 is formed as a portion of the grounding 21 is removed so that the antenna line 31 can be easily soldered to the inside of the transmitting and receiving unit 24 .
[0049] As shown in FIG. 5, the transmitting and receiving unit 24 includes a first transmitting and receiving part 24 - 1 connected to a vertical protrusion portion 28 formed vertically and integrally at one end of the antenna line fixing unit 23 and formed in parallel with a certain space at the antenna line fixing unit 23 , and a second transmitting and receiving part 24 - 2 formed by being extended from the connection protrusion portion 27 protrudingly formed at the first transmitting and receiving part 24 - 1 and formed in parallel in a longitudinal direction of the first transmitting and receiving part 24 - 1 .
[0050] The second transmitting and receiving part 24 - 2 is formed shorter than the first transmitting and receiving part 24 - 1 . The reason for the different lengths is that the first transmitting and receiving part 24 - 1 and the second transmitting and receiving part 24 - 2 are designed to have a length of λ/4 electrically in the frequency band of 2.4 GHz and in the frequency band of 5.2 GHz and thus operated in a double band.
[0051] The length between the grounding unit 21 and the transmitting and receiving unit 24 of the multi-band antenna is the same with or smaller than the protrusion length of the connection portion 10 of the bracket 9 . The height between the connection unit 22 and the transmitting and receiving unit 24 of the multi-band antenna 6 is the same with or smaller than the height of the liquid crystal frame 8 or the bracket 9 .
[0052] An inner copper wire of the antenna line 31 is connected with the transmitting and receiving unit 24 by soldering, being connected to make a power feed point 24 a, and an inner grounding line of the antenna line 31 is connected to the antenna line fixing unit 23 by soldering to make a grounding point 23 a.
[0053] As shown in FIGS. 6 and 7, the antenna line 31 connected to a LAN card installed inside the main body 3 is bonded at the antenna fixing unit 23 and the transmitting and receiving unit 24 of the multi-band antenna 6 . A portion of the grounding unit 21 has a removed portion 32 for soldering of the antenna line 31 .
[0054] [0054]FIG. 8 is a sectional view showing how the antenna line 31 is installed in the bracket 9 . A multi-band antenna line installing unit 41 is formed at about the middle portion of the bracket 9 , being protruded toward the side wall 12 b of the lower case 12 . As illustrated, the antenna line 31 connected from the multi-band antenna 6 of the bracket 9 toward the LAN card is placed at a certain height of the side of the bracket 9 by means of the multi-band antenna line installing unit 41 .
[0055] [0055]FIG. 9 is a front view of a multi-band antenna in accordance with the second embodiment of the present invention. The basic structure of the multi-band antenna in accordance with the second embodiment of the present invention is similar to that of the first embodiment of FIG. 4.
[0056] In comparison with the first embodiment, a second transmitting and receiving part 24 - 2 is formed longer than a first transmitting and receiving part 24 - 1 . The first transmitting and receiving part 24 - 1 receives an electromagnetic wave in high frequency band, while the second transmitting and receiving part 24 - 2 receives an electromagnetic wave in low frequency band.
[0057] [0057]FIG. 10 is a front view showing a multi-band antenna in accordance with the third embodiment of the present invention. A basic structure of multi-band antenna in accordance with the third embodiment of the present invention is similar to that of the first embodiment of FIG. 4.
[0058] In comparison with the first embodiment, a second transmitting and receiving part 24 - 2 is extended from the connection protrusion portion 27 a protruded from the antenna line fixing unit 23 , being parallel to the first transmitting and receiving part 24 - 1 . The second transmitting and receiving part 24 - 2 is formed shorter than the first transmitting and receiving part 24 - 1 and handles the radio frequency band.
[0059] [0059]FIG. 11 is a front view of a multi-band antenna in accordance with the fourth embodiment of the present invention. A basic structure of the multi-band antenna in accordance with the fourth embodiment of the present invention is similar to that of the first embodiment of FIG. 4.
[0060] As a difference in comparison with the first embodiment, a second transmitting and receiving part 24 - 2 is connected to a vertical protrusion portion 28 , being formed with certain interval in parallel to a first transmitting and receiving part 24 - 1 and an antenna line fixing unit 23 . The second transmitting and receiving part 24 - 2 is shorter than the first transmitting and receiving part 24 - 1 .
[0061] In the present invention, the grounding unit 21 of the multi-band antenna 6 is positioned between the liquid crystal frame 8 and the bracket 9 . But in a different way, the liquid crystal frame 8 , the bracket 9 and the grounding unit 21 can be sequentially disposed and then the bracket 9 and the ground unit 21 can be fixed to the liquid crystal frame 8 with a screw.
[0062] In addition, in the present invention, the multi-band antenna 6 and the bracket 9 are simultaneously fixed at the liquid crystal frame 8 by using one screw 26 . But the multi-band antenna 6 can be fixed at the bracket 9 with a screw or by soldering and then the bracket 9 can be fixed at the liquid crystal frame 21 .
[0063] In the above-described embodiments, the transmitting and receiving unit 24 of the multi-band antenna 6 is operated at the double band frequency formed with the first transmitting and receiving part 24 - 1 and the second transmitting and receiving part 24 - 2 . But without being limited thereto, it is natural that several transmitting and receiving parts 24 can be formed with different lengths according to a frequency band to be transmitted and received, to correspond to a multi-band.
[0064] As so far described, the multi-band antenna and the notebook computer with a built-in multi-band antenna have the following advantages.
[0065] That is, for example, first, the antenna is installed at the inner side of the upper and lower cases of the display device and since the grounding unit is insertedly installed to contact widely between the liquid crystal frame and the bracket, the liquid crystal frame and the bracket can be used as a grounding unit. The transmitting and receiving unit for transmitting and receiving a radio wave is divided into two parts to transmit and receive a radio wave in a multi-band. And, since the antenna transmitting and receiving unit and the liquid crystal are separated as long as from the grounding connection unit, shielding of electromagnetic wave due to the liquid crystal and the liquid crystal frame can be prevented.
[0066] In addition, the antenna line fixed at the antenna line fixing unit is disposed in a loop shape and the multi-band antenna line disposed together is connected toward the LAN card so as to be positioned with a certain height at the side of the bracket, which is favored for a radio communication when a user uses the computer by standing up the display device. Thus, an efficiency of the radio frequency communication is improved. Besides, since the multi-band antenna is positioned between the liquid crystal and the lower case, the horizontal length of the display device is not increased. Since the multi-band antenna can be formed as high as or smaller than the liquid crystal frame or the bracket, the overall height of the multi-band antenna can be reduced, and thus, the thickness of the part of the display device inevitably protruded due to installation of the multi-band antenna can be reduced.
[0067] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.
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A multi-band antenna and a notebook computer with a built-in multi-band antenna are disclosed. Since the multi-band antenna is installed at the inner side of a upper and a lower case, it is much favored for a radio communication when a computer is in use by standing up a display device. The multi-band antenna includes at least two transmitting and receiving parts formed with different lengths to fit frequency bands, so that a remote communication of at least two or more bands can be made. The multi-band antenna is positioned between liquid crystal and a side wall of the lower case, and a grounding unit is installed to contact a liquid crystal frame. That is, since the grounding unit is grounded to the liquid crystal frame and the bracket, substantially, the liquid crystal frame and the bracket are wholly grounded to ensure a stable radio frequency communication.
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FIELD OF THE INVENTION
The present invention generally relates to tires and, more specifically, to pneumatic off-road vehicle tires.
BACKGROUND OF THE INVENTION
Pneumatic tires for off-road vehicles incorporate a tread designed to provide high traction in non-paved surfaces, such as soft earth or ground, frequently encountered by earthmoving equipment, agricultural vehicles, sport utility vehicles, military vehicles, lawn and garden vehicles, all-terrain vehicles (ATV's), and dirt bikes. Frequently, pneumatic tires for off-road applications have low operating pressures and minimal belt reinforcements. For example, ATV tires generally operate at a pressure of less than 5 pounds per square inch (psi) and frequently lack any belt reinforcing structure.
Pneumatic off-road tires are prone to sidewall punctures resulting in a loss of tire pressure or deflation. Sidewall punctures arise from penetrating or sharp objects such as rocks, thorns, sticks, stubble, or bushes, in the surrounding environment that contact and penetrate the sidewall causing the tire to lose tire pressure either quickly or gradually. The sidewall punctures may be manifested as perforations or slits affording an escape route for the pressurized fluid filling the tire. The occurrence of sidewall punctures is unpredictable and, typically, off-road vehicles carry a repair kit or a spare tire in anticipation of such an event. Repair kits are inconvenient to carry and, although simple perforations can be repaired using the repair kit, large perforations and slits are, at the least, more difficult to repair. In addition, repairs made using the repair kit may be time consuming and, in many conditions such as mud, snow, and uneven rocky terrain, may be challenging to perform. If a spare tire is unavailable or the repair kit is ineffective for repairing the sidewall puncture, the vehicle occupants, such as farmers, hunters, fishing enthusiasts and recreational ATV riders, must travel by foot from a remote location over potentially difficult terrain to obtain assistance.
Thickening the sidewall may reduce the likelihood that a sharp object can puncture the sidewall of an off-road tire. Conventional approaches for thickening the sidewall include either adding material in the form of additional plies or an increased rubber thickness. In particular, conventional run-flat or tires have been developed that incorporate relatively thick sidewalls having an increased rigidity capable of carrying the full vehicle load in the absence of inflation pressure. Due to the enhanced sidewall thickness, run-flat tires also provide tremendous puncture resistance. However, such conventional solutions do significantly increase the cost of manufacturing the off-road tire, which is ultimately transferred to the consumer in the retail price.
Pneumatic off-road tires may include a single, circumferential scuff rib that projects outwardly from the sidewall. Typically, the scuff rib provides resistance to sidewall scuffing arising from the abrasive effects of recurring contact between the tire sidewall and immovable objects, such as a curb or the like. The scuff rib typically extends from a planar outer surface toward the sidewall at an angle greater than about 45° measured relative to a base surface of the sidewall. However, the scuff rib can only assist in preventing sidewall punctures from sharp objects over the portion of the base surface actually covered by the scuff rib. The scuff rib cannot provide puncture resistance to sharp objects over the exposed base surface of the sidewall, which represents the greater part of the sidewall surface area.
For these and other reasons, it would be desirable to provide a pneumatic off-road tire having an improved sidewall puncture resistance while thickness of protective material incorporated into the sidewall.
SUMMARY OF THE INVENTION
The invention is directed to pneumatic off-road tires that significantly decrease the likelihood of a sidewall puncture. A pneumatic off-road tire constructed according to the principles of the invention includes a carcass having a circumferential sidewall, a tread radially outward of the carcass, and a plurality of axially-projecting deflection pads each of which extends circumferentially about the sidewall. In addition, each of the deflection pads includes a first tapered surface inclined in a first axial direction oriented generally toward the sidewall and a second tapered surface inclined in a second axial direction oriented generally away from the sidewall.
In an alternative embodiment of the invention, a pneumatic off-road tire includes a carcass having a circumferential sidewall, a tread radially outward of the carcass, and an axially-projecting deflection pad extending circumferentially about the sidewall in a spiral pattern. The deflection pad includes a first tapered surface inclined in a first axial direction oriented generally toward the sidewall and a second tapered surface inclined in a second axial direction oriented generally away from the sidewall.
A pneumatic off-road tire constructed with one or more deflecting pads according to the principles of the invention minimizes tire damage due to sidewall punctures without significantly increasing tire weight or degrading tire performance.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
FIG. 1 is a side view of an off-road tire according to the principles of the invention.
FIG. 2 is a cross-sectional view taken generally along line 2 — 2 in FIG. 1 .
FIG. 3 is an enlarged view of a portion of FIG. 2 .
FIG. 3A is a cross-sectional view similar to FIG. 3 depicting an alternative embodiment of a deflection pad according to the principles of the invention.
FIG. 3B is a cross-sectional view similar to FIGS. 3 and 4 depicting an alternative embodiment of a deflection pad according to the principles of the invention.
FIG. 4 is a perspective view of a portion of the off-road tire of FIG. 1 .
FIG. 5 is a side view of an off-road tire according to an alternative embodiment of the invention.
DEFINITIONS
“Axial” and “axially” means the lines or directions that are parallel to the axis of rotation of the tire.
“Axially Inward” means in an axial direction toward the equatorial plane.
“Axially Outward” means in an axial direction away from the equatorial plane.
“Bead” means the circumferentially substantially inextensible metal wire assembly that forms the core of the bead area, and is associated with holding the tire to the rim.
“Carcass” means a laminate of tire ply material and other tire components, excluding the tread.
“Circumferential” means circular lines or directions extending along the surface of the sidewall perpendicular to the axial direction.
“Inner” means toward the inside of the tire.
“Lugs” refer to discontinuous radial rows of tread rubber in direct contact with the road surface.
“Off-road tire” means a pneumatic tire having a primary use or working surface condition that is not on a paved road. Such tires include earthmover tires, agricultural tires, lawn and garden tires, and all-terrain vehicle tires, including, but not limited to off-road dirt bike tires and ATV tires.
“Outer” means toward the tire's exterior.
“Pneumatic tire” means a laminated mechanical device of generally toroidal shape usually an open-torus having beads and a tread and made of rubber, chemicals, fabric and steel or other materials. When mounted on the wheel of a motor vehicle, the tire through its tread provides traction and contains the fluid that sustains the vehicle load.
“Radial” and “radially” mean directions radially toward or away from the axis of rotation of the tire.
“Shoulder” means the upper portion of sidewall just below the tread edge.
“Sidewall” means that portion of a tire between the tread and the bead area.
“Tread” means a molded rubber component which, when bonded to a tire casing, includes that portion of the tire that comes into contact with the road when the tire is normally inflated and under normal load.
DETAILED DESCRIPTION
With reference to FIGS. 1 , 2 and 4 , a pneumatic off-road tire 10 according to the invention includes a carcass 12 , a ground-engaging tread 14 , an outer sidewall 16 , and an inner sidewall 18 . Sidewall 16 faces axially outward when tire 10 is mounted to a rim and attached to a wheeled apparatus, such as a motor vehicle. Sidewall 16 is unprotected or unshielded by surrounding structure of the wheeled apparatus and, as a result, is subject to contact by penetrating or sharp objects present in the environment of the wheel apparatus. Sidewall 16 extends from a radially-inward bead 20 to a radially-outward shoulder 22 defined where the sidewall 16 merges with the tread 14 . Tread 14 consists of a pattern of lugs 21 disposed radially outward of the carcass 12 . The lugs 21 may be arranged in any pattern and may have any construction suitable to provide the necessary traction and lateral stability for operation of an off-road vehicle in an off-road environment and to expel earth accumulated in the channels between adjacent lugs 21 laterally of the tire 10 . Carcass 12 and tread 14 have a conventional construction as apparent to persons of ordinary skill in the art, such as the tire construction for an all-terrain vehicle disclosed in U.S. Pat. No. 6,401,774.
Positioned on the sidewall 16 radially between bead 20 and shoulder 22 is a plurality of, for example, eight deflection pads 24 . Disposed among the deflection pads 24 is a single curb scuff rib 26 that projects axially outward from the sidewall 16 and that extends about a circumference of the sidewall 16 . The scuff rib 26 has a generally trapezoidal cross-sectional profile viewed in a direction tangent to the circumference of the sidewall 16 at any position about the circumference of tire 10 . The scuff rib 26 typically extends toward the sidewall 16 at an angle greater than about 45° from a radially-outermost planar surface 26 a toward a base surface 30 (FIG. 3 ). It is contemplated that the scuff rib 26 may be omitted from tire 10 without departing from the spirit and scope of the invention.
With continued reference to FIGS. 1 , 2 and 4 , the deflection pads 24 are arranged in a substantially concentric pattern centered on a centerline 28 of the tire 10 . Typically, the centerline 28 coincides with an axis of rotation of the tire 10 when mounted to a motor vehicle. Each of the deflection pads 24 is continuous and uninterrupted in a circumferential direction about the sidewall 16 . Discontinuous structures raised axially from the sidewall 16 would result in the transfer of intermittent impulses or jolts to the motor vehicle from objects contacting the sidewall 16 of tire 10 . The number of deflection pads 24 is determined such that sufficient puncture protection from sharp objects is provided over the entire outwardly-facing area of the sidewall 16 as tire 10 rotates. Typically, the number of deflection pads 24 ranges between four and twelve, although the invention is not so limited.
With reference to FIG. 3 , each of the deflection pads 24 projects axially outwardly from sidewall 16 an axial distance from the base surface 30 of the sidewall 16 . Base surface 30 extends radially and circumferentially over portions of the sidewall 16 exposed between adjacent pairs of deflection pads 24 and beneath the deflection pads 24 . Typically, the radial dimension of each of the exposed portions, which are not covered by the deflection pads 24 , is less than or equal to about 0.25 inches (6.4 mm). It is appreciated that the deflection pads 24 may be arranged on sidewall 16 such that the exposed portions are absent. The base surface 30 has a slight convex curvature with a radius of curvature of SW-R between the bead 20 and shoulder 22 , which causes each deflection pad 24 to possess a slight curvature.
Each deflection pad 24 includes an opposed pair of radial surfaces or sides 32 , 34 that are interconnected by an apex or planar surface 36 . The deflection pads 24 operate for deflecting away objects impinging against the sidewall 16 , when in service on a moving motor vehicle, otherwise capable of puncturing the sidewall 16 . Specifically, the deflection pads 24 deflect objects radially, which reduces the axial component of a penetration force applied by the contacting object to sidewall 16 . The deflection pads 24 also increase the effective thickness of covered portions of base surface 30 for enhancing puncture resistance.
With continued reference to FIG. 3 , the opposed radial sides 32 , 34 of each deflection pad 24 have a dimension or thickness measured axially relative to base surface 30 that varies according to the radial position between the bead 20 and shoulder 22 . Radial side 32 is sloped radially inwardly at an inclination angle, α, measured relative to base surface 30 so that the thickness increases with increasing radius toward shoulder 22 . Radial side 34 is sloped radially outwardly at an inclination angle, β, measured relative to base surface 30 , so that the thickness decreases with increasing radius toward shoulder 22 . The inclination angle of each of the radial sides 32 , 34 is typically in a range of less than, or equal to, about 30° and, more typically, between about 10° and about 20°. The slope of each of the radial sides 32 , 34 is approximately linear so that, for example, the axial dimension of each is approximately halved at the respective midpoints between the base and planar surfaces 30 , 36 . It is contemplated by the invention that the individual inclination angles of the radial sides 32 , 34 may differ so that radial sides 32 , 34 are asymmetrical relative to the mid-point of planar surface 36 .
Each of the deflection pads 24 also has an axial height, H, measured relative to the base surface 30 and, typically, measured between the base and planar surfaces 30 , 36 . It is contemplated by the invention that the planar surface 36 may be omitted such that the radial sides 32 , 34 converge at an apex formed by a circumferentially-extending ridge (not shown). Typically, the axial height of each deflection pad 24 is less than about 0.2 inches (5.1 mm) and may be as small as 0.1 inch (2.5 mm) for small-diameter tires, such as ATV tires.
Each of the radial sides 32 , 34 has a dimension, B, proportional to the axial height and the corresponding inclination angle, which is measured in a direction tangent to the circumference of deflection pad 24 . In the illustrated embodiment, the radial dimension is the length of the hypotenuse of a right triangle defined by each of the radial sides 32 , 34 . It is appreciated by persons of ordinary skill in the art that the tire manufacturing process will introduce concave or convex irregularities in radial sides 32 , 34 that result in deviations from absolute planarity. Planar surface 36 typically has a radial dimension, A, of less than or equal to about 0.2 inches (5.1 mm) so as not to inhibit the ability of the deflection pads 24 to radially deflect objects encountered by the tire 10 .
With reference to FIG. 3A in which like reference numerals refer to like features in FIG. 3 and in an alternative embodiment, tire 10 is provided with deflection pads 40 each constructed according to the principles of the invention with cusped or concave radial surfaces or sides 42 , 44 joined by a planar surface 46 . Each of radial sides 42 , 44 deviates in geometrical shape from a planar surface, indicated diagrammatically by a dashed line 48 in FIG. 3 A. Specifically, the radial sides 42 , 44 each have a corresponding radius of curvature, R 1A and R 1B , capable of deflecting objects radially and away from contact with base surface 30 . Radial side 42 is sloped radially inwardly so that the thickness increases with increasing radius toward shoulder 22 . Radial side 44 is sloped radially outwardly so that the thickness decreases with increasing radius toward shoulder 22 . As used herein, the terms “sloped,” “tapered” and “inclined” may mean either planar or concave. The radius of curvature should provide a material thickness, measured axially relative to the base surface 30 and radially at the surface mid-point, B/2, which is at least 25 percent of the axial height, H, of the deflection pad 40 and less than 50% of the axial height. The length of the radius of curvature determines the degree of curvature of each of the radial sides 42 , 44 . It is contemplated by the invention that the radius of curvature of radial side 42 may differ from the radius of curvature of radial side 44 may differ.
The deflection pads 40 are spaced apart in a radial direction such that portions of base surface 30 are exposed. Planar surface 46 typically has a radial dimension, Λ, of less than or equal to about 0.2 inches (5.1 mm) so as not to inhibit the ability of the deflection pads 40 to radially deflect objects encountered by the tire 10 . Typically, each deflection pad 40 projects outwardly from the base surface 30 by an axial height of less than 0.2 inches (5.1 mm). Typically, the radial dimension of each of the exposed portions, which are not covered by the deflection pads 40 , is less than or equal to about 0.25 inches (6.4 mm).
With reference to FIG. 3B in which like reference numerals refer to like features in FIGS. 3 and 3A and in an alternative embodiment of the invention, tire 10 is provided with a plurality of between four and twelve deflection pads, of which two deflection pads 50 a and 50 b are shown. Deflection pad 50 a has a pair of cusped or concave radial surfaces or sides 52 a,b joined by a planar surface 56 . Similarly, deflection pad 50 b has a pair of cusped or concave radial sides or surfaces 54 a,b joined by a planar surface 58 . Radial side 52 b of deflection pad 50 a is smoothly continuous with radial side 54 a of the adjacent deflection pad 50 b . Specifically, radial sides 52 b and 54 a are curved about a shared or common radius of curvature, R 2 , which is selected in magnitude for deflecting objects radially and away from contact with base surface 30 . The radius of curvature should provide a material thickness, measured relative to the base surface 30 and radially at the mid-point of each of surfaces 52 b , 54 a , which is at least 25 percent of the axial height, H, of the deflection pads 50 a,b . Radial side 52 b is sloped with a decreasing thickness in a radial-outward direction toward the shoulder 22 and radial side 54 a is sloped with a decreasing thickness in a radially-inward direction toward bead 20 . The length of the radius of curvature determines the degree of curvature of the radial sides 52 b , 54 a . Adjacent pairs of radial sides of the remaining deflection pads on tire 10 may have a similar or identical construction to radial sides 52 b , 54 a.
The radial sides 52 b , 54 a merge or converge so that base surface 30 is not exposed. Planar surfaces 56 and 58 typically have a radial dimension, A, of less than or equal to about 0.2 inches (5.1 mm) so as not to inhibit the ability of the deflection pads 50 a,b to radially deflect objects encountered by the tire 10 . Typically, each of the deflection pads 50 a,b projects outwardly from the base surface 30 by an axial height of less than 0.2 inches (5.1 mm).
With reference to FIG. 5 in which like reference numerals refer to like features in FIGS. 1 , 2 and 4 and in an alternative embodiment of the invention, tire 10 may be provided with a single deflection pad 60 that traces a spiral path about the sidewall 18 . Deflection pad 60 progressively increases in radial dimension relative to centerline 28 between a terminal end 62 adjacent to the bead 20 and a terminal end 64 proximate to the shoulder 22 . The deflection pad 60 is continuous and uninterrupted in the circumferential direction and has a substantially uniform intra-pad spacing in the radial direction. The deflection pad 60 may have a cross-sectional profile, in a direction tangent to the circumference of the deflection pad 60 , similar or identical to any of the cross-sectional profiles shown herein in FIGS. 3 , 3 A and 3 B that is capable of deflecting objects encountered by the tire 10 in a radial direction.
While the present invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of applicant's general inventive concept.
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Pneumatic off-road tires having structure for improving sidewall puncture resistance to penetrating objects. The structure may include multiple deflection pads arranged concentrically about the sidewall or a single deflection pad extending in a spiral about the sidewall. Each deflection pad incorporates inclined surfaces arranged for deflecting penetrating objects in a radial direction so that the likelihood of a sidewall puncture is significantly reduced.
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This application is a divisional application of U.S. application Ser. No. 09/941,281 filed Aug. 28, 2001, now U.S. Pat. No. 6,669,993.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional application Serial No. 60/233,681 filed Sep. 19, 2000, entitled “Overfinish Application, Process, Apparatus and Product”.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods and devices for applying finish to yarns in motion at high speeds of about 3000 meters per minute (m/min) or greater, and to the products formed thereby.
2. Description of the Related Art
Liquid finishes are typically complex mixtures of water, oils, polymers, and surfactants applied to yarns to achieve desired processability characteristics including lubricity and reduction of static electricity, and to improve end use properties. For some applications, such as tire cord yarns, more than one finish, is applied. A first finish is applied to facilitate drawing operations during yarn manufacture. A second finish or overfinish is applied to aid in bonding the yarn to rubber during tire construction.
The function of a finish applicator device is to apply finish at an even rate to a travelling yarn so that the filaments of the yarn are evenly coated with the finish. Conventionally, yarn finishes are applied by advancing a running yarn threadline in contact with the surface of a “kiss roll” rotated in a liquid reservoir containing the desired finish, or by means of applicator tips or sprays.
As used herein, “active finish application” refers to a method by which finish is supplied to the yarn using force, such as pressure or injection. The finish may be applied by impingement of a jet under pressure or by full immersion under pressure. Active finish application is in contrast to the prior art methods which are herein termed passive wherein the finish is provided at about atmospheric pressure on a roll or applicator tip and the yarn picks up some finish as it passes through a film of finish. As used herein, pressure means the highest pressure at the finish-yarn interface along the yarn path through an applicator device.
Prior art finish applicators are described for example in U.S. Pat. No. 2,294,870 to Kline et al.; U.S. Pat. No. 3,244,142 to Walker; U.S. Pat. No. 3,754,530 to Pierce; U.S. Pat. No. 3,988,086 to Marshall et al.; U.S. Pat. No. 4,325,322 to Louch et al.; U.S. Pat. No. 4,329,750 and U.S. Pat. No. 4,397,164 to Binnersley; U.S. Pat. No. 4,526,808 to Strohmaier; U.S. Pat. Nos. 4,544,579 and 4,565,154 to Mullins et al; U.S. Pat. No. 4,851,172 to Rowan et al.; U.S. Pat. No. 4,891,960 to Shah; U.S. Pat. No. 4,984,440 to McCall; U.S. Pat. No. 5,181,400 to Hodan; U.S. Pat. Nos. 5,679,158 and 6,067,928 to Holzer, Jr. et al.; United States Statutory Invention Registration H153 to Sadler et al.; and DD 122,108 to Henssler. However, difficulties with these devices arise when yarn speeds increase to about 3000 m/min or even less. In none of these devices was there an attempt to disengage or block an air boundary layer in motion with the yarn.
A running thread line entrains a boundary layer of the fluid, air or liquid, through which it passes. The boundary layer of fluid moves at the speed of the thread line at its surface. The mechanics of boundary layers have been analyzed most notably by H. Schlichting, Boundary Layer Theory , McGraw Hill, New York, 1960 and in the context of moving continuous surfaces by B. C. Sakiadis, A.I.Ch.E. Journal, 7(1,2 & 3), 26-28, 221-225, 467-472 (1961). A thread line moving at high speed in air, when brought into contact with a liquid, creates a violent turbulence at the intersection where the air boundary layer in motion with the thread line impinges on the liquid. In the context of application of liquid finishes to high speed running yarns by conventional kiss rolls and applicators, the air boundary layer limits the concentration of finish that is applied to the yarn, causes large variation in finish pickup and creates excessive spraying of finish to surrounding areas.
Prior art attempts to resolve these problems have been described for example in U.S. Pat. Nos. 4,253,416, 4,255,472, 4,255,473 and 4,268,550 to Williiams Jr.; and U.S. Pat. Nos. 4,675,142 and 4,855,099 to D'Andolfo et al.
EP 0195 156 A2 describes spinning and applying finish to yarns at speeds of about 4000 m/min by means of spray nozzles.
The disclosures of Williams Jr. attempt to ameliorate the effect of the air boundary layer on the finish supply without actually interrupting the air boundary layer. These disclosures qualitatively describe more uniform finish application by the patented devices but no quantitative information is provided regarding the concentration of finish on the yarn or the finish uniformity.
U.S. Pat. Nos. 4,675,142 and 4,855,099 to D'Andolfo et al. apply finish to the yarn by means of opposing spray nozzles. No attempt is made in D'Andolfo et al. to influence the air boundary layer prior to finish application. Instead, the excess finish sprayed from the yarn is captured in large fixed enclosures. In U.S. Pat. No. 4,675,142 finish concentrations on the yarn up to 1.36% by weight are reported but finish concentrations varied by 15% to 35% of the average value.
In a different area, U.S. Pat. No. 5,624,715 to Gueggi et al.; U.S. Pat. No. 6,146,690 to Kustermann; and U.S. Pat. No. 6,248,407 B1 to Hess describe methods of applying a coating to a moving planar surface involving interruption of the air boundary layer in motion with the surface.
A need exists for finish applicator devices capable of actively applying finish to one or more yarns running at speeds over 3000 m/min, uniformly and at sufficient concentrations. A further need is for these devices to contain the finish and prevent spraying and contamination of surrounding areas. A yet further need is for these devices to be small, portable and easily installed at a variety of positions on a fiber processing line.
In the manufacture of yarns for in-rubber applications, such as tires belts and hoses, it is necessary to apply an overfinish to facilitate bonding of the yarn to rubber. It appears to be an invariable practice to apply the overfinish after the yarn is drawn and immediately before winding. See for example U.S. Pat. No. 5,562,988. This practice results in winding a wet yarn where the finish can pool and cause subsequent variations in rubber adhesion. A need exists for a finish applicator device that may be placed in a position between heated rolls on a yarn draw panel to permit drying the overfinish before winding.
SUMMARY OF THE INVENTION
The invention provides methods and devices to actively apply finish to one or more yarns in motion at speeds greater than about 3000 m/min, to achieve a finish application of 0.2 wt. % or more, and with a coefficient of variation of finish concentration of 10% or less. The devices are compact, portable and readily installed at a variety of positions on a fiber processing line. The devices of the invention contain the finish so that contamination of the surrounding areas is prevented.
The devices may be used to provide an overfinish to a moving yarn between heated godet rolls. The so-provided heating may be used to dry the yarn and to promote curing reactions in the finish and between the yarn and finish compounds. As used herein, “curing” refers to any reaction, which may be accelerated by heat. Non-limiting examples include crosslinking reactions and polymerization reactions. Such curing reactions may serve to enhance properties of the yarn. Non-limiting examples of such enhanced properties are adhesion to rubber, fatigue resistance and cohesion.
In one embodiment, the invention is a method for applying a liquid finish to one or more running yarns at speeds greater than 3000 m/min comprising the steps of:
a) passing the yarns into a finish applicator device while substantially blocking the entry of the air boundary layers in motion with the yarns into said finish applicator device;
b) contacting the yarns with a liquid finish under pressure;
c) substantially disengaging the excess finish from the yarns; and
d) passing the yarns out of the applicator device.
In another embodiment, the invention is a method for applying a liquid finish to one or more running yarns at speeds greater than 3000 m/min comprising the steps of:
a) passing one or more running yarns into an finish applicator device;
b) substantially blocking and disengaging the air boundary layer in motion with each yarn and venting it to the exterior of said finish applicator device;
c) contacting the yarns with a liquid finish under pressure;
d) substantially disengaging the excess finish from the yarns; and
e) passing the yarns out of the applicator device.
The invention also includes a yarn manufacturing method comprising the steps of: applying a liquid finish to one or more yarns running at speeds greater than about 3000 m/min at a position between heated rolls on a draw panel; drying said finish between said rolls; and collecting a dry drawn yarn on a winder.
The invention further includes the devices utilized in the above methods. In one embodiment termed an “immersion applicator”, the invention is a device for applying a liquid finish to one or more high speed running yarns comprising an essentially box-like device having yarn entry openings constricted to substantially block entrance of the air boundary layer entrained by each yarn. The device is internally divided into two or more chambers along the yarn path connected by constricted passages. In at least one of these chambers, the yarn is contacted with finish liquid under pressure. Excess finish liquid is captured and drained from one or more succeeding chambers.
In another embodiment termed a “slotted applicator”, the invention is a device for applying a finish liquid to one or more high speed running yarns utilizing an essentially box-like device having yarn entry openings and ducts behind the yarn entry openings to divert and discharge the air boundary layers at the lateral surfaces of the device. Within the device, one or more pressurized jets of finish liquid impinge on the yarns traveling in a channel. Excess finish liquid is captured and drained from one or more internal downstream chambers.
The invention also includes the finished yarn products so produced. A yarn with improved finish uniformity is provided with an overfinish actively applied and dried on the draw bench before the first winding operation. The yarn products of the invention may be used in textile and leisure fiber applications, and in industrial fiber applications, such as in tires.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawing figures:
FIG. 1 shows a sectional sketch of a first finish applicator of the invention termed an “immersion applicator”.
FIG. 2 shows a sectional sketch of a second finish applicator of the invention termed a “slotted applicator”.
FIG. 3 shows a prior art draw panel with an prior art finish applicator located after the draw rolls and before a winder.
FIG. 4 shows a draw panel with an inventive overfinish applicator located before the final pair of draw rolls.
FIG. 5 shows the same draw panel as FIG. 4 with the inventive overfinish applicator and the adjacent draw rolls enclosed in a vented box.
DETAILED DESCRIPTION OF THE INVENTION
While the invention will be described with reference to the treatment of yarn, it should be understood that the invention can be used to treat, in single filaments or bundles of filaments, any type of yarn, string or thread. Similarly, while the invention will be described in terms of a finish, it would be understood that the invention can be used to treat yarn with a wide variety of treatment agents, such as for example, coatings of various types, dyes and chemical treatments.
The invention provides methods and devices to actively apply finish and/or overfinish to one or more yarns in motion at speeds greater than about 3000 m/min, to achieve 0.2 wt. % or more of finish application on the yarns, and with a coefficient of variation of finish concentration of 10% or less. As used herein throughout, finish concentrations are expressed as finish weight divided by the sum of finish weight and yarn weight. The methods and devices are also suitable to achieve 0.2 wt. % or more of finish application on one or more yarns with a coefficient of finish concentration of 10% or less at yarn speeds greater than about 5000 m/min and greater than about 8000 m/min.
In a first embodiment, the invention is a method for applying a liquid finish to one or running yarns at speeds greater than 3000 m/min comprising the steps of: passing the yarns into a finish applicator device while substantially blocking the entry of the air boundary layers in motion with the yarns into said finish applicator device; contacting the yarns with a liquid finish under pressure; substantially disengaging the excess finish from the yarns; and passing the yarns out of the applicator device.
For the purposes of each embodiment of this invention, the pressures at the finish/yarn interface are obtained from finite element analysis using the software designated CFDesign obtained from Blueridge Numerics Inc., Charlottesville, Va. For the purposes of the invention, such analysis is based on one phase flow of a liquid having a viscosity and density dependent only on temperature.
In one realization of the first embodiment a liquid finish is applied to one or more high speed running yarns utilizing an essentially box-like device having yarn entry openings constricted to substantially block entrance of the air boundary layer entrained by each yarn. The device is internally divided into two or more chambers along the yarn path connected by constricted passages. At least one of these chambers is positively fed with liquid finish. The yarn is contacted with the finish liquid under pressure. Excess finish liquid is captured and drained from one or more succeeding chambers.
More specifically, in this realization, the invention is a method for applying a liquid finish to running yarns at speeds greater than 3000 m/min as follows:
One or more running yarns is passed into a first chamber of an applicator device through constricted yarn entry openings that substantially block the air boundary layer entrained by each yarn.
A yarn passes from the first chamber through a constricted yarn passage into second and sequential chambers further connected by constricted yarn passages.
Liquid finish is positively fed from an external source to at least one of the chambers traversed by each yarn.
Each yarn is contacted with the liquid finish under pressure.
Excess finish liquid is substantially disengaged from each yarn in at least one of the chambers.
Excess liquid finish is drained to an external receptor.
The yarns are passed out of the last chamber of the applicator device through exit openings.
As used herein throughout, pressure means the highest pressure at the finish-yarn interface along the yarn path through the device. This highest pressure is expected to be localized in the vicinity of the restricted yarn passages (see below).
Preferably, the liquid finish contacts the yarn at a pressure at least about 10 psi (68.9 kPa). More preferably, the liquid finish contacts the yarn at a pressure at least about 20 psi (138 kPa). Most preferably, the liquid finish contacts the yarn at a pressure at least about 40 psi (276 kPa).
Preferably, the liquid finish is supplied continuously using a pump. Increasing the finish feed rate to the applicator device yields an increase in finish on the yarn at a given yarn speed. The finish feed rate required to apply a given level of finish at a particular yarn speed and for particular applicator dimensions is readily found by calibration of the device.
The finish applied to the yarn in traversing the applicator device is preferably about 0.2 wt. % to about 5 wt. % with a coefficient of variation (COV) less than about 10%. More preferably, the finish applied is about 0.4 to about 4 wt. % with a COV less than about 10%. Most preferably, the finish applied is about 0.5 wt. % to about 2 wt. % with a COV less than about 10%.
The invention includes the apparatus by which the above method may be practiced. In this embodiment termed an “immersion applicator” illustrated in part by a sectional sketch in FIG. 1, the invention is an applicator device for applying finish liquid to one or more high speed running yarns. The applicator device has a top portion ( 50 ) and a mated bottom portion ( 60 ) sealed to the top portion at its exterior surfaces. This seal may be provided by machining the top and bottom portions to close tolerances. However, separate sealing means such as seals or gaskets are preferred to be placed between the top and bottom portions to prevent external leakage at their mated surfaces.
The bottom portion has yarn entry openings in its front surface for each individual yarn ( 5 ) and exit openings ( 7 ) in its rear surface for each individual yarn. The yarn entry openings are constricted to substantially block air boundary layers entrained by each yarn.
The bottom portion has one or more interior walls dividing the bottom portion into two or more consecutive chambers ( 40 ). Each of the interior walls in the bottom portion has constricted yarn passages ( 6 ), individual for each yarn, connecting the preceding and succeeding chambers. The constricted yarn passages also serve as yarn guides and may be inserts made of materials such as ceramics different than the surrounding wall materials. Such passages are open at their intersections with the top surface of the bottom portion for ease of yarn string-up. In operation of the finish applicator device, the tops of the passages are closed by the bottom surface of the top portion.
At least one of the chambers in the bottom portion is in communication with external source of finish liquid through a finish liquid supply duct ( 11 ) to permit feeding liquid from below the yarn path. At least one of the chambers in the bottom portion is in communication with an external drain ( 20 ).
The top portion has one or more interior walls dividing the top portion into consecutive chambers ( 70 ) corresponding in number and location to mating chambers in the bottom portion. At least one of the chambers in the top portion is in communication with an external source of finish liquid ( 10 ).
The dimensions of the chambers in the top and bottom portions are chosen by compromise between desire for compactness and flexibility of operation. Greater chamber length in the direction of yarn travel accommodates higher levels of finish application or higher yarn speeds, but less compactness. It is preferred that the length of the chambers in the direction of yarn travel is between about 1 cm to about 10 cm, and more preferably is between about 1.25 cm and 7 cm. The width of the chambers is preferred to be between about 0.2 cm and 2 cm. The depth of the chambers is preferred to be between about 1 cm and about 7 cm.
It is preferred that finish liquid is fed to two or more sequential chambers and that excess finish liquid is disengaged from the yarn in two or more subsequent chambers.
There are also means (not shown) to hold the bottom surface of the top portion and said top surface of the bottom portion together in mated and sealed position.
Preferably, the top portion and the bottom portion are connected at one of their side surfaces by hinge means. Preferably, the top portion and the bottom portion are connected at the other of their side surfaces by quick opening clamps means. The finish applicator device is quickly and easily opened for yarn string-up along the bottom portion and quickly and easily closed and placed in service.
A two yarn-end applicator of this design has been fabricated.
Without being held to a particular theory of why the invention works, it is believed that the constriction of the yarn entry openings ( 5 ) and the constricted yarn passages between chambers ( 6 ) are essential features of the device. The constrictions of the yarn entry openings substantially block the air boundary layers surrounding the yarns from entry into the device. This minimizes interference of the air with contact between the yarn and the finish in the chambers. The high speed running yarn in contact with the liquid finish in a chamber entrains a liquid boundary layer. Stagnation of the high speed liquid boundary layer at the face of a constricted yarn passage converts kinetic energy into pressure head. Finite element modeling indicates such constriction of the yarn passages between the chambers gives rise to high localized contact pressures between the liquid finish and the yarn at the entrance of, and within the yarn passages. The contact pressures so generated are expected to be much higher than, and add to, the liquid finish pressure at the inlets to the device ( 10 , 11 ).
The cross-sections of the yarn passages into and through the device ( 5 , 6 , 7 ) may be circular, oval, rectangular or some more complex shape. Preferably, the yarn entry openings ( 5 ) have constant dimensions in the direction of yarn travel. The yarn passages within the device ( 6 ) may be straight, tapered or pulsatile. Preferably, the yarn entry openings ( 5 ), and the yarn passages ( 6 ) are so constricted as to have no dimension greater than about ten times the effective yarn diameter. More preferably, the yarn entry openings ( 5 ), and the yarn passages ( 6 ) are so constricted as to have no dimension greater than about six times the effective yarn diameter. The effective yarn diameter is obtained from the following relationship: ED = 1.33 4 d 9 × 10 5 πρ
where:
ED is the effective yarn diameter, cm
d is the yarn denier
ρ is the density of the polymer constituting the yarn filaments (1.39 g/cm 3 for polyethylene terephthalate)
Preferably also, the dimensions of the yarn entry openings ( 5 ) are so constricted as to block at least about 75% of the cross-sectional area of the air boundary layer entrained with each yarn. For the purposes of this invention, the cross-sectional area of the air boundary layer is as calculated by Equations (26) to (31) of B. C. Sakiadis, A.I.Ch.E. Journal, 7(3), 467-472 (1961). The thickness of the air boundary layer calculated in this manner is believed to be a minimum bound (most conservative estimate) of the actual air boundary layer dimensions.
The dimensions of the air boundary layer depend on the denier of the yarn, the yarn speed and the distance along the yarn from the last solid surface traversed. Table I shows the air boundary layer thickness calculated by the above referenced Sakiadis relationships for poly(ethylene terephthalate) yarns of 50 to 3000 denier, yarn speeds of 3000 to 10,000 m/min, and distances from the last solid surface of 0.2 and 0.813 m. Also shown in Table I is the percentage of the air boundary layer cross-sectional area that is blocked by an applicator yarn entry opening having a cross-sectional area of 0.0335 cm 2 and no dimension greater than the boundary layer thickness.
TABLE I
δ,
boundary
Distance
layer
Yarn velocity,
along yarn,
thickness,
% of boundary
Yarn denier
m/min
M
cm
layer blocked
50
3000
0.2
0.233
81
50
3000
0.813
0.446
95
50
5400
0.2
0.218
78
50
5400
0.813
0.417
94
50
10000
0.2
0.203
75
50
10000
0.813
0.388
93
100
3000
0.2
0.269
86
100
3000
0.813
0.517
96
100
5400
0.2
0.251
84
100
5400
0.813
0.483
96
100
10000
0.2
0.234
81
100
10000
0.813
0.450
95
300
3000
0.2
0.336
91
300
3000
0.813
0.652
98
300
5400
0.2
0.313
90
300
5400
0.813
0.609
97
300
10000
0.2
0.291
88
300
10000
0.813
0.567
97
1000
3000
0.2
0.426
95
1000
3000
0.813
0.837
99
1000
5400
0.2
0.396
94
1000
5400
0.813
0.781
98
1000
10000
0.2
0.366
93
1000
10000
0.813
0.726
98
3000
3000
0.2
0.522
97
3000
3000
0.813
1.045
99
3000
5400
0.2
0.484
96
3000
5400
0.813
0.974
99
3000
10000
0.2
0.447
95
3000
10000
0.813
0.904
99
It will be seen from Table I that at least 75% of the cross-sectional area of the air boundary layer in motion with the yarn is blocked for all of the above combinations of yarn denier, speed and distance when the applicator yarn entry opening has a cross-sectional area of 0.0335 cm 2 . Preferably, the cross-sectional area of each yarn entry opening and each yarn passage is no greater than about 0.0335 cm 2 .
In another embodiment, the invention is a method for applying a liquid finish to one or more high speed running yarns comprising the steps of:
passing one or more running yarns into a finish applicator device; substantially blocking and disengaging the air boundary layer in motion with each yarn and venting it to the exterior of said finish applicator device; contacting the yarns with a liquid finish under pressure; substantially disengaging the excess finish from the yarns; and passing the yarns out of the applicator device.
In one realization of this embodiment, the invention is a method for applying a finish liquid to one or more high speed running yarns utilizing an essentially box-like device having yarn entry openings and ducts behind the yarn entry openings to divert and discharge the air boundary layers at the lateral surfaces of the device. Within the device, one or more pressurized jets of finish liquid impinge on the yarns traveling in a channel. Excess finish liquid is captured and drained from one or more internal downstream chambers.
More specifically, in this realization, the invention is a method for applying a liquid finish to high speed running yarns as follows:
One or more running yarns are passed into an applicator device.
Each yarn is passed through a constricted passage within the applicator device that substantially blocks the air boundary layer entrained with the yarn.
The air boundary layer entrained by each yarn is vented to the exterior of the applicator device.
One or more jets of finish liquid supplied under pressure from an external source are impinged onto each yarn within the applicator device.
Each yarn passes into one or more sequential chambers in which excess liquid finish is substantially disengaged from the yarn.
Excess finish liquid is drained from the chambers to an external receptor.
The yarns are passed out of the last chamber of the applicator device.
Preferably, the liquid finish contacts the yarn at a pressure at least about 10 psi (68.9 kPa). More preferably, the liquid finish contacts the yarn at a pressure at least about 20 psi (138 kPa). Most preferably, the liquid finish contacts the yarn at a pressure at least about 40 psi (276 kPa).
The finish applied to the yarn in traversing the applicator device is preferably about 0.2 wt. % to about 5 wt. % with a coefficient of variation (COV) less than about 10%. More preferably, the finish applied is about 0.4 to about 4 wt. % with a COV less than about 10%. Most preferably, the finish applied is about 0.5 wt. % to about 2 wt. % with a COV less than about 10%.
Venting of the air boundary layer to the exterior of the device may optionally be aided by applying suction from an exterior vacuum producing means such as a vacuum pump or aspirator.
The invention includes the apparatus by which the above method may be practiced illustrated in part by a sectional sketch in FIG. 2 . The invention is an applicator device termed a “slotted applicator” for applying finish liquid to one or more high speed running yarns. The applicator device has a top portion ( 50 ) and a mated bottom portion ( 60 ) sealed to the top portion. This seal may be provided by machining the top and bottom portions to close tolerances. However, it is preferred that separate sealing means such as seals or gaskets be provided between the top and bottom portions to prevent external leakage at their mated surfaces.
The top portion has grooved channels in its bottom surface, individual for each yarn, extending from the front surface of the top portion to a position intermediate of the distance to the rear surface of the top portion. The bottom portion has grooved channels in its top surface, individual for each yarn, extending from the front surface of the bottom portion to a position intermediate of the distance to the rear surface of the bottom portion. The grooved channels in the top surface of the bottom portion are aligned with the grooved channels in the mating bottom surface of the top portion. Yarn entry openings ( 5 ) are formed by the intersection of the aligned grooved channels in the top and bottom portions with their respective front surfaces.
The width of the grooved channels in the top and bottom portions is not critical. For compactness, the width of the channels is preferably between about 3 times and 20 times the effective diameter of the yarn to be treated. The depth of the channels is preferably between 1.5 times and 10 times the effective diameter of the yarn to be treated.
Air boundary layer diversion ducts ( 15 ) in the top portion communicate between each of the grooved channels and the top surface of the top portion. Air boundary layer diversion ducts ( 16 ) in the bottom portion communicate between each of the grooved channels and the bottom surface of the top portion. Each of the air boundary layer diversion ducts in the top portion and in the bottom portion intersect its corresponding grooved channel in the vicinity of the respective front surfaces of the top and bottom portions forming an acute angle of about 10 to about 50 with the corresponding grooved channel, said acute angles opening outward rearward.
A first restriction ( 30 ) in the dimensions of each grooved channel is placed rearward of, and in the proximity of the intersection of the air boundary layer diversion duct with the grooved channel. The dimensions of the first restriction are critical (see below).
One or more liquid supply ducts ( 10 ) communicates between each of the grooved channels and an external pressurized source of finish liquid. The liquid supply ducts are placed rearward of the first restriction in the dimensions of each grooved channel. The terminus of each liquid supply duct at its intersection with its corresponding grooved channel is constricted so as to form a jet nozzle. The terminus of each liquid supply duct at its intersection with its corresponding grooved channel also forms a second and subsequent restriction ( 8 ) in its corresponding channel.
The bottom portion has rearward of the most rearward liquid supply duct, one or more internal walls defining two or more chambers ( 70 ). The chambers communicate with an external drain ( 20 ).
The dimensions of the chambers are not critical. For compactness, it is preferred that the length of the chambers in the direction of yarn travel is between about 1 cm to about 10 cm, and more preferably is between about 1.25 cm and 7 cm. The width of the chambers is preferred to be between about 0.2 cm and 2 cm. The depth of the chambers is preferred to be between about 1 cm and about 7 cm. It is preferred that the excess finish is disengaged from the yarn in two or more sequential chambers.
An exit opening ( 7 ) for each yarn is present in the rear surface of the bottom portion.
Means (not shown) are provided to hold the top portion and the bottom portion together in sealed and mated position. Preferably, the top portion and the bottom portion are connected at one of their side surfaces by hinge means and are connected at the other of their side surfaces by quick opening clamps means.
The first restrictions ( 30 ) in the grooved channels are so dimensioned as to block at least about 75% of the cross-sectional area of the air boundary layer entrained with each yarn. Preferably, the cross-sectional area of the first restriction is less than about 0.0335 cm 2 . Preferably, the cross-sectional area of the second and subsequent restrictions ( 8 ) in the grooved channels are no more than about five times the cross-sectional area of the first restriction.
The first ( 30 ) and subsequent restrictions ( 8 ) in the grooved channels as well as the air boundary layer diversion ducts ( 15 and 16 ) are believed to be essential features of the device. The first restriction substantially blocks the air boundary layers in motion with the yarns. The air boundary layer diversion ducts vent the entrained air to the exterior of the device before the yarn contacts the finish. Finite element modeling indicates that the subsequent restrictions of the grooved channels give rise to high contact pressures between the liquid finish and the yarn at the entrance of, and within the restricted channels. Such pressures are expected to be much higher than, and add to, the liquid finish pressure at the inlets to the device ( 10 ).
A one yarn-end applicator of this design has been fabricated.
The finish applicator devices of the invention are advantageously used directly on a draw panel in-line with spinning. A representative prior art four-zone draw panel is shown in FIG. 3 . After spinning (not shown), a yarn end ( 49 ) contacts a first finish kiss roll ( 71 ) which applies a first finish on the yarn intended to help processability and drawability. The yarn end is then fed in sequence to a first drawing zone between driven roll ( 51 ) and idler roll ( 53 ) and driven roll pair ( 55 & 57 ); to a draw assist device ( 73 ) such as a steam jet; to a second draw zone between roll pairs ( 55 & 57 ) and ( 59 & 61 ); and to third and fourth drawing zones using heated roll pairs ( 63 & 65 ) and ( 67 & 69 ), respectively. The yarn end ( 49 ) then contacts an overfinish applicator device ( 75 ) which may be similar to that described in U.S. Pat. No. 4,268,550 and the yarn is fed to a winder (not shown).
There are several difficulties with the prior art draw panel that are resolved by the present invention. First, the prior art overfinish applicators are unable to achieve necessary finish concentrations and uniformity at yarn speeds of about 3000 m/min and above. This limits process productivity. Second, the prior art finish applicators produce a spray of finish in the vicinity of the device, thus creating safety and environmental problems. Third, the spray problem is more severe when the overfinish is applied to a yarn running in a horizontal plane rather than in a vertical plane. This limits the ability to apply overfinish between the heated draw rolls in a conventional draw panel, and therefore to dry and cure the finish before the yarn reaches the winder. With the prior art finish applicator in the arrangement shown, the finish on the yarn may still be wet as the yarn reaches the winder. These difficulties reinforce one another creating an overall problem greater than the sum of its parts.
In contrast, a finish device of the invention may be located on a draw panel where the yarn runs in a horizontal plane between heated draw rolls as illustrated in FIG. 4 . The draw panel may be either a four-zone or five-zone panel. In either configuration, the inventive finish device is preferably located in the final draw zone. Shown in FIG. 4 is the same four-zone draw panel as that in FIG. 3 . The part numbers correspond in FIGS. 3 and 4. However, in FIG. 4, the prior art overfinish applicator has been removed and an inventive finish device is located between heated roll pairs ( 63 & 65 ) and ( 67 & 69 ). The inventive finish applicator provides the ability to overfinish the yarn to desired finish concentrations and uniformity, and with little or no spray. Equally significant, the finish on the yarn may now be dried and cured to enhance yarn properties on-line.
The invention includes a yarn finishing method comprising the steps of: applying a liquid finish to one or more yarns running at speeds greater than about 3000 m/min at a position between heated rolls on a draw panel; drying said finish during passage over said rolls; and collecting a dry drawn yarn on a winder.
It should be noted that as some overfinishes may contain substances that are hazardous when volatilized on the heated draw rolls, it may be necessary to evacuate the volatiles from the working area. This may be done by installing an exhaust hood above the last draw zone, or optionally, placing an vented enclosure ( 79 ) around the last draw zone as shown in FIG. 5 .
The invention also includes an overfinished yarn product prepared by the process comprising the steps of:
a) actively applying an overfinish to a yarn at a position between heated rolls, at a yarn speed greater than about 3000 m/min at a concentration of about 0.2 wt. % to about 5 wt. %, with a coefficent of variation of concentration of 10% or less,
b) drying said overfinish during passage over said heated rolls.
Yarns suitable for use in the invention include any yarn to which finish is applied including yarn made of polyamides, polyesters, polyolefins, poly(aramides) and polybenzazoles. Specific polyamides include nylon-6 and nylon6,6. Specific polyesters include poly(ethylene terephthalate), poly(trimethylene terephthalate) and poly(ethylene naphthalate). Specific polyolefins are polyethylene and polypropylene. Specific polyaramides include ortho-, meta- and para-poly (phenylene terepthalamide). Specific polybenzazoles include poly(benoxazole) and poly(benzthiazole).
Filaments may have round or other cross-sectional shapes.
Finish on the yarn (FOY) is routinely determined using NMR (nuclear magnetic resonance) previously calibrated against known standards. As used herein, FOY is the “total finish” and refers to the sum of a first finish and any overfinish on the yarn.
NMR offers rapid analysis but it is not a primary method. Primary standards are prepared for each spin finish and overfinish system that is used. FOY values for these standards are determined by extracting the finish with a known good solvent for the finish (e.g cyclohexane, methanol) and determining the weight of the extract after evaporation of the solvent. The NMR measurements are correlated with the extraction data.
The method of determining FOY using NMR is as follows: a yarn sample (about 2 grams) is weighed, placed in a glass tube and inserted into the NMR cavity. A strong magnetic field causes the protons (hydrogen atoms) in the oil portion of the finish to line up. A radio frequency pulse is then applied at the resonance frequency to produce a signal called a free induction decay. The magnitude of this signal is proportional to the number of protons in the finish and hence its concentration. The calibration standards are retained and used to check the stability of the calibration daily.
Unknown samples are measured in the same way as the standards. A sample of about 2 grams is placed in the glass tube and the NMR signal is measured. Since the relationship between NMR signal and FOY is thus known, FOY is calculated by the software and displayed by the instrument. An overfinish may also be analyzed by x-ray fluorescence (XRF) when the overfinish contains silicon. Such overfinishes are described for example, by U.S. Pat. Nos. 4,617,236 and 4,397,985, hereby incorporated by reference herein to the extent not incompatible herewith. Again the XRF method is not a primary method and must be calibrated against standard samples analyzed by extraction. However, the XRF method, because of its sensitivity to the silicon component, can determine the concentration of overfinish separately from the concentration of a lubricating spin finish.
The following examples are presented to provide a more complete understanding of the invention. The specific techniques, conditions, materials, proportions and reported data set forth to illustrate the principles of the invention are exemplary and should not be construed as limiting the scope of the invention.
EXAMPLES
Comparative Example 1
A 250 filament polyethylene terephthalate (PET) yarn was drawn on a draw panel as shown in FIG. 3. A spin finish was applied to the yarn using a rotating ceramic kiss roll of 5.5 inch (14 cm) diameter partially immersed in a pan of spin finish. The spin finish kiss roll was located at the entrance to the draw panel at the position labeled ( 71 ) in FIG. 3 . The finish roller speed was 13 RPM.
A package of yarn was collected under these conditions and then rewound with a yarn sample taken for determination of FOY approximately every 500 meters. The average of seventeen determinations of FOY was 0.354 wt. %
A PET yarn of 200 filaments was drawn in the same manner as described above. Fourteen FOY determinations approximately every 500 meters along the yarn averaged 0.386 wt. %.
Comparative Example 2 and Examples 1 and 2
An experiment was performed to compare overfinish application on a draw panel at a yarn speed of about 5400 m/min by the following means:
a) In Comparative Example 2, a prior art applicator similar to that described in U.S. Pat. No. 4,268,550.
b) In Example 1, an “immersion applicator” of the invention (FIG. 1) having a single liquid fed chamber having a length of 3.95 inches (10.03 cm) in the direction of yarn travel;
c) In Example 2, a “slotted applicator” of the invention (FIG. 2)
The yarn in each case was a 300-filament PET. Approximately 0.386 wt. % spin finish was applied by a kiss roll applicator (at position 71 in FIGS. 3 and 4) to each yarn at speed of about 2800 meters per minute at the entrance to the draw panel.
Overfinish was applied to the yarns by each of the devices listed above. The overfinish composition was similar to those described in U.S. Pat. No. 4,617,236 having a room temperature viscosity of 4.8 centistokes and a density of 0.98 g/cm 3 . The speed of the yarn as it passed the overfinish applicator was about 5400 meters per minute in each case. The yarn denier at each overfinish applicator was about 1000 denier.
Comparative Example 2
The prior art finish applicator was located after the draw panel and before the winder in the position labeled 75 in FIG. 3. A very high degree of finish spray to the surrounding area was generated at the finish applicator. The total finish on yarn (FOY) averaged 0.465 wt. %. The overfinish picked up from the prior art applicator at 5400 m/min was therefore only about 0.465−0.386=0.079 wt. %.
It should be noted that the magnitude of the spraying with prior art applicator prevented its placement in the last draw stage. The finish spray created with this device would build up on the draw rolls and eventually cause yarn defects or breakage. It should also be noted that with placement of the prior art finish applicator after the last draw stage, the yarn going to the winder was wet with uncured overfinish. Pooling of the wet overfinish where yarns were in contact on the wound package produced further non-uniformity in finish coverage.
Example 1 and Example 2
A finish applicator of the invention was place in the location labeled 77 in FIG. 4 between the heated roll sets in the final draw stage. The distance from the roll labeled 65 to the entrance of an inventive finish applicator was 32 inches (0.813 meters).
The cross-sectional area of the yarn entry openings (FIG. 1, yarn entry opening ( 5 )), and the area of the constricted passages (FIG. 1, constricted yarn passage ( 6 )) of the “immersion applicator” were 0.0335 cm 2 . No dimension of the yarn entry openings was greater than 5.5 times the effective diameter of the yarn. In the “slotted applicator” the cross-sectional area of the first restriction (FIG. 2, first restriction ( 30 )) in the channel was 0.0116 cm 2 . The cross-sectional areas of the subsequent restrictions in the channel were 0.0503 cm 2 or about 4.3 times the cross-sectional area of the first restriction.
The percent of the air boundary layer cross-section that was blocked by each of the inventive finish applicators was at least 98%. Yarn-finish contact pressures in each of the inventive finish applicators estimated from finite element numerical modeling were greater than 40 psi 5 (276 kPa).
Finish was supplied to each of the inventive finish applicators from a reservoir by means of positive displacement gear pump with a variable speed drive. The finish feed rate to the applicators was varied and is shown in Table II. Excess finish was disengaged from the yarn within an applicator, drained, and sent to a reservoir for recycling.
The overfinish and the FOY (spin finish plus overfinish) applied to the yarns is listed in Table II. Little, if any finish spray to the environment was generated at any finish level.
TABLE II
Overfinish
Overfinish, wt. %
FOY, %
Feed
Example 1
Example 2
Example 1
Example 2
Rate,
“immersion”
“slotted
“immersion”
“slotted
ml/min
applicator
applicator”
applicator
applicator”
22
0.17
—
0.56
—
130
1.03
0.084
1.42
0.47
380
2.95
—
3.34
—
670
5.20
2.93
5.59
3.32
Examples 1 and 2 of the invention demonstrate that at a yarn speed of 5400 m/min, an inventive active finish applicator can provide finish application of about 5.2% and levels of FOY up to about 5.6 wt. %. Comparison of the FOY data for Examples 1 and 2 with Comparative Example 2 demonstrate that at a yarn speed of 5400 m/min, the inventive active finish applicators can provide significantly higher levels of FOY compared to the prior art kiss roll, and without generating spray to the environment. It is expected that finish levels of 6 wt. % or more may be applied by the methods and devices of the invention at speeds greater than 5000 m/min, and possibly greater than 8000 m/min or greater than 9000 m/min.
In contrast to Comparative Example 2 therefore, the inventive finish applicators were readily placed in the last draw stage. The yarn products after passing over the last heated roll set were dry. This is a substantial advantage of the inventive method, and a novel feature of the yarns so produced.
The data also demonstrate that the finish application by the inventive applicators can be controlled by the finish feed rate.
Example 3
A 250 filament, 1000 denier PET yarn was overfinished at 5400 m/min using an “immersion applicator” similar to that described in Example 1 but having two liquid fed chambers whose total length in the direction of yarn travel was 1.5 inches (3.81 cm). The cross-sectional area of the yarn entry openings (FIG. 1, yarn entry opening ( 5 )), and the area of the constricted passages (FIG. 1, constricted passages (6)) of the “immersion applicator” were 0.0335 cm 2 . No dimension of the yarn entry openings was greater than 5.5 times the effective diameter of the yarn. The percent of the air boundary layer cross-section that was blocked from entry into the finish applicator was at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling was greater than 40 psi (276 kPa).
Approximately 0.386 wt. % spin finish was applied by a kiss roll applicator at a speed of about 2800 meters per minute at the entrance to the draw panel. The placement of the “immersion applicator” between heated godets was as described in Example 1. The overfinish feed rate to the applicator was about 250 ml/min. The overfinish composition was similar to one described in U.S. Pat. No. 4,617,236 having a room temperature viscosity of 4.8 centistokes and a density of 0.98 g/cm 3 .
The yarn was dry as it left the last heated godet. A package of yarn was collected and then rewound with a yarn sample taken for determination of FOY approximately every 500 meters. The results of the determinations are shown in Table III below.
TABLE III
Rewind package
number
FOY, wt. %
1
1.48
2
1.40
3
1.26
4
1.31
5
1.50
6
1.34
7
1.36
8
1.24
9
1.33
10
1.17
11
1.36
12
1.21
13
1.09
14
1.30
15
1.29
16
1.36
17
1.26
Average
1.31
COV, %
7.9
The overfinish applied, by difference between the FOY and the spin finish, was about 1.31 wt. %−0.386 wt. %=0.92 wt. %.
The data of Example 3 demonstrate that yarn with about 0.9 wt. % overfinish and more than 1 wt. % FOY and can be prepared with a uniformity (COV) of less than 10% using a finish applicator and method of the invention.
Example 4
A 250 filament, 1000 denier PET yarn is overfinished at 3000 m/min using an “immersion applicator” and overfinish as described in Example 3. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 99%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 10 psi (68.9 kPa).
Approximately 0.4 wt. % spin finish is applied by a kiss roll applicator at a speed of about 1550 meters per minute at the entrance to the draw panel. The placement of the “immersion applicator” between heated godets and the procedure are as described in Example 3. The finish feed rate to the applicator is about 250 ml/min.
Overfinish applied to the yarn is about 0.7 wt. % with a COV of about 8%. FOY is about 1.1 wt. %. The yarn is dry as it leaves the last heated godet.
Example 5
A 250 filament, 1000 denier PET yarn was overfinished at 5400 m/min using an “immersion applicator” and overfinish as described in Example 3. The placement of the “immersion applicator” between heated godets and the procedure were as described in Example 3. The percent of the air boundary layer cross-section that was blocked from entry into the finish applicator was at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling was greater than 40 psi (276 kPa).
Approximately 0.40 wt. % spin finish was applied by a kiss roll applicator at a speed of about 2800 meters per minute at the entrance to the draw panel. The finish feed rate to the applicator was about 165 ml/min. The overfinish composition was the same as in Example 3.
The yarn was dry as it left the last heated godet. A package of yarn was collected and then rewound with two yarn samples (labeled “A” and “B”) taken at the same point for duplicate determinations of FOY approximately every 500 meters. The results of the determinations are shown in Table IV below.
TABLE IV
FOY, %
Rewind package number
“A” Sample
“B” Sample
1
—
0.87
2
—
0.90
3
0.93
0.85
4
1.07
1.03
5
1.12
1.02
6
0.96
0.94
7
1.07
1.00
8
0.97
1.01
9
0.97
0.98
10
0.89
0.94
11
0.97
0.93
12
0.95
0.98
13
1.07
0.94
14
0.99
0.96
15
0.91
0.94
16
1.01
1.06
17
0.82
0.98
Average
0.98
0.96
COV
8.1%
5.0%
An analysis of variance of the data of Table IV shows the standard error of measurement of FOY between any two samples at the same position was 0.079% FOY. The variation of FOY along a yarn overfinished by a device of the invention was about the same as the error in the measurement.
The overfinish applied, by difference between the FOY and the spin finish, was about 0.97 wt. % −0.40 wt. %=0.57 wt. %.
Example 6
A 300 filament, 1000 denier PET yarn was overfinished at 5300 m/min using an “immersion applicator” and overfinish as described in Example 3. The placement of the “immersion applicator” between heated godets and the procedure were as described in Example 3. The percent of the air boundary layer cross-section that was blocked from entry into the overfinish applicator was at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling was greater than 40 psi (276 kPa).
Approximately 0.38 wt. % spin finish was applied by a kiss roll applicator at a speed of about 2700 meters per minute at the entrance to the draw panel.
The overfinish feed rate to the “immersion applicator” was varied with the resulting finish application shown in Table V. The yarn was dry as it left the last heated godet.
TABLE V
Overfinish
Feed Rate,
Overfinish,
ml/min
wt %
FOY, wt. %
0
0
0.38
84
0.27
0.65
96
0.38
0.77
96
0.28
0.67
96
0.40
0.79
108
0.31
0.69
120
0.32
0.71
120
0.40
0.79
120
0.43
0.81
132
0.48
0.87
144
0.65
1.04
144
0.52
0.91
144
0.52
0.91
The data of Example 6 illustrate the response of the overfinish application rate to the overfinish feed rate in the range of about 0.2 wt. % to about 0.7 wt. % overfinish.
Example 7
Approximately 0.39 wt. % spin finish is applied to a 250 filament, 1920 denier PET yarn at about 4000 m/min. The yarn is overfinished between heated godets at about 8,100 m/min using an “immersion applicator” as described in Example 3. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 60 psi (414 kPa). The placement of the overfinish applicator and the procedure are as described in Example 3. The finish feed rate to the applicator is about 370 ml/min.
Overfinish applied to the yarn is about 0.51 wt. % with a COV of about 9%. FOY is about 0.9 wt. %. The yarn is dry as it leaves the last heated godet.
Example 8
Approximately 0.4 wt. % spin finish is applied to a 250 filament, 1920 denier PET yarn at 5200 m/min using the “immersion applicator” and overfinish as described in Example 3. The yarn enters the applicator at a distance of 1.5 meters from the last driven roll. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 40 psi (276 kPa). Spin finish feed to the applicator is about 100 ml/min.
The yarn is overfinished between heated godets at 10,000 m/min using an “immersion applicator” as described in Example 3. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 75 psi (517 kPa). The placement of the overfinish applicator and the procedure are as described in Example 3. The finish feed rate to the applicator is about 500 ml/min.
Overfinish applied to the yarn is about 0.5 wt. % with a COV of about 9%. FOY is about 0.9 wt. %. The yarn is dry as it leaves the last heated godet.
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Methods and devices are provided to actively apply finish to one or more yarns in motion at speeds greater than about 3000 m/min, to achieve a finish application of 0.2 wt. % or more, and with a coefficient of variation of finish concentration of 10% or less. The devices are compact, portable and readily installed at a variety of positions on a fiber processing line. The devices of the invention contain the finish so that contamination of the surrounding areas is prevented.
The devices may be used to provide an overfinish to a moving yarn between heated godet rolls. The so-provided heating may be used to dry the yarn and to promote curing reactions in the finish and between the yarn and finish compounds.
The invention also includes the finished yarn products so produced. A yarn with increased finish uniformity is provided with an overfinish actively applied and dried on the draw bench before the first winding operation. The yarn products of the invention may be used in textile and leisure fiber applications, and in industrial fiber applications, such as in tires.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wireless communication, and more particularly, to a method and an apparatus for cell search and synchronization for a subscriber station of the Long Term Evolution (LTE) system. In the LTE system, a base station will transmit a specific primary synchronization signal in each frame to allow a subscriber station to detect the cell arrangement in the LTE system, thereby establishing system synchronization. The method proposed by the present invention can accurately and effectively detect various primary synchronization signals used by different base stations and simultaneously complete system synchronization and the detection of the integer carrier frequency offset (ICFO).
2. Description of the Prior Art
Currently, various communication standards, such as E-UTRA (the abbreviation for evolved UMTS Terrestrial Radio Access), also referred to as Long Term Evolution (LTE), have been developed to provide relatively high data rate so as to support high quality services. LTE is a 3rd Generation Partnership Project (3GPP) standard that provides for an uplink speed of up to 50 Mbps and a downlink speed of up to 100 Mbps. The LTE/E-UTRA standard represents a major advance in cellular technology. The LTE/E-UTRA standard is designed to meet current and future carrier needs for high-speed data and media transport as well as high-definition video support. The LTE/E-UTRA standard brings many technical benefits to cellular networks, some of which include the benefits provided by Orthogonal Frequency Division Multiplexing (OFDM) and Multiple Input Multiple Output (MIMO) data transmission.
An OFDM system is characterized by high spectrum efficiency, frequency selective fading resistance, multipath fading resistance, inter-symbol interference (ISI) resistance and adaptive transmission mechanism, and is capable of using a simple frequency domain equalizer (FDE) as data recovery of a receiver. In addition, in the LTE system, Orthogonal Frequency Division Multiple Access (OFDMA) and Single Carrier-Frequency Division Multiple Access (SC-FDMA) are used on the downlink (DL) and on the uplink (UL), respectively.
Mobility management represents an important aspect of the LTE/E-UTRA standard. As a mobile device, also called user equipment (UE) in the LTE/E-UTRA standard, moves within an LTE/E-UTRA coverage area, the transmission of synchronization signals and cell search procedures provide a basis for the mobile device or UE to detect and synchronize with individual cells. To communicate with a particular cell, mobile devices in associated LTE/E-UTRA coverage area need to determine one or more cell specific transmission parameters such as symbol timing, radio frame timing, and/or a cell identification (ID). In the LTE/E-UTRA standard, the cell-specific information is carried by reference and synchronization signals. The latter forms the basis for DL synchronization and cell specific information identification at the mobile devices within the associated LTE/E-UTRA coverage area. Two DL synchronization signals, namely Primary Synchronization Signal (PSS) and Secondary Synchronization Signal (SSS), are used to allow the mobile devices to synchronize with the transmission of the particular cell, thereby obtaining cell specific information.
The traditional synchronization technique for the LTE system detects the primary synchronization signal based on a joint detection of the unique identification to which the primary synchronization signal corresponds and the ICFO. Traditional methods are complicated and require a huge amount of hardware resource. Moreover, the robustness of traditional detection techniques in resisting frequency selective fading caused by the wireless channel is poor, thus the accuracy of the detection and the communication quality are compromised. Therefore, the above-mentioned traditional methods still have many defects and need to be improved.
In view of the above-mentioned defects in traditional methods, the inventor endeavors to develop a method and an apparatus for cell search and synchronization for a subscriber station of the LTE system.
SUMMARY OF THE INVENTION
In view of the above-mentioned problems in the prior art, an object of the present invention is to provide a method and an apparatus for cell search and synchronization for a subscriber station of the LTE system, in which the subscriber station detects the specific primary synchronization signal transmitted by the base station within each fame to obtain correct clock pulses of the LTE system when intending to access the LTE system, thereby the sequential transmission of control signals and data between the base station and the subscriber station can be performed smoothly.
Another object of the present invention is to provide a method and an apparatus for detecting the ICFO even under the circumstance that the unique identification used by the primary synchronization signal is undetermined. The method and apparatus employs the central symmetry property of all primary synchronization signals to estimate the ICFO without the exact ID of the current primary synchronization signal. Then, the method and apparatus determines the unique ID of the primary synchronization signal based on the estimated ICFO, thereby forming a sequential detection. The sequential detection can overcome the defect of high complexity of traditional methods that employ a joint detection to simultaneously detect the unique cell ID and the ICFO, effectively reduce the hardware resource consumption, and improve the communication quality of the LTE system.
Another object of the present invention is to provide a normalization procedure that enables the detection method of the present invention to effectively eliminate the negative impact of frequency selective fading, improve the detection accuracy and enhance the communication quality of the LTE system.
The method and apparatus for cell search and synchronization for a subscriber station of the LTE system aim to detect a primary synchronization signal transmitted by a base station. According to the LTE standard, there are three different primary synchronization signals defined in the LTE system. Therefore, the subscriber station needs to detect the primary synchronization signal used in the cell and the sector region where it is currently located to carry out subsequent data communications. According to the present invention, the symbol boundary detection is performed when the subscriber station first receives the base station signals. After the symbol boundary is determined, the location of each symbol can be obtained with the guard intervals (GI) between symbols in the OFDM system removed. After the Fast Fourier Transform (FFT) is performed, the detection of the ICFO and the identification of the primary synchronization signals can be made. According to the present invention, the ID of the primary synchronization signal is determined based on the correlation between the received signal and different primary synchronization signals. The signal with the greatest correlation will be elected as the primary synchronization signal used in the region where the subscriber station is located.
The method and apparatus for cell search and synchronization for a subscriber station of the LTE system of the present invention comprises six units, including: (1) an analog to digital conversion (ADC) unit, (2) an energy detector, (3) a symbol boundary detector, (4) an FFT unit, (5) an ICFO detector and (6) a primary synchronization signal detector. The ADC unit is utilized to convert analog signals to digital signals to realize signal processing in digital format. Next, the energy detector detects the energy of the received signals accumulated for a period of time, and such information will serve as normalization reference value for the subsequent unit. In the symbol boundary detector, the Cyclic Prefix (CP) of an OFDM symbol is utilized to detect the symbol boundary. Next, the FFT unit is utilized to transform the synchronization signal from time domain to frequency domain. The frequency domain signal is sent to the ICFO detector. According to the present invention, this unit employs the central symmetry property of the primary synchronization signal sequence to obtain the estimated ICFO and then compensate the ICFO effect. After the frequency domain signal is compensated, the primary synchronization signal detector detects which region the subscriber station locates to facilitate the subsequent transmission of data with the base station. Meanwhile, a normalization procedure is applied to the ICFO detector and the primary synchronization signal detector to effectively improve the accuracy of the detection and the robustness against channel fading.
The aforementioned aspects and other aspects of the present invention will be better understood with reference to the following exemplary embodiments and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the system framework of a method and an apparatus for cell search and synchronization designed for the Long Term Evolution (LTE) system in accordance with the present invention.
FIG. 2 is a block diagram showing an energy detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention.
FIG. 3 is a block diagram showing a symbol boundary detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention.
FIG. 4 is a schematic view showing the placement of the primary synchronization signal sequence on the resource units of the frequency domain of the corresponding symbol timing.
FIG. 5 is a block diagram showing an ICFO detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention.
FIG. 6 is a block diagram showing a primary synchronization signal detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention.
FIG. 7 is a graph showing an ICFO detection result of the simulation comparison between a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention and a traditional method.
FIG. 8 is a graph showing a detection result of the unique ID to which the primary synchronization signal corresponds of the simulation comparison between a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention and a traditional method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. Numerals mentioned in the following description refer to those shown in the drawings. It should be noted that the words “comprising” or “including” used in the description shall be interpreted as open-ended terms with the meaning of “including but not limited to.” Moreover, those of ordinary skill in the art should understand that, there may be different designations for the same component/product; for example, a “delay device” or a “delay counter (DC)” may refer to the same component/product. Therefore, components/products that are of the same technical field and similar to those mentioned in the following description should also be included in the scope of the present application.
The present invention is a method and an apparatus for cell search and synchronization designed for the LTE system, in which the primary synchronization signal sequence transmitted by the base station is detected at the subscriber station so that the subsequent transmission of control signals and data between the base station and the subscriber station can be performed at correct clock pulses. Meanwhile, the subscriber station can use the primary synchronization signal sequence to estimate the ICFO inflicted on the received signal, thereby providing reference for the subsequent signal processing. The present invention provides a reliable and less complicated method for cell search and synchronization, which is capable of detecting various primary synchronization signal sequences used by different base stations.
FIG. 1 is a block diagram showing the system framework of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention. According to the present invention, there is a method and an apparatus for cell search and synchronization designed for the LTE system comprising:
an ADC unit 1 receiving an analog signal 7 transmitted by a base station and performing an ADC processing thereon to output a digital signal 10 , wherein the sampling frequency used during the conversion depends on the frequency bandwidth used by the system;
an energy detector 2 receiving the digital signal 10 and detecting the energy of the received signals accumulated for a period of time to obtain a detection result and output a normalization reference value 20 ;
a symbol boundary detector 3 receiving the digital signal 10 and the normalization reference value 20 and utilizing the property of the cyclic prefix type guard interval (GI) to detect the location of the symbol boundary of the system transmission, wherein the symbol boundary detector 3 receives the normalization reference value 20 based on which correlation values are normalized to determine the location of the final GI and output a detection result 30 ;
a FFT unit 4 receiving the detection result 30 , removing samples which belongs to the GI and transforming the digital signal from time domain to frequency domain, wherein FFT units of various lengths are selected according to different frequency bandwidths in the system specification and the FFT units specified in the system specification can have the lengths of 128, 256, 512, 1024, 1536 and 2048 and output a primary synchronization signal 40 ;
an ICFO detector 5 receiving the primary synchronization signal 40 and employing the central symmetry property of the primary synchronization signal 40 to obtain the estimated ICFO value and output an ICFO signal 50 ; and
a primary synchronization signal detector 6 receiving the primary synchronization signal 40 and ICFO signal 50 and calculating the correlation between the primary synchronization signal 40 and different primary synchronization signals to determine the unique ID to which the primary synchronization signal finally received by the subscriber station corresponds and output an unique ID 60 .
FIG. 2 is a block diagram showing an energy detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention. The energy detector 2 comprises a first complex multiplier 21 , a first conjugate complex processor 22 , a first register 23 , a first complex adder 24 , a first delay device 25 , a second complex adder 26 and a first cross-symbol accumulator 27 . The first conjugate complex processor 22 receives the digital signal 10 and performs a conjugate complex processing thereon to output a first conjugate complex signal 221 . The first complex multiplier 21 receives the digital signal 10 and the first conjugate complex signal 221 and performs a multiplication processing thereon to output a first product signal 211 , as expressed in equation (1):
Y 1 ( n )= r ( n )* r* ( n ) (1)
The first register 23 receives and stores the first product signal 211 . The first register 23 has a length G, which is equivalent to the length of the GI, and is a First-In First-Out (FIFO) register that outputs a first temporary signal 231 at the time of (n-G) when the time is n. When the time is n, the output of the first delay device 25 is the result of the accumulation of the output of the first complex multiplier 21 by the time of previous G, as expressed in equation (2):
P
(
n
-
1
)
=
∑
i
=
n
-
G
-
1
n
-
1
Y
1
(
i
)
(
2
)
wherein i denotes the sampling time. P(n−1) denotes a first delay signal 251 outputted by the first delay device 25 when the time is n. The first complex adder 24 receives the first product signal 211 and the first delay signal 251 and performs an adding processing thereon to output a first summation signal 241 , as expressed in equation (3):
Q ( n )= Y 1 ( n )+ P ( n− 1) (3)
The second complex adder 26 receives the first summation signal 241 and the first temporary signal 231 and performs a subtraction processing thereon to output a second summation signal 261 , which is the result of the energy of the digital signal accumulated from n−G+1 to n when the time is n, as expressed in equation (4):
P ( n )= Q ( n )− r ( n−G )* r* ( n−G ) (4)
The first cross-symbol accumulator 27 receives the second summation signal 261 and performs a cross-symbol energy accumulation processing on the second summation signal 261 , i.e. the result of equation (4) calculated by previous I OFDM symbols (inclusive of the current moment), to output the normalization reference value 20 . The first cross-symbol accumulator 27 is configured to mitigate the impact of noise on the signal transmitted by the base station and passing the channel and to reduce the interference of the noise. The I value can be adjusted according to the environment where the user is located. If the user is in a location where the signal quality is relatively poor, the I value can be increased to reduce the interference of the noise. When the user is in a location where the signal quality is relatively good, the I value can be decreased to reduce the complexity in calculation. The I value can be set to be a minimum of 1.
FIG. 3 is a block diagram showing a symbol boundary detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention. The symbol boundary detector 3 comprises a second delay device 31 , a second conjugate complex processor 32 , a second complex multiplier 33 , a second register 34 , a third complex adder 35 , a fourth complex adder 36 , a third delay device 37 , a second cross-symbol accumulator 38 , an absolute value processor 39 , a divider 310 and a magnitude comparator 311 . The second conjugate complex processor 32 receives the digital signal 10 and performs the conjugate complex processing thereon to output a second conjugate complex signal 322 . The second delay device 31 receives the digital signal 10 and performs the delay processing with a delay of N sampling time thereon to output a second delay signal 312 , wherein N is the length of a FFT unit specified in the system specification at a specific frequency bandwidth. The second complex multiplier 33 receives the second conjugate complex signal 322 and the second delay signal 312 and performs the multiplying processing thereon to output a second product signal 332 , which represents the correlation between the second conjugate complex signal 322 and the second delay signal 312 . When the signal received by the second complex multiplier 33 is in the corresponding location in the Cyclic Prefix, there is a highly positive correlation between the second conjugate complex signal 322 and the second delay signal 312 . When the time is n, the correlation between the two signals is expressed as equation (5):
X 1 ( n )= r ( n−N )* r* ( n ) (5)
wherein X 1 (n) is the second product signal 332 when the time is n. The second register 34 receives and stores the second product signal 332 to output a second temporary signal 342 . The second register 34 has a length G, which is equivalent to the length of the GI, and is a FIFO register that outputs the calculation result of the second complex multiplier 33 at the time of (n−G) when the time is n. The third complex adder 35 receives the second product signal 332 and a third delay signal 372 and performs the adding processing thereon to output a third summation signal 352 . When the time is n, the third delay device 37 outputs the third delay signal 372 , which is the result of the accumulation of the output of the second complex multiplier 33 by the time of previous G, and G is the number of samples in the GI, as expressed in equation (6):
Φ
(
n
-
1
)
=
∑
i
=
n
-
G
-
1
n
-
1
X
1
(
i
)
(
6
)
wherein i denotes the sampling time. Φ(n−1) is the output of the third delay device 37 with a delay of one sampling time unit when the time is n. The third complex adder 35 receives the second product signal 332 and the third delay signal 372 and performs the adding processing thereon to output the third summation signal 352 , as expressed in equation (7):
K ( n )= X 1 ( n )+Φ( n− 1) (7)
wherein K(n) is the third summation signal 352 . The fourth complex adder 36 receives the third summation signal 352 and the second temporary signal 342 and performs the subtraction processing thereon to output a fourth summation signal 362 , which is the result of the accumulation of correlation values from time n−G+1 to n when the time is n, as expressed in equation (8):
Φ( n )= K ( n )− r ( n−G−N )* r* ( n−G ) (8)
wherein φ(n) is the fourth summation signal 362 calculated by previous I OFDM symbols (inclusive of the current moment). The second cross-symbol accumulator 38 receives the fourth summation signal 362 and performs the accumulation processing on correlation values across symbols for the fourth summation signal 362 to output a cross-symbol accumulation signal 382 . The absolute value processor 39 receives the cross-symbol accumulation signal 382 and performs the absolute value processing thereon to output an absolute value signal 392 . The divider 310 receives the absolute value signal 392 and the normalization reference value 20 and performs the dividing processing thereon to output a first normalization signal 313 . In the symbol boundary detector 3 , the symbol energy is normalized because the energy of each sample is different and the determination made based directly on the accumulated correlation values will be influenced by the magnitude of samples easily. The first normalization signal 313 is expressed as equation (9):
Γ
(
n
)
=
Φ
(
n
)
P
(
n
)
(
9
)
The magnitude comparator 311 receives the first normalization signal 313 , searches the maximum value of the first normalization signal 313 among the N+G samples and outputs the detection result 30 . N is the length of the FFT unit specified in the system specification at a specific frequency bandwidth, and G is the number of samples in the GI. The number of samples for an OFDM symbol is the length of the FFT unit specified in the system specification at a specific frequency bandwidth added with the number of samples in the GI. In the magnitude comparator 311 , the critical reference value of Γ(n) is set to be 0.05 to prevent the interference of noise which occurs when there is no data point transmission. When the magnitude comparator 311 determines that the maximum value among the N+G samples is greater than the critical reference value, the time n to which the maximum value corresponds is determined to be the location to which the symbol boundary corresponds, and the detection result 30 is outputted to the FFT unit 4 to be processed. If the maximum value is not greater than the critical reference value, the above step is repeated to calculate the location of the sample to which the symbol boundary corresponds.
After the symbol boundary is successfully detected, the symbol to which the primary synchronization signal corresponds can be obtained, and the signal is sent to the FFT unit 4 to be transformed from time domain to frequency domain. Next, the ICFO detector 5 and the primary synchronization signal detector 6 are utilized to detect the estimated ICFO value and the unique ID to which the primary synchronization signal received by the subscriber station corresponds.
In the LTE system, the primary synchronization signal transmitted by the base station is a Zadoff-Chu sequence having a length of 62. The base station has various unique IDs for different areas where different users are located. Different unique IDs correspond to different root indices of the Zadoff-Chu sequence and thus different primary synchronization signal sequences are generated. In the LTE system specification, there are three different unique IDs, 0, 1 and 2, corresponding respectively to three different root indices, 25, 29 and 34. The primary synchronization signal sequence is expressed as equation (10):
d
u
(
n
)
=
{
ⅇ
-
j
π
un
(
n
+
1
)
63
n
=
0
,
1
,
…
,
30
ⅇ
-
j
π
u
(
n
+
1
)
(
n
+
2
)
63
n
=
31
,
32
,
…
,
61
(
10
)
As shown in equation (10), u is the root index and d u (n) is the generated primary synchronization signal sequence. The primary synchronization signal sequence has the following characteristics.
1. The absolute value of each element in the primary synchronization signal sequence is a constant 1.
2. The primary synchronization signal sequence is characterized by the central symmetry property, that is, the value of the element whose location is 0 is equivalent to the value of the element whose location is 61, and other locations can be derived in the same way.
3. The sequence with a root index of 29 and the sequence with a root index of 34 are conjugate sequences, that is, elements at the same locations in the two sequences are conjugate complex numbers with respect to each other.
When the base station transmits the primary synchronization signal sequence, the primary synchronization signal sequence is placed on the resource element (RE) of the frequency domain of certain symbol. Referring to FIG. 4 , the primary synchronization signal sequence is placed on 31 sub-carriers at each of the left side and the right side of the sub-carrier of the central frequency, wherein the sub-carriers of the central frequency carry no data. D u (n) denotes the last transmitted primary synchronization signal sequence. The primary synchronization signal sequence received by the receiving end will be affected by the channel and noise, and the finally received primary synchronization signal sequence is Z(n).
As the oscillation frequency used in the base station may be inconsistent with that of the subscriber station, such inconsistency will damage the orthogonality between the sub-carriers of the signal received by the subscriber station and cause Inter-Carrier Interference (ICI), thus the location of the sub-carrier in the frequency domain where the data received by the subscriber station is located may be offset to the location of another sub-carrier. The frequency band used in the LTE system is 2 GHz, the tolerance range within which the oscillator used by the base station does not match that of the subscriber station is ±20 ppm, and the system sub-carrier spacing is 15 kHz. Therefore, the maximum offset range of the sub-carrier frequency is the spacing of ±3 sub-carriers. Regarding the signal processing performed at the subscriber station, the sub-carrier frequency offset needs to be estimated first so as to obtain the required data at the correct RE location in the frequency domain. For the above-mentioned reason, it requires the detection of the ICFO to obtain the correct location of the primary synchronization signal sequence after the FFT unit 4 is utilized to transform the primary synchronization signal from time domain to frequency domain. Therefore, the result outputted from the FFT unit 4 is sent to the ICFO detector 5 .
FIG. 5 is a block diagram showing an ICFO detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention. The ICFO detector 5 comprises a first coordinate arithmetic unit 51 , a first sine/cosine generator 52 , a fourth delay device 53 , a third conjugate complex processor 54 , a third complex multiplier 55 , a channel subdivider 56 , a third register 57 , a fourth register 58 , a first control unit 59 , a fourth complex multiplier 510 , a first accumulator 511 and an ICFO decision unit 512 . As the range of the ICFO is the spacing of ±3 sub-carriers, the data which are sequentially inputted to the overall 69 REs at both sides of the central frequency are Z(−34)˜Z(34). The first coordinate arithmetic unit 51 receives the primary synchronization signal 40 and performs an angle calculation thereon to output a first digital signal angle 513 . The first sine/cosine generator 52 receives the first digital signal angle 513 and performs a normalization processing thereon to output a second normalization signal 523 , as expressed in equation (11):
Z
n
(
i
)
=
Z
(
i
)
Z
(
i
)
(
11
)
The third conjugate complex processor 54 receives the second normalization signal 523 and performs the conjugate complex processing thereon to output a third conjugate complex signal 543 . The fourth delay device 53 receives the second normalization signal 523 and performs the delay processing thereon with a delay of one sampling time to output a fourth delay signal 533 . The third complex multiplier receives the fourth delay signal 533 and the third conjugate complex signal 543 and performs the multiplying processing thereon to output a third product signal 553 , as expressed in equation (12):
J ( i )= Z n*( i )* Z n ( i− 1) (12)
wherein J(i) is the third product signal 553 after the input of the i th RE. In order to eliminate the channel effect imposed on the primary synchronization signal sequence after it passes the channel, the conjugate complex number of the data on the i th RE is multiplied by the data on the adjacent RE. The channel subdivider 56 receives the third product signal 553 and performs a distribution processing thereon to output a first distribution signal 563 and a second distribution signal 564 .
As the block diagram of the ICFO detector shows that the data on 69 REs are inputted, there will be 68 sets of third product signals 553 in total. 1 st through 36 th entries of data of the third product signal 553 are sequentially stored in the third register 57 via the channel subdivider 56 while 33 rd through 68 th entries of data of the third product signal 553 are sequentially stored in the fourth register 58 . The third register 57 and the fourth register 58 both have a length of 36. The data stored in the third register 57 is expressed as equation (13):
S 1 ( i+ 34)= J ( i ), i=− 33˜2 (13)
wherein S 1 denotes the data sequence stored in the third register 57 . The data stored in the fourth register 58 is expressed as equation (14):
S 2 ( i+ 34)= J ( i ), i=− 1˜34 (14)
wherein S 2 denotes the data sequence stored in the fourth register 58 . As the primary synchronization signal sequence is characterized by the central symmetry property, the estimation of different ICFOs is performed by using the symmetry to calculate and accumulate their correlation. The first control unit 59 outputs a first control signal 593 and a second control signal 594 according to the correlation of different ICFOs to be estimated at the moment. The third register 57 and the fourth register 58 respectively receive the first control signal 593 and the second control signal 594 and output the corresponding data locations, a third temporary signal 573 and a fourth temporary signal 583 , respectively. Suppose the correlation of the first set of symmetric data under the condition that the ICFO is 0 is to be calculated, the first control unit 59 will retrieve the fourth entry of data from the third register 57 and the fourth entry of data from the fourth register 58 and output the two sets of data as the third temporary signal 573 and the fourth temporary signal 583 , respectively. The fourth complex multiplier 510 receives the third temporary signal 573 and the fourth temporary signal 583 and performs the multiplying processing thereon to output a fourth product signal 514 , as expressed in equation (15):
M 1 (1)= S 1 (4)* S 2 (4) (15)
wherein M 1 (1) is the fourth product signal 514 . Next, the first control unit 59 retrieves the data about the corresponding locations of the second set of symmetric data in the third register 57 and the fourth register 58 , and outputs such data as the third temporary signal 573 and the fourth temporary signal 583 , respectively. The fourth complex multiplier 510 receives the third temporary signal 573 and the fourth temporary signal 583 and performs the multiplying processing thereon to output a fourth product signal 514 . The first control unit 59 will repeat the above step to retrieve 30 sets of symmetric data. The first accumulator 511 receives the fourth product signal 514 and performs the accumulation processing on the 30 sets of fourth product signals 514 to output a first accumulation signal 515 . The ICFO decision unit 512 receives the first accumulation signal 515 , and there are seven possible ICFOs because the range of the ICFO is the spacing of ±3 sub-carriers. The first control unit 59 will retrieve the symmetric data to which the seven ICFOs correspond, and there are 30 sets of symmetric data for each ICFO. The first accumulator 511 will respectively accumulate the result of the correlation values of the seven ICFOs. The first accumulator 511 has seven outputs in total. The outputs of the first accumulator 511 correspond to different estimated ICFO values and are calculated as the first accumulation signal 515 , as expressed in equation (16):
Ω
(
v
)
=
∑
i
=
-
30
-
1
S
1
(
i
+
v
)
*
S
2
(
-
i
+
1
+
v
)
(
16
)
wherein ν denotes different estimated ICFO values and has a range of ±3. Ω(ν) denotes the first accumulation signal 515 to which different estimated ICFO values correspond. The seven outputs of the first accumulator 511 are sent to the ICFO decision unit 512 . The ICFO decision unit 512 receives the first accumulation signal 515 and outputs the ICFO signal 50 , which is used to calculate the distances between the seven complex values of the first accumulator 511 and the point (30+0i), and the ICFO value to which the minimum distance corresponds serves as the final estimated value for the ICFO in the system. The calculation is made with equation (17):
({circumflex over (ν)})=arg min|(ν)−(30+0 i )| (17)
wherein {circumflex over (ν)} is the ICFO signal 50 , i.e. the result of the ICFO that affects the system as finally estimated by the ICFO detector 5 .
When the ICFO detector 5 is utilized to obtain the ICFO value, the location of the primary synchronization signal sequence data in the RE of the frequency domain can be obtained. The primary synchronization signal data outputted by the FFT unit 4 is sent to the primary synchronization signal detector 6 to determine the unique ID issued by the base station for the area where the user is located, and the best matching result will be selected.
FIG. 6 is a block diagram showing a primary synchronization signal detector of a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention. The primary synchronization signal detector 6 comprises a second coordinate arithmetic unit 61 , a second sine/cosine generator 62 , a fifth delay device 63 , a fourth conjugate complex processor 64 , a fifth complex multiplier 65 , a fifth register 66 , a second control unit 67 , a primary synchronization signal storing unit 68 , a sixth complex multiplier 69 , a second accumulator 610 and an unique ID decision unit 611 . As the range of the ICFO is the spacing of ±3 sub-carriers, the data which are sequentially inputted to the overall 69 REs at both sides of the central frequency are Z(−34)˜Z(34), as shown in the block diagram of the primary synchronization signal detector. The second coordinate arithmetic unit 61 receives the primary synchronization signal 40 and performs the angle calculation thereon to output a second digital signal angle 612 . The second sine/cosine generator 62 receives the second digital signal angle 612 and performs the normalization processing thereon to output a third normalization signal 622 . The value of the third normalization signal 622 is expressed as equation (18):
Z
n
(
i
)
=
Z
(
i
)
Z
(
i
)
(
18
)
The fourth conjugate complex processor 64 receives the third normalization signal 622 and performs the conjugate complex processing thereon to output a fourth conjugate complex signal 642 . The fifth delay device 63 receives the third normalization signal 622 and performs the delay processing thereon with a delay of one sampling time to output a fifth delay signal 632 . The fifth complex multiplier 65 receives the fifth delay signal 632 and the fourth conjugate complex signal 642 and performs the multiplying processing thereon to output a fifth product signal 652 , as expressed in equation (19):
H ( i )= Z n*( i )* Z n ( i− 1) (19)
wherein H(i) is the fifth product signal 652 outputted after the input of the i th RE. In order to eliminate the channel effect imposed on the primary synchronization signal sequence after it passes the channel, the conjugate complex number of the data on the i th RE is multiplied by the data on the adjacent RE. Referring to FIGS. 5 and 6 , the functions of the first coordinate arithmetic unit 51 , the first sine/cosine generator 52 , the fourth delay device 53 , the third conjugate complex processor 54 and the third complex multiplier 55 are the same as those of the second coordinate arithmetic unit 61 , the second sine/cosine generator 62 , the fifth delay device 63 , the fourth conjugate complex processor 64 , and the fifth complex multiplier 65 , thus the hardware resource of this part is shared in one embodiment. The fifth register 66 sequentially receives the fifth product signal 652 and performs the storing processing thereon sequentially. The data stored in the fifth register 66 is expressed as equation (20):
S 3 ( i+ 34)= H ( i ), i=− 33˜34 (20)
wherein S 3 denotes the data sequence stored in the fifth register 66 . The fifth register 66 has a length of 68. In the block diagram of the primary synchronization signal detector, the primary synchronization signal detector 6 receives the output of the ICFO detector 5 .
Under the circumstance that the ICFO is known, a third control signal 672 and a fourth control signal 673 outputted by the second control unit 67 are respectively sent to the fifth register 66 and the primary synchronization signal storing unit 68 , the correct data location corresponding to the received data affected by the ICFO is retrieved from the fifth register 66 via the third control signal 672 outputted by the second control unit 67 . For example, when the ICFO is 0, the correct location of the primary synchronization signal 40 stored in the fifth register 66 after being processed is S 3 (4)˜S 3 (65) The primary synchronization signal storing unit 68 stores the possible results obtained by performing the conjugate complex multiplication on the elements and the adjacent elements in all potential primary synchronization signal sequences transmitted by the base station.
As the primary synchronization signal sequence is characterized by the central symmetry property and two sequences with a root index of 29 and a root index of 34 are conjugate sequences, the primary synchronization signal storing unit 68 causes the storing of the result obtained by performing the conjugate complex multiplication on the elements at the left side of each of the two sequences with a root index of 25 and a root index of 29 and the adjacent elements. The unique ID transmitted by the base station can be estimated by calculating and accumulating the correlation between the primary synchronization signals with three different known root indices and the received primary synchronization signal. Next, the best matching result will be selected to be the detected unique ID. As there are three different unique IDs corresponding to three root indices, the fifth register 66 and the primary synchronization signal storing unit 68 respectively receive the third control signal 672 and the fourth control signal 673 and respectively output a fifth temporary signal 662 and a primary synchronization signal storage signal 682 when the correlation value is calculated at the root index of 25. The sixth complex multiplier 69 receives the fifth temporary signal 662 and the primary synchronization signal storage signal 682 at the first corresponding data. Suppose the detection result of the ICFO is 0, a sixth product signal 692 is outputted, as expressed in equation (21):
M 2 (1)= S i (4)* D 25*(− 31)* D 25 (−30) (21)
Wherein M 2 (1) is the sixth product signal 692 . The second control unit 67 retrieves the data to which the second symmetric data correspond in the fifth register 66 and the primary synchronization signal storing unit 68 and outputs such data to the sixth complex multiplier 69 . The second control unit 67 repeats this step to retrieve 60 sets of symmetric data. The second accumulator 610 receives the sixth product signal 692 and performs the accumulation processing thereon (i.e. the correlation value obtained after the sixth complex multiplier 69 calculates the accumulated data of the 60 sets of symmetric data) to output a second accumulation signal 613 . The unique ID decision unit 611 receives the second accumulation signal 613 under the circumstance that there are three different root indices and seven different ICFO results detected by the ICFO detector 5 . The calculation of the second accumulation signal 613 corresponding to different root indices is made with equation (22):
Λ
(
u
)
=
∑
k
=
-
31
-
2
S
3
(
k
+
v
+
35
)
*
D
u
*
(
k
)
*
D
u
(
k
+
1
)
+
∑
k
=
1
30
S
3
(
k
+
v
+
35
)
*
D
u
*
(
k
+
1
)
*
D
u
(
k
)
(
22
)
Λ(u) denotes the corresponding second accumulation signal 613 at different root indices. The unique ID decision unit 611 receives three sets of second accumulation signals 613 . The unique ID decision unit 611 calculates the magnitude of the three sets of second accumulation signals 613 , retrieves the corresponding unique ID of the root index to which the set of second accumulation signal 613 with the greatest magnitude corresponds as the final estimated value of the unique ID for the system, and outputs the unique ID 60 . The calculation is made with equation (23):
û =arg max Λ( u ) (23)
In equation (23), û is the result of the unique ID for the system finally estimated by the primary synchronization signal detector 6 . The method for cell search and synchronization designed for the LTE system ends with the primary synchronization signal detector 6 outputting the unique ID 60 .
All the above-mentioned functions can be performed by a processor, such as a microprocessor, a controller, a micro-controller or an application specific integrated circuit (ASIC), in accordance with the software or program code for executing such functions. The mobile subscriber station generally employs an ASIC. In real practice, it requires three real complex multipliers and five real adders to realize the complex multiplier. It requires two real adders to realize the complex adder. Table 1 below lists the respective computation loads required for the present invention and the traditional technique and the ratio of the computation load of the present invention and that of the previous invention.
TABLE 1
Real Complex
Real Adder
Multiplier
Traditional
9072
3906.
Technique
The Present
2811
1341.
Invention
Percentage
30.9%
34.3%
FIG. 7 is a graph showing an ICFO detection result of the simulation comparison between a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention and a traditional method. FIG. 7 shows two simulation results, the simulation result 71 of the traditional method and the simulation result 72 of the present invention. The simulation is carried out for 500 thousand times, and the ICFO that affects the receiving e is randomly generated. As can be seen from FIG. 7 , the ICFO detection result obtained using the present invention is better than that of the traditional method and the computation load of the present invention is reduced to 31% of that of the traditional method.
FIG. 8 is a graph showing a detection result of the unique ID to which the primary synchronization signal corresponds of the simulation comparison between a method and an apparatus for cell search and synchronization designed for the LTE system in accordance with the present invention and a traditional method. FIG. 8 shows two simulation results, the simulation result 81 of the traditional method and the simulation result 82 of the present invention. The simulation is carried out for 500 thousand times, and the primary synchronization signal sequence transmitted by the transmitting station is randomly generated. As can be seen from FIG. 8 , the detection result of the unique ID of the present invention shows better accuracy compared with that of the traditional method, and the computation load of the present invention is reduced to 31% of that of the traditional method.
To sum up, the method and apparatus for cell search and synchronization designed for the LTE system of the present invention has the following advantages compared with the prior art technique:
1. When performing cell search and synchronization, the present invention utilizes simple signal detection techniques to detect the location of the OFDM symbol first so that the complexity of the subsequent calculation can be reduced and the accuracy can be improved;
2. The present invention utilizes the energy of the digital signal as the basis for normalization in tracing the boundary of the OFDM symbol. The result of tracing the boundary of the OFDM symbol will not be easily affected by the gain of the channel through which the signal passes and the number of samples so that the location of the boundary of the OFDM symbol can be detected accurately;
3. When detecting the ICFO and the unique ID to which the primary synchronization signal corresponds, the present invention employs the central symmetry property of the primary synchronization signal first so that the extent to which the system is affected by the ICFO can be accurately and effectively detected;
4. The present invention can detect different primary synchronization signal sequences used by the base station, and can obtain the received primary synchronization signal sequence at a correct location of the RE when the ICFO value is acquired. The unique ID to which the primary synchronization signal used by the base station in the region where the subscriber station is located corresponds is obtained by comparing different primary synchronization signal sequences; and
5. Compared with the traditional method, the computation load of the method and apparatus for cell search and synchronization designed for the LTE system of the present invention is reduced by 69%. Compared with the traditional method, the present invention's efficiency in detecting the ICFO and the unique ID to which the primary synchronization signal corresponds is better or almost unaffected.
The present invention has been described with exemplary embodiments and drawings, thus those skilled in the art understand that various modifications can be made to the forms and details, and that the embodiments are not intended to limit the patent scope of the present invention. Any implementation or alteration having equivalent effect without departing from the spirit of the present invention falls within the patent scope of the present invention.
The preferred embodiments of the method and apparatus for cell search and synchronization for the LTE system of the present invention have been described with reference to the accompanying drawings. All the features disclosed in this specification may be combined with other methods. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, except for those particularly distinctive features, each feature disclosed herein is only an example of a generic series of equivalent or similar features. Given the above description of preferred embodiments, those skilled in the art would understand that the present invention possesses novelty and inventive step over the prior art and is industrially applicable. Various modifications may be made by those skilled in the art without departing from the scope of the present invention.
|
The present invention provides a method and an apparatus for cell search and synchronization for subscriber stations of the Long Term Evolution (LTE) system. The invention uses primary synchronizing signal of primary synchronization code in each frame structure to establish synchronization with the base station when a subscriber station accesses the LTE network. With such synchronization between the subscriber station and the base station, control signals and transmission data may be correctly exchanged between them.
| 7
|
FIELD OF THE INVENTION
[0001] The present invention relates to a vacuum boring and mud recovery container.
BACKGROUND OF THE INVENTION
[0002] Current state of the art vacuum boring and mud recovery systems, such as U.S. Pat. No. 6,453,584 by the present inventor, have a vacuum container having a vacuum capable of boring and mud recovery and provide simultaneously, vacuum fill, store and dispense. However problems arise from the horizontally mounted debris tank when trying to dispose of the debris.
[0003] The primary objective of the present invention is to provide a vacuum boring and mud recovery container having a fixed slope to allow a greater percentage of fill of the debris tank before the debris full level reaches the vacuum cut off valve, provides compact size, concentrated weight, efficient plumbing and debris to be emptied from the vacuum container by gravity when the access door is opened.
SUMMARY OF THE INVENTION
[0004] The above described objectives and others are met by a vacuum container mounted at a fixed slope and supported by a liquid water container. The fixed slope may be of sufficient angle to allow debris to be emptied from the vacuum container by gravity when the access door is opened. A filter housing may be mounted to and supported by the vacuum container. By flush mounting the clean out end of the filter housing. with the clean out end of the vacuum container, a single access clean out door may be used to access both simultaneously. This compact design provides efficient interaction and plumbing between the water tank, vacuum tank and filter housing as well as concentrating weight and reducing floor space. Two parallel tubular support means may be added at the base of the above described unit and extended past the water container sufficient length to mount a support base for a power plant, which may consist of an engine, a vacuum producing means, a vacuum/blower, a water pump, a water jetter pump, a hydraulic pump and reservoir, an air compressor and air tank, an electric generator, a heater, controls, monitor, sensors, or a goose neck trailer coupler.
[0005] The above described unit may be efficiently and quickly convertible from a skid mount unit to a pick-up truck bed mounted unit secured by the goose neck ball located in the bed of a pick-up truck, converted to a forklift mounted unit or a skid steer mounted unit or be converted to a trailer mounted unit dependent on the users need for the days activity. A vibrating screen may be mounted by flexible connections on the inside of the vacuum container, preferably to the inside of the access door, to separate liquids from solids.
[0006] Liquid cleaning, purification or sterilizing means may be added within the vacuum container or be mounted to the exterior of the vacuum container for the purpose of pretreatment of the water as it is recycled. A liquid dispensed means, such as a pump, may dispense liquid from the vacuum container vibrating screen effluent through the desired pretreatment means and into the liquid holding container with or without eliminating the vacuum within the vacuum container, thus recycling liquid for reuse. This technique allows the original liquid carried to a work site to be reused multiple times.
[0007] The vacuum container may have a screw conveyor means attached so as to dispense solids from the vacuum container with or without eliminating the vacuum within the vacuum container. An air nozzle means may be attached to the discharge orifice of the screw conveyor so as to further convey the solids by air. The air discharge from the vacuum-producing device may be utilized as the source of air supplied to the air nozzles for the purpose of conveying the solids dispensed by the screw conveyor. The air blower technique further improves efficiency and provides a compact system by using a single air blower device to provide both a vacuum for the vacuum container and an air volume under pressure to convey the dispensed solids.
[0008] A powered rotating, telescoping articulated boom with one or more arms, elbows and knuckles may be attached so as to convey through the boom conduit the air conveyed solids to a dispensing point of choice such as a dump truck bed or recycled back into a ditch or hole from which it was removed. A cyclone may be attached to the end of the boom conduit to separate the solids from the air volume used to convey the solids.
[0009] The above described system may be stationary or mobile. Mobility may be obtained by mounting the system on a trailer, powered vehicle, truck, zero turn radius drivable vehicle, fork lift, skid steer, barge, or railcar.
[0010] The above vacuum system is further empowered by vacuum hose end attachments, which may be applied so as to improve the vacuum ability of substances such as dirt, gravel, asphalt, concrete, or surface cleaning such as hydrocarbons, rust, or paint. The above vacuum system processes wet and/or dry material, thus providing means to separate rust, paint chips, sand, dirt, or asphalt from liquids, and further remove hydrocarbons from water and sterilize the cleaned water if needed. The high pressure water pumps provide water to a wide variety of spray nozzles at a variety of pressures for cleaning, cutting, emulsifying or demolition.
[0011] Numerous other embodiments are also possible. These elements of the embodiments described herein can also be combined in other ways, or with other elements to create still further embodiments.
BRIEF DESCRIPTION OF DRAWINGS
[0012] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which may be regarded as forming the present invention, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying drawings, in which:
[0013] FIG. 1 is a side view of a vacuum container mounted at a fixed slope according to a preferred embodiment of the invention.
[0014] FIG. 2 is a side view of the vacuum container unit of FIG. 1 , arranged on the bed of a pick-up, according to an embodiment of the invention.
[0015] FIG. 3 is a side view of the vacuum container unit of FIG. 1 , showing the solids/liquid separator and jetter water pump, according to an embodiment of the invention.
[0016] FIG. 4 is a side view of the vacuum container unit of FIG. 1 , arranged on a skid steer according to an embodiment of the invention.
[0017] FIG. 5 is a side view of the vacuum container unit of FIG. 1 , showing the rotating, articulating, telescoping, vacuum conduit boom, according to an embodiment of the invention.
[0018] FIG. 6 is a side view of the vacuum container unit of FIG. 1 , arranged on a zero turn radius vehicle according to an embodiment of the invention.
[0019] FIG. 7 is a side view of the vacuum container unit of FIG. 1 , showing the solids dispensing unit according to an embodiment of the invention.
[0020] FIG. 8 is a side view of the vacuum container unit of FIG. 1 , arranged on a zero turn radius vehicle according to an embodiment of the invention.
[0021] FIG. 9 is a side view of the vacuum container unit of FIG. 1 , arranged on a zero turn radius vehicle according to an embodiment of the invention.
[0022] FIG. 10 is a side view of the vacuum container unit of FIG. 1 , arranged on a trailer towed by a truck according to an embodiment of the invention.
[0023] FIG. 11 is a side view of the vacuum container unit of FIG. 1 according to an embodiment of the invention.
[0024] FIG. 12 is a side view of the vacuum container unit of FIG. I arranged on a zero turn radius vehicle according to an embodiment of the invention.
[0025] FIG. 13 is a side view of a vacuum container unit according to an embodiment of the invention.
[0026] FIG. 14 is a side view of an articulating jetter boom according to an embodiment of the invention.
[0027] FIG. 15 is a side view of a vacuum container according to an embodiment of the invention.
[0028] FIG. 16 is a side view of a vacuum container unit according to an embodiment of the invention.
[0029] FIG. 17 is a side view of a vacuum container unit according to an embodiment of the invention.
[0030] FIG. 18 is a side view of a vacuum container unit arranged on a skid steer, according to an embodiment of the invention.
[0031] FIG. 19 is a side view of the vacuum container unit of FIG. 1 arranged on a zero turn radius vehicle, according to an embodiment of the invention.
[0032] FIG. 20 is a side view of the vacuum container unit of FIG. 1 arranged on a zero turn radius vehicle according to an embodiment of the invention.
[0033] FIG. 21 is a side view of a vacuum container unit according to an embodiment of the invention.
[0034] FIG. 22 is a side view of a vacuum container unit arranged on a zero turn radius vehicle, according to an embodiment of the invention.
[0035] FIG. 23 is a side view of a vacuum container unit according to an embodiment of the invention.
[0036] FIG. 24 is a side view of the vacuum container unit of FIG. 1 according to an embodiment of the invention.
[0037] FIG. 25 a is a plan view of a rotating head sprayer according to an embodiment of the invention.
[0038] FIG. 25 b is a side sectional view of a sprayer according to an embodiment of the invention.
[0039] FIG. 26 is a side view of the vacuum conduit according to an embodiment of the invention.
[0040] FIG. 27 a is a side view of a sound reduction muffler according to an embodiment of the invention.
[0041] FIG. 27 b is a side view of a sound reduction muffler according to an embodiment of the invention.
[0042] FIG. 28 is a cross sectional side view of a vacuum hose end according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] Referring to FIG. 1 , a vacuum container ( 12 ) is mounted at a fixed slope and supported by a liquid water container ( 8 ). The fixed slope may be of sufficient angle to allow debris to empty by gravity when the access door ( 18 ) is opened. This arrangement creates a compact package unit, reduces floor space needed to contain both liquid container ( 8 ) and vacuum debris container ( 12 ) and condenses the weight of the water container ( 8 ) and vacuum debris container ( 12 ) combination. The dual container combination lends itself, by compactness, to use as a multifunctional convertible unit capable of being quickly converted from a skid mount unit ( 64 ) to a trailer mount unit, to a gooseneck hitch coupled ( 63 ) pick up truck bed unit, to a fork lift or skid steer transported unit. A filter housing ( 62 ) may be mounted piggyback onto the outer shell of the vacuum debris container ( 12 ) thus further compacting the space required for the system and again condensing weight and increasing the efficiency of interaction between the water tank ( 8 ), vacuum container ( 12 ) and filter housing ( 62 ). By flush mounting the clean out end of the filter housing ( 62 ) with the clean out access end of the vacuum container ( 12 ), a single door ( 18 ) may be utilized to access both vacuum container ( 12 ) and filter housing ( 62 ) simultaneously. A power plant ( 67 ) may consist of an engine, vacuum/blower, water pump, hydraulic pump, air compressor or electric generator and may be mounted with the vacuum tank and water tank. A hose reel ( 37 ) and water fill pipe ( 65 ) are attached to water tank ( 8 ).
[0044] Referring to FIG. 2 , a vacuum debris tank ( 12 ) is mounted at a fixed slope and supported by a water tank ( 8 ). A filter housing ( 62 ) is mounted on the vacuum debris tank ( 12 ). The water tank ( 8 ) is mounted on the bed of a truck secured by the goose neck trailer coupler ( 63 ) for easy transportation means. Alternative means for easy transportation can also be achieved through mounting the system on a trailer ( 31 , FIG. 3 ), a skid steer ( 36 , FIG. 4 ), or a zero turn radius vehicle ( 31 , FIG. 6 ). The zero turn radius vehicle operates by maneuvering a tilt-away tow hitch and 360 degree swivel front wheels.
[0045] Referring to FIGS. 3 and 8 , a vibrated screen ( 21 ) may be mounted by flexible connector ( 68 ) to the inside of the vacuum debris container access door ( 18 ) to separate liquids ( 2 ) from the solids ( 6 ), which have been vacuumed into the vacuum container ( 12 ). Liquids ( 2 ) may be piped from the inner part vibrated screen ( 21 ), through the access door ( 18 ) and into a pump dispensing means ( 1 ) strong enough to overcome vacuum within the vacuum container. A liquid conduit ( 5 ) recycles the liquid ( 2 ) through a liquid purification or sterilization means ( 74 ) then back to the water tank ( 8 ). The liquid purification or sterilization means ( 74 ) may include a hydro cyclone ( 25 ), vortex generator, sand filter, activated carbon, zealite, sterilizing elements, filters, ozone, peat, sawdust, shavings, or hydrocarbon absorbing means which may be added in the vacuum container ( 12 ) or external to the vacuum container ( 12 ) to clean, or sterilize the recycled liquid. A jetter water pump ( 7 ) is attached to the water tank ( 8 ) and used to pressurize the water to the hose conduit ( 5 ).
[0046] Referring to FIG. 4 , a skid steer ( 36 ) can be used for easy mobility of the mounted system as well as providing direct power to the system by connecting the system's engine and vacuum blower power supply ( 67 ) to the skid steer's hydraulics.
[0047] Referring to FIGS. 5-14 , a powered, rotating, articulating, telescoping vacuum conduit boom ( 36 ) may be mounted onto the vacuum debris tank ( 12 ) in order to move the vacuum hose and it's attachments into place for vacuuming at a desired place to vacuum solids or liquids. The vacuum conduit boom ( 36 ) may be light weight to only move a vacuum hose or the boom ( 36 ) or may be strong enough to support and operate both a telescoping vacuum conduit and a bucket for digging or motorized attachments to pull a vacuum hose into and through a lateral drainage pipe which needs cleaned. The vacuum conduit boom ( 36 ) may also have multiple rotating swivel knuckles to aid in directing the vacuum hose into horizontal as well as vertical locations. The vacuum conduit boom ( 36 ) may also be equipped with hose reels and means to dispense both vacuum hoses and/or water jetter hoses to a point of use along with their individual attachments, such as jetter nozzles or tractors to pull a hose or operate sensors or digging or cleaning means.
[0048] The same boom ( 36 ) may have one or more hose reels attached so as to dispense vacuum hose ( 17 ), and/or water hose ( 5 ), and/or air hose, and/or hydraulic hose, and/or electrical power cords to a desired location for the purpose of vacuuming solids or liquids or making solids or liquids vacuumable, or monitoring or controlling the progress of the vacuuming process, or distributing a power source, for example, to a tractor or jetter nozzle, to pull a hose to a further location. The vacuum hose boom may also have multiple powered articulating arms, elbows, and knuckles to allow it to reach into manholes, or lateral lines leading to or from a manhole, or into silos or storage bens or railcar or tankers.
[0049] The vacuum conduit boom ( 36 ) may be constructed of sufficient strength to support and operate a bucket for digging as needed. The boom may also have quick change end attachments for vacuuming, surface cleaning with water pressure, demolition, grinding, jettering, or preparing surfaces as well as attachments to remove or replace manhole covers, or monitor or control the operation of attachments or sensors to detect obstacles or located utilities.
[0050] A screw conveyor ( 10 ) is used to move solids from the vacuum debris tank ( 12 ) to the solids dispensing telescoping and articulating boom ( 70 ) for disposal. The boom ( 70 ) could dispose of the solids within the bed of a dump truck ( FIG. 10 ), within a disposal pile away from the digging site, or any other means necessary. The conveyor ( 10 ) may be a compacting screen conveyor emptying into an air conveyor discharged from a blower ( 11 ) to convey solids.
[0051] Referring to FIG. 9 , a sensor/monitor may be used in order to detect buried utilities for the purpose of finding the utilities so they can be serviced, or in order to avoid damage to the utilities. The sensor my be located on the end of an articulating vacuum conduit boom ( 36 ) and be connected to a monitor located near the operator for ease of viewing. An attachment on the end of the articulating vacuum conduit boom ( 36 ) may include one or more of a water jet, vacuum, cleaning, demolition or sand blasting attachment in order to help in loosening the digging area.
[0052] A jetter nozzle ( 39 ) may be attached to a jetter hose ( 58 ) on the end of a dual articulating knuckle joint to align the jetter and/or vacuum hose ( 17 ) into a lateral drainpipe or manhole lateral. Water jets ( 40 ) on the jetter nozzle ( 39 ) are used to propel debris ( 45 ) towards the vacuum hose ( 17 ) and to move the jetter nozzle ( 39 ) along the drainpipe ( 38 ). A vacuum conduit tractor ( 51 ) may also be used to clean debris by clearing debris with an articulating suction head ( 53 ) connected to the vacuum conduit ( 17 ) and having a vacuum conduit tractor sensor controller ( 52 ) to guide the vehicle. Various other means of clearing the drainpipe ( 38 ) could be employed.
[0053] A vacuum and water hose reel ( 54 ) may be attached ( FIG. 11 ) in order to keep the vacuum and water hose lines clear from kinks or getting tangled in order to provide for an easy means to dispense and retract the various hoses.
[0054] Referring to FIG. 26 , vibrators may be added to the vacuum hose end to loosen hard to vacuum materials such as dry chemicals or elements in cyclones, storage bends, or railcars. Metal may be cleaned and prepared for welding or painting by water pressure. Adding lubricants to the water helps reduce the rust causing effect of using water pressure to remove scale, rust, primers, or paint from metals. Abrasive elements may also be added to the pressurized water to aid in loosing scale, rust, primers, or paint from metal. Once the pressure water loosens the above, the vacuum system described above vacuums the liquid and debris from the steel surface. Heated air under pressure may be blown onto the steel after vacuuming so as to remove remaining water residue. The vacuum/blower unit can double as both the source of vacuum and the source of heated air, since the vacuum producing means heats the air vacuumed from the vacuum container before the air is exhausted. The above described water pressure nozzle jet and vacuum system function as an alternative to using sand blasting as a means to clean and prep metal and clean welds.
[0055] Referring to FIGS. 27 a and 27 b , the air entering into or discharged from the combination blower/vacuum producing device may be passed through a muffler to reduce audible sounds conveyed by the blower air. The muffler of choice consists of passing the air through a perforated conduit wrapped with serwool or mineral wool or acoustic absorbing media. A protective outer surface is attached to contain and protect. The acoustic sound waves are absorbed into the wool or acoustic media For yet further sound reduction the air may then be diffused through additional tubes and orifices.
[0056] FIG. 28 is a means of using a water header ( 78 ) as the outer circumference ( 80 ) of the suction end of a vacuum hose ( 17 ). The water header ( 78 ) is supplied by a water supply hose ( 5 ), which may be placed in parallel proximity to the vacuum hose ( 17 ) and may be articulated by the same vacuum boom. The vacuum hose ( 17 ) suction end circumference water header ( 77 ) may have two or more orifices ( 76 ) and/or spray nozzles ( 82 ) to distance the water under pressure. A pulsing jet of water is preferred in many applications. A rotary spray nozzle, jetter nozzle, or air or water pulsing means ( 82 ) often reduces water consumption and simultaneously improves mass impact for loosening or emulsifying items to be vacuumed. A preferred arrangement is to have a vacuum hose ( 17 ) and circumference ( 80 ) configured as a water reservoir ( 77 ) to supply water to two or more pulse spray nozzles or jetter nozzles ( 82 ) arranged as the circumference ( 80 ) of the vacuum hose ( 17 ) suction end. The circumference ( 80 ) water reservoir is supplied by a pressure water hose ( 5 ) or conduit, a water pump, pressure regulation, controller, and sensors incorporated within the system.
[0057] While particular embodiments of the invention have been shown, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. Reasonable variation and modification are possible within the scope of the foregoing disclosure of the invention without departing from the spirit of the invention.
[0000] # Definition
[0000]
1 —Dispensing means
2 —Liquid
3 —Liquid Discharge conduit from Hydro cyclone 25
4 —Solids Discharge conduit from Hydro cyclone 25
5 —Discharge conduit from Liquid transfer pump 7
6 —Solids
7 —Liquid Transfer pump
8 —Container to hold dispensed liquids
9 —Container to hold dispensed solids
10 —Solids dispenser
11 —Vacuum producing means
12 —Vacuum container
13 —Conduit to connect Vacuum container 12 —vacuum producing means 11
14 —Discharge conduit from Vacuum producing means 11
15 —Utility
16 —Inlet conduit to Hydro cyclone 25
17 —Vacuum conduit
18 —End door to Vacuum container 12
19 —Means to secure end door 18
20 —Hinge for End door 18
21 —Screen
22 —Spring on Screen 21
23 —Vibrator
24 —Support for Springs 22
25 —Hydro cyclone
26 —Liquid sprayer
27 —Grinder
28 —Pivot support for Vacuum container 12
29 —Cylinder to Raise and Lower Vacuum Container 12
30 —Wheels on Mobile Platform 31
31 —Mobile Platform
32 —Cutting, Demolition, Cleaning and Blasting attachment means
33 —Utility Sensor means
34 —Monitor and/or Controller
35 —Ground Surface being dirt, asphalt, stone, or concrete
36 —Means to Mobilize Vacuum conduit 17 with attachment 32
37 —Hose Reel
38 —Drain Conduit
39 —Jetter
40 —Water Jet
41 —Means to power the Articulating Vacuum Boom
42 —Telescoping Vacuum conduit
43 —Digging Bucket
44 —Structural Means to Support and Articulate Vacuum Conduit
45 —Debris
46 —Man Hole Cover
47 —Means to Remove Man Hole Cover such as Electric Magnet, suction, mechanical fastener
48 —Power to Man Hole Cover removal means 47
49 —Solids Conveyer
50 —Boom Section
51 —Vacuum conduit Tractor
52 —Vacuum conduit Tractor Sensor Controller
53 —Vacuum conduit Tractor Articulating Suction Head
54 —Vacuum Hose Reel
55 —Purification Elements such as ozone, activated carbon or zealite
56 —Hydro carbon Absorbing means
57 —Sterilization means
58 —Jetter Hose
59 —Man Hole
60 —Articulating Jetter Boom
61 —Telescoping Jetter Conduit
62 —Filter Housing
63 —Goose Neck Trailer Coupler
64 —Skid and Lifting Receiver
65 —Fill Pipe to Water Tank
66 —Inside Debris Tank Center Door Closure Means
67 —Power Plant
68 —Flexible Connector for Vibrated Screen
69 —Air Nozzle Orifice to blow and convey solids and convey solids by air through the Boom Conduit
70 —Solids dispensing, telescoping and Articulating Boom
71 —Air Discharge from Vacuum Blower
72 —Combination Vacuum Hose and Jetter Water Hose articulated Telescoping Boom
73 —Swivel articulated Knuckle Joint to align Jetter and/or Vacuum Hose into a lateral line.
74 —Recycled Water Purification and Sterilization System
75 —Independent Hydraulic Drive Wheels
76 —Water Jet Orifice
77 —Water Reservoir Header
78 —Water Pressure
79 —Circumference of Vacuum Hose
80 —Circumference of Water Reservoir
81 —Center of Vacuum Hose
82 —Pulse or Rotary Jet or Jetter Nozzle
83 —Hydraulic Power Supply
84 —Hydraulic Tool and Equipment connection
85 —Hydraulic driven motor or Electric driven motor
86 —Articulating Boom Arm
87 —Control system for Drive Motor
88 —Revolution and/or Torque counter for Drive Motor
89 —.
90 —GPS (Global Positioning System) to map location of drive motor operation such as the location of a valve to be opened or closed or a core sample to be taken or a man hole location or repair point location or bored hole location
91 —Adapters for the drive motor such as extensions to reach and connect to valve stems or augers.
92 —Valve with valve stem
93 —Hose
94 —Hydrant
95 —Water pressure reducer-diffuser
96 —Hose Storage
97 —Liquid such as water from a hydrant
98 —In ground casing to valve stem
99 —Bafflers to absorb energy and reduce water pressure
100 —Hitch receiver
101 —Hitch receiver plugin
102 —Hitch stabilizing means
103 —Vehicle plug in power supply
104 —Power supply for drive motor
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A vacuum container mounted on an inclined slope and having a liquid water storage container mounted beneath the incline of the vacuum container. The water storage container may support the vacuum container. The slope may be of sufficient angle to allow debris to be emptied from the vacuum container by gravity when the access door is opened. A filter housing may be mounted to and supported by the vacuum container. By flush mounting the clean out end of the filter housing with the clean out end of the vacuum container, a single access clean out door may be used to access both simultaneously. This compact design provides efficient interaction and plumbing between the water tank, vacuum tank and filter housing as well as concentrating weight and reducing floor space.
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CROSS-REFERENCE TO A RELATED APPLICATION
[0001] This application is a National Phase Patent Application of International Application Number PCT/DE2004/000300, filed on Feb. 13, 2004, which claims priority of German Patent Application Number 103 10 018.0, filed on Feb. 28, 2003.
BACKGROUND
[0002] The invention relates to a device for fixing a belt lock of a safety belt on a vehicle seat.
[0003] From U.S. Pat. No. 3,977,725 a longitudinally displaceable vehicle seat is known having a seat underframe which is connected to the floor of the vehicle through a longitudinal adjustment device. The longitudinal adjustment device comprises two longitudinal rail guides with guide rails extending in the longitudinal direction of the seat and displaceable relative to each other in the seat longitudinal direction and of which a bottom rail is connected to the vehicle floor and a top rail guided in the bottom rail is connected to the seat underframe so that adjusting the longitudinal position of the vehicle seat can be carried out by moving the top rail.
[0004] The vehicle seat is assigned a belt lock of a safety belt which serves to secure the position of a vehicle occupant sitting on the vehicle seat. The belt lock is on the one hand fixed to a top rail of the longitudinal adjustment device of the vehicle seat so that during longitudinal adjustment of the vehicle seat for comfort reasons the belt lock always retains the same position on the seat underframe. The connection of the belt lock to the top rail of the longitudinal adjustment device is provided by a retaining angle with a fixing point in the rear end region of the seat underframe to which the seat back is attached. In addition the belt lock is fixed on a bolt which is connected to a seat height adjusting mechanism of the vehicle seat so that the belt tension is not changed when adjusting the seat height. However the bolt does not serve to take up the cash forces which act on the vehicle seat or a person seated on the vehicle seat in the event of a crash.
[0005] When fixing a belt lock on a longitudinal guide rail for a vehicle seat there is basically the problem that in the event of a crash very severe forces act on the belt lock when a vehicle occupant seated on the seat is restrained by the safety belt assigned to this belt lock. This can lead in particularly serious accidents to either the retaining angle becoming deformed, i.e. stretched so that the belt point is shifted undesirably forwards or the retaining angle becoming detached from the top rail for example by a welded seam which serves to connect the retaining angle to the top rail being sheared off, or the connection between the top rail and bottom rail of the longitudinal rail guide becoming detached which leads to uncontrolled movement of the vehicle seat with the vehicle occupant located thereon.
[0006] The problems outlined above can be further increased in that in the event of a short distance between the longitudinal rail guides a correspondingly longer lever is required on the retaining angle in order to produce a connection between the top rail and a side of the vehicle seat. The extended angle of the retaining angle leads with the same crash forces to an increase in the torque acting on the fixing point of the retaining angle on the top rail so that the risk of damage to the connection between the retaining angle and top rail, the risk of the top rail tearing away from the connection with the bottom rail and the risk of the retaining angle stretching are all increased.
[0007] The object of the present invention is therefore to provide a device for fixing a belt lock of a safety bolt on a vehicle seat of the type mentioned above which eliminates or at least minimises the risk of a crash-conditioned sharp forward displacement of the belt point or the separation of the connection of the belt lock with the fixing in the vehicle seat without changing the operating comfort.
BRIEF DESCRIPTION
[0008] The solution according to the invention removes or minimises the risk of a crash-conditioned sharp forward displacement of the belt point or of a separation of the connection of the belt lock with the fixing on the vehicle seat without reducing the operating comfort when adjusting the length or height of the vehicle seat since a constant optimum positioning and alignment of the belt lock makes it easier to open and close the safety belt despite the swivel movement of the cross tube.
[0009] The solution according to the invention has proved advantageous particularly in the case of longitudinal rail guides having a small gap where the risk of damage to the connection between the belt lock and vehicle seat is particularly great as a result of a long lever arm of the retaining angle.
[0010] With the fixing device according to the invention crash-conditioned forces are introduced directly into the cross tube so that no additional connecting or reinforcement means are required which cause the problems mentioned above. Since the cross tube connecting the top rails is designed to take up the crash-conditioned forces and in the event of a crash distributes the strain starting from the safety belt out to both longitudinal rail guides, the risk of the top rail assigned to the belt lock fixing becoming separated from the bottom rail is minimised.
[0011] An advantageous development of the solution according to the invention is characterised in that the locator has an adapter connected to the cross tube and provided with an adapter flange for connecting the belt lock.
[0012] The adapter can be connected optionally fixed to the cross tube and thus follow a rotational movement of the cross tube or alternatively can be fitted onto the cross tube so that the cross tube engages through an opening in the adapter flange with rotational movement and the alignment of the adapter remains independent of any rotation of the cross tube which may be necessary for example for adjusting the seat height.
[0013] The configuration and attachment of the adapter can be provided in different ways. In a first embodiment the adapter is in particular pushed onto the cross tube and connected to a base element of the vehicle seat through a connecting flange. Through these means the adapter retains a predetermined alignment so that additional guide means for aligning the belt lock are not required.
[0014] The base element to which the connecting flange is connected for example through a welded joint, can consist for example of a bearing block holding the cross tube and for example connected to the top rail of the longitudinal rail guide, or of a seat side part of the vehicle seat.
[0015] Alternatively the adapter can have a bolt insertable in the side end of the cross tube, and an adapter flange for connecting the belt lock.
[0016] This configuration of the adapter is then particularly advantageous when the distance between the longitudinal rail guides corresponds roughly to the width of the vehicle seat so that an additional connecting flange can be omitted.
[0017] More particularly with a rotationally secured connection of the adapter for connecting the belt lock to a rotatable or pivotal cross tube of in particular a height-adjustable seat underframe, as additional means for uniform alignment of the belt lock can be provided an additional belt lock guide for holding and aligning the belt lock which is preferably connected to a cover panel of the seat side part of the vehicle seat. The belt lock guide can however also be provided in the case of an adapter fitted onto the cross tube wherein the cross tube engages rotationally movable through an opening in the adapter flange and thus the alignment of the adapter is independent of the rotation of the cross tube which may be necessary for example for adjusting the seat height.
[0018] The locator according to the invention can be provided on an end region of the cross tube or on both end regions of the cross tube so that the vehicle seat can be used both on the right and left hand side of the vehicle.
[0019] The invention will now be explained in further detail with reference to embodiments illustrated in the drawings.
[0020] FIG. 1 is a perspective view of a seat underframe with adapters mounted on the end regions of a cross tube;
[0021] FIG. 2 is a front view of the seat underframe according to FIG. 1 ;
[0022] FIG. 3 is an enlarged detailed view of the adapter mounted on the cross tube according to FIGS. 1 and 2 with a fixing of the adapter on a bearing block of the cross tube;
[0023] FIG. 4 is an enlarged view of an adapter fixed on a seat side part;
[0024] FIG. 5 is a sectional view through an adapter having a stepped bolt and an adapter flange and insertable in the end region of a cross tube; and
[0025] FIG. 6 is a perspective view of an adapter connected rotationally secured to a cross tube and of a belt lock guide fixed on a cover panel of a seat side part.
DETAILED DESCRIPTION
[0026] FIG. 1 shows in a perspective view a seat underframe 1 of a longitudinally adjustable vehicle seat with two longitudinal rail guides 2 a and 2 b of a longitudinal adjustment device of a vehicle seat each with a bottom rail 21 , 23 connected to the vehicle floor in which according to FIG. 2 top rails 22 , 24 are guided adjustable in the longitudinal direction.
[0027] For the longitudinal adjustment of the vehicle seat an adjusting drive 11 is provided which is connected for example to the top rails 22 , 24 and whose shaft engages through pinions at the ends into toothed racks connected to the bottoms rails 21 , 23 so that a corresponding seat adjustment takes place by turning the motor shaft of the adjusting drive 11 in one or other rotational direction.
[0028] To the front ends of the top rails 22 , 24 are connected front bearing blocks 31 , 32 which take up a cross bar 3 whose ends are fitted with front pivotal supports 33 , 34 for holding the front end of a seat trough of the vehicle seat. The rear ends of the top rails 22 , 24 are fitted with rear bearing blocks 41 , 42 in which a cross tube 4 is mounted. The cross tube 4 is connected to rear pivotal supports 43 , 44 and 45 , 46 respectively which can be connected through bores 48 , 49 to the rear end of the seat trough of the vehicle seat. The cross tube 4 is furthermore connected to a drive motor 12 through a crank 47 and during actuation of the drive motor 12 is turned in one or other direction so that the rear pivotal supports 43 , 44 and 45 , 46 are adjusted through the crank 47 and the seat trough of the vehicle seat is raised or lowered to adjust the height of the vehicle seat.
[0029] To the end regions 40 a , 40 b of the cross tube 4 protruding beyond the rear bearing blocks 41 , 42 are connected adapters 5 which are comprised of an adapter flange 50 and a connecting flange 53 and have a bore 52 for connecting a belt lock or a belt lash connected at the end to a belt lock. The adapter flange 50 has an opening 51 which can be pushed over the cross tube 4 so that the adapter flange 50 is mounted close to the side end 40 of the cross tube 4 . The connecting flange 53 is in this embodiment angled at right angles away from the adapter flange 50 and is connected to the bearing block 41 , 42 for example through a welded seam 54 .
[0030] The opening 51 of the adapter flange 50 is pushed according to the detailed view in FIG. 3 with a tight fit over the cross tube 4 whilst still allowing the cross tube 4 to rotate inside the opening 51 . By connecting the adapter 5 to the bearing blocks 41 , 42 the connection point for the belt lock in relation to the seat trough or seat side part of the vehicle seat remains constant independently of the height adjustment of the vehicle seat so that no additional measures are required to align the belt lock.
[0031] By connecting the adapter 5 directly to the cross tube 4 crash forces acting on the seat belt and thus on the belt lock are introduced directly through the adapter flange 50 and the bore 51 into the cross tube 4 so that no force diversion takes place through a retaining angle or the like. Crash forces emanating from the safety belt are distributed through the bearing blocks 41 , 42 to the top rails 22 , 24 of the longitudinal rail guides 2 a , 2 b so that a substantially uniform load distribution takes place over the longitudinal rail guides 2 a , 2 b of the longitudinal adjustment device.
[0032] The detailed view shown in perspective in FIG. 4 shows a connection of the adapter 5 to the seat side part 10 of the vehicle seat wherein the connecting flange 53 of the adapter 5 is connected to the seat side part 10 through a welded joint 54 . The construction and function of the adapter 5 corresponds to the construction of the adapter 5 illustrated in FIGS. 1 to 3 and its arrangement on the cross tube 4 and its function so that reference is made to the preceding description.
[0033] The length of the connecting flange 53 depends substantially on its connection to a fixing means of the seat underframe, for example the bearing blocks 41 , 42 or side part 10 as well as on the distance of the adapter flange 50 from the fixing means. Since the adapter flange 50 owing to the connection and alignment of the belt lock is preferably mounted in the region of the side end 40 of the cross tube 4 the length of the connecting flange 53 depends on the end regions 40 a , 40 b of the cross tube 4 which project sideways beyond the bearing blocks 41 , 42 . Where the distance between the longitudinal rail guides 2 a , 2 b is shorter than the distance between the longitudinal rail guides 2 a , 2 b shown in FIGS. 1 and 2 , the length of the end regions 40 a , 40 b of the cross tube 4 is correspondingly shortened so that the length of the connecting flanges 53 is also shortened correspondingly.
[0034] Whereas with the arrangement shown in FIGS. 1 to 3 owing to the connection of the cross tube 4 to the top rails 22 , 24 of the longitudinal rail guides 2 a , 2 b the adapter 5 is located at a constant height remote from the vehicle floor, with the arrangement according to FIG. 4 it is ensured that the adapter 5 retains a constant position in relation to the seat trough and thus in relation to the seat cushion of the vehicle seat independently of the height adjustment of the vehicle seat since the cross tube 4 is supported in this embodiment on the seat side part 10 and is connected through the pivotal supports to the top rails 22 , 24 of the longitudinal rail guides 2 a , 2 b of the longitudinal adjustment devices.
[0035] As an alternative to the structural form of the adapter 5 shown in FIGS. 1 to 4 and its arrangement on the cross tube 4 the adapter flange 50 can also be mounted on the inside of the bearing blocks 41 , 42 and a connecting flange can be extended sideways from the adapter flange 50 to connect the belt lock.
[0036] A further alternative is illustrated in FIG. 5 . The embodiment illustrated in FIG. 5 is particularly suitable for cases where the side end 40 of the cross tube 4 is located directly on the bearing block 41 so that the adapter 5 illustrated in FIGS. 1 to 4 would be mounted by its adapter flange 50 on the side of the bearing block 41 remote from the side end 40 of the cross tube 4 .
[0037] With the embodiment illustrated in FIG. 5 the adapter 6 consists of a stepped bolt 61 which can be inserted in the side end 40 of the cross tube 4 and which is connected to an adapter flange 60 on which a connection 62 is provided for connecting with the belt lock. The stepped bolt 61 can be inserted for example by a press fit into the side end opening 40 of the cross tube 4 and connected to the cross tube 4 through a screw connection or in any other way whereby it is ensured that crash forces are safely transferred to the cross tube 4 .
[0038] The connection of the stepped bolt 61 to the adapter flange 60 can be made rotationally secured or rotatable so that during rotation of the cross tube 40 the adapter flange 60 follows the rotation of the cross tube 4 or is aligned constant through a corresponding connection of the adapter flange 60 to a fixing means of the vehicle seat such as shown in FIGS. 1 to 4 .
[0039] FIG. 6 shows in a diagrammatic perspective view the arrangement of the adapter 6 illustrated in FIG. 5 at the side end of a cross tube 4 which is guided in a bearing block 41 which is connected to the top rail 24 of a longitudinal adjustment device of a vehicle seat. The adapter 6 is connected rotationally secured to the cross tube 4 so that during rotation of the cross tube 4 it changes its alignment and thus the connection point 42 of the adapter flange 61 .
[0040] FIG. 6 shows the different alignment of the adapter flange 61 and thus the connection point 62 in solid and dotted lines. Since the alignment of the belt lash 80 and thus of the belt lock 8 would change with a change in the connection point 62 on the adapter flange 60 of the adapter 6 , but a constant alignment is unacceptable as regards operating comfort, a belt lock guide 9 is provided in which the belt lock 8 is mounted. The belt lock guide 9 is mounted on a cover panel 13 on the seat side part of the vehicle seat. The alignment of the belt lock 8 which is connected through the belt lash 80 to the connecting point 62 of the adapter 6 thereby remains independent of the angular position of the cross tube 4 and thus of the alignment of the adapter 6 whereby during displacement of the cross tube 4 only the upper edge of the belt lock 8 for holding the safety belt 7 changes.
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The invention relates to a device for fixing a belt lock to a vehicle seat comprising a seat underframe which has at least one pivotally mounted crosstube extending crosswise relative to the rail longitudinal guides of a longitudinal adjustment device of the vehicle seat. According to the invention, one locating element is arranged at least in one end area of the crosstube for tying up the belt lock and a device for decoupling or compensating for the movement of the crosstube.
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FIELD OF THE INVENTION
[0001] This invention relates to rattan and, more particularly, to the treatment of rattan. More specifically, although of course but solely limiting thereto, this invention relates to multi-coloured rattan stems and furniture made therewith.
BACKGROUND OF THE INVENTION
[0002] The use of rattan, or more specifically rattan stems, for furniture making has had a long history. Rattan furniture is highly popular because of the soft and classic appearance as well as the comfortable feel plus the well known characteristics of being cool in summer and warm in winter. Furniture made from natural rattan is typically slightly brown in colour and may look somewhat dull for some people or occasions. As a result, furniture makers began to dye rattan stems in order to make or weave rattan furniture with coloured rattans.
[0003] Traditionally, rattan stems are either coloured by dipping or by coating. In the dipping method, a whole piece of rattan stem is soaked in a dispersion of dyes or other colouring agents so that colour pigments can be attached at least on the surface of the rattan stem. A rattan stem made by this method is generally characterized by a generally uniform colour along the whole length of the rattan stem. In the coating method, dyes, coating agents or paints are directly applied generally onto the surface of the rattan stems.
[0004] The coloured rattan stems are then generally used to make, weave or constrict pieces of rattan furniture or other articles. Rattan furniture constructed from rattan stems coloured by the conventional colouring methods is generally not particularly colourful because the rattan stems made by such conventional methods arc usually of a single colour or at most of a dual colour.
[0005] As there is always a need from consumers of more colourful furniture, including rattan furniture, it is therefore desirable to provide multi-coloured rattan stems as well as methods for making same in order to facilitate the construction or making of more colourful rattan furniture.
OBJECT OF THE INVENTION
[0006] Accordingly, it is therefore an object of the present invention to provide multi-coloured rattan stems as well as a method of making same. Of course, it will be appreciated that when multi-coloured rattan stems are readily available, the making and construction of more colourful furniture would follow as a matter of course for the benefit of the general public. It is therefore also an object of the present invention to provide furniture including multi-coloured rattan stems. At a minimum, it is an object of the present invention to provide a new kind of multi-coloured rattan stems as well as rattan furniture for the easeful choice of the general public.
SUMMARY OF THE INVENTION
[0007] According to the first aspect of the present invention, there is provided a rattan stick including a plurality of coloured sections which are sequentially coloured.
[0008] According to a second aspect of the present invention, there is provided a method for colouring rattan.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0009] A preferred embodiment as an illustrative example of the present invention will be described in further detail below.
[0010] Firstly, a quantity of rattan sticks or stems meeting a certain selection criteria, such as, length, quality, uniformity, appearance or other suitable criteria are selected.
[0011] In order to impart desirable colours to the rattan stems or sticks, a plurality of colour baths dispersed or provided with dyes, colouring agents or coating agents are preferably prepared beforehand. In order to provide distinctive colouring effects from each of the colour baths, the colour baths are preferably stored in separate containers. Furthermore, it may be preferable to maintain the colour baths at certain temperature ranges in order to achieve more satisfactory colouring effects to the rattan sticks. For simplicity and convenience, the present invention would be explained by reference to four colour baths of distinct colours. In order to provide the effect of a multi-colour scheme on a rattan stick, it is preferable that a length of a rattan stick is coated with a plurality of colours of various combinations. For example, a rattan stick may be coloured with alternate colouring zones of two different colours. Of course, the colour zones on a rattan stick may include a plurality of colours, preferably more than two colours and yet, more preferably, between two to four. Preferably, the lengths of the coloured sections are between 10 cm-50 cm and more preferably, between 10 cm-20 cm and 40 cm-50 cm. More preferably, the coloured sections on a rattan stick are generally equi-distant, or in other words, of equal lengths. The length of a preferred rattan stick is preferably between 3m-4m along the general length is likely to be between 0.5m-8m. Of course, other lengths of rattan sticks may be used and other lengths of colour sections may be selected as and when desired without loss of generality. In order to more accurately colour the relevant sections, the limits of the sections to the coloured are preferably marked before colour is applied.
[0012] Turning to the colouring of the rattan stick, firstly, a rattan stick of a preferred length and with markings indicating the limits of each and every colour sections are prepared and ready. The preferred length is between 3-4 metres and the preferred colouring sections are between 10 cm-50 cm. The colouring sections, or in other words, the sub-sections, may be appropriately selected. In general, the length of the colouring or the sub-sections are preferably between 10 cm-20 cm or between 40 cm-50 cm.
[0013] Next, the rattan stick is dipped into a first colour bath containing a first colouring means with the first sub-section dipped inside the colouring bath. The colouring means may contain, for example, a bath of colouring dyes, agents or other appropriate compositions suitable for colouring rattan sticks.
[0014] After the first sub-section of the rattan stick has been coloured, this sub-section is then dried. After that, it is dipped sequentially into a second colouring bath, a third colouring bath and a fourth colouring bath for respectively colouring the second, third and the fourth sub-sections of the rattan stick. Of course, the coloured rattan stick will be sufficiently dried before moving onto the next colour bath. Of course, the colouring baths may also contain thinners for diluting the colouring agents or compositions.
[0015] In general, where the colour agents or compositions are in powder form or as a coating, the thinner or otherwise solvent for diluting the colouring agent may be water. Where the colouring agents are a type of paint, the thinners is typically an organic solvent commonly known as thinners. The above colouring procedure may be repeated for colouring additional or further sub-sections to provide a more colourful rattan stick.
[0016] As a result of the colouring process, a more colourful rattan stick with a plurality of colours to be determined by the colouring process will be obtained and can be used for the making of more colourful rattan furniture or other rattan articles with enhanced aesthetic appeal, thereby enhancing the value of the rattan furniture or rattan articles made with such rattan sticks.
[0017] In the above example, the use of four different colouring baths, and therefore four different colours on the same stick, have been illustrated to assist understanding of the present invention. Of course, any suitable number of colours, where practicable, can be applied on a rattan stick without loss of generality. Furthermore, the colours may be different or may be the same colour of different tones. In addition, the colour at the transitional regions between adjacent colouring sections may carry a colour which is a result of the mixing or combination of the two adjacent colours. Of course, the junction between two adjacent colouring sub-sections may be very short by accurate controlling of the dipping process, thereby resulting in a short transition and possibly sharp colour change between the adjacent sub-sections.
[0018] Furthermore, to utilize coloured rattans of the present invention and taking generally the advantage of the equi-distant sub-sections, the furniture preferably includes sub-sections of different length so that colour uniformity can be achieved at the desirable portions as calculated.
[0019] While the present invention has been explained by reference to the preferred embodiments described above, it will be appreciated that the embodiments are only examples provided to illustrate the present invention and are not meant to be restrictive on the scope of the present invention. This invention should be determined from the general principles and spirit of the invention as described above. In particular, variations or modifications which are obvious or trivial to persons skilled in the art, as well as improvements made on the basis of the present invention, should be considered as falling within the scope and boundary of the present invention. Furthermore, while the present invention has been explained by reference to a rattan stick or stem, it should be appreciated that the invention can apply, whether with or without modification, to a plurality of stems to be treated together.
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A multi-colored rattan stick is made by marking a plurality of subsections along the length of the stick. A first subsection of the stick is dipped into a first color bath containing a coloring agent. After the first subsection has dried, second and subsequent subsections are sequentially dipped into respective color baths, and dried between each dipping. The various coloring agents can be different tones of the same color.
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CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
This application claims priority from U.S. Provisional Patent Application Ser. No. 60/116,691, filed on Jan. 21, 1999.
FIELD OF THE INVENTION
The present invention generally relates to arrangements for three-dimensional imaging.
BACKGROUND OF THE INVENTION
Generally, a need has been recognized for what may be termed “kinder gentler stereo”.
In this context, “stereo” refers to a system for putting information on a two-dimensional, essentially flat screen surface (such as front and back projection “movie” screens, CRTs, LCDs, etc.) in a way that causes the observer to see an image in depth corresponding to the depth in the original scene. The scene could be a real scene captured by an appropriate camera system, a virtual scene generated by a computer, or a hybrid of these.
The term “kinder gentler” is provided as a contrast to what has been experienced with known conventional devices. Particularly, conventional stereo displays often involve various types of physical and mental discomfort, to varying degrees. One commonly encountered example of such discomfort is “virtual reality sickness”. Technical inconveniences have also been noted among known devices, such as specialized types of eyewear that must be worn and “viewing zones” that are often perceived to be bothersome.
At a basic level of the musculature of the human visual system, there is a well-known conflict, known as convergence-accommodation (sometimes termed “vergence-accommodation”, among other things) that makes it difficult to achieve the desired consistency among stimuli (or cues). That is, because the information is presented on a 2D “flat” screen surface, the eyes focus (i.e., accommodate) on that surface. However, the directions-of-gaze of the eyes have been found to converge not on the screen but onto a center-of-interest which generally exists someplace in front of or behind the screen at a distance corresponding to the virtual location of the point or region at the momentary center-of-interest.
The conflict between what the convergence muscles and the focusing muscles are each communicating to the brain about the scene's depth is thus a major disturbing conflict. A need has thus been recognized to overcome this and other conflicts of less severe nature.
SUMMARY OF THE INVENTION
As a significant departure from known devices, at least one presently preferred embodiment of the present invention involves a stereo display system, with corresponding scene capture or scene generating components, that is natural and undisturbing to view, that involves neither eyewear nor viewing zones, and does not induce the perceptual conflicts that underlie “virtual reality sickness” and other bothersome features of existing stereo displays.
These features are achieved, in accordance with at least one embodiment of the invention, by recognizing and incorporating in the image capture or image generation system, and in the display technology, a consistent set of the numerous stimuli that contribute to depth perception.
The aforementioned conflict between what the convergence muscles and the focusing muscles are each communicating to the brain about the scene's depth is believed to be overcome in connection with at least one presently preferred embodiment of the present invention.
In accordance with at least one presently preferred embodiment of the present invention, “center-of-interest correction” (or, alternatively, “center-of-interest compensation”) is contemplated. This may be carried out by optical or algorithmic means, or by a combination of the two. The left-right perspective disparity is adjusted to be zero (or near zero) at the center-of-interest.
Since the center-of-interest is generally subjective, it will typically be selected by a person. However, the present invention also broadly contemplates the possibility of selecting the center-of-interest by automatic means.
The selection of center-of-interest can preferably be accomplished by sliding the left-right perspective images over each other until they coincide at the center-of-interest. The images can then be suitably cropped so that the two fields-of-view coincide at the distance of the center-of-interest. Alternatively, the camera sensors (CCD's) could be shifted at the time of image capture. This would avoid the need to crop, such that picture area would not be lost, nor would the desirable constancy of aspect ratio be compromised.
In accordance with at least one presently preferred embodiment of the present invention, it is also recognized that it is possible to significantly decrease the disparities (corresponding to interocular separations between the real or virtual cameras generating the left and right eye views) needed to sufficiently stimulate binocular depth perception. The degree to which this is possible has been found to be quite surprising. Assuming, for mechanical convenience (as is often the case), that a human scale is employed for artificial cameras, then the standard of normal human interocular separation employed in that connection can be in the range of 60 to 65 mm. In this context, it has been found, in conjunction with at least one presently preferred embodiment of the present invention, that a 2 mm camera separation by comparison is usually completely sufficient, and even 1 mm is often adequate. This effect is to be termed “microstereopsis”. A proportionately scaled interocular reduction can, of course, also be enjoyed in connection with systems that are not originally built on the aforementioned human scale.
It has been found that the combination of center-of-interest correction and microstereopsis greatly minimizes the convergence-accommodation conflict. When consistently combined with other depth cues, this combination effectively achieves the desirable consequence, encountered in accordance with at least one embodiment of the present invention, that the viewer sees the scene in depth without experiencing the undesirable side effects (e.g., “virtual reality sickness”) that are normally regarded as a necessary accompaniment of 3D-stereoscopic displays.
In accordance with at least one presently preferred embodiment of the present invention, it is also recognized that the combination of center-of-interest correction and microstereopsis has the desirable side effect of enabling an entirely new class of stereoscopic display hardware paradigms, in view of a surprisingly effective utilization of “crosstalk” in accordance with at least one presently preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention and its presently preferred embodiments will be better understood by way of reference to the detailed disclosure herebelow and the accompanying drawings, wherein:
FIG. 1 a is a schematic representation of right and left human eyes showing their locations and viewing directions in relation to a flat display screen on which is rendered imagery that is perceived in three-dimensions by the human brain;
FIG. 1 is a schematic representation of the relative locations on the screen of FIG. 1 a at which are rendered right eye views and left eye views of objects at background distance, screen distance, and foreground distance from the viewer for the case of a conventional three-dimensional display;
FIG. 2 is a schematic representation of the relative locations on the screen of FIG. 1 a at which are rendered right eye views and left eye views of objects at background distance, screen distance, and foreground distance from the viewer for the case of a three-dimensional display utilizing “microstereopsis”;
FIG. 3 is a schematic demonstration of microstereopsis; and
FIG. 4 is a schematic representation of an autostereoscopic arrangement utilizing microstereopsis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Three-dimensional imagery can be displayed a flat screen 001 with the arrangement illustrated in FIG. 1 a . As shown, right eye 002 and left eye 003 , respectively, perceive screen points 007 and 008 along respective lines of sight 009 and 010 . Shutter, barrier, or other means not illustrated explicitly in FIG. 0 are employed to prevent right eye 002 from perceiving screen point 007 intended for left eye 003 , and to prevent left eye 003 from perceiving screen point 008 intended for right eye 002 . Lines of sight 009 from right eye 002 and 010 from left eye 003 converge at virtual scene point 006 behind screen 001 . The human brain fuses separate right eye 002 and left eye 003 perceptions of screen points 007 and 008 into a single three-dimensional perception at virtual scene point 006 . The distance 012 between corresponding screen points 007 and 008 is called the “disparity”.
Conventional 3D displays use large on screen disparities, as illustrated in FIG. 1 . As shown, the left eye and right eye views ( 100 a and 100 b , respectively) of an object 100 in the foreground coincide to a greater degree than the left eye and right eye views ( 102 a and 102 b , respectively) of an object 102 on the screen, and greater still than the left eye and right eye views ( 104 a and 104 b , respectively) of an object 104 in the background.
It can thus be appreciated that, with the conventional arrangement shown in FIG. 1 , conflict between focusing the eyes on the screen and converging the eyes on the foreground or background results in eye strain, fatigue and “virtual reality sickness”. The image looks “ghosted” (doubled) if it is viewed without special equipment that would otherwise direct the left eye's view to only the left eye and the right eye's view to only the right eye.
In contrast, the inventive concept of microstereopsis contemplates the use of an appropriately configured and of appropriately conducted processing to make the background and foreground disparities very small, and the on-screen disparity zero, as shown in FIG. 2 . Particularly, FIG. 2 illustrates that the left eye and right eye views ( 200 a and 200 b , respectively) of an object 200 in the foreground almost completely coincide, as do the left eye and right eye views ( 204 a and 204 b , respectively) of an object 204 in the background, while the left eye and right eye views ( 202 a and 202 b , respectively) of an object 202 on the screen coincide virtually completely.
In accordance with the arrangement illustrated in FIG. 2 , there is no discomfort with stereo viewing, and no ghosting with normal viewing. Perception with microstereopsis is soft and natural, like the perception of depth in the natural world. As in the natural world, depth perception with microstereopsis is enhanced by cues that complement binocular perspective disparity: mainly occlusion, shading and size familiarity with statically displayed images, and aided by motion parallax, interposition, and possible dynamic monocular depth perception (MDP) effect when the displayed image does not have to be constant in time, e.g., in video or movie images as opposed to still images.
Microstereopsis can be demonstrated using the type of off-the-shelf display equipment that is used to view left/right image pairs with strong binocular disparity, as shown in FIG. 3 . Particularly, right eye views 300 b , 302 b and 304 b , corresponding to an object in the foreground, an object on the screen and an object in the background, respectively, combine with corresponding left eye views 300 a , 302 a and 304 a (foreground, screen and background, respectively), to result in the type of imaging shown in diagram 306 .
There exist many arrangements, such as the one shown in FIG. 3 , that can involve the use of some type of eyewear to select the left and right images at the left and right eyes. Although lenticular (tiny lens array) autostereoscopic (requiring no glasses) displays and the like (e.g. barrier-type displays) exist, they have inconvenient viewing zones and they reduce the horizontal resolution of the images.
Because the left and right microstereopsis images are almost identical, with microstereopsis it may be less important to completely select the left and right images at the left and right eyes than it is with strong binocular stereopsis; in other words, crosstalk between the left and right eye information channels, which is a serious defect for strong binocular stereopsis displays, may not be a significant worry with microstereopsis.
To expound on this point, crosstalk, in a stereo display, is the mixing of some information intended for the left-eye into the right-eye's view, and vice versa. The perceptual effect of crosstalk in conventional 3D-stereoscopic display systems is “ghosting”, a perceived image doubling due to each eye receiving some of the other eye's image, whereas a complete separation of these information streams is ultimately desired.
A requirement to eliminate ghosting, and thus to eliminate crosstalk, can severely restrict one's options in developing a stereo display. However, it has been recognized, with relation to at least one presently preferred embodiment of the present invention, that when center-of-interest correction is applied to microstereoptically captured or generated images, that is, when left-right on-screen image disparities are very small, crosstalk does exist, but is not perceived as the highly objectionable phenomenon of ghosting. Instead, the crosstalk will be perceived as the natural and acceptable phenomena of foreground and background blurring, almost identical with the blurring associated with the finite depth of field of camera lenses and human eye lenses.
Thus, at least one presently preferred embodiment of the present invention broadly contemplates 3D-stereoscopic display systems based on principles, and employing parameters, such that any crosstalk between left and right eye channels is perceived as foreground and background blur (comparable to the blur expected from lens depth-of-focus) rather than as ghosting.
When crosstalk is perceived as foreground and background blur (which is generally perceived as not being objectionable), in contrast with its perception as ghosting (which is generally perceived as being objectionable), this essentially enables an enormous new class of display system paradigms in which the left and right eye channels do not need to be completely separated. In other words, it would essentially be sufficient for some bias to exist, so that the right eye sees more right- than left-eye image, and vice versa for the left eye.
With this in mind, the auto-microstereoscopic display depicted schematically in FIG. 4 is broadly contemplated in accordance with at least one presently preferred embodiment of the present invention.
As illustrated in FIG. 4 , in accordance with a preferred embodiment of the present invention, a three-state electronically switched non-lambertian light source 400 may be provided. This could be embodied by a liquid crystal directional display or equivalent apparatus.
Three states will preferably be attainable by way of light source 400 , namely: state 402 , which is for viewing the left frame of a microstereoscopic image pair; state 404 , for viewing monoscopic images; and state 406 , for viewing the right frame of a microstereoscopic image pair.
As illustrated in the diagram 402 a , state 402 involves greater light source brightness when the eye is left of the screen center and less light source brightness when the eye is right of the screen center. In contrast, as shown in diagram 406 a , state 406 involves greater light source brightness when the eye is right of the screen center and less light source brightness when the eye is left of the screen center. In either case, it is preferably the case that the transition from the brighter to the less bright zones is gradual.
As opposed to the aforementioned “left” and “right” states 402 and 406 , the selectable monoscopic state 404 will preferably involve brightness that is always uniform across the screen (diagram 404 a ).
In accordance with an embodiment of the invention, a transmissive display panel 408 is preferably provided in which a toggling arrangement 410 serves to toggle between the left and right images provided by the light source, that is, between state 402 and state 406 . The rapidity of the toggling will preferably be governed by that which is appropriate for ensuring that the aggregate image (contributed to by the left and right images) is perceived as a 3-D image without the assistance of special eyewear. A conceivable rendering of such an aggregate image is indicated in FIG. 4 at 412 .
The toggle rate will preferably be comparable to that encountered in current “strong stereo” time-multiplexed systems, e.g., greater than 60 Hz per eye (30 Hz overall) and preferably close to 120 Hz per eye (60 Hz overall).
It should be appreciated that, in accordance with the embodiment illustrated in FIG. 4 , the light source 400 will preferably function in such a manner that, from essentially any viewing angle, the illumination appears constant over the full area of the light source whereby, however, the intensity of the illumination depends on the viewing angle. Thus, the right eye would see the right eye image ( 406 a ) more brightly than it sees the left eye image ( 402 a ), and the left eye would see the left eye image ( 402 a ) more brightly than it sees the right eye image ( 406 a ).
In recapitulation, one example of an embodiment of the present invention that could be implemented using existing liquid crystal display (LCD) technology, is a “non-lambertian angularly coded screen” (NLAC). A conceivable substitute for the LCD display is suspended particle display technology, or perhaps even reverse emulsion display technology. The NLAC embodiment involves a light source (behind the normally pixelated image display panel), or a filtering screen (in front of the display panel), that exhibits an electrically switchable angular nonuniformity such that, from any position, it looks brighter to the right eye than to the left eye during times when the right eye image is on the pixelated display, and it looks brighter to the left eye than to the right eye during times when the left eye image is on the pixelated display. If the right and left eye images, and the corresponding biases of the NLAC, are alternated rapidly, then depth should be perceived by any observer in any location from which the display is visible. This is in contrast to the situation with existing lenticular autostereoscopic displays (i.e., in which no eyewear needed), in which correct stereoscopy is achieved for observers in certain “sweet spot” zones, left-right reversed stereoscopy (or pseudoscopy) occurs for observers in other zones, and ghosting is seen by observers in still other zones.
An analogous, simulated, example carried out in experimentation involved a conventional LCD shutter eyewear-based 3D-stereoscopic display whose electronics were modified to make it function adjustably “imperfectly”, that is, so that there was (characteristically undesirable) crosstalk between the left and right eye images. The eyewear was adjusted so that crosstalk was perceived and stereoscopy was lost with a conventional stereoscopic image pair on the screen. This image pair was then be replaced by a center-of-interest adjusted microstereoptical image which, without further adjustment of the eyewear control, was perceived stereoscopically.
Thus, to achieve an autostereoscopic realization (i.e., no eyewear is involved), at least one presently preferred embodiment of the present invention contemplates an NLAC screen. A “static” analog might be the “privacy screen” material manufactured by 3M, commonly used to prevent bystanders from reading over a customer's shoulder at ATMs (automatic teller machines). The “privacy screens” available off the shelf are usually center-biased, but types are available with off-center bias, so that, for instance, a co-worker to one's right could read what is on one's computer monitor, but a customer to one's left sees only a black screen. In accordance with at least one embodiment of the present invention, it is contemplated that the property just described be electronically switchable between left and right bias.
At least one presently preferred embodiment of the present invention broadly contemplates, in addition to NLAC screens in general, any plausible principles that could be used to implement NLAC screens. Possibilities include (as mentioned) LCDs, suspended particle displays, and reverse emulsion displays. Other possibilities, to name just a few, include micromechanical “venetian blinds”, micromirror displays (as in the projectors manufactured by Texas Instruments), holographic optical elements, and coherently emitting displays in which diffraction and interference effects can be exploited in any conceivable way.
In experimentation, it was found that, in attaining microstereopsis, frames offset by camera shifts of only a few millimeters (down to 1 mm) can be viewed binocularly using the same viewing apparatus that is normally used with frame pairs whose perspectives are offset for 50–100 mm (normally 65 mm, the typical human interocular separation). The effect was a strong perception of depth with none of the sense of discomfort that usually accompanies binocular viewing of stereo pairs.
It was found that a practical bonus of microstereopsis is that the disparity between left and right eye images is so small that no doubling is visible when the display screen is viewed without the eyewear needed to see the stereo. That is, when the screen is viewed without glasses it looks like a normal 2D-display; when it is viewed with glasses it is seen in 3D-stereo, without conflict or discomfort.
If not otherwise stated herein, it may be assumed that all components and or processes described herein may, if appropriate be considered to be interchangeable with similar components and/or processes disclosed elsewhere herein, unless an express indication is made to the contrary.
If not otherwise stated herein, any and all patents, patent publications, articles and other printed publications discussed or mentioned herein are hereby incorporated by reference as if set forth in their entirety herein.
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A viewing system and method for producing at least one image for being perceived as three-dimensional, including at least one of: a provision for compensating the center-of-interest of the at least one image in such a manner as to reduce convergence-accommodation conflict; a provision for configuring the viewing system such that crosstalk produced by a stereo display is perceived as foreground and background blur instead of ghosting; and a provision for viewing the at least one image via automicrostereopsis.
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BACKGROUND OF THE INVENTION
The present invention relates to a chain link, and, more particularly, to a polymeric chain link having a telescoping barrel.
The use of polymeric materials in power transmission and conveyor chain is a relatively recent development. Such chain has been found to be particularly suited for uses in which the features of light weight, low coefficient of friction and the ability to withstand corrosive environments are needed, such as in the food industry.
Metal chain links, which are adapted to be used with a roller, have existed for some time. For example, U.S. Pat. Nos. 1,734,960, Nov. 12, 1929; 673,748, May 7, 1901; and 1,587,054, June 1, 1926 all disclose pintle-type links made of metal in which the barrel portion of the links is made in two parts, so that a roller may be slipped onto the outside of the barrel prior to assembly of the links. Such metal chain has the disadvantage of being heavy and of corroding in environments such as corrosive solutions and high humidity. It also generally requires lubrication, whereas, if the appropriate polymeric materials were used, lubrication would not be necessary. The methods of coupling the barrel portions used in those patents are not particularly suited for use with a polymeric chain.
A primary object of the present invention is to provide a standard, polymeric link which can be used in power transmission and conveyor chain, and which can be used either with or without a roller mounted over the barrel of the link.
SUMMARY OF THE INVENTION
The present invention comprises a polymeric chain link which is made in two parts. Each part includes a sidebar with an integral barrel portion projecting inward from at least one end of the sidebar. The male barrel portion of one sidebar fits inside the female barrel portion of the other sidebar, and the surfaces of the male and female barrel portions are contoured such that when the male barrel portion is inserted into the female barrel portion with some force applied to it, the outer mating surface of the male barrel portion couples with the inner mating surface of the female barrel portion, such that the barrel portions mechanically lock together, forming a barrel for the link. A roller may be placed over the female barrel portion prior to coupling the barrel portions, or the link may be assembled without a roller, thereby providing a standard, polymeric link which can be used either with or without a roller.
For a more detailed explanation of the invention, reference should be made to the drawings and description in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a preferred embodiment of the present invention, showing a pintle-type link with internal and hidden features shown by phanton lines.
FIG. 2 is a partial cross-sectional top view of the male barrel portion, with part of the sidebar broken away, with the bore through the barrel shown by phantom lines.
FIG. 3 is a cross-sectional top view of the female barrel portion and its sidebar, with part of the sidebar broken away.
FIG. 4 is a side view of the female barrel portion and its sidebar.
FIG. 5 is a partial cross-sectional top view of the roller, with internal features shown by phantom lines.
FIG. 6 is a top view of a second preferred embodiment of interconnected block links and pin links constructed in accordance with the principles of the present invention, with internal and hidden features shown by phantom lines.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As seen in FIG. 1, one embodiment of the present invention is a pintle-type link 10 which is comprised of two sidebars 12, 14 and barrel 16 between the sidebars 12, 14. The barrel 16 is in the shape of a hollow cylinder, as it has a bore 18 along its axis. There are also bores 20, 22 through the sidebars 12, 14 at the pin end 23 of the sidebars 12, 14. The midpoint of barrel 16 is at point 51.
In order to construct a chain using several of the links, the barrel 16 of one link is placed between the pin end 23 of the sidears 12, 14 of the next adjacent link so that the bore 18 through the barrel 16 of the first link is aligned with the bores 20, 22 through the sidebars 12, 14, and a pin is inserted through the bores 20, 18, 22 to hold the two links together. The type of pin described in U.S. Pat. No. 4,220,052, hereby incorporated by reference, is preferred for use with the present invention, although other pins may also be used. This is repeated, adding one link after another to form a chain.
FIG. 1 further shows that the barrel 16 is made up of two parts, a male barrel portion 24 and a female barrel portion 26, which will be described in detail later. Wear shows 28, 30 are also illustrated in FIG. 1. These wear shoes 28, 30 provide a wear surface when the link is not used with a roller, as well as acting as strengthening members.
FIG. 2 shows the male barrel portion 24 more clearly. It can be seen that the male barrel portion 24 is an integral part of sidebar 12 and extends inward from sidebar 12. The outer mating surface 32 of male barrel portion 24 has an annular surface portion of small outer diameter 34, which is bounded on both sides by surface portions of larger diameter 36, 38.
There is a sloping surface portion 40 on the outer mating surface 32 to facilitate insertion of the male barrel portion 24 into the female barrel portion 26. The outer mating surface 32 also has a longitudinal tab 42, with a tapered lead-in edge 44. Also shown at the barrel end of sidebar 12 is a roller mounting surface 46. The edge 47 of roller mounting surface 46 is located away from the critical stress points at point 49 where barrel 16 meets sidebar 12 and at midpoint 51. Corner 45 is shown where barrel 16 meets sidebar 12.
FIG. 3 shows the female barrel portion 26 more clearly. The female barrel portion 26 is an integral part of sidebar 14 and extends inward from sidebar 14. The inner mating surface 48 of female barrel portion 26 has an annular surface portion of small internal diameter 50, which is bounded on both sides by surface portions of larger diameter 52, 54. Annular surface portion 50 is located away from critical stress points at midpoint 51 and at point 55, where barrel 16 meets sidebar 14. Corner 45 is shown where barrel 16 meets sidebar 14.
Surface portion 52 slopes to facilitate insertion of the male barrel portion into the female barrel portion. On the inner mating surface 48 is a longitudinal slot 56. The outside surface of the female barrel portion 26 is also a roller mounting surface 58.
In order to couple the male and female barrel portions 24, 26, the male barrel portion 24 is inserted into the female barrel portion 26. The male barrel portion 24 cannot be completely inserted unless tab 42 is aligned with slot 56. This ensures that sidebars 12, 14 will be properly aligned when coupling occurs and prevents sidebars 12, 14 from rotating relative to each other after coupling. The tapered lead-in edge 44 of tab 42 facilitates insertion of tab 42 into slot 56. As the male barrel portion 24 is pushed further into the female barrel portion 26, surface 40 contacts surface 52. Surfaces 40, 52 are sloping and act as ramps, aiding in the gradual elastic deformation which is required in order for surface 38 to move past surface 50. A polymeric material having the necessary elastic properties is used to make the barrel portions so that they can be coupled in this manner. Once surface 38 has moved past surface 50, most of the compression forces are released, and the surfaces return almost to their original shape. There is, however, a slight interference fit between the annular surface portions of small diameter 34, 50, such that a certain amount of compression force remains, giving integrity to the barrel so formed. It is to be noted that, once the barrel portions 24, 26 are coupled, relative movement between the portions is restrained.
Roller mounting surface 46 prevents the male barrel portion 24 from being further inserted into the female barrel portion 26, and flat surfaces 60, 62 on the female barrel portion 26 and male barrel portion 24, respectively, retain the male barrel portion 24 inside of the female barrel portion 26.
FIG. 4 is a side view of sidebar 14, showing the wear shoe 30, bore 22 through sidebar 14 at the pin end 23, female barrel portion 26, and slots 56.
FIG. 5 shows roller 64 which is adapted to be mounted over roller mounting surfaces 46, 58. The inside surface 66 of roller 64 is shaped to fit smoothly over roller mounting surfaces 46, 58 when the male and female barrel portions 24, 26 are coupled, with mating corner radii to prevent roller-barrel cutting. The corner radius of corner 65 of roller 64 is generous in size and is larger than corner radius of corner 45 so as not to interfere with barrel 16.
In order to mount the roller 64 over the barrel 16, roller 64 is placed over roller mounting surface 58 on female barrel portion 26 prior to coupling male and female barrel portions 24, 26.
Link 10 may be used with or without roller 64, as wear shoes 28, 30 serve as contact surfaces when no roller is present.
FIG. 6 shows block-type links 68, which are a second embodiment of the invention. Block-type link 68 is made up of two sidebars 12, 14 with wear shoes 28, 30 as was the pintle-type link 10 shown in FIG. 1. However, unlike the pintle-type link 10, block-type link 68, when assembled, has two barrels 16. Both sidebars 12, 14 have a male barrel portion 24 and a female barrel portion 26 at their ends. These barrel portions 24, 26 are the same as the barrel portions 24, 26 shown in FIG. 1, with the only difference being that in the block-type link 68 each sidebar has two barrel portions rather than just one. Again, roller 64 could be placed over each barrel 16 prior to mating the male and female barrel portions 24, 26. It is not necessary that each sidebar have both a male and female barrel portion as shown here. Instead, one sidebar could have two male barrel portions and the other two female barrel portions. However, if the sidebars are made as shown in FIG. 6, only one mold is required, because the sidebars are identical. In order to form a chain using block links 68, a second type of link called a pin link 70 is used. The pin links 70 have a bore 72 at each end. The bore 72 through the pin links is aligned with the bore 18 through the barrel 16, and a pin is inserted through two pin links 70 and one barrel 16. This is done on each end of the pin links, thereby attaching two block-type links together. This can be done repeatedly to form a chain.
There is thus provided a non-metallic chain link that is easily assembled and may be used with or without a roller, resulting in a standardized link for both applications.
It should be apparent to those skilled in the art that modifications can be made without departing from the scope of the invention as defined in the following claims.
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A polymeric chain link including two sidebars and a barrel connecting the sidebars. The barrel is comprised of a male barrel portion and a female barrel portion, each barrel portion being an integral extension of one of the sidebars. The male barrel portion fits inside the female barrel portion, and the inner mating surface of the female barrel portion cooperates with the outer mating surface of the male barrel portion to couple the two portions, mechanically locking them together.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 826,545 filed on Feb. 2, 1986, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a rotary brush sweeper including a debris pan having an inlet or scoop portion that may pass over a surface to be cleaned in close proximity thereto, and more particularly to the construction of a debris pan with a scoop portion.
Rotary brush sweepers are equipped with debris pans for collection of debris swept into the pans by the rotary brush. To assure highly effective cleaning of a surface by such a sweeper, it would be desirable for the front of the debris pan, constituting an inlet portion, to pass over a surface being cleaned in close proximity thereto. It would be particularly desirable for the inlet portion of the debris pan to actually glide on a surface being cleaned for maximum cleaning results.
It would further be desirable, for facilitating the passage of debris into the debris pan, to cover the inlet portion of the debris pan with low friction material, such as vinyl. It would be further desirable that such low friction material be constructed in such manner that it may be readily mounted onto a debris pan by an unskilled worker, without the use of adhesive or screws or the like.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to provide a rotary brush sweeper including a debris pan having an inlet portion which passes over a surface to be cleaned in close proximity thereto or which actually glides on such surface.
A further object of the invention is to provide a debris pan for a rotary brush sweeper in which an inlet portion of the pan is covered with low friction material to facilitate passage of debris through the inlet portion and into the pan.
Another object of the invention is to provide a debris pan for a rotary brush sweeper having a low friction covering on an inlet portion of the pan wherein such low friction covering is configured in such a manner as to be easily mounted onto the inlet portion of the pan without adhesives or screws or the like.
A still further object of the invention is to provide a debris pan for a rotary brush sweeper in which a low friction covering on an inlet portion to the pan is provided with an abrasion-resistant portion to prolong the lifetime of the covering.
Yet another object of the invention is to provide a debris pan for a rotary brush sweeper including a gliding portion situated rearwardly of an inlet portion for minimizing wear and damage to the inlet portion.
The invention relates to a rotary brush sweeper for removing debris from a surface. Such a sweeper includes a housing having front and rear portions with respect to movement of the sweeper. A brush is rotatably supported by the housing, and drive means are included for rotating the brush. The sweeper includes a debris pan situated rearwardly of the brush for collection of debris swept thereinto by the brush. A pan support means supports the debris pan with respect to the housing but permits an inlet portion of the debris pan to pass over a surface being cleaned in close proximity thereto. The inlet portion to the debris pan includes a scoop with a first surface inclined upwardly and rearwardly with respect to normal forward movement of the sweeper for directing debris into the pan. The scoop includes a second surface beneath the first surface and facing downwardly at any surface to be cleaned. The scoop is provided with a covering of low friction material over the first and second surfaces.
The covering of low friction material is preferably configured to mechanically grip onto the inlet portion, and to this end, may include a downwardly inclined portion situated on the leeward side of the first surface of the scoop, and an upwardly extending ridge adapted to fit within a corresponding groove in the first surface of the scoop. The covering advantageously includes an abrasion-resistant tip region located at the front of the scoop for retarding wear of the covering. Such abrasion-resistant region may be coextruded with the remainder of the covering so as to be integrally bonded to such remainder and provide lowcost construction.
The invention will be better understood and its various objects and advantages will be more fully appreciated from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified view in perspective of a rotary brush sweeper in accordance with the present invention, and illustrates selected parts of the sweeper.
FIG. 2 is a perspective view of the rotary brush sweeper of FIG. 1 with various portions removed or cut away to better illustrate a drive mechanism of the sweeper.
FIG. 2A is a detailed view in cross section of the axle support arrangement of FIG. 2, further illustrating a bushing that may be provided between the axle of the rotary brush and a portion of the housing that supports the axle.
FIG. 3 is a perspective view of an exemplary debris pan in accordance with the invention.
FIG. 4 is a detailed view of an inlet portion of the debris pan of FIG. 3.
FIG. 5 is a side plan view of the rotary brush sweeper of the invention illustrating a support means for the debris pan.
FIG. 6 is a detailed view of a rear support arrangement for the debris pan shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 illustrates selected parts of a rotary brush sweeper 10 in accordance with the present invention. Sweeper 10 includes a housing 12 of plastic, for example, onto which a pair of rear wheels 14 and 16 and a front wheel 18 are mounted. Wheels 14, 16 and 18 are shown schematically in FIG. 1. Preferably, rear wheels 14 and 16 each comprises a rubber tire mounted on a plastic hub, and front wheel 18 comprises a caster.
Rotary brush 20, preferably of the type having a twisted wire axle, is rotatably mounted onto housing 12 behind front wheel 18. Situated immediately behind rotary brush 20 (i.e., to the right in FIG. 1) is a debris pan 22 which collects debris that is swept into the pan by rotary brush 23. Debris pan 22 is described in more detail hereinafter.
A handle 24 is attached to housing 12. Handle 24 includes a yoke portion (not shown) which may be conveniently grasped manually. Handle 24 may be conveniently mounted on axle 26 for rear wheel 14, for example.
FIG. 2 depicts rotary brush sweeper 10 with various portions removed or cut away to expose a drive system 50 for rotating rotary brush 20. Drive system 50 includes a drive pulley 52 fixedly mounted on rear axle 26, on which wheel 14 (FIG. 1) is also fixed, such that rotation of wheel 14 rotates drive pulley 52. The other rear wheel is free to idly revolve about rear axle 26. Drive system 50 also includes a driven pulley 53 so that rotary brush 20 is rotated at a higher rate than drive wheel 14 (FIG. 1). An endless rubber belt 56 that is slightly elastic is mounted under tension in respective circumferential grooves 52a and 53a on pulleys 52 and 53 and this transfers rotational movement of drive pulley 52 to drive pulley 53.
Further illustrated in FIG. 2 is a support panel 58, which depends from the upper portion of housing 12 and which supports the left-hand, or "drive", ends of rear axle 26 and rotary brush axle 55. The opposite, or right-hand, ends of axles 26 and 55 (not shown) are suitably supported by conventional bushings that permit free rotation of the axles. Rear axle 26 may be supported by panel 58 by extending through an aperture (not shown) in the panel, without a bushing for the axle. Support panel 58 includes a notch 60 in which axle 55 is received. The axle preferably is received in a bushing 62 mounted in notch 60. Notch 60 extends rearwardly and upwardly in support panel 58 from its opening. This simple mounting arrangement provided by notch 60 enables insertion of axle 55 into notch 60 and enables securement of the axle in position in the notch by belt 56 when the belt is under tension due to its mounting on pulleys 52 and 53.
Referring to FIG. 2A, bushing 62 between rotary brush axle 55 and support panel 58 has flat bottom grooves 62a on its opposite edges and these receive the portions of the support panel 58 forming the sides of notch 60, which prevents rotation of the bushing. The bushing includes an aperture 62b through which brush axle 55 extends. Bushing 62 may be of low-friction plastic or other low friction material.
Debris pan 22 is partially shown in FIG. 1 and shown in detail in FIG. 3. Debris pan 22 is rigid and may be of metal or plastic, such as polypropylene. Debris pan 22 includes a flat bottom 70, a curving rear wall 72 into which the bottom 70 merges, and confronting sides 74 and 76. Sides 74 and 76 are joined to bottom 70, curving rear wall 72, and confronting sides 74 and 76. Sides 74 and 76 cooperate with bottom 70 and rear wall 72 to form an open topped enclosure in which debris is collected. The top of housing 12 completes that enclosure. A rib 78 extends upwardly from pan bottom 70 and from side 74 to side 76. Rib 78 separates the interior of debris pan 22 into separate bins so as to minimize shifting of any debris in debris pan 22.
The front of pan bottom 70 comprises a scoop portion 85, which is configured in arcuate fashion to facilitate sweeping of debris into debris pan 22. The upper edge of scoop portion 85 comprises a ridge 82 extending between pan sides 74 and 76, and, together with lateral rib 78, scoop portion 85 forms a forward bin in debris pan 22. It is preferred that scoop portion 85 at the front of the pan include a covering of low friction material 86, as shown in the detail view of scoop portion 85 in FIG. 4. Layer 86 may comprise vinyl, by way of example. Layer 86 enhances the gliding of the pan over a surface being cleaned and protects the front of the pan from excessive damage and wear.
In accordance with an important feature of the present invention, covering 86 extends along the upwardly and rearwardly inclined surface 100 of pan 22 from a forward tip 102 of the pan to ridge 82 of the pan and then downwardly on the leeward side of the scoop, as at 104, to aid covering 86 in mechanically gripping onto scoop region 85 of the pan. Covering 86 preferably extends from tip portion 102 of pan 106 along the underside 108 of the scoop portion 85. Underside 108 preferably includes one or more grooves 110 into which corresponding ridges of covering 86 extend, as illustrated in FIG. 4.
Covering 86 may beneficially include a tip portion 112 of high abrasion resistance material, such as polyurethane. Tip portion 112 may advantageously be coextruded with the remainder of covering 86 so as to form a unitary and inexpensive part. Covering 86 may be held on scoop portion 85 solely from mechanical gripping of such portions. To this end, covering 86 is preformed to maintain its shape as illustrated, and the ridges of the covering received within grooves 110 are formed to be oversized and then are squeezed into such grooves. Covering 86, accordingly, can be easily mounted on scoop portion 85 of debris pan 22, and is inexpensive and durable in construction.
Adjoining the underside of pan bottom 70 is a plurality of front-to-rear extending rails 84 which are intended to glide upon a surface being cleaned, while setting the usual height of the front of scoop 85. The rails 84 extend downwardly at least as far as the bottom of covering 86 (FIG. 4) so as to bear a substantial portion of the weight of debris pan 22 relative to scoop portion 85. A resulting benefit is the reduction in wear of covering 86 of scoop portion 85.
Debris pan 22 includes various features used in supporting the pan within housing 12 (FIG. 1) of sweeper 10. Pan 22 includes an aperture 94 through which a cooperating member of housing 12 is intended to protrude, as described below. An additional aperture 95 is provided above aperture 94. The aperture 95 cooperates with a detent in housing 12, described below, so that pan 22 is supported by the housing in a sturdy fashion.
The front of pan 22 includes laterally-projecting members 90 and 92 which extend forwardly from pan sides 74 and 76, respectively. The members 90 and 92 are adapted to rest on a cooperating support structure mounted on housing 12, as described below.
FIG. 5 illustrates the mounting of debris pan 22 to housing 12. Front support member 92 is normally disposed by a distance "D" above a cooperating support member 130 mounted on the inner side of housing 12. Support element 130 may suitably comprise a bushing in which the far end of brush axle 55 (FIG. 2) is received. The other front support member 90 (not shown in FIG. 5), similarly, is normally situated above a support element corresponding to element 130, which may comprise a bushing unit into which the nearer end of the brush axle is received. The clearance "D" allows the pan to glide over surface 200, even if the contour of the surface changes. Support element 92 rests on support element 130 when the front of the sweeper is lifted, for example, to prevent debris from falling away from housing 12.
To support the rear of debris pan 22, a rearwardly projecting tab 140 protrudes through aperture 94 of the debris pan. Thus, housing tab 140 supports the rear of pan 22.
To hold debris pan 22 sturdily in position, rearwardly projecting detent 97 is provided in housing 12. The detent passes into aperture 95 (FIG. 6) in the pan. To bias detent 97 into the aperture, upwardly projecting portion 142 of housing tab 140 pulls against downwardly projecting flange 98 of debris pan 122.
The foregoing describes a rotary brush sweeper having a debris pan that may glide over a surface to be cleaned. The pan automatically disengages from the sweeper should the pan become snagged by an obstacle on the surface. The pan includes an inlet, or scoop portion, covered with low friction material to facilitate sweeping of debris into the pan. The covering may be configured in such a way as to be mounted on an inlet portion of the pan by mere mechanical gripping of the covering onto the inlet portion. The covering may include an integrally formed abrasion-resistant tip portion to prolong the life of the covering.
Although the present invention has been described in connection with a preferred embodiment thereof, many variations and modifications will now become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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A rotary brush sweeper includes a debris pan with an inlet portion that glides on a surface being cleaned. The debris pan automatically disengages from the sweeper upon being engaged by an obstacle in the path of the sweeper. The debris pan is configured with an inlet portion or scoop for directing debris propelled by a rotary brush into the debris pan. The scoop portion has a first upwardly and rearwardly inclined surface and a second surface beneath the first surface and facing downwardly. A low friction material covers the first and second surfaces of the scoop to facilitate collection of debris into the debris pan. The covering may include an integrally formed tip portion of abrasion-resistant material, and is preferably configured in cooperation with the scoop to mechanically grip onto the scoop without the need for screws or adhesives.
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BACKGROUND TO THE INVENTION
1. Field of the Invention
The invention relates to a method of spin-welding a moulded plastics end component into an open end of an extruded plastics tube.
Spin-welding is a well known technique for welding together plastics components which are assembled with opposed annular surfaces, in which one of the components is spun at high speed relative to the other to cause welding and subsequent fusion of the plastics material at the interface of the opposed surfaces.
It has been found in the past that a certain radial pressure is necessary at the welding interface to generate the heat required for melting of the plastics material. This radial pressure has been provided in the past by an interference fit between the components and by external supporting means which restrain radial expansion of the components during assembly and subsequent spin welding. One of the drawbacks of spin-welding has been the fact that very fluid liquid plastics material--"flash"--can often escape from the weld area and may solidify as unsightly debris.
2. Prior Art
U.S. Pat. No 3,982,980 describes a method of making a cartridge for dispensing materials. A resin tube is extruded to have constant inside and outside diameters and the tube is cut off in equal lengths to provide the barrels of the cartridges and having ends evenly severed in planes perpendicular to the longitudinal axes of the barrels. Injection moulded end caps are fitted into the cut ends of the barrels with an interference fit and are then spin welded. During the assembly and spin welding process, the barrels are restrained against radial expansion by a surrounding tool which rotates with the end cap and is provided with cutting surfaces for the removal of flash debris.
There are several disadvantages associated with this prior method. First, the provision of an external restraint inevitably leads to marking of the external surface of the tube. Second, the plastics components and the surrounding tool must be manufactured within strict tolerances if reliable welds are to be produced. In this respect, the extrusion and cooling of the tubing must be controlled to keep the tubing accurately to the desired internal and external diameters. A third disadvantage arises from the configuration of the end cap which is of a countersunk design and has a tendency to dome outwardly when the container is pressurised, thus subjecting the weld to peel stresses which are likely to cause failure.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an improved method of spin-welding a moulded plastics end component in the open end of an extruded plastics tube which does not suffer from the disadvantages of the prior art.
According to the invention, there is provided a method of spin-welding a moulded plastics end component into an open end of an extruded plastics cylindrical tube, wherein the end component comprises a substantially cylindrical flange dimensioned to fit within the open end of the cylindrical tube and an annular flange extending from the outer end of the cylindrical range and overlying the end face of the cylindrical tube when the end component and cylindrical tube are assembled, the method comprising the steps of
(a) extruding the cylindrical tube from a die head and shock cooling the external surface of the cylindrical tube immediately after its emergence from the die head;
(b) cutting the cylindrical tube such that hoop stresses generated in step (a) cause the cut-end of the cylindrical tube to contract radially;
(c) inserting the end component into the contracted open end of the cylindrical tube such that the opposing cylindrical surfaces of the tube and the end component provide an area to be welded; and
(d) spin-welding the end component to the cylindrical tube; wherein during step (d), an axial pressure is applied to the assembly sufficient to substantially prevent the escape of flash from the weld area but no radial pressure is applied to the assembly in the region of the weld area other than that provided by the interference fit between the end component and the tube and by the hoop stresses generated in the tube.
By the due recognition and use of the hoop stresses formed in a shock-cooled extruded plastic tube, the invention provides a method of spin-welding in which it is not necessary to apply radial pressure or a radial restraint to the weld area during welding, since the necessary radial forces are provided by the hoop stresses in the cut end of the tube. In this method, strict manufacturing tolerances are not required to provide an accurate interference fit between the components since the radially contracted cut end of the tube will resiliently accommodate variations in diameter of the end component. The escape of flash from the weld area is substantially prevented by the application of an axial pressure to the components during welding.
In the case where the end component and the cylindrical tube form a container, the construction of the end component is such that the weld will be subjected to shear stresses when the container is pressurised and thus the ability of the container to withstand internal pressure will be limited only by the strength of the end component.
In a preferred method, the end of the tube is cut in a manner which provides a chamfered profile such that during welding the axial pressure applied to the components is concentrated in the angle between the cylindrical and annular flanges of the end component.
The tube and end component are both preferably made from high-density polyethylene. In order to provide for preferential melting of the tube over the end component, the materials of the tube and end component may be chosen such that the latent heat of fusion of one is greater than the other.
To enhance ease of assembly of the components, the cylindrical flange of the end component may have a slight taper and may be provided at its inner end with a chamfered end or similar lead-in feature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a sectional view through a cut end of a tube;
FIG. 2 shows a sectional view through an end component fitted into the cut end of a tube;
FIG. 3 shows a part sectional view of an alternative form of end component;
FIG. 4 shows a sectional view through a spin-welding chuck with an end component engaged therewith;
FIGS. 5a and 5b are redrawn oscilloscope traces of motor speed and torque during welding;
FIG. 6 is a sectional view through a modified form of end component; and
FIG. 7 is an enlarged sectional view of a part of the end component shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The tube and end components shown in the drawings are intended for making a tubular dispensing container for mastic material. In this respect, the end component comprises a conical nozzle which may be cut to permit dispensing of material therethrough.
FIG. 1 shows the cut end 2 of a length of relatively thick-walled extruded high-density polyethylene tube 1. The external surface of the tube has been shock-cooled using chilled water immediately after emerging from the die head, thereby encouraging the creation of a less dense amorphous polymer structure towards the outside of the tube wall thickness, whilst inner portions of the wall thickness are enabled to cool more slowly and thereby naturally form a more dense crystalline structure.
Considerable hoop stresses are formed within the wall of such tubing and the partial relaxation of these stresses is manifested in a flaring in of the tube at its cut end.
FIG. 2 shows a high-density polyethylene moulded end component 3 fitted into the open end 2 of the tube 1. It can be seen in FIG. 2 that the cut end of the tube has a chamfered profile which occurs naturally as a result of the stressed tube being cut from the outside by means of a rotary knife cutter. The end component comprises a substantially cylindrical range 4 which provides a welding skirt extending into the open end of the tube 1 and a transverse end wall 5. The wall 5 provides an annular flange 6 which extends radially outwardly from the outer end of the flange 4 and which overlies the chamfered open end of the tube 1. In the centre of the end component, the wall 5 is provided with a conical nozzle 7 and spaced around the base of the nozzle 7 are six webs 8 which are to be engaged for spinning the end component as will be described below. As can be seen in FIG. 2, the welding skirt is provided with a slight inwardly inclined taper in its outer surface. The taper angle is preferably in the range of 1°- 3° and is ideally about 2°. The end of the welding skirt which first extends into the tube during assembly is provided with a lead-in surface 9 chamfered at about 45° to assist in assembly. FIG. 3 shows an alternative construction of the end component in which the lead-in surface is provided by a radial inturn 10 at the free end of the welding skirt 4.
FIG. 4 shows a drive chuck 11 which, during the welding operation, engages with the webs 8 on the end component by means of dogs 12. The chuck comprises an inner cylindrical sleeve 13 and an outer cylindrical sleeve 14. The outer sleeve is mounted via a range 15 to the end of a drive shaft 16 and the inner sleeve is axially displaceable within the outer sleeve against the action of a spring 17. Rotary drive is transmitted to the inner sleeve by pins 18 formed on the sleeve 14 and which engage in blind bores 19 formed in the sleeve 13.
Rotary drive of the chuck 11 is provided via drive shaft 16 which is connected directly or indirectly to an appropriately sized programmable servo-motor (not shown). During the welding process the servo-motor rapidly accelerates the end component, whilst the tube is clamped, to a high peripheral speed of between 8 and 13 m/s. and maintains this speed for a length of time necessary only to form sufficient melt between the tube and the end component to form a fully integral weld. The servo-motor is then employed to brake all relative motion rapidly and the weld is allowed to solidify. A typical total acceleration, spin and brake time for a 50 mm diameter mastic tube and end component both made of high density polythene is about 0.22 s using a weld speed of about 10.8 m/s (4000 rpm), wherein the acceleration up to weld speed takes about 0.05 s and the corresponding deceleration takes about 0.08 s. A redrawn oscilloscope trace showing the spinning speed of the end component during a typical welding cycle is shown in FIG. 5a. FIG. 5b is a redrawn oscilloscope trace showing the torque applied by the servo motor during the welding operation.
The necessary radial contact pressure "PC" required to ensure welding between the tube and the welding skirt is provided primarily by the hoop stresses in the cut end of the tube. In FIG. 2, the maximum outside diameter of the welding skirt 6 is shown to be equal to the inside bore diameter of the tube 1. The contact pressure may be increased, however, by dimensioning the end component such that the maximum external diameter of the welding skirt 4 is greater than the internal diameter of the tube by up to about 0.375 mm. Any greater diametral interference can cause undesirable radial deflection of the tube walls. The use of a programmable servo-motor enables the energy input during welding to be precisely controlled and it is thus possible to substantially restrict the heat which is rapidly generated to the localised interface between the tube and the welding skirt, thus minimising any loss of hoop stress in the tube. This accurate control of the frictional heat energy between the contacting surfaces is made possible by the use of a powerful high speed programmable servo-motor and its associated drive and control electronics. One consequence of the very rapid localised generation of heat at the contacting surfaces is the formation of a very fluid molten polymer which has a tendency, unless prevented, to flow upwards and outwards between the end of the tube and the overlying flange 6 of the end component 3, thereby giving rise to unsightly and aesthetically unattractive flash. Any loss of material in this way also detracts significantly from the integral nature of the cylindrical weld formed between the tube 1 and the end component 3 such that leaks may result. In accordance with the present method, suitable preventative action consists of the application during the welding cycle of an axial pressure "PT" between the open end of the tube 1 and the overlying range 6 of the end component of a magnitude sufficient to effectively dam the upward and outward flow of melt from the main weld area, but not so high as to cause a separate source of melt generated by contact between the end of the tube and the flange 6. For 50 mm diameter polyethylene tubes as described it has been found that a minimum axial load, "PT", between the tube and the end component of about 0.22 N/mm 2 is required to dam the melt flow. Experiments have shown that an ideal axial load is about 0.4 N/mm 2 . In practice, the required axial loading is provided by means of the spring loading of the inner sleeve 13 of the chuck 11. This loading can be adjusted as required by means of the screw 20.
With the controlled application of "PT" no hard, knobbly flash is produced which would require cutters to remove, but as a consequence of the finite contact pressure between the end of the tube and the flange 6 of the end component, some fine particulate debris may be produced when using high density polyethylene although this is so friable in nature that it has been found possible to remove it using only a light brushing action at a machine station immediately after the spin-welding station.
The characteristics of melt damming provided by the contact between the end of the tube 1 and the end component 3 have been found to be improved by the chamfered profile of the end of the tube which arises from the cutting of the tube as described above and which, in practice, limits the contact between the end of the tube and the overlying flange 6. The angle of the chamfer may be increased by cutting the tube at an inclination to its axis. Welds have been satisfactorily produced using tubes having their ends chamfered at an angle of between 50° and 70° to the axis of the tube. Chamfering of the end of the tube leads to the maximum axial pressure between the tube and the end component being located in the corner between the annular flange 6 and the cylindrical range 4 of the end component. This in turn leads to very efficient damming of the melt formed at the weld surfaces.
A further embodiment of an end component for use in the method of the present invention is shown in FIGS. 6 and 7, in which a small annular projection 25 is provided on the underside of the range 6. Such a projection will engage the end of the tube during welding and will provide effective damming of the melt from the weld when the appropriate axial loading "PT" is applied. The annular projection may be provided as an alternative to chamfering the end of the tube 1 or may be provided in combination therewith.
In a preferred method the materials selected for the tube and the end component have different characteristics. All high density polyethylenes have a similar melting point of about 130° C. but their latent heat of fusion dHm (the amount of heat energy necessary to melt one gram of material at the melting point temperature) varies according to their crystalline content. In general, the more crystalline the polymer, the greater the latent heat of fusion dHm. By selecting the materials used for making the tube and the end component, one or other can be made to melt preferentially at the weld area. Such a selection of materials is particularly advantageous in respect of the end component shown in FIG. 6 and in an example the end component was made of high density polyethylene having a dHm of 176 J/gm whereas the tube was made of a high density polyethylene having a dHm of 148 J/gm. During spin-welding, the tube melts more readily than the end component and thus the annular projection 25 is able to survive the welding operation and provide effective damming of the flow of melt from the weld area.
Through the due recognition and use of hoop stresses formed in extruded plastic tube, through the design of the end component to enable easy assembly, through the application of axial pressure during welding and through the controlled generation of frictional heat with respect to rate and magnitude using a high speed programmable servo motor, a substantially flash-free and unmarked container can be produced by spin-welding a plug fit end component into the open end of an extruded plastics tube.
Although the method described in relation to the drawings relates to the formation of a container having an end component which provides a nozzle for the dispensing of material from the container, it will be understood that the end component may be of a different construction and may provide, for example a substantially flat end wall for a cylindrical tube or a ring component adapted to receive a plug or lid.
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An end component 3 is spin-welded into the cut end of an extruded tube 1 with the application of axial pressure but without the application of radial pressure to the weld area. The radial forces required to create a weld are provided by hoop stresses which are formed in the tube by shock-cooling the tube as it emerges from the extrusion die. When the tube is cut, the hoop stresses cause the cut end of the tube to contract radially prior to insertion of the end component. To assist in insertion of the end component, a cylindrical skirt thereof 4 is provided with a chamfered end 9.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to bearing pullers and more particularly to pullers of bearings from bearing cups, such as nose cones and other closed end fixtures.
(2) Description of the Prior Art
It has been recognized that bearings often wear out and need replacement. If the bearing is located at the end of a shaft within a closed end fixture some mechanical device is needed to assist in the removal of the bearing.
An example of such a bearing is upon the nose cone of cotton strippers. A hexagonal shaft extends downward and terminates within a nose cone. This nose cone is in the form of a cup. A bearing having a hexagonal hole therethrough is within the cup and the hexagonal shaft fits within the hexagonal hole. The removal of these bearings from the nose cone presents a difficult problem and the common commercial practice today is to cut them out.
Before this application was filed, an independent search was made which produced the following references:
______________________________________ Alspaugh 869,861 Beddard 1,289,611 Campbell 1,464,693 White 2,036,665 Harrington 2,290,427 Layne 3,691,612______________________________________
HARRINGTON discloses a bearing puller incorporating an expanding sleeve which pulls the bearing from a blind hole. A bolt is threaded through a spool which expands the sleeve.
LAYNE discloses a sleeve which is a cylinder liner. The puller which has a movable member which is inserted sideways and then swings out to engage the bottom of the sleeve. This unit requires clearance at the bottom of the sleeve.
The other four patents do not appear to be as pertinent as HARRINGTON and LAYNE.
SUMMARY OF THE INVENTION
(1) New and Different Function
I have solved the problem of removing bearings from bearing cups such as nose cones and other closed end fixtures, which have a limited space between the bearing and the closed bottom of the bearing cup. This is accomplished by inserting a spool with a hexagonal flange on the end thereof through the bearing opening which is the same size and correlative shape as the flanged end of the spool. The flange is rotated beneath the inner race of the bearing. The bearing is removed as a bolt threaded through the spool is turned relative to the spool.
Thus, it may be seen that the total function is far greater than the sum of the individual functions of the spool, bolt, flanges, etc.
(2) Objects of the Invention
An object of this invention is to pull bearings.
Another object is to provide a bearing puller for a bearing in a blind hole.
Further objects are to achieve the above with a device that is sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, operate and maintain.
Other objects are to achieve the above with a method that is versatile, ecologically compatible, energy conserving, rapid, efficient, and inexpensive, and does not require skilled people to adjust, operate, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing, the different views of which are not scale drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a bearing puller according to my invention.
FIG. 2 is a top plan view of a bearing in a cup showing a square hole in the inner race.
FIGS. 3 and 4 are similar views to FIG. 2 showing different configurations of the opening in the inner race.
FIG. 5 is a bottom view of the puller of FIG. 1 showing a square flange.
FIG. 6 is a cross-sectional view of the puller of FIG. 1 and bearing in a bearing cup.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a bearing puller comprising spool 14 having a bottom and a top end. Flange 16 is on the bottom end of the spool 14. Neck 18 on the spool 14 is of lesser cross-section than the flange 16. The neck 18 is cylindrical. It is not essential for the neck 18 to be cylindrical, but it is necessary that the greatest distance across the neck 18 be less than the least dimension across the flange 16. Wrench flats 20 are on the top end of the spool 14. Axial hole 22 extends through the spool 14. Bolt 24 is threaded through the spool 14.
FIG. 2 shows a bearing 26 having outer race 28, and inner race 30. Non-circular hole 32 is in the inner race.
FIGS. 3 and 4 show similar bearings having different non-circular openings in the inner race 30. These openings may be of any non-circular cross section, although the most common is hexagonal (FIG. 3). The openings could be square (FIG. 2) or rectangular, having a length greater than the width (FIG. 4).
FIG. 6 shows the bearing puller inserted through bearing 26 which has been installed in bearing cup 34 having closed bottom 36 and cylindrical sides 38. A limited space 40 exists between the inner race 30 and the closed bottom 36.
Flange 16 on the bottom end of the spool 14 is of correlative cross-section as the hole 32 in the inner race 30 and smaller than the hole 32 so that the flange 16 will fit snugly, yet move smoothly through the hole 32. The embodiment shown in FIGS. 1 and 5 show this flange to be square so that it would fit with the square hole 32 of FIG. 2. The thickness of the flange 16 is such that it is less than the space 40 between the inner race 30 and the closed bottom 36 of the bearing cup 34.
Neck 18 of the spool 14 is of circular cross-section and the maximum diameter of the neck 18 is less than the smallest diameter of the hole 32 in the inner race 30 of bearing 26.
The bearing puller has hole 22 bored through its longitudinal axis, but only that portion of the hole 22 at the bottom end of the spool 14 and through the flange 16 is threaded. The remainder of the bored hole 22 is of a greater diameter.
The bearing 26 is removed from the cup 34 by placing the flange 16 through the non-circular hole 32 which has an axis into the space 40 between the inner race 30 and the closed bottom 36. The spool with the flange 16 is then rotated about the axis of the hole so that a portion of the flange 16 is beneath the inner race 30. The bolt 24 is rotated in the spool 14 until the end of the bolt 24 contacts the closed bottom 36 of bearing cup 34. The flange 16 is then locked against the inner race 30 of the bearing 26. As the bolt 24 is further rotated, bearing 26 is removed from the bearing cup 34. The wrench flats 20 on the top of the spool 14 provide a means for gripping the puller with a wrench, while the head on the bolt provides a similar means for gripping it.
The embodiment shown and described above is only exemplary. I do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of my invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. The restrictive description and drawing of the specific example above do not point out what an infringement of this patent would be, but are to enable the reader to make and use the invention.
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A special tool removes bearings with hexagonal holes from bearing cups. A spool with a hexagonal flange on its end is inserted through the hexagonal hole and is locked behind the bearing. A bolt, threaded through the spool, forces the bearing out of the cup.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cosmetic techniques and, more particularly, to methods and compositions for cosmetic treatment of the skin.
2. Description of the Prior Art
In general, two broad categories of treatments have evolved for beautifying one's skin. Among the first category are creams, astringents and lotions which are massaged into the skin. A second category includes powders or coatings which are used to mask or cover portions of the skin. U.S. Pat. No. 3,862,309 is representative of the latter group wherein a composition is disclosed which is left on the skin to smoothout and/or mask wrinkles. The composition contains a small percentage of high molecular weight sodium polystyrene sulfonate and may include color pigments when functioning as a makeup.
The above-patented treatment is unlike the present invention because it relies on the presence of a skin covering to mask one's skin. The system described herein provides a natural two-stage skin treatment whereby the skin is cleansed and plumped by the application and removal of a low molecular weight sodium polystyrene sulfonate-based film followed by the application of a cosmetic oil composition. The present system is not dependent on the durability or strong adherence of a film over skin nor is it concerned with skin remolding by external means.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a novel cosmetic skin treating system which cleanses the skin and diminishes wrinkles without the necessity of a user wearing a tight adherent skin cover. The system utilizes a 2-25 weight percent aqueous solution of sodium polystyrene sulfonate having a molecular weight below about 200,000. The solution is applied to one's skin and allowed to dry. It is then removed and a moisture barrier preparation applied. The combined treatment produces a natural long-lasting youthful skin appearance which is not attainable with an oil or cleansing lotion treatment alone.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The skin treating formulations used in the process of this invention comprise aqueous solutions of polystyrene sulfonate salts which contain effective amounts of a viscolizer and a liquid modifier defined as a plasticizer and/or surfactant depending on the specific end product desired. Additional additives may be used for obtaining particular effects such as preservatives, volatile solvents, humectants, fragrances and dermotrophic agents.
In general, the polystyrene sulfonate salt should be present in a concentration ranging from about 2-25 percent by weight of the total aqueous composition with the liquid modifier and viscolizer each being present in amounts ranging between about 0.1-20 weight percent.
The sulfonated polystyrene salts useful in the practice of this invention have molecular weights less than about 200,000 and are produced by sulfonating styrene polymers and treating the product with neutralizing bases such as sodium hydroxide, ammonium hydroxide, potassium hydroxide or sodium carbonate. Sodium salts of the sulfonated polymers are preferred.
In general, the basic oil formulation of the present invention may comprise any one or combination of animal, vegetable or mineral oils to achieve the desired effect of forming a barrier to prevent tissue moisture loss. Mineral oil may be used as the main barrier as well as vegetable oils such as soybean oil, castor oil, avocado, corn and the highly unsaturated oils such as safflower oil, olive oil, rice bran oil and peanut oil. Synthetic esters such as isopropyl myristate, octyl stearate, dioctyl adipate are useful as well as porosity esters such as 2-ethyl hexyl stearate and 2-ethyl hexyl palmitate which are miscible with mineral and vegetable oils. Other additives such as oil soluble proteins and vitamins such as A, D and E can be added to enhance the cosmetic effects of the oil formulas. Various animal derived oils such as mink oil may be used also.
Liquid modifiers such as plasticizers and/or surfactants which are useful in conjunction with the present invention may be characterized as anionic, cationic, nonionic and amphoteric compounds suitable for physiological use. Representative of such compounds are silicone fluids, water soluble polyoxyethylene fatty ethers, propylene glycol, polysorbate 20 and 80, glycerin, sorbitol, and acetylated esters of the ethoxylated ether of lanolin alcohols. These materials are used to adjust the spreading ability of the film solutions. They also facilitate removal of the dried film. Other compounds useful for the above purposes are imidazoline type zwitter ions and betaines.
Viscolizers suitable for use in controlling the viscosity of the sulfonated polystyrene solutions are natural gums such as tragacanth, acacia, guar, gelatin, pectin, carrageenan, sodium alginate and dextrin. Synthetic gums such as methyl cellulose, carboxymethylcellulose, polyvinylpyrrolidone, polyvinylpyrrolidone/vinyl alcohol copolymer, polymers of acrylic acid (carboxy vinyl polymers), polyvinyl alcohol, and vinyl pyrrolidone/vinyl acetate copolymer are also useful.
The drying time of the films can be shortened by the addition of volatile solvents such as alcohol, e.g. denatured ethanol. Conversely, the drying time can be increased with the addition of small amounts of glycerin or other humectants. The inclusion of a small amount of preservative or physiological bactericides in the film solutions may be appropriate to prevent microbial growth. Suitable physiological bactericides are methyl parahydroxybenzoate and other parahydroxybenzoic acid esters, formaldehyde, imidazolidinyl urea, quaterninum-15, sorbic acid, and 2-bromo-2-nitropropane, 1,3-diol quaternary ammonium salts and formaldehyde donners.
A wide variety of optional dermotrophic agents can be incorporated in the film solution to create certain desirable effects on the skin. Peripheral vasodialators such as methyl salicylate and nicotinic acid and its esters can be incorporated in the film composition. Examples of herbal additives are Azulene, Chamomile flowers, Witch hazel leaves, Arnica flowers. Other agents that can be used are powdered milk, proteolytic enzymes, urea, egg oil, egg powder, avocado powder, modified starches, bentonites, clays, ichthammol, vitamins such as vitamins A, B, C, D and E, vegetable extracts and amino acids, polypeptides and proteins. Certain polyvalent metals such as aluminum chloride might be used to produce an astringent effect. Small quantities of cationics such as dimethyl-aminopropyl lanolin (acid) amide diethosulfate quaternium may be used as a "skin feel" agent.
The invention will now be illustrated by the following specific examples, but it is intended that the invention shall not be limited thereby.
EXAMPLES
Each of the skin formulations are prepared in substantially the same manner. The viscolizers are added to cold water. With constant stirring, the water is heated to 175° F. and the polystyrene sulfonate salt is added. While the solution is allowed to cool, the plasticizers, surfactants, preservatives and other desired ingredients are added. When the temperature reaches about 90° F., the volatile materials are added such as solvents and fragrances. The pH is adjusted to a range between 3.5 to 8.0 and optional colorants are added to the desired shade.
EXAMPLE 1
______________________________________Skin Formulation: Weight Percent______________________________________Polystyrene sulfonate salt 15.0Carrageenan 1.0Alpine herbs 2.0Polysorbate 80 0.5Alcohol 5.0Germall 115 1.0Water 75.5______________________________________
The formulation is prepared as described above and applied to one's skin by brushing or dabbing with cotton pads to form an even film thereover. The film is allowed to dry under ambient conditions for 10 to 45 minutes. A cool water rinse is used to remove the film and the area covered by the film is treated immediately with an oil formulation as follows:
______________________________________ Weight Percent______________________________________Wickenol 163 55.0Castor oil 18.55Avocado oil 10.0Camellia oil 10.0Vitamin E Natural 1100 3.0Lecithin 2.0Isostearic Hydrolyzed animal protein 1.0Vitamin A & D 0.33Butyl paraben 0.1Mixed tocopherols 0.02Fragrance q.s.______________________________________
EXAMPLE 2
Example 1 was repeated with the following compositions:
______________________________________ Weight Percent______________________________________Skin Formulation:Polystyrene sulfonate salt 12.0Hydrolyzed collagen protein 3.0Polysorbate 20 1.0Glycerin 2.0Dowacil 200 0.1Fragrance 0.2Citric Acid q.s. pH5.5Water 81.7Oil FormulationMineral oil 60.0Isopropyl myristate 20.0Butyl paraben 0.1Avocado oil 19.9______________________________________
EXAMPLE 3
Example 1 was repeated with the following:
______________________________________ Weight Percent______________________________________Skin Formulation:Polystyrene sulfonate salt 5.0Carbopol 910 1.0Polysorbate 20 1.0Carbowax 200 2.0Aloe Vera 200 1.0F.D.&C. Blue No. 1 0.01Fragrance 0.30Methyl paraben 0.10Propyl paraben 0.05Germall 115 0.10Water 86.40Poly vinyl alcohol 3.04Oil Formulation:Isopropyl palmitate 80.0Safflower oil 15.0Butyl paraben 0.1Vitamin E Natural .9Corn oil 4.0______________________________________
EXAMPLE 4
Example 1 was repeated with the following:
______________________________________ Weight Percent______________________________________Skin Formulation:Polystyrene sulfonate salt 22.50Vitamin E 0.10Vitamin A & D 0.10Vitamin B Complex 0.50Amphoteric -6 2.0Bronopol 0.1Fragrance 0.5Color q.s.Water 74.2Oil Formulation:Mink oil 40.0Sesame oil 40.0Buyl paraben 0.2Dioctyl adipate 19.5Perfume 0.3______________________________________
EXAMPLE 5
Example 1 was repeated with the following:
______________________________________Weight Percent______________________________________Skin Formulation:Polystyrene sulfonate salt 15.0Nicotinic acid 0.25Carbowax 400 3.0Baureth-23 2.0Fragrance 0.5Germall 115 1.0Color q.s.Water 78.25Oil Formulation:2-ethyl hexyl stearate 10.02-ethyl hexyl palmitate 10.0di (2-ethyl hexyl) adipate 20.0Mineral oil 40.0Isopropyl Myristate 15.0Butyl paraben 0.1Perfume 0.1Camellia oil 4.8______________________________________
Skin treated in accordance with the above was cleansed and refreshened. Half face tests resulted in visual natural plumping of the skin and substantial diminution of skin lines. The test subjects reported a fresh youthful appearance not attainable with available lotions or face masks.
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A two-stage skin treating technique wherein a film of sodium polystyrene sulfonate cosmetic solution is applied to predetermined areas of the skin and allowed to dry. The dried film tightens the skin and enhances blood circulation which causes an increase in subcutaneous fluids and diminishes skin lines. When the film is removed, scurf skin and sebaceous soil is also removed thereby creating a highly effective cleansing action. A moisture barrier formulation is subsequently applied to enhance and protect the skin moisture level while creating a fresh youthful appearance and feeling.
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REFERENCE TO OTHER APPLICATIONS
This application is a division of application Ser. No. 171,579, filed July 23, 1980, which is a division of application Ser. No. 56,660, filed July 11, 1979, now U.S. Pat. No. 4,252,945.
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to a process for preparing pyrazolo[1,5-c]quinazolines of the structure ##STR3## wherein X is O or S;
R 1 is hydrogen, lower alkyl, hydroxymethyl, phenyl-lower alkyl, phenyl or phenyl substituted with halogen, lower alkyl, lower alkoxy, or trifluoromethyl;
R 2 is lower alkoxy, phenyl-lower alkoxy, phenoxy, or phenoxy substituted with lower alkyl or lower alkoxy;
R 3 and R 4 are the same or different and are selected from the group consisting of hydrogen, alkyl of 1 to 4 carbons, alkoxy of 1 to 4 carbons, lower alkanoyloxy of 1 to 4 carbons, nitro, benzyloxy, benzyloxy having a single mono-lower alkoxy substituent, halogen, hydroxy, and trifluoromethyl.
The present invention also related to a process for preparing pyrazolo[1,5-c]quinazolines of the structure ##STR4## wherein R 1 , R 3 , R 4 and X are as defined above and R 2' is CH 2 OH or CH 2 Hal wherein Hal is Cl, Br or F, and which process may also include the preparation of compounds of the structure ##STR5## wherein R 1 , R 3 , R 4 and X are as defined above and R 2" is lower alkanoyloxy, phenyl-lower alkanoyloxy or benzyloxy.
Essentially all of the above pyrazolo[1,5-c]quinazolines are disclosed in U.S. Pat. Nos. 4,076,818 and 4,112,096, as well as in U.S. application Ser. No. 900,050, filed Apr. 26, 1978, now abandoned and are useful as anti-allergy agents.
In addition, novel intermediates are also provided which are prepared in the course of carrying out the processes of the invention and have the structures ##STR6## wherein R 1 , R 2 , R 3 and R 4 are as defined above and R 5 is lower alkyl.
DETAILED DESCRIPTION OF THE INVENTION
Unless otherwise indicated the term "lower alkyl" or "alkyl" as employed herein includes both straight and branched chain radicals of up to eight carbon atoms, for instance, methyl, ethyl, propyl, isopropyl, butyl, t-butyl, isobutyl, pentyl, hexyl, isohexyl, heptyl, 4,4-dimethylpentyl, octyl, 2,2,4-trimethylpentyl, and the like.
Unless otherwise indicated, the term "lower alkoxy" or "alkoxy" includes straight and branched chain radicals which correspond to the above lower alkyl groups attached to an oxygen atom.
Unless otherwise indicated, the term "lower alkanoyl" or "alkanoyl" as employed herein includes any of the above lower alkyl groups linked to a carbonyl group.
Unless otherwise indicated, the term "substituted phenyl" includes radicals, such as lower alkyl phenyl (e.g., o-, m- or p-tolyl, ethylphenyl, butylphenyl, and the like), di(lower alkyl)phenyl (e.g., 2,4-dimethylphenyl, 3,5-diethylphenyl, and the like), halophenyl (e.g., chlorophenyl, bromophenyl, iodophenyl, fluorophenyl), lower alkoxyphenyl (e.g., methoxyphenyl or ethoxyphenyl); or trifluoromethylphenyl.
Unless otherwise indicated, the term "lower alkanoyloxy" or "alkanoyloxy" as employed herein includes any of the above defined "lower alkanoyl" or "alkanoyl" groups linked to an oxygen atom.
The process in accordance with the present invention for preparing the formula I compounds ##STR7## includes the steps of reacting a quinolone compound of the structure ##STR8## with a hydrazine compound, preferably a hydrazine dihydrohalide, such as hydrazine dihydrochloride, and hydrazine, in the presence of a high boiling solvent (for example, boiling at above about 150° C.), such as ethylene glycol or anisole, to form a 5-(2-aminophenyl)-pyrazole of the structure VI ##STR9## wherein R 1 , R 2 , R 3 and R 4 are as defined above, employing the procedures similar to those outlined in U.S. Pat. No. 3,313,815; Bowie et al, J. Chem. Soc. Perkin I, 1972, 1106; Field et al, J. Org. Chem., 36, 2968 (1971); de Stevens et al, Angew. Chemie, 74, 249 (1962); and Alberti, Gazz. Chim. Ital., 87, 772 (1957).
The above reaction is preferably carried out at a temperature of from about 150° to about 230° C., more preferably from about 160° to about 180° C., for a period ranging from about 3 to about 24 hours, more preferably from about 3 to about 6 hours, employing a molar ratio of V:hydrazine compound of from about 0.05:1 to about 1:1, more preferably from about 0.05:1 to about 0.2:1.
The 5-(2-aminophenyl)-pyrazole VI is then cyclized by reaction with a cyclizing agent of the structure VII
CXCl.sub.2 VII
where X is O or S (that is, phosgene or thiophosgene) or ethyl chloroformate, to form a pyrazolo[1,5-c]quinazoline of the structure I, employing procedures similar to those outlined in U.S. Pat. Nos. 3,531,482, 3,313,815 and 3,899,508, as well as in de Stevens et al, J. Org. Chem. 28, 1336 (1963), and the de Stevens et al, Field et al, and Bowie et al references mentioned above. The latter reaction is carried out in the presence of a basic solvent such as pyridine, triethylamine, quinoline, dimethylaniline and the like, at a temperature ranging from about 60° to about 240° C., more preferably from about 80° to about 120° C., for a period ranging from about 3 to about 24 hours and more preferably from about 12 to about 24 hours employing a molar ratio of VI to cyclizing agent of from about 0.2:1 to about 1:1, and more preferably from about 0.3:1 to about 1:1.
In preferred embodiments of the invention, the starting quinolone V will have the following structure ##STR10## and the cyclizing agent preferably employed will be phosgene, so that the final products of structure I will have the following structure ##STR11##
The compounds of formula II which include a CH 2 R 2' group at the 2-position, representing CH 2 OH or CH 2 Hal, are prepared, in accordance with the present invention, by reacting a compound of formula I with a halogen acid such as HBr, HCl or HF, preferably in a molar ratio of I:halogen acid of within the range of from about 0.01:1 to about 1:1, and more preferably from about 0.03:1 to about 0.06:1. The above reaction may be carried out at a temperature of from about 20° to about 130° C., and more preferably from about 80° to about 120° C. and most preferably at reflux temperature for periods of about 30 minutes or less to ensure a larger proportion of hydroxymethyl compound IIa ##STR12## and a smaller proportion of halomethyl compound IIb ##STR13## Such reaction may be carried out for a period of from about 15 minutes to about 4 hours, and preferably from about 30 minutes to about 1 hour.
In accordance with the process of the invention, a mixture of the compounds IIa and IIb may be converted to the more desirable compound IIa by simply heating the mixture at a temperature ranging from about 20° to about 100° C., and preferably from about 80° to about 100° C., in the presence of water, for periods of from about 1 hour to about 24 hours and preferably from about 4 to about 6 hours.
Alternatively, the mixture of compounds IIa and IIb may be converted to the more desirable compound IIa by reacting the mixture of compounds IIa and IIb with an alkali metal compound
MR.sup.2" VIII
wherein M is an alkali metal and R 2" is lower alkanoyloxy, phenyl-lower alkanoyloxy or benzoyloxy, and the corresponding carboxylic acid
R.sup.2" H IX
wherein R 2" is as above, to form the formula III compound ##STR14## or ##STR15## where R is lower alkyl, phenyl or phenyl-lower alkyl.
The latter reaction is preferably carried out at a temperature ranging from about 20° to about 150° C., and more preferably from about 80° to about 120° C., for a period of from about 1 to about 24 hours and preferably from about 10 to about 16 hours. The compound IIa preferably will be employed in a molar ratio to compound IX of within the range of from about 0.01:1 to about 0.1:1, and more preferably from about 0.03:1 to about 0.05:1, while the compound IIb will be employed in a molar ratio to compound VIII within the range of from about 0.2:1 to about 1:1, and more preferably from about 0.4:1 to about 0.5:1.
The formula III or IIIa compound may be converted to the hydroxymethyl compound of formula IIa by simply reacting the formula III or IIIa compound with a strong base, such as sodium hydroxide or potassium hydroxide, in the presence of a lower alkanol solvent, such as methanol or ethanol, (molar ratio of base:alkanol, preferably being from about 0.5:1 to about 0.1:1) for a period ranging from about 3 to about 24 hours and preferably from about 3 to about 6 hours and thereafter neutralizing the reaction mixture with a concentrated mineral acid, such as hydrochloric acid or sulfuric acid.
The quinolone starting material V is a new compound and may be prepared by reacting an aniline compound X ##STR16## wherein R 3 and R 4 are as defined above with a carboxylic acid ester of the structure XI ##STR17## wherein R 1 and R 2 are as defined above and R 5 is lower alkyl, in a molar ratio of X:XI preferably of 1:1 to form an intermediate of the structure IV ##STR18## wherein R 1 , R 2 , R 3 , R 4 and R 5 are as defined above. The above reaction is preferably carried out in the presence of a weak organic acid, such as acetic acid or propionic acid, and an aromatic solvent such as benzene or toluene, or hexane at a temperature ranging from about 60° to about 120° C. and preferably from about 60° to about 80° C. for a period of from about 1 hour to about 12 hours and preferably from about 2 to about 3 hours.
As indicated, the intermediate IV represents a new compound and as such forms a part of the present invention.
The quinolone compound V (also a new intermediate) is then prepared by simply reacting the intermediate IV with diphenyl ether in a molar ratio of IV:ether of from about 0.1:1 to about 0.5:1, and preferably from about 0.1:1 to about 0.2:1, at a temperature ranging from about 180 to about 270° C., and preferably from about 240° to about 260° C. for a period of from about 30 minutes to about 2 hours, and preferably from about 30 minutes to about 1 hour.
In a preferred embodiment, aniline itself (the formula X compound) is reacted with the carboxylic acid ester ##STR19## so that the intermediate IV will have the structure ##STR20## and the quinolone V produced will have the structure Va.
The carboxylic acid ester starting material XI may be prepared as described in U.S. Pat. No. 3,775,467.
Alternatively, the formula V quinolone may be prepared by reacting an isatoic anhydride ##STR21## with a carboxylic acid ester XI, in a molar ratio of XII:XI of from about 0.5:1 to about 1:1, and preferably about 1:1 in the presence of an inert solvent such as tetrahydrofuran or dioxane, and a strong base such as sodium or potassium hydroxide, at a temperature ranging from about 40° to about 100° C., and preferably from about 60° to about 70° C. to form a compound of the structure XIII ##STR22## which is then hydrolyzed and neutralized to form the corresponding carboxylic acid XIV ##STR23## which is then decarboxylated at a temperature ranging from about 180° to about 300° C. and preferably from about 240° to about 260° C. to the formula V quinolone.
The following Examples represent preferred embodiments of the present invention.
EXAMPLE 1
β-Anilino-γ-methoxycrotonate
A solution containing 9.3 g (0.1 mol) of aniline, 14.6 g (0.1 mol) of methyl γ-methoxyacetoacetate and 1 ml of acetic acid in 100 ml of benzene is refluxed for 3 hours with azeotropic removal of water. Evaporation under reduced pressure gives 21.8 g (95%) of the crude β-anilino-γ-methoxycrotonate.
EXAMPLE 2
2-Methoxymethyl-4-quinolone
The crude crotonate (21.2 g/0.096 mol) from Example 1 is added over a 30 minute period to 75 ml of refluxing diphenyl ether. The reaction mixture is refluxed for 30 minutes, cooled, and 300 ml of hexane added. The resulting crude product is filtered, washed three times with 150 ml of hexane and dried overnight under vacuum at 60° C. Recrystallization of the crude product (15.2 g/83.5%) from water with Darco treatment gives 10.6 g (58.2%) of 2-methoxymethyl-4-quinolone as creme-colored needles, m.p. 183.5°-185.0° C.
EXAMPLE 3
2-Methoxymethylpyrazolo[1,5-c]quinazoline-5-one
A. 5-(2-Aminophenyl)-3-methoxymethylpyrazole
A mixture of 7.5 g (0.04 mol) of 2-methoxymethyl-4-quinolone, 4.2 g (0.04 mol) of hydrazine dihydrochloride, 12.8 ml (0.4 mol) of 95% hydrazine and 30 ml of ethylene glycol is slowly heated to reflux. The resulting solution is refluxed for 5 hours, cooled, diluted with 200 ml of distilled water, and extracted twice with methylene chloride (1×400 ml, 1×200 ml). The combined methylene chloride extracts are washed with 100 ml of distilled water, dried over sodium sulfate, and evaporated to 8.0 g of clear oil. Trituration with 25 ml of hexane gives 6.95 g (86%) of the 5-(2-aminophenyl)-3-methoxymethylpyrazole as a white powder, m.p. 74.0°-78.0° C.
B. 2-Methoxymethylpyrazolo[1,5-c]quinazoline-5-one
A solution of 4.9 g (0.024 mol) of 5-(2-aminophenyl)-3-methoxymethylpyrazole in 135 ml of pyridine is prepared and 55 ml of a 12.5% phosgene in benzene solution is slowly added. After refluxing 22 hours, the reaction is cooled, diluted with 50 ml of distilled water, and evaporated to a dark black paste. Distilled water (200 ml) is added and the reaction mixture is extracted with methylene chloride (2×300 ml). The combined methylene chloride layers are washed with 1 N HCl (2×200 ml) and distilled water (2×200 ml). After drying over sodium sulfate, evaporation gives the crude product which is recrystallized with Darco treatment from acetonitrile to give 2.76 g (49%) of the desired ether, m.p. 192.5°-195.0° C.
EXAMPLE 4
Mixture of 2-Bromo-methylpyrazolo[1,5-c]quinazoline-5-one and 2-Hydroxymethylpyrazolo[1,5-c]quinazoline-5-one
A mixture of 1.1 g (0.0048 mol) of 2-methoxypyrazolo[1,5-c]quinazoline-5-one and 15 ml of 48% HBr is refluxed for 30 minutes, cooled, and diluted by the addition of 100 ml of cracked ice and 100 ml of distilled water. The crude product is filtered and washed with 2×25 ml of cold distilled water. TLC and NMR show the crude product (1.03 g) to be a mixture of 2-hydroxymethylpyrazolo[1,5-c]quinazoline-5-one and 2-bromo-methylpyrazolo[1,5-c]quinazoline-5-one.
EXAMPLE 5
2-Acetyloxymethylpyrazolo[1,5-c]quinazoline-5-one
The crude product (0.9 g) from Example 4 is refluxed with 0.3 g of sodium acetate in 18 ml of acetic acid for 15.5 hours. The reaction mixture is cooled, evaporated, dissolved in 50 ml of distilled water, and extracted with methylene chloride (1×100 ml, 1×50 ml). The combined methylene chloride layers are washed with 100 ml of distilled water, dried over sodium sulfate, and evaporated to 1.01 g (81.5%) of fluffy white 2-acetyloxymethylpyrazolo[1,5-c]quinazoline-5-one, m.p. 186.0°-187.0° C.
EXAMPLE 6
2-Hydroxymethylpyrazolo[1,5-c]quinazoline-5-one
The crude acetate product from Example 5 is slurried in a solution of 0.3 g of sodium hydroxide in 10 ml of aqueous methanol (1:1). After stirring for 5 hours, the reaction mixture is neutralized with concentrated hydrochloric acid followed by the addition of 13 ml of distilled water. After stirring overnight, the product is filtered, washed with cold distilled water and dried under vacuum at 60° C. to 0.62 g (72%) of white product, m.p. 285.0°-288.0° C.
EXAMPLES 7 TO 24
Following the procedure of Examples 1 and 2 except substituting the aniline compound shown in Column I of Table A below and substituting the carboxylic acid ester shown in Column II, the intermediates shown in Columns III and IV are obtained.
TABLE A__________________________________________________________________________Column I Column II ##STR24## ##STR25##Ex.No. R.sup.3 (position) R.sup.4 (position) R.sup.1 R.sup.2 R.sup.5__________________________________________________________________________7. CH.sub.3 (2) H H C.sub.2 H.sub.5 O CH.sub.38. F(4) H CH.sub.3 C.sub.6 H.sub.5CH.sub.2 O CH.sub.39. Cl(2) CH.sub.3 O(4) C.sub.2 H.sub.5 C.sub.6 H.sub.5 O C.sub.2 H.sub.510. ##STR26## H CH.sub.2 OH CH.sub.3 O C.sub.2 H.sub.5 ##STR27## H C.sub.6 H.sub.5 CH.sub.2 CH.sub.3 O CH.sub.3 C.sub.2 H.sub.5 (3) C.sub.2 H.sub.5 (4) C.sub.6 H.sub.5 C.sub.2 H.sub.5 O CH.sub. 3 CF.sub.3C.sub.6 H.sub.4 H H C.sub.6 H.sub.5 O C.sub.2 H.sub.5 H H H p-CH.sub.3C.sub.6 H.sub.4 O n-C.sub.3 H.sub.7 H H CH.sub.3 m-CH.sub.3 OC.sub.6 H.sub.4 O i-C.sub.3 H.sub.7__________________________________________________________________________Column III Column IV ##STR28## ##STR29##Ex. R.sup.3 R.sup.4 Ex. R.sup.3 R.sup.4No. (position) (position) R.sup.1 R.sup.2 R.sup.5 No. (position) (position) R.sup.1 R.sup.2__________________________________________________________________________ .BHorizBrace. .BHorizBrace. .BHorizBrace.7. as in Column I as in 16. CH.sub.3 (8) H as in Column II Column II8. 17. F(6) H9. 18. Cl(8) CH.sub.3 O(6)10. 19. ##STR30## H11. 20. ##STR31## H12. 21. C.sub.2 H.sub.5 (7) C.sub.2 H.sub.5 (6)13. 22. H H14. 23. H H15. 24. H H__________________________________________________________________________
EXAMPLES 25 TO 33
Following the procedure of Example 3 except substituting the quinolones of Examples 16 to 24, Column IV, Table A for 2-methoxymethyl-4-quinolone, (shown in Column I of Table B below), and the cyclizing agent shown in Column II, the pyrazolo[1,5-c]quinazoline shown in Column III is obtained.
TABLE B__________________________________________________________________________ Column I Column II Column III ##STR32## CXCl.sub.2 ##STR33##Ex. R.sup.3 R.sup.4 R.sup.3 R.sup.4No. (position) (position) R.sup.1 R.sup.2 X (position) (position) X R.sup.1 R.sup.2__________________________________________________________________________ .BHorizBrace. .BHorizBrace. CH.sub.3 (8) H H C.sub.2 H.sub.5 O O CH.sub.3 (7) H as in as in F(6) H CH.sub.3 C.sub.6 H.sub.5CH.sub.2 O S F(9) H Col. Col. I Cl(8) CH.sub.3 O(6) C.sub.2 H.sub.5 C.sub.6 H.sub.5 O O Cl(7) CH.sub.3 O(9) ##STR34## H CH.sub.2 OH CH.sub.3 O S ##STR35## H ##STR36## H C.sub.6 H.sub.5 CH.sub.2 CH.sub.3 O O ##STR37## H30. C.sub.2 H.sub.5 (7) C.sub.2 H.sub.5 (6) C.sub.6 H.sub.5 C.sub.2 H.sub.5 O S C.sub.2 H.sub.5 (8) C.sub.2 H.sub.5 (9) H H H C.sub.6 H.sub.5 O O H H H H H p-CH.sub.3C.sub.6 H.sub.4 O S H H H H CH.sub.3 m-CH.sub.3 OC.sub.6 H.sub.4 O O H H__________________________________________________________________________
EXAMPLES 34 TO 42
Following the procedure of Examples 4 and 5, except substituting the quinazoline of Examples 25 to 33 (shown in Column I of Table C below) and substituting for the sodium acetate and acetic acid, the salt and acid shown in Column II, the quinazoline shown in Column III is obtained.
TABLE C__________________________________________________________________________Column I Column II ##STR38## ##STR39##Ex.No. R.sup.3 (position) R.sup.4 (position) X R.sup.1 R.sup.2 R M__________________________________________________________________________ CH.sub.3 (7) H O H C.sub.2 H.sub.5 O CH.sub.3 K F(9) H S CH.sub.3 C.sub.6 H.sub.5CH.sub.2 O C.sub.2 H.sub.5 Na Cl(7) CH.sub.3 O(9) O C.sub.2 H.sub.5 C.sub.6 H.sub.5 O C.sub.6 H.sub.5 Na ##STR40## H S CH.sub.2 OH CH.sub.3 O C.sub.6 H.sub.5 CH.sub.2 Na ##STR41## H O C.sub.6 H.sub.5 CH.sub. 2 CH.sub.3 O n-C.sub.4 H.sub.9 K C.sub.2 H.sub.5 (8) C.sub.2 H.sub.5 (9) S C.sub.6 H.sub.5 C.sub.2 H.sub.5 O n-C.sub.3 H.sub.7 K40. H H O H C.sub.6 H.sub.5 O C.sub.2 H.sub.5 Na H H S H p-CH.sub.3C.sub.6 H.sub.4 O CH.sub.3 Na H H O CH.sub.3 m-CH.sub.3 OC.sub.6 H.sub.4 O C.sub.2 H.sub.5 K__________________________________________________________________________ Column III ##STR42## Ex. No. R.sup.3 (position) R.sup.4 (position) R.sup.1 X R__________________________________________________________________________ .BHorizBrace. .BHorizBrace. 34. as in Column I as in 35. Column II 36. 37. 38. 39. 40. 41. 42.__________________________________________________________________________
EXAMPLES 43 TO 51
Following the procedure of Example 6 except substituting the quinazolines of Examples 34 to 42 (shown in Column I of Table D below), the corresponding hydroxymethyl compound shown in Column II is obtained.
TABLE D__________________________________________________________________________Column I Column II ##STR43## ##STR44##Ex.No. R.sup.3 (position) R.sup.4 (position) X R.sup.1 R R.sup.3 (position) R.sup.4 (position) R.sup.1 X__________________________________________________________________________ .BHorizBrace. CH.sub.3 (7) H O H CH.sub.3 as in Column I F(9) H S CH.sub. 3 C.sub.2 H.sub.5 Cl(7) CH.sub.3 O(9) O C.sub.2 H.sub.5 C.sub.6 H.sub.5 ##STR45## H S CH.sub.2 OH C.sub.6 H.sub.5 CH.sub.2 ##STR46## H O C.sub.6 H.sub.5 CH.sub.2 n-C.sub.4 H.sub.9 C.sub.2 H.sub.5 (8) C.sub.2 H.sub.5 (9) S C.sub.6 H.sub.5 n-C.sub.3 H.sub.7 H H O H C.sub.2 H.sub.550. H H S H CH.sub.3 H H O CH.sub.3 C.sub.2 H.sub.5__________________________________________________________________________
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A process is provided for preparing pyrazolo[1,5-c]quinazoline derivatives of the structure ##STR1## wherein X is O or S; R 1 is hydrogen, lower alkyl, hydroxymethyl, phenyl-lower alkyl, phenyl or phenyl substituted with halogen, lower alkyl, lower alkoxy, or trifluoromethyl; R 2 is lower alkoxy, phenyl-lower alkoxy, phenoxy, or phenoxy substituted with lower alkyl or lower alkoxy; and R 3 and R 4 are the same or different and are selected from the group consisting of hydrogen, alkyl of 1 to 4 carbons, alkoxy of 1 to 4 carbons, lower alkanoyloxy of 1 to 4 carbons, nitro, benzyloxy, benzyloxy having a single mono-lower alkoxy substituent, halogen, hydroxy, and trifluoromethyl, wherein quinolone compounds of the structure ##STR2## which are new intermediates, are reacted with a hydrazine compound to form a 5-(2-aminophenyl)pyrazole which is then cyclized to the product.
In addition, the above product may be reacted with a halogen acid to form the corresponding hydroxymethyl compound.
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This is a divisional of application Ser. No. 11/190,081 filed Jul. 25, 2005, now U.S. Pat No. 7,351,350.
BACKGROUND OF THE INVENTION
This invention relates to agents for the processing of synthetic fibers and methods of processing synthetic fibers.
The production speed of synthetic fibers is increasing rapidly in recent years. At the same time, there is a tendency to increase the production of new kinds of synthetic fibers such as low denier synthetic fibers, high multifilament synthetic fibers and modified cross-section synthetic fibers. If synthetic fibers of such new types are produced at a higher speed, their friction increases with the yarn passing, guides, rollers and heater. This causes an increase in the friction-charged electrostatic potential, resulting in low cohesion and unwanted tension variations of synthetic fibers, and the problems of fluffs and yarn breaking tend to occur. The present invention relates to agents for and methods of processing synthetic fibers capable of sufficiently preventing the occurrence of fluffs and yarn breaking as well as dyeing specks even when synthetic fibers of the aforementioned new kinds are produced at an increased production rate.
Examples of prior art processing agent for synthetic fibers for preventing the occurrence of fluffs and yarn breaking at the time of their high rate of production include (1) processing agents for synthetic fibers containing polyether compounds with molecular weight of 1000-20000, having dialkylamine with random or block addition of alkaline oxide with 2-4 carbon atoms (such as disclosed in Japanese Patent Publication Tokkai 6-228885); (2) processing agents for synthetic fibers containing branched-chain polypropylene glycol having 4 or more branched chains (such as disclosed in Japanese Patent Publication Tokkai 10-273876); (3) processing agents for synthetic fibers containing a polyether lubricant having 10-50 weight % of polyether block of number average molecular weight of 1000-10000 with block copolymerization of ethylene oxide and propylene oxide at weight ratio of 80/20-20/80 (such as disclosed in Japanese Patent Publication Tokkai 2001-146683); and (4) processing agents for synthetic fibers containing polyoxyalkylene glycol with number average molecular weight of 5000-7000 with copolymerization of ethylene oxide and propylene oxide at weight ratio of 40/60-20/80, monocarboxylic acid with 8-14 carbon atoms and alkyl amine salt with 6-14 carbon atoms or quaternary ammonium salt (such as disclosed in Japanese Patent Publication Tokkai 10-245729).
These prior art processing agents are not sufficiently capable of preventing the occurrence of fluffs, yarn breaking and dyeing specks when synthetic fibers are produced at a fast rate and in particular when synthetic fibers of the aforementioned new kinds are produced at a fast rate.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a processing agent and a process method capable of sufficiently prevent the occurrence of fluffs, yarn breaking and dyeing specks even when new kinds of synthetic fibers such as low denier synthetic fibers, high multifilament fibers and modified cross-section synthetic fibers are produced at a fast rate
The present invention is based on the discovery by the present inventor, as a result of his studies in view of the object described above, that a processing agent containing hydroxy compound of a specified kind at least as a part of functional improvement agent at a specified rate should be applied to the synthetic fibers.
DETAILED DESCRIPTION OF THE INVENTION
The invention firstly relates to a processing agent for synthetic fibers characterized as containing a lubricant and a functional improvement agent and containing hydroxy compound as described below in an amount of 1-30 weight % at least as a part of the functional improvement agent. The invention secondly relates to a processing method for synthetic fibers characterized as comprising the step of applying a processing agent of this invention to synthetic fibers so as to be 0.1-3 weight % with respect to the synthetic fibers. In the above, hydroxy compound is one or more selected from the group consisting of compounds shown by Formula 1 and the group consisting of compounds shown by Formula 2 where Formula 1 is:
and Formula 2 is:
where R 1 , R 2 , R 3 and R 4 are each hydrogen atom or aliphatic hydrocarbon group with 1-12 carbon atoms (only two or less of them being hydrogen atom at the same time); R 7 , R 8 , R 9 and R 10 are each hydrogen atom or aliphatic hydrocarbon group with 1-12 carbon atoms (only two or less of them being hydrogen atom at the same time); R 5 , R 6 , R 11 and R 12 are each hydrogen atom, methyl group or acyl group with 1-3 carbon atoms; and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of (poly)alkyleneglycol having (poly)oxyalkylene group formed with a total of 1-30 oxyalkylene units with 2-4 carbon atoms.
Processing agents for synthetic fibers according to this invention (hereinafter referred to simply as processing agents of this invention) will be described first.
Processing agents of this invention are characterized as containing a lubricant and a functional improvement agent and containing hydroxy compound of a specified kind at least as a part of the functional improvement agent.
What is herein referred to as hydroxy compound of a specified kind is one or more selected from the group consisting of compounds shown by Formula 1 and the group consisting of compounds shown by Formula 2.
Regarding Formula 1, R 1 , R 2 , R 3 and R 4 are each hydrogen atom or aliphatic hydrocarbon group with 1-12 carbon atoms but only two or less of them may be both hydrogen atom. Thus, there are (1) examples where two of them are each aliphatic hydrocarbon group with 1-12 carbon atoms, the remaining two being each hydrogen atom; (2) examples where three of them are each aliphatic hydrocarbon group with 1-12 carbon atoms, the remaining one being hydrogen atom; and (3) examples where each of them is aliphatic hydrocarbon group with 1-12 carbon atoms. Among these examples, the examples in (1) are preferred. Examples of aliphatic hydrocarbon group with 1-12 carbon atoms in (1)-(3) include methyl group, ethyl group, butyl group, hexyl group, heptyl group, octal group, only group, decal group, unduly group, codicil group, isopropyl group, t-butyl group, isobutyl group, 2-methylpentyl group, 2-ethyl-hexyl group, 2-propel-heptyl group, 2-butyl-octal group, vinyl group, allyl group, hexane group and 10-unevenly group. Among these, aliphatic hydrocarbon groups with 1-6 carbon atoms are preferable and those for which the total number of carbon atoms for R 1 -R 4 is 2-14 are particularly preferable. R 5 and R 6 are each (1) hydrogen atom, (2) methyl group or (3) acyl group with 1-3 carbon atoms such as formal group, acetyl group or propyonyl group. Among these, however, hydrogen atom is preferred.
The hydroxy compounds shown by Formula 1 themselves can be synthesized by a conventional method such as disclosed in Japanese Patent Publication Tokkai 2002-356451.
Regarding compounds shown by Formula 2, R 7 -R 10 are the same as described above regarding R 1 -R 4 , and R 11 and R 12 are the same as described above regarding R 5 and R 6 . A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of (poly)alkyleneglycol having (poly)oxyalkylene group formed with a total of 1-30 oxyalkylene units with 2-4 carbon atoms. Examples of what A 1 and A 2 may each be include (1) residual groups obtainable by removing hydrogen atoms from all hydroxyl groups of alkyleneglycol having oxyalkylene unit formed with one oxyalkylene unit with 2-4 carbon atoms and (2) residual groups obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 2-30 oxyalkylene units with 2-4 carbon atoms, and examples of oxyalkylene unit with 2-4 carbon atoms forming such polyoxyalkylene group include oxethylene unit, ox propylene unit and oxybutylene unit. Among these, residual group obtainable by removing hydrogen atoms from all hydroxyl groups of ethylene glycol, residual group obtainable by removing hydrogen atoms from all hydroxyl groups of propylene glycol and residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 2-12 ox ethylene units and ox propylene units are preferable. If the polyalkylene group is formed with two or more different oxyalkylene units, their connection may be random connection, block connection or random-block connection.
The hydroxy compounds shown by Formula 2, as explained above, themselves can be synthesized by a conventional method such as disclosed in Japanese Patent Publication Tokkai 3-163038.
Processing agents of this invention are characterized as containing a lubricant and a functional improvement agent and containing one or more of hydroxy compounds selected from the group of compounds shown by Formula 1 and the group of compounds shown by Formula 2 as described above in an amount of 1-30 weight % at least as a part of the functional improvement agent but those containing such hydroxy compounds in an amount of 2-25 weight % are preferable and those containing such hydroxy compounds in an amount of 5-20 weight % are even more preferable.
Processing agents of this invention may contain functional improvement agents other than the hydroxy compounds shown by Formula 1 and Formula 2. Examples of such other functional improvement agent include those conventionally known kinds such as (1) antistatic agents including anionic surfactants such as organic sulfuric acid salts and organic aliphatic acid salts, cationic surfactants such as laurel trim ethyl ammonium sulfate, and impolitic surfactants such as octal diethyl ammonioacetate; (2) oiliness improvement agents such as organic phosphoric acid salts and aliphatic acid salts; (3) penetration improvement agents such as polyether modified silicone having polydimethyl siloxane chain with average molecular weight of 1500-3000 as main chain and polyoxyalkylene chain with average molecular weight of 700-5000 as side chain and surfactant having perfluoroalkyl group; (4) cohesion improvement agents such as polyether polyesters; (5) extreme-pressure additives such as organic titanium compounds and organic phosphor compounds; (6) antioxidants such as phenol antioxidants, phosphate antioxidants and throatier antioxidants; and (7) antirust agents.
When a processing agent of this invention contains such other functional improvement agents, their content should preferably be 0.2-15 weight % and more preferably 1-12 weight %.
Processing agents of this invention contain a lubricant and a functional improvement agent as explained above. Examples of such lubricant include conventionally known kinds such as (1) polyether compounds; (2) aliphatic ester compounds; (3) aromatic ester compounds; (4) (poly)ether ester compounds; (5) mineral oils; and (6) silicone oils.
Examples of aforementioned polyether compound include polyether monopoly, polyether idol and polyether triol, all having polyoxyalkylene group in the molecule. Among these, however, polyether compounds with average molecular weight of 700-10000 are preferred and polyether compounds with average molecular weight of 700-10000 with monohydric-trihydric hydroxy compound with 1-18 carbon atoms having block or random attachment of alkylene oxide with 2-4 carbon atoms are particularly preferable.
Examples of aforementioned aliphatic ester compound include (1) ester compounds obtainable by esterification of aliphatic monohydric alcohol and aliphatic monocarboxylic acid such as butyl stearate, octyl stearate, oleyl stearate, oleyl oleate and isopentacosanyl isostearate; (2) ester compounds obtainable by esterification of aliphatic polyhydric alcohol and aliphatic monocarboxylic acid such as 1,6-hexanediol didecanoate and trimethylol propane monooleate monolaurate; and (3) ester compounds obtainable by esterification of aliphatic monohydric alcohol and aliphatic polycarboxylic acid such as dilauryl adipate and dioleyl azelate. Among these, however, aliphatic ester compounds with 17-60 carbon atoms are preferable and aliphatic ester compounds with 17-60 carbon atoms obtainable by esterification of aliphatic monohydric alcohol and aliphatic monocarboxylic acid or aliphatic polyhydric alcohol and aliphatic monocarboxylic acid are particularly preferable.
Examples of aforementioned aromatic ester compound include (1) ester compounds obtainable by esterification of aromatic alcohol and aliphatic monocarboxylic acid such as benzyl stearate and benzyl laureate; and (2) ester compounds obtainable by esterification of aliphatic monohydric alcohol and aromatic carboxylic acid such as diisostearyl isophthalate and trioctyl trimellitate. Among these, however, ester compounds obtainable by esterification of aliphatic monohydric alcohol and aromatic carboxylic acid are preferable.
Examples of aforementioned (poly)etherester compound include (1) (poly)etherester compounds obtainable by esterification of (poly)ether compound obtainable by adding alkylene oxide with 2-4 carbon atoms to monohydric-trihydric aliphatic alcohol with 4-26 carbon atoms and aliphatic carboxylic acid with 4-26 carbon atoms; (2) (poly)etherester compounds obtainable by esterification of (poly)ether compound obtainable by adding alkylene oxide with 2-4 carbon atoms to monohydric-trihydric aromatic alcohol and aliphatic carboxylic acid with 4-26 carbon atoms; and (3) (poly)etherester compounds obtainable by esterification of (poly)ether compound obtainable by adding alkylene oxide with 2-4 carbon atoms to aliphatic alcohol with 4-26 carbon atoms and aromatic carboxylic acid.
Examples of aforementioned mineral oil include mineral oils of various kinds having different viscosity values. Among these, however, those with viscosity 1×10 −6 -1.3×10 −1 m 2 /s at 30° C. are preferable and those with viscosity 1×10 −6 -5×10 m 2 /s are even more preferable. Examples of such preferable mineral oil include fluid paraffin oil.
Examples of aforementioned silicone oil include silicone oils of various kinds having different viscosity values. Among these, however, linear polyorganosiloxane with viscosity 1×10 −3 -1 m 2 /s at 30° C. is preferable. Examples of such linear polyorganosiloxane include linear polydimethylsiloxane without substituent and linear polydimethylsiloxane with substituent, all with viscosity 1×10 −3 -1 m 2 /s at 30° C. Examples of substituent in these cases include ethyl group, phenyl group, fluoropropyl group, aminopropyl group, carboxyoctyl group, polyoxyethylene oxypropyl group and ω-methoxy polyethoxypolypropoxy propyl group. Among these, linear polydimethylsiloxane without substituent is preferable.
Among processing agents of this invention, those containing a lubricant as described above in an amount of 50-90 weight % and a functional improvement agent as described above in an amount of 1-30 weight % are preferable. Those further containing a hydroxy compound shown by Formula 1 or Formula 2 as described above in an amount of 1-30 weight % as the functional improvement agent are even more preferable.
Processing agents of this invention may further contain an emulsifier. An emulsifier of a known kind may be used. Examples of emulsifier of a known kind that may be used for the purpose of this invention include (1) nonionic surfactants having polyoxyalkylene group in the molecule such as polyoxyalkylene alkylethers, polyoxyalkylene alkylphenylethers, polyoxyalkylene alkylesters, alkylene oxide adducts of castor oil and polyoxyalkylene alkylaminoethers; (2) partial esters of polyhydric alcohol type nonionic surfactants such as sorbitan monolaurate, sorbitan trioleate, glycerol monolaurate and diglycerol dilaurate; and (3) partial esters of polyhydric alcohol type nonionic surfactants such as alkylene oxide adducts of partial esters of trihydric-hexahydric alcohol and aliphatic acid and partial or complete esters of alkylene oxide adduct of trihydric-hexahydric alcohol and aliphatic acid. Among these, however, polyoxyalkylenealkylethers having polyoxyalkylene group with 3-10 oxyethylene units and alkyl group with 8-18 carbon atoms in the molecule are preferable.
If processing agents of this invention contain an emulsifier as described above, it is preferable that such an emulsifier be contained in an amount of 2-30 weight %.
Among the processing agents of this invention containing an emulsifier, those containing a lubricant in an amount of 50-90 weight %, a functional improvement agent in an amount of 1-30 weight % and an emulsifier in an amount of 2-30 weight % (with a total of 100 weight %) are preferable. Those containing a hydroxy compound shown by Formula 1 or Formula 2 as described above in an amount of 3-25 weight % at least as a part of this functional improvement agent are even more preferable.
Next, the method according to this invention for processing synthetic fibers (hereinafter referred to simply as the method of this invention) is explained. The method of this invention is a method of applying a processing agent of this invention as described above at a rate of 0.1-3 weight % and more preferably 0.3-1.2 weight % of the synthetic fibers to be processed. The fabrication step during which a processing agent of this invention is to be applied to the synthetic fibers may be the spinning step or the step during which spinning and drawing are carried out simultaneously. Examples of the method of causing a processing agent of this invention to be attached to the synthetic fibers include the roller oiling method, the guide oiling method using a measuring pump, the emersion oiling method and the spray oiling method. The form in which a processing agent of this invention may be applied to synthetic fibers may be as a neat, as an organic solution or as an aqueous solution but the form as an aqueous solution is preferable. When an aqueous solution of a processing agent of this invention is applied, it is preferable to apply the solution at a rate of 0.1-3 weight % and more preferably 0.3-1.2 weight % as the processing agent with respect to the synthetic fiber.
Examples of synthetic fibers that may be processed by a method of this invention include (1) polyester fibers such as polyethylene terephthalate, polypropylene terephthalate and polylactic ester fibers; (2) polyamide fibers such as nylon 6 and nylon 66; (3) polyacryl fibers such as polyacrylic and modacrylic fibers; (4) polyolefin fibers such as polyethylene and polypropylene fibers and polyurethane fibers. The present invention is particularly effective, however, when applied to polyester fibers and polyamide fibers.
The invention is described next by way of test examples but it goes without saying that these examples are not intended to limit the scope of the invention. In what follows, “part” will mean “weight part” and “%” will mean “weight %” unless otherwise specified.
Part 1 (Preparation of Hydroxy Compounds)
Preparation of Hydroxy Compound (A-1)
Potassium hydroxide powder (purity 95%) 47.5 g and naphthen solvent (range of boiling point 210-230° C., specific weight 0.79) 400 g were placed inside a 1-liter autoclave and methylethyl ketone 50 g was further added after acetylene was introduced to the gauge pressure of 0.02 MPa. A reaction mixture was obtained after temperature was kept at 25° C. for 2 hours. This reaction mixture 500 g was transferred into a separation funnel and after it was washed with water to remove the potassium hydroxide, an organic phase was separated. After hydrochloric acid with concentration of 0.1 mol/L was added to this organic phase to neutralize the remaining potassium hydroxide, an organic phase 456 g containing 3,6-dimethyl-4-octine-3,6-diol was separated. This organic phase 456 g was taken inside a separation funnel, dimethyl sulfoxide 90 g was added, and it was left stationary after shaken. The lower layer 151 g formed by layer separation was collected, the naphthen solvent 363 g was added, and it was left stationary after shaken. The lower layer 140 g formed by layer separation was collected and distilled at a reduced pressure to obtain 3,6-dimethyl-4-octyne-3,6-diol as hydroxy compound (A-1).
Preparation of Hydroxy Compounds (A-2)-(A-12) and (a-1)
Hydroxy compounds (A-2)-(A-12) and (a-1) were prepared similarly as hydroxy compound (A-1) explained above.
Preparation of Hydroxy Compound (A-15)
Hydroxy compound (A-1) as described above 170 g (1 mole) and boron trifluoride diethyl ether 5 g were placed inside an autoclave and after the interior of the autoclave was replaced with nitrogen gas, a mixture of ethylene oxide 352 g (8 moles) and propylene oxide 464 g (8 moles) was pressured in under a pressured and heated condition at 60-70° C. for a reaction. A reaction product was obtained after an hour of ageing reaction. This reaction product was analyzed and found to be hydroxy compound (A-15) according to Formula 2 wherein R 7 and R 10 are each methyl group, R 8 and R 9 are each ethyl group, R 11 and R 12 are each hydrogen atom, and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 8 oxyethylene units and oxypropylene units.
Preparation of Hydroxy Compounds (A-16)-(A-20) and (a-2)
Hydroxy compounds (A-16)-(A-20) and (a-2) were prepared similarly as hydroxy compound (A-15) explained above.
Preparation of Hydroxy Compound (A-21)
Hydroxy compound 694 g (1 mole) obtained by adding 10 moles of ethylene oxide to 1 mole of 2,2,7,7-tetramethyl-3,6-diethyl-4-octine-3,6-diol and 48% aqueous solution of potassium hydroxide 14.5 g were placed inside an autoclave and dehydrated with stirring at 70-100° C. under a reduced pressure condition. After an etherifecation reaction was carried out by maintaining the reaction temperature at 100-120° C. and pressuring in methyl chloride 106 g (2.1 moles) until the lowering of pressure inside the autoclave became unnoticeable, a reaction product 765 g was obtained by filtering away the potassium chloride obtained as by-product. This reaction product was analyzed and found to be hydroxy compound (A-21) according to Formula 2 wherein R 7 and R 10 are each ethyl group, R 8 and R 9 are each t-butyl group, R 11 and R 12 are each methyl group, and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyethylene group formed with a total of 5 oxyethylene units.
Preparation of Hydroxy Compounds (A-14) and (a-3)
Hydroxy compounds (A-14) and (a-3) were prepared similarly as hydroxy compound (A-21) explained above.
Preparation of Hydroxy Compound (A-22)
Hydroxy compound 1420 g (1 mole) obtained by adding 8 moles of ethylene oxide and 14 moles of propylene oxide to 1 mole of 2,9-dimethyl-4,7-diethyl-5-decyne-4,7-diol, glacial acetic acid 144 g (2.4 moles) and concentrated sulfuric acid 12 g were placed inside a flask for an esterification reaction with stirring by maintaining the reaction temperature at 100-110° C. and dehydrating under a reduced pressure condition. After the reaction was completed, it was cooled and the concentrated sulfuric acid and the non-reacted acetic acid were neutralized with 48% potassium hydroxide 70 g and the generated water was distilled away under a reduced pressure condition. A reaction product 1420 g was obtained by filtering away organic salts obtained as by-products. This reaction product was analyzed and found to be hydroxy compound (A-22) according to Formula 2 wherein R 7 and R 10 are each ethyl group, R 8 and R 9 are each isobutyl group, R 11 and R 12 are each acetyl group, and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 11 oxyethylene units and oxypropylene units.
Preparation of Hydroxy Compound (A-13)
Hydroxy compound (A-13) was prepared similarly as hydroxy compound (A-21) explained above.
Details of all these hydroxy compounds obtained above are shown below, those corresponding to Formula 1 being shown in Table 1 and those corresponding to Formula 2 being shown in Table 2.
TABLE 1
R 1
R 4
R 2
R 3
*1
R 5
R 6
A-1
Methyl
Methyl
Ethyl
Ethyl
6
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-2
Hydrogen
Hydrogen
Methyl
Methyl
2
Hydrogen
Hydrogen
atom
atom
group
group
atom
atom
A-3
Ethyl
Ethyl
Ethyl
Ethyl
8
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-4
Methyl
Methyl
n-propyl
n-propyl
8
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-5
Methyl
Methyl
Isopropyl
Isopropyl
8
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-6
Methyl
Methyl
n-butyl
n-butyl
10
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-7
Methyl
Methyl
Isobutyl
Isobutyl
10
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-8
Hydrogen
Hydrogen
n-pentyl
n-pentyl
10
Hydrogen
Hydrogen
atom
atom
group
group
atom
atom
A-9
Hydrogen
Hydrogen
n-hexyl
n-hexyl
12
Hydrogen
Hydrogen
atom
atom
group
group
atom
atom
A-10
Methyl
Methyl
t-butyl
t-butyl
12
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-11
Methyl
Methyl
Isopentyl
Isopentyl
12
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-12
Lauryl
Lauryl
Isobutyl
Isobutyl
32
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-13
Ethyl
Ethyl
Isopentyl
Isopentyl
14
Acetyl
Acetyl
group
group
group
group
group
group
A-14
Ethyl
Ethyl
Isopentyl
Isopentyl
14
Methyl
Methyl
group
group
group
group
group
group
a-1
Methyl
Methyl
Octa-
Octa-
38
Hydrogen
Hydrogen
group
group
decenyl
decenyl
atom
atom
group
group
In Table 1:
*1: Sum of carbon atom numbers of R 1 -R 4
TABLE 2 A 1 A 2 R 7 R 10 R 8 R 9 *2 *3 *3 R 11 R 12 A-15 MG MG EG EG 6 EO/4 EO/4 HA HA PO/4 PO/4 A-16 MG MG IPG IPG 8 EO/2 EO/2 HA HA PO/2 PO/2 A-17 MG MG IBG IBG 10 EO/7 EO/7 HA HA A-18 MG MG IPNG IPNG 12 EO/15 EO/15 HA HA PO/5 PO/5 A-19 MG MG EG EG 6 EO/1 EO/1 HA HA A-20 HA HA EG EG 4 EO/25 EO/25 HA HA A-21 EG EG tBG tBG 12 EO/5 EO/5 MG MG A-22 EG EG IBG IBG 12 EO/4 EO/4 AG AG BO/7 BO/7 a-2 MG MG IPG IPG 6 EO/20 EO/20 HA HA PO/20 PO/20 a-3 EG EG IPG IPG 6 EO/5 EO/5 BG BG In Table 2: *2: Sum of carbon atom numbers of R 7 -R 10 *3: Kind/Repetition number of oxyalkylene units EO: Oxyethylene unit PO: Oxypropylene unit BO: Oxytetramethylene unit HA: Hydrogen atom MG: Methyl group EG: Ethyl group IPG: Isopropyl group IPNG: Isopentyl group IBG: Isobutyl group tBG: t-butyl group AG: Acetyl group BG: Butyl group
Part 2
TEST EXAMPLE 1
Preparation of Processing Agent (P-1)
Processing agent (P-1) of Test Example 1 for synthetic fibers was prepared by uniformly mixing together 75 parts of lubricant (B-1) described below, 7 parts of hydroxy compound (A-1) shown in Table 1 as functional improvement agent, 10 parts of another functional improvement agent (C-1) described below, 1 part of still another functional improvement agent (E-1) described below and 7 parts of emulsifier (D-1) described below.
Lubricant (B-1): Mixture at weight ratio of 11/14/29/46 of dodecyl dodecanate, ester of α-butyl-ω-hydroxy (polyoxyethylene) (n=3) and dodecanoic acid, polyether monool with number average molecular weight of 3000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to butyl alcohol, and polyether monool with number average molecular weight of 1000 obtained by block addition of ethylene oxide and propylene oxide at weight ratio of 40/60 to butyl alcohol.
Functional improvement agent (C-1): Mixture at weight ratio 50/50 of potassium octadecenate and potassium decanesulfonate.
Functional improvement agent (E-1): Octyl diphenyl phosphite (antioxidant).
Emulsifier (D-1): Glycerol monolaurate.
TEST EXAMPLES 2-23 AND COMPARISON EXAMPLES 1-5
Preparation of Processing Agents (P-2)—(P-23) and (R-1)-(R-5)
Processing agents (P-2)-(P-23) and (R-1)-(R-5) of Test Examples 2-23 and Comparison Examples 1-5 for synthetic fibers were prepared similarly as processing agent (P-1) described above.
Details of these processing agents are summarized in Table 3.
TABLE 3 Functional improvement agents Hydroxy Lubricant compound Others Emulsifier Kind Kind Ratio Kind Ratio Kind Ratio Kind Ratio Test Exam- ples 1 P-1 B-1 75 A-1 7 C-1 10 D-1 7 E-1 1 2 P-2 B-1 65 A-2 12 C-2 9 D-2 14 3 P-3 B-1 55 A-3 18 C-1 9 D-3 18 4 P-4 B-2 65 A-4 7 C-1 13 D-2 14 E-2 1 5 P-5 B-2 55 A-5 12 C-2 15 D-3 18 6 P-6 B-3 75 A-6 7 C-1 11 D-1 7 7 P-7 B-3 65 A-7 7 C-2 11 D-3 16 E-3 1 8 P-8 B-4 65 A-8 12 C-3 7 D-3 16 9 P-9 B-1 65 A-9 18 C-1 3 D-2 14 10 P-10 B-2 65 A-10 7 C-2 11 D-3 16 E-3 1 11 P-11 B-1 65 A-11 12 C-4 9 D-2 14 12 P-12 B-2 80 A-12 3 C-5 5 D-2 12 13 P-13 B-1 54 A-13 26 C-6 5 D-3 15 14 P-14 B-1 65 A-14 7 C-1 12 D-3 16 15 P-15 B-1 75 A-15 7 C-1 11 D-1 7 16 P-16 B-2 65 A-16 12 C-2 8 D-2 14 E-1 1 17 P-17 B-2 55 A-17 18 C-1 9 D-3 18 18 P-18 B-3 65 A-18 12 C-1 9 D-2 14 19 P-19 B-4 65 A-18 12 C-2 8 D-2 14 E-3 1 20 P-20 B-1 65 A-19 12 C-1 9 D-2 14 21 P-21 B-2 80 A-20 2 C-5 6 D-1 12 22 P-22 B-5 54 A-21 28 C-6 3 D-3 15 23 P-23 B-2 65 A-22 10 C-5 11 D-2 14 Com- parison Exam- ples 1 R-1 B-2 65 a-1 18 C-3 3 D-2 14 2 R-2 B-2 65 a-2 18 C-3 3 D-2 14 3 R-3 B-2 65 a-3 18 C-3 3 D-2 14 4 R-4 B-2 70 A-14 0.5 C-3 14.5 D-2 15 5 R-5 B-2 54 A-14 33 C-3 7 D-2 6 In Table 3: Ratio: Weight part; B-1: Mixture of dodecyl dodecanate, ester of α-butyl-ω-hydroxy (polyoxyethylene) (n = 3) and dodecanoic acid, polyether monool with number average molecular weight of 3000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to butyl alcohol, and polyether monool with number average molecular weight of 1000 obtained by block addition of ethylene oxide and propylene oxide at weight ratio of 40/60 to butyl alcohol at weight ratio of 11/14/29/46; B-2: Mixture of lauryl octanate, polyether monool with number average molecular weight of 3000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 65/35 to butyl alcohol, and polyether monool with number average molecular weight of 2500 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 40/60 to butyl alcohol at weight ratio of 30/20/50; B-3: Mixture of polyether monool with number average molecular weight of 10000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to butyl alcohol, polyether monool with number average molecular weight of 2500 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to lauryl alcohol, and polyether monool with number average molecular weight of 1000 obtained by block addition of ethylene oxide and propylene oxide at weight ratio of 45/55 to octyl alcohol at weight ratio of 30/50/20; B-4: Mixture of lauryl octanate and mineral oil with viscosity 1.3 × 10 −5 m 2 /s at 30° C. at weight ratio of 67/33; B-5: Mixture of mineral oil with viscosity 3.0 × 10 −5 m 2 /s at 30° C., lauryl acid ester of α-butyl-ω-hydroxy (polyoxyethylene) (n = 8), and polyether monool with number average molecular weight of 1800 obtained by block addition of ethylene oxide and propylene oxide to butyl alcohol at weight ratio of 24/16/60; A-1-A-22, a-1-a-3: Hydroxy compounds prepared in Part 1 and described in Tables 1 and 2. D-1: Glycerol monolaurate; D-2: α-dodecyl-ω-hydroxy (polyoxyethylene) (n = 7); D-3: Mixture of castor oil with addition of 20 moles of ethylene oxide and diester of 1 mole of polyethylene glycol with average molecular weight of 600 and 2 moles of lauric acid at weight ratio of 80/20; C-1: Mixture of potassium octadecenate and potassium decane sulfonate at weight ratio of 50/50; C-2: Mixture of butyl diethanol amine laurate, sodium octadecyl benzene sulfonate, and potassium phosphoric acid ester of α-lauryl-ω-hydroxy (trioxyethylene) at weight ratio of 50/25/25; C-3: Mixture of tributyl methyl ammonium diethylphosphate and sodium octadecyl benzene sulfonate at weight ratio of 60/40; C-4: Mixture of dimethyl lauryl amine oxide and tributylmethyl ammonium diethyl phosphate at weight ratio of 50/50; C-5: Mixture of tributylmethyl ammonium diethyl phosphate and lauryl trimethyl ammonium ethylsulfate at weight ratio of 60/40; C-6: Mixture of decyl dimethyl ammonio acetate and N,N-bis(2-carboxyethyl)-octylamine at weight ratio of 50/50; E-1: Octyl diphenyl phosphite (antioxidant); E-2: 3,5-di-t-butyl-4-hydroxy-toluene (antioxidant); E-3: dilauryl-3,3′-thiopropionate (antioxidant).
Part 3 (Attachment of Processing Agents to Synthetic Fibers, False Twisting and Evaluation)
Each of the processing agents prepared in Part 2 was diluted with water to prepare a 10% aqueous solution. After polyethylene terephthalate chips with intrinsic viscosity of 0.64 and containing titanium oxide by 0.2% were dried by a known method, they were spun at 295° C. by using an extruder. The 10% aqueous solution thus prepared was applied onto the yarns extruded out of the nozzle to be cooled and solidified by a guide oiling method using a measuring pump such that the attached amount of the processing agent became as shown in Table 4. Thereafter, the yarns were collected by means of a guide and wound up at the rate of 3000 m/minute without any drawing by a mechanical means to obtain partially oriented 56 decitex-144 filament yarns as wound cakes of 10 kg.
False Twisting
The cakes thus obtained as described above were subjected to a false twisting process under the conditions described below by using a false twister of the contact heater type (product name of SDS1200 produced by Teijinseiki Co., Ltd.):
Fabrication speeds: 800 m/minute and 1200 m/minute; Draw ratio: 1.652; Twisting system: Three-axis disk friction method (with one guide disk on the inlet side, one guide disk on the outlet side and four hard polyurethane disks); Heater on twisting side: Length of 2.5 m with surface temperature of 210° C.; Heater on untwisting side; None; Target number of twisting; 3300 T/m.
The false twisting process was carried out under the conditions given above by a continuous operation of 25 days.
Evaluation of Fluffs
In the aforementioned false twisting process, the number of fluffs per hour was measured by means of a fly counter (produce name of DT-105 produced by Toray Engineering Co., Ltd.) before the false twisted yarns were wound up and evaluated according to the standards as described below:
A: The measured number of fluffs was zero;
A-B: The measured number of fluffs was less than 1 (exclusive of zero);
B: The measured number of fluffs was 1-2;
C: The measured number of fluffs was 3-9;
D: The measured number of fluffs was 10 or greater.
The results of the measurement are shown in Table 4.
Evaluation of Yarn Breaking
The number of occurrences of yarn breaking during the 25 days of operation in the false twisting process described above was converted into the number per day and such converted numbers were evaluated according to the standards as described below:
A: The number of occurrence was zero;
A-B: The number of occurrence was less than 0.5 (exclusive of zero);
B: The number of occurrence was 0.5 or greater and less than 1;
C: The number of occurrence was 1 or greater and less than 5;
D: The number of occurrence was 5 or greater.
The results are shown in Table 4.
Dyeing Property
A fabric with diameter of 70 mm and length of 1.2 m was produced from the false-twisted yarns on which fluffs were measured as above by using a knitting machine for tubular fabric. The fabric thus produced was dyed by a high temperature and high pressure dyeing machine by using disperse dyes (product name of Kayalon Polyester Blue-EBL-E produced by Nippon Kayaku Co. Ltd.). The dyed fabrics were washed with water, subjected to a reduction clearing process and dried according to a known routine and were thereafter set on an iron cylinder with diameter 70 mm and length 1 m. An inspection process for visually counting the number of points of densely dyed potion on the fabric surface was repeated five times and the evaluation results thus obtained were converted into the number of points per sheet of fabric. The evaluation was carried out according to the following standards:
A: There was no densely dyed portion;
A-B: There was 1 point of densely dyed portion;
B: There were 2 points of densely dyed portion;
C: There were 3-6 points of densely dyed portion;
D: There were 7 or more points of densely dyed portion.
The results are shown in Table 4.
This invention, as described above, has the favorable effects of sufficiently preventing the occurrence of fluffs, yarn breaking and dyeing specks even when synthetic fibers of new kinds such as low denier synthetic fibers, high multifilament synthetic fibers and modified cross-section synthetic fibers are being produced at a fast rate.
TABLE 4
Processing agent
Rate of
800 m/minute
1200 m/minute
attachment
Yarn
Dyeing
Yarn
Dyeing
Kind
(%)
Fluffs
breaking
property
Fluffs
breaking
property
Test
Example
24
P-1
0.4
A
A
A
A
A
A
25
P-1
0.8
A
A
A
A
A
A
26
P-2
0.6
A
A
A
A
A
A
27
P-2
0.3
A
A
A
A
A
A
28
P-3
0.6
A
A
A
A
A
A
29
P-3
0.8
A
A
A
A
A
A
30
P-4
0.4
A
A
A
A
A
A
31
P-5
0.5
A
A
A
A
A
A
32
P-6
0.4
A
A
A
A
A
A
33
P-7
0.4
A
A
A
A
A
A
34
P-8
0.4
A
A
A
A
A
A
35
P-9
0.4
A
A
A
A-B
A
A
36
P-10
0.4
A
A
A
A
A-B
A
37
P-11
0.4
A
A-B
A
A
A-B
A
38
P-12
0.4
A-B
A
A
A-B
A-B
A-B
39
P-13
0.4
A
A-B
A
A-B
A-B
A-B
40
P-14
0.5
A-B
A
A
A-B
A-B
A-B
41
P-15
0.4
A-B
A-B
A
A
A
A
42
P-16
0.4
A
A
A
A-B
A
A
43
P-17
0.4
A
A
A
A-B
A
A
44
P-18
0.5
A
A
A
A-B
A
A
45
P-19
0.6
A
A
A
A
A
A-B
46
P-20
0.4
A-B
A-B
B
B
A-B
B
47
P-21
0.4
A-B
B
A-B
A-B
B
B
48
P-22
0.4
A-B
B
A-B
B
B
A-B
49
P-23
0.4
A-B
B
A-B
B
B
A-B
Comparison
Example
6
R-1
0.4
D
D
D
C
D
C
7
R-2
0.4
C
C
C
D
D
D
8
R-3
0.4
C
D
C
D
D
C
9
R-4
0.4
C
C
D
D
D
D
10
R-5
0.4
C
C
D
D
D
D
|
A processing agent for synthetic fibers contains a lubricant, a functional improvement agent and an emulsifier, each containing a specified kinds of components by a specified amount and also by a specified amount and also by specified total amount so as to have improved characteristics of preventing occurrence of fluffs, yard breaking and uneven dyeing when applied to synthetic fibers at a specified rate.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None
FIELD OF THE INVENTION
[0002] The present invention relates to a system for measurement of clock skew in an packet network for use with data transmissions between transmitting and receiving units having independent clocks.
BACKGROUND OF THE INVENTION
[0003] The quality of service of realtime voice and video communication data transmissions over packet-switched networks, such as the Internet, is typically compromised by packet transmission delay and jitter that are inherent to an IP network. Achieving high-quality transmissions between two or more ports of isochronous, asynchronous, and plesiosynchronous data is critical for voice, video, and data communications all over the world.
[0004] Network protocols permit data, voice, and video communications to be digitized and transmitted via packets in a network system. Voice over packet networks, or VoIP, requires that the voice or audio signal be packetized and then transmitted. The transmission path will typically take the packets through both packet switched and circuit switched networks between each termination of the transmission. The analog voice signal is first converted to a digital signal and compressed at a gateway connected between a terminal equipment and the packet network. The gateway produces a pulse code modulated (PCM) digital stream from the analog voice.
[0005] To transmit the digitized data within packets between communication ports, receiving and transmitting systems are needed. Typically, the receiving and transmitting systems are modems, telephones, or other communication ports. A receiving and transmitting system typically supports independent clocks which have matched frequencies in order to minimize loss of data and/or synchronization. Packets are routed through the packet network based upon the IP address information. The packet may pass through several switches and routers and the signal in digital and analog form and may pass through both packet switches and circuit switches respectively. The packets are likely to accumulate delay as they pass between the near and far end terminal equipment, through the near and far end gateways, through the packet and PSTN networks and through switches.
[0006] Because this accumulated delay is erratic and unpredictable and further because each packet may take a different path through the networks, delay can cause the packets to arrive out of sequence and/or with gaps or overlaps. Gapping and overlapping of packets is referred to as delay and the variance in delay from one packet to the next is called jitter. Delay and jitter are measured by comparison of the end time stamp of one packet with the start time stamp of the next packet. If the next packet is received before the end time stamp of the previous packet, there is overlapping delay. If the latest packet is received after the end time stamp of the current packet, the difference in the time is the delay gap. Conditions in the packet network can also cause the loss of packets, referred to as packet loss.
[0007] One method for removing timing jitter from incoming packets at a receiver is to use a playout buffer. To correct for out of sequence packets, the system may use time identification stamps that are placed into packets at the transmitter. U.S. Pat. No. 5,790,538 describes how the transmitter inserts the contents of a free running packet counter into each transmitted packet, allowing the receiver to detect lost packets and to properly reproduce silence intervals during playout. A last packet reply request is inserted into the buffer if it detects the loss of one or more packets. A receive sequence counter increments at the local packet rate to schedule playouts for multiple voice segments. Upon arrival of the first packet in the voice segment, the system sets the receiving sequence equal to the sequence number of the incoming packet and inserts a delay of several packets into the buffer before inserting the first codeword of the segment. The buffer has a storage device delay that has the effect of centering the buffer in order to smooth out jitter during playout, after which the entire voice segment is played out in a uniform rate.
[0008] Using time stamps to transmit packets is dependent upon both receiving and transmitting ends using the same timestamp identifiers and protocols. In addition, not all protocols use timestamps.
SUMMARY
[0009] It is a common occurrence to have the receiving system's data clock differ in frequency from the transmitter's clock frequency. This frequency difference, even if minute, is especially a problem during playout of voice packets and voice band data packets. If left unaddressed, this frequency mismatch causes the sample buffer in the receiving unit to overflow or collapse. This in turn results in poor quality voice playout, or in the case of voiceband data, a reset of the modem, or if sending encrypted data, a complete loss of information. As such, packet networks require that the systems be synchronized, or the loss of packets must be tolerated.
[0010] A clock frequency recovery is utilized where the receiver clock frequency differs from the transmitter clock frequency. The system increases or decreases the playout rate from the buffer after packets have been re-assembled according to their sequence.
[0011] Inside of transmitting and receive IP communication gateways on a network are independent clocks. Often the clocks are implemented at high frequencies that become divided down to 8 kHz. One of the main problems causing synchronisation problems in such a network is that no two clocks have exactly the same frequency. The two different, independent clocks will have a slight error, such as 0.001% which is a low error, but it is still an error. Most Internet telephony communications systems cannot function with greater than a 1% error in clock synchronization. If the receiver has the faster of the two clocks, it will drain a buffer faster causing the buffer to underflow. A slower clock will drain the buffer slower causing the buffer to overflow. Data buffer underflows or overflows can cause the data transmission to drop one or more frames and cause a retrain to occur on modem connections. A typical modem has an approximate 100 ms buffer, so when a clock error between the transmitting and receiving clock reaches 100 ms, the modem may retrain.
[0012] The present invention measures the error in a buffer so that data to a resampler can be corrected to compensate for clock errors. A resampler receives data from the buffer and passes the packets through a filter such that the data in the packets will actually match the transmitting clock. A resampler can create or remove data samples and will actually increase or decrease playout speed so that the playout is smooth and the modems will not retrain.
[0013] To provide adaptive playout in an IP telephony device without timestamps in the packets, the clock skew between two telephony devices operating from independent clock sources is measured and recorded. Using the PCM resampler of the preferred embodiment, the change in depth of the playout buffer during transmission is analyzed, and this change indicates the difference in clock rate and so infers the clock rate associated with the transmission. If the playout buffer in the near end device grows or shrinks, then the local clock is slower or faster than the far end device clock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Preferred embodiments of the invention are discussed hereinafter in reference to the drawings, in which:
[0015] [0015]FIG. 1 is a diagram of a network having communication devices transmitting over Internet protocol.
[0016] [0016]FIG. 2 is a diagram of a the resampling unit of the preferred embodiment;
[0017] [0017]FIG. 3 is a flowchart representing decision steps of the resampling unit;
[0018] [0018]FIG. 4 is a diagram of a Random Walk Filter.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to FIG. 1, a typical packet network utilizing Internet protocol is illustrated. At the near end, a personal computer 10 is connected to gateway 16 through modem 12 . Modem 12 connects to gateway 16 through the public switched telephone network (PSTN) 14 . An Internet protocol (IP) telephone 18 is also directly connected to communications port on gateway 16 through a network connection 20 . Gateway 16 is connected to a packet network, such as the Internet 24 with a broadband or high-speed connection 22 such as a digital subscriber line (DSL) or T1/T5 line. At the far end, a similar network is configured through gateway 26 that is connected to the Internet 24 via a high-speed connection 28 . PC 30 is connected to gateway 26 through modem 32 , and IP telephone 34 is directly connected to a communication port on gateway 26 through a network connection 36 .
[0020] The system of the present invention can be implemented on either the near end's gateway 16 alone or both the near and far end 26 gateways. When implemented only on one end, inference must be made regarding the clock on the far end without having any data or specifications regarding the far end clock. A gateway clock that is controlled by a separate system may cause underflows or overflows and retrains for the receiving and transmitting modems, but a near end gateway implementing the present invention will avoid such problems to occur from the near end.
[0021] Referring to FIG. 2, a diagram of the resampler system of the preferred embodiment is illustrated. FIG. 3 also illustrates a flow diagram of the preferred embodiment and is referenced throughout the description. The system is implemented to track frequency offsets between a transmitter's nominal 8 kHz pulse code modulation (PCM) clock and a local receiver's nominal 8 kHz playout clock. The resampler system comprises a Voice Playout Unit (VPU) 38 having a First In First Out (FIFO) playout buffer and a Resampler Unit (RSU) 40 comprising Timing Logic module 42 , a packet sample buffer 44 (RSU buffer) and a resampler 46 . The RSU 40 sits on the communications receiver side only. RSU 40 receives one frame of data at the transmitter's clock rate and sends out one frame of re-sampled data at the receiver's clock rate. A FIFO is a storage method that retrieves items stored the for longest time first. The VPU playout buffer 38 is a buffer that contains the resampled data. The VPU playout buffer size serves as the input to Timing Logic 42 . RSU packet sample buffer 44 is a temporary storage for received packets prior to sending them to the resampler. A buffer is used in a protocol to reduce variances in gaps between packets in a receiver, making the total delay a minimum time and increase smoothness in the playout. Sample packets are received into the RSU buffer 44 from the VPU buffer 38 and extracted from the RSU buffer 44 into the resampler 46 .
[0022] The smoothed overall RSU buffer size y n is calculated at the arrival of every data segment 48 by adding VPU playout buffer 38 size to the RSU buffer 46 size x n using the following formula:
y n =α*( x n −y n−1 )+ y n−1 where α=2 −10
[0023] As the result of using the VPU playout buffer 38 size as the input of Timing Logic 42 , the resampler 46 cannot work properly when adaptive playout is enabled. The resampler also cannot function properly when voice activity detection (VAD) is enabled for the communications channel.
[0024] Timing Logic 42 generates a timing phase advance/retard signal e based on the change of the smoothed overall buffer size. The frequency offset estimate of e is updated over a certain period of time, which should be long enough to minimize the jitter effect and short enough to compensate the worst frequency offset. In the preferred embodiment, e is updated every two seconds 50 using the following equation:
ɛ = ɛ + μ × ( Change in smoothed buffer size ) × ( Interpolation Factor ) 2 × ( Updated interval in samples )
[0025] Where μ is 0.03, Interpolation Factor is 32 and Update interval in samples is 16,000. ε is a fraction much less than 1. However, ε must be large enough to allow the system to track the worst case clock frequency offset. The upper and lower boundaries of ε an be calculated using the following equation as suggested by Anandakumar and McCree:
Max ɛ = 0.5 × Interpolation factor × Maximum frequency offset NominalFrequency
[0026] Outside of the boundaries established by Max ε, the system will not track the clock skew. In the preferred embodiment, the maximum frequency offset is set to 2 Hz.
[0027] As the sampling phase is advanced or retarded, samples are removed from the packet buffer either slightly faster or slower. An equilibrium is reached, the transmit and receive clocks are synchronized. To avoid the unstable buffer size effect at the beginning of the connection time, which can cause lower connection rates, the resampler parameters are updated after the first minute.
[0028] The resampler is implemented by an interpolation filter bank. The filter bank comprises a set of L number of finite impulse response (FIR) subfilters. The 1-th subfilter interpolates between received samples by a time interval of 1/L of the sampling period where 0≦1≦L−1. when the transmitter's and receiver's clocks are synchronized, the same subfilter is used to generate an output sample from the received input sample. Otherwise, the Timing Logic increments or decrements the subfilter index appropriately. Occasionally, the subfilter index will be incremented to L. In this case, an extra sample must be extracted 64 from the sample buffer to be used for the next interpolation and the subfilter index must be reset to 0. Similarly, the index can be decreased to 0. Then a sample must be pushed back 72 to the packet buffer and the subfilter index set to L−1.
[0029] To accomplish the above, the sample buffer size must be three times the frame size to backup one extra frame of data and to hold the pushed back samples. This also introduces one frame delay to the system. Most of the time, VPU 38 sends out one segment from playout FIFO every frame time. But when sample buffer size reaches zero, RSU 40 sends a message to VPU through SIU asking for two segments from VPU playout FIFO 38 and when sample buffer size reaches two segments, RSU 40 asks zero segment from VPU 38 . In this way, VPU 38 can sends out one, two, or zero segments from playout FIFO each time, as required, to prevent over or under flow. Typically, the frequency offset is very small and infrequent changes to the subfilter index is needed. The timing phase updating mechanism should not cause significant jitter or hunting of the subfilter index. This can be accomplished by the Random Walk filter.
[0030] The Random Walk filter (RWF) is illustrated in the block diagram of FIG. 4. The Random Walk Filter establishes the parameters for upsampling or downsampling within the filter bank. Each change between the subfilters will use the RWF to determine if the sample moves to the consecutive upper filter or a consecutive lower filter within the filter bank according to a threshold. Z−1 blocks 44 , 48 represent the FIR subfilters in the RSU and Overflow/Underflow logic 42 is the Timing Logic 42 of FIG. 2. As signal ε enters the filter, it is received into the Threshold Detect 78 . An accumulator, ρ, is updated 52 at every data sample that is passed through the RWF. Most often the Threshold Detect 78 output, I, is 0 since ρ is iterative and accumulated from a very small ε. That is,
π=ρ+ε
[0031] If output ρ=0.5 ( 54 ) then as shown on graph 76 , I=1 ( 58 ). The phase is greater than the interpolation factor 60 resulting in a phase=1 ( 62 ) and the sample it upfiltered 64 . If output ρ=−0.5 ( 56 ) then according to graph 76 , I=0 and the filter phase is equal to −1 ( 66 ). Since the phase is less than 1 ( 68 ) the phase equals the interpolation factor 70 and the sample is downfiltered 72 . In other words, when the Threshold Detect 78 outputs a 1 or −1, the subfilter index increases or decreases by one, respectively. After analysis through the RWF, the sample is then passed to an FIR filter 74 in the subfilter bank 74 of the resampler 46 .
[0032] The FIR subfilter bank size in the preferred embodiment is 32. However, as one skilled in the art will observe, the filter bank size and specifications could vary without departing from teaching or claims of the present invention. Each filter is linear phase, symmetric, and in the order of 64. The coefficients of each filter can be generated with simulation software. The cutoff frequency of the filter bank is larger than 3800 Hz. The phase shift between the conjunction filters is (2π/8000)/32.
[0033] Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A system and method to measure the clock skew between transmitting and receiving devices operating with independent clock sources over a packet network is described. To provide adaptive playout in an IP telephony device without a sequencing scheme in the packets, the clock skew is measured and recorded. Using a PCM resampler that is implemented with an interpolation filter bank of FIR subfilters, the change in depth of the playout buffer during transmission is analyzed, and this change infers the clock rate associated with the transmission.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor integrated circuit device to which a plurality of integrated circuits such as, microprocessors, logic circuits and the like are connected in series.
2. Description of the Related Art
Recently, the degree of integration of an integrated circuit device has been significantly improved, and in a semiconductor memory of a giga (G) bit order, several hundred million elements are integrated in one chip. In a 64-bit microprocessor, several million to ten million elements are integrated in one chip. The improvement of the degree of the integration is achieved by downsizing the elements. In the case of a 1 G-bit DRAM (dynamic random access memory), MOS (metal oxide semiconductor) transistors having a gate length of 0.15 μm are used, and for a higher degree of integration, MOS transistors having a gate length of 0.1 μm or less are used.
In a MOS transistor of such a small size, deterioration of transistor characteristics occurs because of the generation of a hot carrier, or breakdown of insulation films occurs because of the TDDB (time dependent dielectric breakdown). Further, in the case where the concentration of impurities in a bulk or a channel portion is raised in order to suppress a decrease in threshold voltage caused by shortening of the channel length, the junction breakdown voltage between a source and a drain, is decreased.
In order to maintain the reliability of these fine elements, it is effective to decrease the supply voltage. More specifically, the generation of a hot carrier is avoided by weakening the electric field running in the lateral direction between the source and drain, and the TDDB is prevented by weakening the electric field running in the vertical direction between the gate and bulk. Further, by decreasing the supply voltage, a reverse bias acting on the junction between the source and the bulk or between the drain and the bulk, is decreased, thus making it possible to follow up a decrease in the junction breakdown voltage.
In the meantime, in a bipolar transistor, a high-speed operation can be achieved by shortening the base width; however if the base width is excessively shortened, the bipolar transistor cannot function as a transistor because of punch through. In order to avoid this, it is necessary to increase the concentration of impurities in the base. Further, if the current density is increased, the cutoff frequency is decreased. In order to avoid this so-called Kirk effect (or base pushout effect), it is necessary to increase the concentration of impurities in the collector.
In the downsized bipolar transistor, the concentration of the impurities in the base and the collector region must be increased, and with an increase in the concentration, the base-collector junction breakdown voltage is decreased. In order to avoid this, a decrease in the supply voltage is effective as in the case of the MOS transistor.
As described above, in the case where elements are downsized, it is necessary to decrease the supply voltage in order to maintain the reliability of the device; however, at the same time, the structure of the device is complicated for a user who actually deals with the semiconductor integrated circuit device (semiconductor chip), creating a problem. In other words, for a user, it is not preferable that the supply voltage should differ from one chip to another among a plurality of semiconductor chips. Further, it is not preferable that the supply voltage which has been used in the conventional structure should become unusable as it is.
Recently, a device as shown in FIG. 1, in which the supply voltage is decreased within a semiconductor chip, has been proposed. In this device, a voltage down converter 111 and an integrated circuit 110 are connected in series between a power line (supply voltage Vcc) and a ground line (ground voltage Vss), thus maintaining the voltage applied to the integrated circuit 110 at Vcc' which is lower than Vcc. With use of the voltage down converter 111, the reliability of the semiconductor chip is increased.
However, in a device of the above-described type, the power consumed in the voltage down converter 111 is wastefully used. Therefore, it is difficult to achieve a power-saving performance of the semiconductor chip as a whole, creating a new problem. For example, in the case where supply voltage Vcc=3 V and the voltage applied to the integrated circuit 110 is 1.5 V, a subtracted voltage difference of 1.5 V is applied to the voltage down converter 111, and thus a half of the total consumption power is used in the voltage down converter 111.
More specifically, the consumption power P of a semiconductor chip as a whole is expressed by P=CV 2 f, where V indicates the difference between the supply voltage and the ground voltage, C indicates the capacitance between the power sources of the semiconductor chip, and f indicates the operation frequency. In FIG. 1, if the capacitance between the power sources of the voltage down converter 111 and the capacitance between the power sources of the integrated circuit 110 are both equal to C1, an equation, Vcc'=Vcc/2, is established. Therefore, the power consumed in the semiconductor chip as a whole is (C1)V 2 f and the power consumed in the voltage down converter 111 is (C1/2)V 2 f. Thus, one half of the consumption power of the semiconductor chip as a whole is consumed by the voltage down converter 111.
For the purpose of suppressing the consumption of the power in a voltage down converter, the following device has been proposed (Jap. Pat. Appln. KOKAI Publication No. H4-3153131). According to this technique, two integrated circuits are connected in series between the power line and the ground line, and the current flowing through the first integrated circuit is recycled in the second integrated circuit. Further, a voltage control circuit is connected to a power line within the semiconductor chip, which is a connection portion between the first and second integrated circuits, so as to maintain a voltage of the power line in the chip at constant.
In this device, however, if the first and second integrated circuits do not function at the same time, the load on the voltage control circuit is increased. Therefore, a voltage control circuit having a drive capability as large as that of the voltage down converter is required. As a result, the consumption power cannot be decreased.
As described above, conventionally, in a semiconductor integrated circuit device employing fine elements, a voltage down converter is used in order to maintain the reliability of the device and to avoid the complexity of the structure; however, the power consumed in such a voltage down converter is wasted.
Meanwhile, in a device in which a plurality of integrated circuits are connected in series without using a voltage down converter, the drive capability of the internal voltage control circuit must be enhanced when these integrated circuits are not operated at the same time. As a result, the power substantially the same as that consumed in a voltage down converter when the voltage down converter is used, is consumed by the voltage control circuit, and such power is wastefully used.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a semiconductor integrated circuit capable of decreasing a voltage applied to an integrated circuit without decreasing the supply voltage or using a voltage down converter, thus decreasing the consumption power.
Another object of the present invention is to provide a semiconductor integrated circuit device capable of decreasing a voltage applied to an integrated circuit without enhancing the drive capability of the voltage control circuit even if a plurality of integrated circuits are not operated at the same time, thus decreasing the consumption power.
According to the first aspect of the present invention, there is provided a semiconductor integrated circuit device comprising a plurality of integrated circuits connected between a power line and a ground line; and means for performing one of (i) setting an input signal frequency for each of the plurality of integrated circuits and (ii) establishing a connection relationship in which the plurality of integrated circuits are arranged in series or in series-parallel, such that serial connecting portion of the plurality of integrated circuits has a predetermined potential.
In the device, the plurality of integrated circuits may be commonly formed on an insulation film of a substrate.
According to the second aspect of the invention, there is provided a semiconductor integrated circuit device comprising a plurality of integrated circuits connected in series between a power line and a ground line, wherein input signal frequencies are set respectively such that products of electrical capacitances of the plurality of integrated circuits and the input signal frequencies are equal to each other.
In the device, it is preferable that voltage differences of the plurality of integrated circuits should be equal to each other.
Further, a structure of at least one of the plurality of integrated circuits may be different from that of another circuit. An electric capacitance of at least one of the plurality of integrated circuits may be different from that of another circuit. The plurality of integrated circuits may include CMOS inverters. At least one of the plurality of integrated circuits may include CMOS inverters having plural stages. At least one of the plurality of integrated circuits may include at least one of an inverter circuit, a NAND circuit and a NOR circuit.
The device may include a voltage down converter capable of switching at least one of the plurality of integrated circuits between an operation state and a standby state. In this case, the application of a voltage between the power line and the ground line is off while the voltage down converter is driven. Those integrated circuits which are in an operation state while the voltage down converter is driven, are supplied with a voltage by means of the voltage down converter.
The device may include the first switching circuit for turning on/off the application of voltage between the power line and the ground line; and the second switching circuit, which operates complementarily with the operation of the first switching circuit, for turning on/off driving of the voltage down converter.
According to the third aspect of the present invention, there is provided a semiconductor integrated circuit device comprising a plurality of integrated circuits; and a scheduling circuit for selecting an arbitrary number of integrated circuit from the plurality of integrated circuit, and connecting the selected integrated circuits between a power line and a ground line such that the selected integrated circuits are arranged in series or in series-parallel.
In the device, it is preferable that the scheduling circuit should serve to set a combination of connection of the selected integrated circuits such that a consumption power of a total of the selected integrated circuits becomes minimum. The scheduling circuit may serve to a combination of connection of the selected integrated circuits such that serial connecting portions of the selected integrated circuits have potentials obtained by equally dividing a difference between a potential at the power line and a potential at the ground line. The scheduling circuit may be designed to operate in accordance with an instruction from outside.
It is preferable that the device further include a voltage control circuit for setting a potential of a serial connecting portion of the selected integrated circuits. In this case, it is preferable that the scheduling circuit should include a plurality of selection circuits for setting a relationship of connection between the selected integrated circuits and the voltage control circuit.
The device may further include an instruction means for giving an instruction which indicates those integrated circuits to be selected and the content of the combination thereof, to the scheduling circuit. Further, the device may further include a memory medium, which is referred to by the instruction means, for storing the content of the combination by which a consumption power becomes minimum, with regard to integrated circuits which can be variously selected.
The device may further include an input output circuit for inputting and outputting data between the selected integrated circuits, and outside. The device may further include a level conversion circuit for converting a level of data between certain integrated circuits.
Additional objects and advantages of the present 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 present invention. The objects and advantages of the present 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 present 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 present invention in which:
FIG. 1 is a block diagram showing an example of the structure of a conventional device employing an voltage down converter;
FIG. 2 is a block diagram showing the structure of a semiconductor integrated circuit device according to the first embodiment;
FIGS. 3A to 3D are diagrams each showing a change in input signal along with time, and a current of each of the integrated circuits in the semiconductor integrated circuit device shown in FIG. 2;
FIG. 4 is a block diagram showing the structure of a semiconductor integrated circuit device according to the second embodiment;
FIGS. 5A to 5C are diagrams each showing a change in input signal along with time, of each of the integrated circuits in the semiconductor integrated circuit device shown in FIG. 4;
FIG. 6 is a block diagram showing the structure of a semiconductor integrated circuit device according to the third embodiment;
FIG. 7 is a block diagram showing the structure of a semiconductor integrated circuit device according to the fourth embodiment;
FIG. 8 is a block diagram showing the structure of a microprocessor according to the fourth embodiment;
FIGS. 9A to 9E are diagrams each showing a change in input signal along with time, and a clock of each of the integrated circuits in the microprocessor shown in FIG. 8;
FIG. 10 is a block diagram showing the structure of a semiconductor integrated circuit device according to the fifth embodiment;
FIG. 11 is a diagram showing an example of the structure of the scheduling circuit shown in FIG. 10;
FIGS. 12A and 12B are diagrams each showing an example of the structure of the data control circuit shown in FIG. 10; and
FIG. 13 is a table showing a relationship between a signal Φab for selecting a necessary one of the integrated circuits shown in FIG. 10, and an instruction I.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will now be described with reference to drawings.
(First Embodiment)
FIG. 2 is a block diagram showing a semiconductor integrated circuit device (semiconductor chip) according to the first embodiment of the present invention. As shown in this figure, n number (n≦2) of integrated circuits 10 (that is, an integrated circuit (1) to an integrated circuit (n)) are connected in series between a power line (supply voltage Vcc) and a ground line (ground voltage Vss). The integrated circuits receive signals Vin1, Vin2, . . . , Vinn, respectively and output signals Vout1, Vout2, . . . , Voutn.
Let us now suppose that a supply voltage applied to an integrated circuit (1) is Vcc1 (=Vcc), a ground voltage thereof is Vss1, a supply voltage applied to an integrated circuit (2) is Vcc2 (=Vss1), a ground voltage thereof is Vss2, a supply voltage applied to an integrated circuit (n) is Vccn (=Vssn-1), and a ground voltage thereof is Vssn (=Vss). Further, capacitances between power sources of integrated circuits, Vcc1 and Vss1, Vcc2 and Vss2, . . . , Vccn and Vssn are assigned as C1, C2, . . . , Cn.
If the frequency of a signal Vin1 input to the integrated circuit (1) is assigned as f1, an average value I1 of currents flowing in the integrated circuit (1) is given by:
I1=f1·C1(Vcc1-Vss1) (1)
Let us assume that an average value of currents flowing to the integrated circuits (2) to (n) is equal to I1, the following relationship can be established for the voltage between terminals of each of the integrated circuits.
V=Vcc1-Vss1=Vcc2-Vss2=Vccn-Vssn (2)
In the case where V is defined as in this equation, and the frequency of a signal Vin2 input to the integrated circuit (2) is set as f=(C1/C2)f1, an average current I2 is given by:
I2=(C1/C2)f1≦C2 V (3)
which is equal to I1. Similarly, in the case where the frequency of a signal Vinn input to an integrated circuit (n) is set as f=(C1/Cn)f1, an average current In is given by:
In=(C1/Cn)f1·Cn·V (4)
which is equal to I1. That is, equation (2) is established by appropriately selecting the frequency of an input signal.
FIG. 3A shows a change in Vin1 along with time, FIG. 3B shows a change in Vin2 along with time, FIG. 3C shows a change in Vinn along with time, and FIG. 3D shows a change in I1, I2 and In along with time. Since the cycle of a signal is an inverse number of the frequency of the signal, when f1=1/T, the cycle of the signal input to the integrated circuit (2) is (C2/C1) T, and the cycle of the signal input to the integrated circuit (n) is (Cn/C1) T.
From the equation (2), the differences between the supply voltages and the ground voltages in the integrated circuits are equal to each other and the average values of the flowing currents are equal to each other; therefore the powers P consumed by the integrated circuits are equal to each other. Consequently, the total power consumed by all of the n number of the integrated circuits is P watts×n.
Conventionally, in order to uniform the reliabilities of the elements with regard to, for example, an integrated circuit (n), the integrated circuits (1) to (n-1) are replaced by voltage down converters. In this case, the power consumed by the voltage down converters is (n-1)×P watts. Consequently, for the n number of integrated circuits, a total power of n×(n-1)×P watts is consumed by all of the voltage down converters. Therefore, with the present invention, the consumption power can be reduced to the level expressed by the equation below, as compared to the conventional technique:
(n×P)/{n×P+n×(n-1)×P}=1/n (5)
As described above, according to the first embodiment, the n number of integrated circuits (1) to (n) are connected between the power line and the ground line in series, and the value of each of input signal frequencies f is set such that the products of the capacitances C of the integrated circuits and the input signal frequencies f become all the same. In this manner, the voltage applied to each integrated circuit can be decreased without lowering the supply voltage as a whole or employing a voltage down converter. Thus, the reliability of the fine element can be maintained and the consumption power can be reduced.
(Second Embodiment)
FIG. 4 is a block diagram showing a semiconductor integrated circuit device (semiconductor chip) according to the second embodiment of the present invention. The second embodiment is an example in which the integrated circuits (1) to (n) of the first embodiment are constituted by CMOS inverters. Therefore, when n=3, it is the case where the semiconductor integrated circuits are constituted by three integrated circuits (1) to (3).
An integrated circuit (1) between a power line (Vcc) and (2/3) Vcc is a one-stage CMOS inverter consisting of MOS transistors M1 and M2. An integrated circuit (2) between (2/3) Vcc and (1/3) Vcc is a two-stage CMOS inverter consisting of MOS transistors M3 to M6. An integrated circuit (3) between (1/3) Vcc and a ground line (Vss) is a three-stage CMOS inverter consisting of MOS transistors M7 and M12.
Let us suppose that the capacitances between power sources of the integrated circuits (1) to (3) are C1, C2 and C3, respectively, and the frequencies of the input signals Vin1, Vin2 and Vin3 are f1, f2 and f3, respectively. Further, supposing that the CMOS inverters are made of MOS transistors of the same size, the following relationships are established. That is, C2=2C1 and C3=3C1. Therefore, when the frequencies are set so as to satisfy f2=(1/2)f1 and f3=(1/3)f1, the average currents I flowing in the integrated circuits (1) to (3) becomes the same, thus satisfying the following relation ship. ##EQU1##
FIGS. 5A to 5C show the waveforms of the input signals of the above case. FIG. 5A shows a change in Vin1 along with time, FIG. 5B shows a change in Vin2 along with time, and FIG. 5C shows a change in Vin3 along with time. As can be understood from the figures, the cycle of Vin2 is two times as long as the cycle T of Vin1 and the cycle of Vin3 is three times as long as the cycle T.
Supposing that the power source Vcc of the semiconductor chip is 3 V and the ground voltage Vss=0 V, the voltage applied to the fine elements in each integrated circuit is 1 V, thus making it possible to maintain a sufficient reliability. Further, the consumption power becomes 1/3 as compared to the case where a voltage down converter is used.
In this embodiment, three integrated circuits made of, for example, CMOS inverter circuits, are provided between Vcc and Vss, and input signals are input to each integrated circuit one at a time; however some other structure is acceptable as long as the products of the capacitances C and the frequencies f are equal to each other.
(Third Embodiment)
FIG. 6 is a block diagram showing a semiconductor integrated circuit device (semiconductor chip) according to the third embodiment of the present invention. The third embodiment is an example in which the integrated circuits of the first embodiment are constituted by inverter circuits, NAND circuits and NOR circuits in combination. Therefore, when n=3, it is the case where the semiconductor integrated circuits are constituted by three integrated circuits (1) to (3).
As in the embodiments described, when the frequencies of the input signals Vin are set such that the average currents I are equal to each other, the consumption power of the semiconductor chip can be reduced while maintaining the reliability of the fine element.
(Fourth Embodiment)
FIG. 7 is a block diagram showing a semiconductor integrated circuit device (semiconductor chip) according to the fourth embodiment of the present invention. The differences between the fourth embodiment and the first embodiment are that a voltage down converter 11 is connected between a power line (power source voltage Vcc) and a ground line (ground voltage Vss) via a switching transistor M13, that an integrated circuit (1) is connected to a power line via a switching transistor M14, and that integrated circuits (1) to (n) are connected to partial voltage output ends of the voltage down converter 11.
FIG. 8 is a block diagram showing a structure of a microprocessor constituted by an arithmetic circuit 10a, a memory circuit 10b and a control circuit 10c corresponding to the above integrated circuit (1) to (3) respectively, in the case where n=3. The scheduling circuit 30 outputs the clock φ and φ - for controlling the switching transistors M13 and M14, and outputs the input signals Vin1, Vin2 and Vin3 having frequencies f1, f2 and f3, respectively. Further, a data control circuit 40 having a buffer circuit and a level conversion circuit (not shown) are provided, in which data-sending/receiving among the arithmetic circuit 10a, the memory circuit 10b and the control circuit 10c is performed.
FIG. 9A shows a waveform of an input signal Vin1 of the arithmetic circuit 10a of this microprocessor. FIG. 9B shows a waveform of an input signal Vin2 of the memory circuit 10b. FIG. 9C shows a waveform of an input signal Vin3 of the control circuit 10c. FIG. 9D shows a waveform of a clock φ for controlling the switching transistor M13. FIG. 9E shows a waveform of a clock φ - for controlling the switching transistor M14.
The frequency f1 of the input signal Vin1 is 1/T, and the arithmetic circuit 10a is operated at this frequency all the time. Meanwhile, the memory circuit 10b and the control circuit 10c are operated only between times t1 and t2, and the frequencies f2 and f3 of the input signals are both 1/2T (f2=f3=1/2T). The clock φ has a high level between times t1 and t2 and a low level at other times, that is, 0 to t1 and t2 or later. The clock φ - is an inversion of the clock φ.
When the switching transistors M13 and M14 are constituted by p-MOS transistors, M13 is turned on between times 0 and t1 since the clock φ is at the low level, and the voltage down converter 11 is operated. Further, since the clock φ - is at the high level, M14 is turned off, and the supply of the supply voltage Vcc via the M14 is stopped. However, voltages Vcc1=Vcc, and Vss1=(2/3)Vcc are applied to the integrated circuit (1), that is, the arithmetic circuit 10a, by the voltage down converter 11, voltages Vcc2=(2/3) Vcc, and Vss2=(1/3)Vcc are applied to the integrated circuit (2), that is, the memory circuit 10b, and voltages Vcc3=(1/3) Vcc, and Vss3=Vss are applied to the integrated circuit (3), that is, the control circuit 10c. Thus, the arithmetic circuit 10a is operated, and the other circuits are set in a standby state.
At this point, the integrated circuits (2) and (3) are in the standby state, no substantial current flows in the integrated circuit (2) or (3), but a current flows through the integrated circuit (1) and the voltage down converter 11. Therefore, according to the fourth embodiment, even if the integrated circuits (2) and (3) are in the standby state, only the integrated circuit (1) can be selectively operated. It should be noted that if it is not necessary to apply a voltage of a certain level to the integrated circuits (2) and (3) in the standby state, the application of the voltage from the voltage down converter 11 to the circuits (2) and (3) can be omitted.
Between the times t1 and t2, the clock φ is at the high level, and therefore M13 is turned off and the voltage down converter 11 is not operated. In other words, Vcc1, Vss1, Vcc2, Vss2, Vcc3 and Vss3 from the voltage down converter 11 are not supplied. Meanwhile, the clock φ - is at the low level, and therefore M14 is turned on, and each of the integrated circuits (1) to (3) is operated as in the case of the first embodiment, making it possible to avoid the wasteful power consumption.
Next, for a time t2 or later, the clock φ is at the low level and the clock φ - is at the high level, the memory circuit 10b and the control circuit 10c is again set in the standby state.
As described, according to the fourth embodiment, the consumption power can be saved when the integrated circuits (1) to (3) connected in series are operated as in the first embodiment, and only one integrated circuit can be selectively operated in accordance with necessity.
(Fifth Embodiment)
FIG. 10 is a block diagram showing a semiconductor integrated circuit device (semiconductor chip) according to the fifth embodiment of the present invention. The device of this embodiment consists of the n number of integrated circuits 10 (namely, circuits (1) to (n)) having different functions from each other, an m-2 number (m is the number of power source lines 50) of voltage control circuits 20 for controlling voltages of the m-2 number of power source lines 50, at constant, of the m number of power source lines 50 (namely, power source lines (1) to (m)), a power line (Vcc) and a ground line (Vss) being eliminated, a scheduling circuit 30 for determining a connection of integrated circuits 10, and a data control circuit 40 for sending or receiving data between the integrated circuits 10 and with regard to the outside.
To the semiconductor integrated circuit device of the fifth embodiment, an instruction I is input from outside. In the case of a memory such as DRAM, the instruction I assigns an operation mode from write, read, refresh, high-speed page mode, nibble mode, static column mode and the like. In the case of a microprocessor, the instruction I assigns transfer of data, comparison, saving, addition, subtraction, multiplication, division and the like.
In the scheduling circuit 30, the instruction I is decoded, and a signal Φab used for selecting a necessary integrated circuit 10 is formed. Further, by means of the signal Φab, the k number (2≦k≦n) of integrated circuits which are necessary are selected from the integrated circuits (1) to (n) (n≧2), and the power line Vcci and the ground line Vssi of a selected integrated circuit (i) (i≦k-1) are connected to the power source lines (1) to (m) (3≦m≦n+1) in series-parallel such that the consumption power becomes the minimum (1≦a≦2n, 1≦b≦m).
The data control circuit 40 consists of an input/output circuit for sending or receiving data with respect to the outside and a level conversion circuit for passing data between the selected integrated circuits (1) to (k). The power source line (1) is connected to Vcc, and the line (m) is connected to Vss. Further, the power source line (2) to the line (m-1) have voltages between Vcc and Vss, and the voltage difference between the lines (i) and (i+1) is a result of the voltage difference between Vcc and Vss equally divided by m-1. Furthermore, a voltage control circuit 20 is connected to each of the power source lines (2) to (m-1).
FIG. 11 is an example of the structure of the scheduling circuit 30 when n=4 and m=3. The circuit 30 consists of a decoder circuit 31 for decoding the instruction I, a signal generating circuit 32 for forming a signal Φab and a selection circuit 33. In the signal generation circuit 32, it is decided whether the signal Φab is set at a high level or low level based on the data stored in a ROM (Read Only Memory) or the like in advance. In the selection circuit 33, one of the power source voltage Vcc, the intermediate voltage Vm and the ground voltage Vss of the semiconductor chip, which should be connected to the power source voltage Vcci and the ground voltage Vssi of the integrated circuits (1) to (4) is selected on the basis of the signal Φab. For example, when Φ11 is at the high level, and Φ12 and Φ13 are at the low level, Vccl is connected to Vcc, or when Φ22 is at the high level, and Φ21 and Φ23 are at the low level, Vss1 is connected to Vm. With regard to a non-selected integrated circuit, all of Φab's are set at the low level, and the power line and ground line of the integrated circuit are connected to the same power source line.
FIGS. 12A and 12B show examples of the structure of the data control circuit 40 in the case where Φab is scheduled with respect to two instructions I1 and I2. As in the case shown in FIG. 11, it is supposed that n=4 and m=3. FIG. 12A shows the case of the instruction I1 and FIG. 12B shows the case of the instruction I2.
As shown in FIG. 13, in the case of the instruction I1, Φ12 and Φ23 are set at the high level and Φ11, Φ13, Φ21 and Φ22 are set at the low level, and therefore the integrated circuit (1) is connected between Vm and Vss. Similarly, Φ32 and Φ43 are set at the high level and Φ31, Φ33, Φ41 and Φ42 are set at the low level, and therefore the integrated circuit (2) is connected between Vm and Vss. Further, Φ51 and Φ62 are set at the high level and Φ52, Φ53, Φ61 and Φ63 are set at the low level, and therefore the integrated circuit (3) is connected between Vcc and Vm. Similarly, Φ71 and Φ82 are set at the high level and Φ72, Φ73, Φ81 and Φ83 are set at the low level, and therefore the integrated circuit (4) is connected between Vcc and Vm. More specifically, as can be seen in FIG. 12A, the integrated circuits (1) to (4) are connected in series-parallel between Vcc and Vss.
While maintaining the above state, the input circuit 41 is connected to the integrated circuit (1), and thus input data DIN is input from the outside and an output from the circuit (1) is input to the circuit (2). An output from the circuit (2) is input to the circuit (3). In order to match the input and output levels with each other, the level conversion circuit 43 is provided. An output from the circuit (3) is input to the circuit (4), and an output from the circuit (4) is output to outside as output data Dout via an output circuit 42. At this point, an integrated circuit connected to the level conversion circuit 43 is selected on the basis of the signal Φab.
Next, in the case of the instruction I2, Φ12 and Φ23 are set at the high level and Φ11, Φ13, Φ21 and Φ22 are set at the low level, and therefore the integrated circuit (1) is connected between Vm and Vss. Similarly, Φ32 and Φ43 are set at the high level and Φ31, Φ33, Φ41 and Φ42 are set at the low level, and therefore the integrated circuit (2) is connected between Vm and Vss. Further, Φ51, Φ52, Φ53, Φ61, Φ62 and Φ63 are all set at the low level, and therefore the integrated circuit (3) is not connected to a power source line. Similarly, Φ71 and Φ82 are set at the high level and Φ72, Φ73, Φ81 and Φ83 are set at the low level, and therefore the integrated circuit (4) is connected between Vcc and Vm. More specifically, as can be seen in FIG. 12B, the integrated circuits (1), (2) and (4) are connected in series-parallel between Vcc and Vss, and the circuit (3) is not connected.
It should be noted that, in order not to select the integrated circuit (3), Φ51 and Φ61 should be set at the high level and Φ52, Φ53, Φ62 and Φ63 should be set at the low level, or Φ52 and Φ62 should be set at the high level and Φ51, Φ53, Φ61 and Φ63 should be set at the low level, or Φ53 and Φ63 should be set at the high level and Φ51, Φ52, Φ61 and Φ62 should be set at the low level.
While maintaining the above state, the input circuit 41 is connected to the integrated circuit (1), and thus input data DIN is input from the outside and an output from the circuit (1) is input to the circuit (2). An output from the circuit (2) is input to the circuit (4). In order to match the input and output levels with each other, the level conversion circuit 43 is provided. An output from the circuit (4) is output to outside as output data DOUT via an output circuit 42. At this point, an integrated circuit connected to the level conversion circuit 43 is selected on the basis of the signal Φab.
In the above-described embodiment, a plurality of integrated circuits are connected in series-parallel; however it suffices only if at least a part contains a connection in series, or all of the selected integrated circuits are connected all in series.
As described, according to the fifth embodiment, the combination of integrated circuits connected in series or in series-parallel, between the power line (Vcc) and the ground line (Vss), can be freely changed in accordance with an instruction input from outside. With this structure, not all of the integrated circuits have to be operated at the same time, but only those of the integrated circuits which should be operated at the same are connected in series or in series-parallel, thus making it possible to reduce the voltage applied to each integrated circuit without varying the supply voltage for the semiconductor chip as a whole.
In other words, the combination by which the consumption power becomes minimum is scheduled for each instruction, thus making it possible to save the consumption power. Further, it is not necessary to provide a voltage control circuit having a drive capability as large as that of the voltage down converter, for a non-operating integrated circuit, and therefore the consumption power of the voltage control circuit can be reduced, thus making it possible to further save the consumption energy.
Moreover, the fifth embodiment is particularly effective for the case where serial data is input/output by a pipe line process, or a microprocessor by a pipe line process. In other words, by selecting circuits which are operated in a pipe line manner on the basis of an instruction, a plurality of integrated circuits which are connected in series-parallel between the power source voltage and the ground voltage can be operated at the same time all the time, thus achieving a semiconductor integrated circuit device of an effectively low consumption power.
The present invention is not limited to the embodiments described above. The integrated circuits, the voltage down converters or the like in each embodiment may be of separate semiconductor chips; however the present invention is still effective even if all these are made in one semiconductor chip.
In this case, the substrate regions of the MOS transistors included in the integrated circuits connected in series-parallel are different in units of the integrated circuits. For example, the MOS transistor formed on the insulation layer on the silicon substrate is applicable for the present invention because the substrate regions of the MOS transistors are different in units of elements.
Further, the structure of the integrated circuits is not limited at all to those discussed above, but can be changed appropriately in accordance with specification. Or the present invention can be remodeled into different versions as long as the essence of the present invention remains.
As described in detail, according to the present invention, a plurality of integrated circuits are connected in series between the power line and the ground line, and the input signal frequencies are set respectively such that the products of the capacitances between powers of the circuits and the input signal frequencies are equal to each other. Therefore, the voltage applied to a fine element within an integrated circuit can be reduced without lowering the supply voltage applied to the semiconductor chip, thus making it possible to improve the reliability of the element and reduce the consumption power.
According to the present invention, the combination of integrated circuits connected in series or in series-parallel, between the power line (Vcc) and the ground line (Vss), can be freely changed in accordance with an instruction input from outside. The combination by which the consumption power becomes minimum is scheduled for each instruction, thus making it possible to save the consumption power.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the present invention in its broader aspects is not limited to the specific details, representative devices, and illustrated examples 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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The semiconductor integrated circuit device of the present invention includes a plurality of integrated circuits. The scheduling circuit selects an arbitrary number of integrated circuit from the plurality of integrated circuits, and connects the selected integrated circuits between the power line and the ground line such that the selected integrated circuits are arranged in series or in series-parallel. The scheduling circuit sets a combination of connection of the selected integrated circuits such that the consumption power of the total of the selected integrated circuits becomes minimum. The voltage control circuit sets a potential of a serial connecting portion of the selected integrated circuits. The data control circuit has an input output circuit for inputting and outputting data between the selected integrated circuits, and the outside, and a level conversion circuit for converting a level of data between certain integrated circuits.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to, U.S. Provisional Patent Application No. 61/296,864 entitled “APPARATUS, SYSTEM, AND METHOD FOR A CONVERTIBLE BLANKET, PAD, AND PILLOW” and filed on Jan. 20, 2010 for Jacob C. Smoot and Reid S. Smoot, which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] This invention relates to wearable blankets and more particularly relates to a container for wearable blankets that converts from a pillow into a seating pad.
[0004] 2. Description of the Related Art
[0005] Many people enjoy being wrapped in a blanket while lounging around the house. However, blankets do not allow for the free motion of a person's arms. To overcome this, the sleeved blanket was developed. Sleeved blankets allow a person to, for example, read a book while enveloped in a blanket. Typically, sleeved blankets are made of a fleece or other plush, comfortable material. The sleeved blanket is ideal for keeping its wearer warm while the wearer watches TV, reads a book, or otherwise goes about his or her daily duties inside the house.
[0006] However, as the use of sleeved blankets increases, people have begun to take sleeved blankets to outdoor activities such as sporting events, concerts, etc. The sleeved blanket is an ideal device for keeping a person warm at an outdoor spectator event. Unfortunately, the plush and comfortable nature of the sleeved blanket does little to protect the wearer from a wet, cold, or rigid seating surface.
SUMMARY
[0007] The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available convertible pillows. Accordingly, the present invention has been developed to provide an apparatus, system, and method for a convertible, blanket, pad, and pillow that overcome many or all of the above-discussed shortcomings in the art.
[0008] The apparatus includes a blanket having arm apertures, and a sleeve coupled to each of the apertures and extending outward from the blanket. The apparatus also includes a pad having a durable surface, a plush surface, and a fastener disposed on a perimeter of the pad. The fastener is configured to form the pad into a container to hold the blanket. The apparatus also includes a fastener disposed on the blanket configured to removably connect the blanket to the pad.
[0009] In one example, the sleeves are removably coupled with the blanket; alternatively, the sleeves are integrally formed with the blanket. In another example, the apparatus includes cushioning disposed between the durable surface and the plush surface. The pad may form a plush container having the plush surface facing outward, or a durable container having the durable surface facing outward. The length of the pad, in one embodiment, is selected to accommodate at least two people. Additionally, the width of the pad is substantially equivalent to the width of a bleacher seat. The length of the pad may be in the range of between about two and five times the width of the pad.
[0010] In a further embodiment, the blanket further comprises an adjustable neck fastener to fasten the blanket around a person's neck. The apparatus also may include carrying straps coupled to the pad.
[0011] The system includes a blanket having arm apertures, a sleeve integrally coupled to each of the apertures and extending outward from the blanket, and a pad. The pad, in one example includes a durable surface, a plush surface, cushioning disposed between the durable surface and the plush surface, and a fastener disposed on a perimeter of the pad, the fastener configured to form the pad into a container to hold the blanket. The length of the pad is in the range of between about 2 and 5 times a width of the pad. The system also includes carrying straps extending from the perimeter of the pad, and a fastener disposed on the blanket configured to removably connect the blanket to the pad.
[0012] A method of the present invention is also presented. The method in the disclosed embodiments substantially includes the steps necessary to carry out the functions presented above with respect to the operation of the described apparatus and system. In one embodiment, the method includes providing the apparatus, forming one of a plush container or a durable container by selecting the durable surface to form the outside of the container or selecting the plush surface to form the outside of the container, fastening the fastener, and placing the blanket inside the container.
[0013] The method may also include fastening the blanket to the pad when the pad is in a seating configuration, and removably coupling each sleeve to each of the apertures. In another embodiment, the method includes integrally forming each sleeve to the blanket, and fastening the blanket around a person's neck.
[0014] Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
[0015] Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.
[0016] These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
[0018] FIG. 1 depicts view of an embodiment of an apparatus for a convertible blanket, pad, and pillow configured as a blanket and pad;
[0019] FIG. 2 depicts a view of an embodiment of an apparatus for a convertible blanket, pad, and pillow configured as a pillow;
[0020] FIG. 3 depicts a view of one embodiment of a pad for a convertible blanket, pad, and pillow;
[0021] FIG. 4 depicts a cross-sectional view of one embodiment of a pad for a convertible blanket, pad, and pillow;
[0022] FIG. 5 depicts a view of one embodiment of a blanket for a convertible blanket, pad, and pillow;
[0023] FIG. 6 depicts a view of one embodiment of a pad with a carrying strap;
[0024] FIG. 7 is a schematic flow chart diagram illustrating one embodiment of a method for wearing the device;
[0025] FIG. 8 is a schematic flow chart diagram illustrating one method of forming a pillow;
[0026] FIG. 9 is a schematic block diagram illustrating one embodiment of a convertible pillow and container; and
[0027] FIG. 10 is a schematic block diagram illustrating one embodiment of a single person pillow/pad/container.
DETAILED DESCRIPTION
[0028] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0029] Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0030] The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.
[0031] Embodiments of a convertible blanket, pad, and pillow are described. The convertible blanket, pad, and pillow provide an easy to carry seating pad and an attachable, wearable blanket. In the pad and blanket configuration, the convertible blanket, pad, and pillow are useful for activities such as attending a sporting event in cold weather. The pad provides a comfortable, insulated seating surface on what could otherwise be a hard, cold bleacher. The wearable blanket provides comfortable, convenient insulation. In addition, the convertible blanket, pad, and pillow may be placed in a pillow configuration by forming the pad into a container and placing the blanket inside the formed container.
[0032] FIG. 1 depicts a view of an embodiment of an apparatus for a convertible blanket, pad, and pillow (hereinafter “device”) 100 configured as a blanket 102 and pad 106 . The device 100 includes a blanket 102 , sleeves 104 , and a pad 106 . The device 100 provides an insulated cover and seat pad.
[0033] The blanket 102 , in some embodiments, is an insulating cover that can be placed over a user. The blanket 102 may be formed of any insulating material. For example, the blanket 102 may be a fleece made from a synthetic material, such as polyethylene terephthalate (PET). In another example, the blanket 102 may be made from a wind resistant material.
[0034] The blanket 102 , in some embodiments is wearable. For example, in one embodiment, the blanket 102 includes one or more sleeves 104 . The sleeves 104 are configured to receive the arms of a wearer. The sleeves 104 help to position and hold the blanket 104 on the wearer, and allow the wearer free use of his or her hands while providing insulation. Alternatively, the blanket 102 may include openings without sleeves that allow a wearer to pass his or her arms through the openings. In another embodiment, the sleeves may be detachable so that the wearer may better regulate his or her temperature. In other words, the detachable sleeves provide the benefit of protecting the arms of the wearer in colder weather, or, enabling the wearer to remove the sleeves if the wearer is getting too warm under the blanket 102 . The detachable sleeves may be attached to the blanked by way of a fastener such as a snap, zipper, or a hook and loop mechanism.
[0035] In certain embodiments, the blanket 102 is printed with a design. For example, the blanket 102 may be printed with a logo, such as a logo for a professional or collegiate sports team.
[0036] The pad 106 , in one embodiment, is an insulating and/or cushioning pad upon which a user may sit. The pad 106 may include any insulating and/or cushioning material. For example, the pad 106 may include polyethylene closed cell foam.
[0037] In certain embodiments, the pad 106 is printed with a design. For example, the pad 106 may be printed with a logo, such as a logo for a professional or collegiate sports team. The pad 106 may be printed with the same logo or a different logo from that printed on the blanket 102 .
[0038] In some embodiments, the device 100 is sized to accommodate one user. In another embodiment, the convertible blanket, pad, and pillow 100 is sized to accommodate two or more users. In a two user device 100 , the blanket 102 may include four sleeves 104 and the pad 106 may be wide enough for two users to sit on the pad 106 .
[0039] FIG. 2 depicts a view of an embodiment of an apparatus for a convertible blanket, pad, and pillow configured as a pillow 200 . The pillow 200 includes the blanket 102 , the pad 106 , and a fastener 202 . The blanket 102 and pad 106 are similar to same numbered components described in relation to FIG. 1 . The pad 106 allows for use of the device 100 as a container for holding the blanket, thereby forming a pillow 200 .
[0040] The fastener 202 , in one embodiment, forms the pad 106 into a container to hold the blanket 102 . In some embodiments, the fastener 202 is disposed on a perimeter of the pad 106 . The fastener 202 may be any type of fastener capable of holding the pad 106 in position to form a container. For example, the fastener 202 may be a zipper located on the perimeter of the pad 106 that zips the pad 106 into a container when the pad 106 is folded in half.
[0041] In some embodiments, the pad 106 has a plush surface. The plush surface may face outward when the pad 106 is formed into a container. For example, a surface of the pad 106 may include a PET fleece and the PET fleece may face outward when the pad 106 is formed into a container. In an alternative embodiment, the pad 106 also includes an abrasion resistant surface or a water-resistant surface. In one example, the container may be formed with the abrasion resistant or durable surface, facing outward. As such, a durable container is formed that protects the blanket.
[0042] FIG. 3 depicts a view of one embodiment of a pad 106 for the device 100 . The pad 106 includes a seam 302 and a blanket fastener 304 . The pad is similar to the same numbered component described in relation to FIG. 1 . The pad 106 provides a plush seating surface, a durable ground-engaging surface, and forms a container for the blanket 102 .
[0043] In one embodiment, the seam 302 joins two segments of the pad 106 . The seam 302 may provide a fold line for the pad 106 on which the pad 106 folds to be formed into a container. The seam 302 may be any type of connection between segments of the pad 106 . For example, the seam 302 may be stitching between segments of the pad 106 . In an alternative embodiment, the seam 302 is located between two portions of a single unit that makes up the pad 106 .
[0044] In one embodiment, the pad 106 has a length and a width, and the length is much greater than the width such that the pad 106 unfolds length-wise to form an elongated pad. In this embodiment, the seam runs across the width of the pad, and bisects the pad into a top section and a bottom section. The length of the pad is in this embodiment at least twice as great as the width of the pad 106 . The length may be at least three times as great, and in further embodiments, at least four times as great as the width. The fastener in this embodiment runs along the top 306 and bottom 308 of a first length, along top 310 and bottom 312 of a width and along a top 314 and bottom 316 of a second length.
[0045] The blanket fastener 304 , in some embodiments, removably fastens the blanket 102 of FIG. 1 to the pad 106 . The blanket fastener 304 may be any type of removable fastener. For example, the blanket fastener 304 may be a snap, a hook, or a hook and loop fastener. By fastening the blanket 102 to the pad 106 using the blanket fastener 304 , the pad 106 may be maintained in a usable location while the user alternates between a sitting and a standing position.
[0046] In some embodiments, the pad 106 includes a single blanket fastener 304 . In an alternative embodiment, the pad 106 includes a plurality of blanket fasteners 304 . In one embodiment, the convertible blanket, pad, and pillow 100 accommodates a plurality of users, and the pad 106 includes at least one blanket fastener 304 for each accommodated user. The blanket fastener 304 secures the blanket to the pad behind the user so that the blanket wraps around the user. Otherwise, the blanket may open in the back and expose the person to adverse weather conditions. In one further embodiment, the blanket may be integrally formed to the pad along the top 314 and bottom 316 edges of the pad 106 . In this arrangement, the blanket is worn in a more traditional manner like a jacket with the opening in the front of a person.
[0047] FIG. 4 depicts a cross-sectional view of one embodiment of a pad 106 for a convertible blanket, pad, and pillow 100 . The pad 106 includes a plush surface (top cover) 402 , a cushion 404 , a durable surface (bottom cover) 406 and a fastener 202 . The fastener 202 is similar to the same numbered component described to FIG. 2 . The pad 106 provides a comfortable seating surface and forms a container for holding the blanket 102 .
[0048] The top cover 402 , in one embodiment, covers a top surface of the cushion 404 . The top cover 402 may include a material upon which it is comfortable to sit. For example, the top cover 402 may be a PET fleece.
[0049] The cushion 404 , in some embodiments, is a compliant material that distributes stresses and strains when compressed. In one embodiment, the cushion 404 restricts the passage of heat, thus providing insulation. For example, the cushion 402 may include polyethylene closed-cell foam.
[0050] In one embodiment, the bottom cover 406 covers a bottom surface of the cushion 404 . The bottom cover 406 may include an abrasion-resistant material that protects the pad 106 from wear. In some embodiments, the bottom cover 406 includes a water-resistant material that protects the pad 106 from spilled liquids or other moisture on a bleacher. For example, the bottom cover 404 may include treated, water-resistant nylon, or other rubberized water-resistant surfaces.
[0051] In some embodiments, the top cover 402 faces outward when the pad 106 is formed into a container for holding the blanket 102 . The top cover 402 forms a comfortable outer surface for the device 100 in a pillow configuration. In some embodiments, the device 100 may be placed in a pillow configuration with the bottom cover 406 facing outward. As such, the bottom cover 406 forms a durable, water-resistant container.
[0052] FIG. 5 depicts a view of one embodiment of a blanket 102 for a convertible blanket, pad, and pillow 100 . The blanket 102 includes a neck fastener 502 , two or more arm apertures 504 , and a pad fastener 506 . The blanket 102 provides insulation to a user.
[0053] The neck fastener 502 , in some embodiments, removably fastens the blanket 102 around a user's neck. Fastened around the user's neck, the blanket 102 is securely worn by the user while providing freedom of movement. The neck fastener 502 may be any type of releasable fastener. For example, the neck fastener 502 may include snaps mounted near opposing edges of the blanket 102 .
[0054] In one embodiment, the neck fastener 502 is adjustable. An adjustable neck fastener 502 may fasten around a user's neck at an adjustable diameter. For example, the neck fastener 502 may be a hook and loop fastener with the hooked portion of the hook and loop fastener attached near an edge of the blanket 102 and the blanket 102 itself acting as the loop portion of the hook and loop fastener. In this example, the hooked portion of the hook and loop fastener may engage the blanket 102 at any point, thus providing adjustability.
[0055] The two or more arm apertures 502 , in one embodiment, provide openings in the blanket 102 through which a user may place his or her arms. In some embodiments, a sleeve 104 is connected to the blanket 102 around an aperture 504 .
[0056] In one embodiment, the pad fastener 506 is removably fastenable to the blanket fastener 304 on the pad 106 . For example, the pad fastener 506 may include a snap that engages the blanket fastener 304 . In an alternative embodiment, the pad fastener 506 attaches directly to the pad 102 . For example, the pad fastener 506 may include a hook and loop fastener that engages the top cover 402 of the pad 106 . The pad fastener 506 removably attaches the blanket 102 to the pad 106 and maintains the pad 106 in a usable position.
[0057] FIG. 6 depicts a view of one embodiment of a pad 106 with a carrying strap 602 . The carrying strap 602 is connected to the pad 106 and provides a convenient mechanism for carrying the apparatus for convertible blanket, pad, and pillow 100 . The carrying strap 602 may include any type of material suitable for forming a carrying strap 602 . For example, the carrying strap 602 may include nylon webbing.
[0058] The carrying strap 602 , in one embodiment, includes one or more small loops sized to allow a user to place his or her hand within the loop to carry the apparatus for convertible blanket, pad, and pillow 100 by hand. In an alternative embodiment, the carrying strap 602 is a long loop suitable for use in carrying the apparatus for convertible blanket, pad, and pillow 100 over a user's shoulder. In some embodiments, the length of the carrying strap 602 is adjustable. In certain embodiments, the carrying strap 602 is partially or completely removable.
[0059] The schematic flow chart diagrams that follow herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.
[0060] FIG. 7 is a schematic flow chart diagram illustrating one embodiment of a method 700 for wearing the device 100 . In one embodiment, the method 700 starts 702 and a convertible blanket, pad, and pillow device 100 are provided. The device 100 is provided as described above, where the blanket is formed of a plush material such as a fleece and has at least one arm aperture. Sleeves are attached to the blanket as described above, and may be removable. The pad is formed having a plush surface and an opposing durable surface. The pad provides a comfortable, cushioned sitting surface for sitting on a bleacher, for example. The durable surface of the pad may be rubberized to protect the pad from water and also grip the ground, bench, or bleacher to prevent the pad from undesired movement.
[0061] The method continues and the container is unfastened 706 to form the pad for sitting. In one embodiment, unfastening 706 the pad includes unzipping the perimeter edges of the pad and folding open the pad to form the elongated seating surface. The person then unfolds the blanket and places 708 his or her arms through the blanket. The person then may fasten 710 the blanket to the pad as described above with reference to FIG. 3 . The method 700 then ends 712 .
[0062] FIG. 8 is a schematic flow chart diagram illustrating one method 800 of forming a pillow. The method 800 starts 802 and a person unfastens 804 the blanket from the pad. As described above with reference to FIG. 3 , the blanket may be attached to the pad to ensure that the blanket covers the back of a person. The person decides whether to form 806 a plush container or a durable container. A person would select a plush container if the person wanted to use the device as a pillow, as the plush surface would be more comfortable against the skin. Alternatively, if the person was travelling, the person might select to form a container with the durable surface facing outward to protect the blanket and the plush surface of the pad.
[0063] If the person decides to form a pillow with a plush surface, the pad is folded with the plush surface facing outward, thereby forming 808 a pillow. Alternatively, the person may form 810 a durable container with the durable surface facing outward. The person then places 812 the blanket inside the durable container or the pillow container and the method 800 ends 814 .
[0064] FIG. 9 is a schematic block diagram illustrating one embodiment of a convertible pillow and container 900 . In one embodiment, the pillow/container 900 converts from a container into a stadium seat as illustrated. The pillow/container 900 is formed having a plush surface 902 and a durable surface 904 , as described above. Alternatively, both surfaces may be formed of the same material. In yet another embodiment, the inner surface 902 and outer surface 904 may be of different colors, designs, etc. For example, the inner surface 902 may be formed having the logo of a first team, while the outer surface 904 displays the logo of a second team. As such, the same container 900 , which is reversible, may be used for sporting events of two different teams. The container 900 also includes a support strap 906 so that when a person sits on the base 908 , the back 910 offers back support to the person.
[0065] FIG. 10 is a schematic block diagram illustrating one embodiment of a single person pillow/pad/container 1000 . The depicted view illustrates the pillow/pad/container 1000 from a top down view. The pillow/pad/container 1000 , in one embodiment, has a fastener on one side only as opposed to the device described above with a zipper that is around the entire perimeter of the device. As such, the pillow/pad/container 1000 forms a reversible pouch having an inner surface and an outer surface. The inner surface may be formed of a plush material as described above, while the outer surface is formed of a durable material, or vice versa. Alternatively, both surfaces may be formed of the same material. The pouch 1000 is capable of storing a blanket as described above with reference to FIG. 1 , or alternatively any object that a person may want to wear to an outdoor spectator event including, but not limited to, coats, ponchos, jackets, etc.
[0066] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An apparatus, system, and method are disclosed for a convertible blanket, pad, and pillow. The apparatus includes a blanket having arm apertures, and a sleeve coupled to each of the apertures. The apparatus also includes a pad having a durable surface, a plush surface, and a fastener disposed on a perimeter of the pad to form the pad into a container to hold the blanket. The apparatus may also include a fastener disposed on the blanket to removably connect the blanket to the pad. The system includes the apparatus, cushioning disposed between the durable surface and the plush surface, and carrying straps extending from the perimeter of the pad. The method includes providing the apparatus, forming either a plush or a durable container by selecting the durable or plush surface to form the outside of the container, fastening the fastener, and placing the blanket inside the container.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to fishing equipment. More particularly, it relates to a parachute assisted fishing device for large game fish.
[0003] 2. Discussion of Related Art
[0004] There are many difficulties involved in catching large game fish, such as such as bluefin and bigeye tuna, marlin, swordfish, or shark. When fishing for large game fish, anglers typically employ multiple rods that rest in rod holders. When a fish is hooked on a particular rod, the angler removes that rod from the holder and makes his way into a fighting chair to assist in the capture of the fish. These fighting chairs are well known in the art. Typical fighting chairs provide the angler with a place to sit while reeling in the hooked fish. They also provide support for the rod and reel. To bring in a large hooked fish, anglers cannot usually simply reel in the fish. The weight and strength of the fish cannot be overcome by the cranking arm on the reel. Furthermore, the fishing line typically is not strong enough to hold the fish if it makes a sudden dart away from the direction of the pole.
[0005] In order to capture a hooked fish, anglers use a combination of several motions to slowly bring the fish towards the boat. The angler pulls the rod toward his body so that it pivots about the butt of the rod. This motion moves the fish towards the boat. The angler then reverses the motion by quickly lowering the tip of the rod and reels in the slack in the line. This motion requires a great deal of strength to pull in a large fish. It becomes easier as the fish tires, but the angler also tires over time.
[0006] In order to prevent line breakage, the reel that holds the line is fitted with a friction drag. Any pull on the line greater than the set amount causes the reel to play out line. When a fish darts quickly away from the boat, the drag is exceeded and the line plays out. The line may also play out simply from a large, strong fish swimming in the opposite direction. As line plays out, the angler has to continue the process to reel in all of the line which has gone out. Additionally, if all of the line on the reel plays out, the line will break and the fish is lost. Many large fish keep away from the fishing boats. In order to catch them, lots of line must be let out before the fish is hooked. A strong fish may be able to pull the rest of the line out.
[0007] Other problems may result in losing a hooked fish. Often a fish will jump out of the water. The stresses on the line and hook change as the fish leaves the water. These changes may allow the hook to come lose and the fish to escape. Also, a fish can change direction fairly quickly. When a fish changes direction, the line bows forming an arc behind the fish. The arc of line is pulled sideways through the water. The stresses created by this movement can exceed the strength of the line causes the line to break.
SUMMARY OF THE INVENTION
[0008] The fishing device of the present invention avoids many problems involved with large game fishing by connecting a parachute to the fishing line near the fish. According to one aspect of the invention, the parachute is enclosed in a container until after a fish is hooked. The container then opens and the parachute is engaged. The parachute provides additional resistance to the fish swimming to limit its speed and tire it more quickly. The lower speed of the fish reduces the changes of a break in a bowed line. The parachute further limits the ability of the fish to break the surface and the associated dislodging of the hook. According to an aspect of the invention, the parachute is unidirectional. It provides resistance to the fish swimming, but not to the line being pulled in by the angler.
[0009] According to one aspect of the invention, the container is positioned near the hook and is designed to function as a lure. According to another aspect of the invention, the container is positioned in the line away from the hook. According to one aspect of the invention, the line passes through the parachute. According to another aspect of the invention, the line does not pass through the parachute, but the top of the parachute is tethered to the line. According to another aspect of the invention, the parachute is packed within the container to allow easy deployment and to prevent tangles in the line and the parachute. According to another aspect of the invention, the parachute includes swivels to allow rotation of the parachute about the line. According to another aspect of the invention, the parachute includes a design to limit rotation of the parachute as it passes through the water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front view of a fishing device in a closed position according to a first embodiment of the present invention.
[0011] FIG. 2 is a front view of a fishing device in an open position according to a first embodiment of the present invention.
[0012] FIG. 3 is an interior view of a fishing device in a closed position according to a first embodiment of the present invention.
[0013] FIG. 4 is a front view of a parachute attachment swivel according to an embodiment of the present invention.
[0014] FIG. 5 is a front view of a fishing device in an open position according to a second embodiment of the present invention.
[0015] FIG. 6 is a front view of a fishing device in a closed position according to a third embodiment of the present invention.
DETAILED DESCRIPTION
[0016] The present invention provides a parachute along a fishing line. The parachute provides a drag on the fish. This drag slows the fish down and tires it more quickly. The slower speed of the fish limits many of the problems involved in fishing for large game fish. The fish cannot pull out the line as fast. Thus, the line is less likely to run out. When the line bows, the slower speed reduces the stresses on the line to limit breakage. The slower fish speed also prevents the fish from leaving the water, which limits the chances for the hook to come loose. These advantages improve the chances of landing a fish once hooked.
[0017] A fishing device 10 according to a first embodiment of the present invention is illustrated in closed and open positions, in FIGS. 1 and 2 , respectfully. The fishing device 10 includes a container having two parts 20 , 30 . The two parts 20 , 30 of the container 10 are connected together in the closed position so that a desired level of force is necessary to separate the two parts. According to an embodiment of the invention, the connection is made by passing cords 21 , 22 in one part 20 of the container through holes 31 , 32 in the other part 30 of the container. The cords 21 , 22 are sized to create friction within the holes 31 , 32 . Thus, a force is necessary to overcome the friction and allow the two parts 20 , 30 of the container to separate. The amount of force required to separate the parts depends upon the relative sizes of the cords and holes and upon the number of them. The amount of force should be such that the drag of the hook and bait through the water will not open the container, but that the forces caused by the fish pulling against the line will.
[0018] Rings 24 , 34 are positioned on opposite ends of the two parts 20 , 30 of the container. One ring 24 is attached to the hook 11 . The other ring 34 is attached to the fishing line 12 . A line 50 extends within the container between the rings 24 , 30 . A parachute 40 is connected to the line 50 . According to an embodiment of the invention, the line 50 is formed of twisted wire cable having a test strength of 800 lbs. The parachute 40 is formed of rip-stop nylon and treated so as to not be permeable. Alternatively, the parachute 40 may be formed of spiderwire. According to an embodiment of the invention, the parachute 40 is 14 inches in diameter. A parachute of this size sufficiently slows most large game fish. According to another embodiment, the parachute 40 has a diameter of 24 inches.
[0019] As illustrated in FIG. 2 , the parachute is domed in the direction of the fishing line 12 . In this manner, when the line 12 is pulled in, the parachute 40 collapses and moves easily through the water. When the fish pulls the line 12 , the parachute 40 catches water and provides drag to the fish. The amount of drag depends, to some degree, on the speed of the fish. As the speed of the fish increases, so does the drag. However, at a certain speed, the amount of drag levels off. The speed at which the drag levels off depends upon the dimensions of the parachute.
[0020] The outer edge of the parachute 40 is connected by suspension lines 42 to a swivel 41 . The suspension lines 42 may be directly attached to the parachute or connected to grommets, loops or other connectors. The suspension lines 42 may be formed of fishing line or spiderwire. Five suspension lines of 20 lb test is sufficient to support the parachute 40 in connection with the speeds of most large game fish. The swivel 41 allows the parachute to rotate without tangling the suspension lines 42 or the line 50 . In the first embodiment of the invention illustrated in FIG. 2 , the line 50 passes through the top of the parachute 40 . A swivel 48 in the top of the parachute 40 is attached to the line 50 . The swivel 48 keeps the parachute 40 properly positioned on the line 50 .
[0021] As the parachute 40 is pulled through the water, it tends to rotate. Holes 46 can be placed near the top of the parachute. The use of three holes limits the rotation of the parachute 40 without significantly limiting the drag of the chute.
[0022] FIG. 4 illustrates an embodiment for attaching the swivel 41 to the line 50 . The swivel 41 is formed of a flat metal disk 141 . The disk 141 has a hole (not shown) in the center through which the line 50 passes. The hole is large enough that the disk 141 can move freely on the line 50 . Additional holes are positioned around the periphery of the disk 141 . The suspension lines 42 connect to these additional holes. The number of holes corresponds to the number of suspension lines 42 . Two additional disks 142 , 143 are positioned on either side of the first disk 141 . These disks also have holes through the middle sized to accommodate the line 50 . Metal bands 145 , 146 are attached to the line 50 on either side of the three disks 141 , 142 , 143 . The bands 145 , 146 limit movement of the disks along the line. A similar structure can be used for the swivel 48 at the top of the parachute 40 .
[0023] FIG. 3 is an interior view of the fishing device in the closed position. The line 50 is coiled within the container. As illustrated in FIG. 3 , the line 50 is coiled in a figure 8 pattern. The number of loops in the line 50 depends upon the length of the wire and the size of the container. Using the figure 8 pattern allows the line to unwind without tangling or kinking. The parachute 40 is trash packed in one of the parts 30 of the container. The rings 24 , 34 are connected to swivels within the container. The ends of the line 50 connect to the other side of the swivels.
[0024] The container may be formed to function as a lure. As illustrated in FIGS. 1 and 2 , the container is shaped to appear as a squid. The cords 21 , 22 form a part of the image. Additional cords 26 , 27 are placed in holes within a part 20 of the container to add to the image. The other part 30 of the container may include details 35 to provide the desired appearance.
[0025] A second attachment mechanism 150 for the parachute 152 is illustrated in FIG. 5 . The parachute 152 is of similar size, shape and material to that of the first embodiment. Suspension lines 155 of fishing line or spiderwire connect the periphery of the parachute 152 to a swivel 151 . The swivel 151 is attached to the line 50 in the same manner as for the first embodiment as illustrated in FIG. 4 . In the second embodiment, the line 50 does not pass through the parachute 152 . Instead, the parachute 152 moves separately from the line 50 . In order to keep the parachute properly positioned to provide drag for the fish but not for the angler, the top of the parachute 152 is tethered to the line 50 . A tether line 153 connects the top of the parachute 152 to the line 50 . The tether 153 is long enough to allow the parachute 152 to fully open without interference from the line. Swivels 154 , 155 are used to connect both ends of the tether. The swivels 154 , 155 allow the parachute 152 to freely rotate about the line 50 .
[0026] Another embodiment of the fishing device 110 of the present invention is illustrated in FIG. 6 . In this embodiment, the container does not function as a lure. As in the first embodiment, the container includes two parts 120 , 130 . The fishing device 110 includes a parachute within the container as in the first embodiment. One part 130 of the container is connected to the fishing line 112 which goes to the rod and reel. The other part 130 of the container attaches to a length of line 113 . The length of line 113 attaches to the hook 111 . The length of line 113 is approximately 8 to 10 feet long. In this embodiment, bait is used on the hook. As in the first embodiment, when the fish is hooked, the two parts 120 , 130 of the container open to release the parachute.
[0027] Having disclosed at least one embodiment of the present invention, various adaptations, modifications, additions, and improvements will be readily apparent to those of ordinary skill in the art. Such adaptations, modifications, additions and improvements are considered part of the invention which is only limited by the several claims attached hereto.
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The fishing device of the present invention provides a parachute on the fishing line for use with large game fish. The parachute is enclosed in a container and released upon hooking a fish. The parachute provides a drag for the fish. The drag slows the fish and tires it more quickly. The slower speeds of the fish caused by the drag help prevent loss of the fish due to line breakage, hook release, or lack of line. The fishing device may also function as a lure.
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BACKGROUND OF THE INVENTION
This invention relates generally to communications and, in particular, to a communications system employing the principle of quantum entanglement.
The constant desire for “greater bandwidth” reflects an ever increasing demand placed on modern communication systems to rapidly transfer large amounts of information from one place to another. Classical communication techniques have been quite effective in meeting this demand, but these techniques are now approaching their theoretical limits.
It is therefore considered desirable to explore non-traditional approaches to enhance communication.
SUMMARY
A non-traditional communications system utilizes the quantum mechanics principle of quantum entanglement. An example communication system employing quantum entanglement includes the steps of projecting a pulse of photons through a nonlinear crystal. Photons making up a portion of this projected pulse are each parametrically down-converted into a signal and idler quantum-entangled photon pair. This conversion results in a series of signal photons and a series of idler photons. Another portion of the projected pulse is not down-converted, resulting in a series of non down-converted pulse photons corresponding to the projected pulse.
The series of signal photons and series of non down-converted pulse photons are projected to a receiver.
The series of idler photons are projected to a transmitter. The transmitter contains a collapse condition wherein a time width of each of the idler photons is altered and wherein a majority of the center wavelengths of each of the idler photons is altered. Because of quantum entanglement, a change to an idler photon results in a corresponding change to a corresponding signal photon as received at the receiver. The transmitter also has a non-collapse condition wherein the time width and center wavelength of each of the idler photons is left unaltered and wherein the time width and center wavelength of each of the corresponding signal photons as received at said receiver are left unaltered. An example of such a collapse condition is a measurement of the frequency of the idler photons, however such a collapse condition may exist upon encountering certain atmospheric conditions such as atmospheric aerosols.
The receiver is used to provide detection of whether the signal photons corresponding to the projected pulse and as received at said receiver have been altered or not. This detection is enhanced by projecting the altered and unaltered signal photons through a nonlinear element that enhances the differences between the two types of signal photons. A cumulative time distribution of the series of signal photons as received at the receiver is then assessed for each pulse or for a number of pulses to determine whether the signal photons have been altered or not.
The purposeful causation of the collapse event or a lack of such purposeful causation can be used for binary communication. In addition, the sensing of an atmospheric condition may be performed by equating changes in received signal photon characteristics with changes in collapse conditions in the atmosphere.
Other objects, advantages and new features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanied drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary pulse source.
FIG. 2 shows an example transmitter.
FIG. 3 depicts a communications receiver.
FIG. 4 illustrates cumulative time distributions of signal photons in altered and unaltered states.
FIG. 5 shows an alternative receiver.
DESCRIPTION
A communications system to be further described herein includes a pulse source, a transmitter, and a receiver. The optical path length from the source to the receiver is made to be slightly greater than the optical path length from the source to the transmitter.
Referring now to FIG. 1 , an example of pulse source 10 includes a laser 12 , a nonlinear crystal 14 , and a wavelength selective mirror 18 .
The laser is chosen to output pulses of photons. Suitable example pulses have full width at half maximum (FWHM) of approximately 200 femtoseconds. A suitable example laser pulse repetition frequency (PRF) is approximately 70 MHz. The pulse amplitude and pulse shape are highly stable from pulse to pulse.
Projected pulse 16 includes pulsed-laser photons. The laser pulse of photons are used as “pump” photons in nonlinear crystal (NLC) 14 . In NLC 14 , a portion of these “pump” photons may be parametrically down-converted into quantum entangled “signal” (S) and “idler” (I) pairs of photons. Another portion of these pump photons pass through NLC 14 in a non down-converted state (P).
Nonlinear crystal 14 is cut to allow parametric down-conversion via colinear, type I phase-matching, non-degenerate, however other cuts are possible. For example, colinear, type II, non-degenerate or degenerate; noncolinear, degenerate, and noncolinear, non-degenerate, type I or type II. The pump pulse photons (P) are assumed as being vertically polarized, and therefore any down-converted signal (S) and idler (I) photons produced will be horizontally polarized. Such signal photons will have a shorter wavelength than the idler photons. Under the type I phase-matching condition, the polarization orientation of the down-converted photons will be of a polarization that is orthogonal to the polarization of the non down-converted pump pulse photons.
An output from NLC ( 14 ) is incident on a wavelength selective mirror (WSM) 18 such as a dielectric mirror. The non down-converted pump pulse (P) photons and any signal (S) photons are totally reflected by WSM 18 and are sent to a receiver 20 , to be further described. The longer-wavelength idler (I) photons are transmitted through WSM 18 and are sent to a transmitter 22 , to be further described.
Both the signal photon (S) and idler (I) photon that are produced by the parametric down-conversion of a pump pulse photon in the nonlinear crystal NLC 14 have wide bandwidths. These wide bandwidths exist because the pump pulse photons have a wide bandwidth, (proportional to the reciprocal of the pulsewidth of the pump pulse), and because of the very large number of different frequency combinations of signal and idler photons allowed by energy conservation and phase matching. Since, quantum mechanically, the signal and idler photons represent a superposition of all allowed possibilities, the bandwidths of the signal and idler photons will be wider than the bandwidth of the pump pulse photons that produced them in NLC 14 . Consequently, the time width of both the signal photon and the idler photon will be shorter than the pulsewidth of the pump pulse.
For an assumed case of a 200 femtosecond (FWHM), Gaussian-shaped pump pulse 16 (center wavelength ˜390 nm), the time width of both the signal photon (center wavelength ˜683 nm) and the idler photon (center wavelength ˜909 nm) will be approximately 44 femtoseconds (FWHM). The time profile of both the signal photon and idler photon will be approximately Gaussian.
Different signal photons are created at different times. However, no inherent photon property distinguishes one signal photon from another signal photon (or one idler photon from another idler photon). As they are produced, each signal photon is identical to any other signal photon (same bandwidth, same time width, same center wavelength). Each idler photon is identical with any other idler photon, since (according to Quantum Mechanics) all allowed possibilities are present in superposition in each individual photon, and the possibilities that are allowed do not change from one photon to the next.
Referring to FIG. 2 , an example transmitter 22 includes a moveable mirror (MM) 24 , a photon detector (PD) 26 , a spectrometer 28 , and a detector array 30 . Moveable mirror 24 can be inserted into or removed from idler photon beam path 32 coming from source 10 of FIG. 1 and may be electro-optically switched.
If moveable mirror 24 is removed, a “collapse” condition beam path 34 results wherein idler photons (I) from source 10 will enter spectrometer 28 . In this condition spectrometer 28 and detector array 30 are used to make a precise measurement of the frequency of the idler photons.
If moveable mirror 24 is inserted into the beam path, the idler photons are reflected at mirror 24 and travel a non “collapse” condition path 36 to be incident on photon detector 26 . In this case, the idler photons are detected, but their energy is not measured.
Referring now to FIG. 3 , example receiver 20 is to be described first in regard to its components and secondly in regard to its use. Receiver 20 includes three polarizing beam splitters ( 38 , 40 and 42 ), a corner cube reflector 44 , three optical mirrors ( 46 , 48 , 50 ), a nonlinear dispersion element 52 , a forty-five degree polarization rotator 54 , a beam stop 56 , an optical Kerr cell (OKC) 58 , one (or more) color filters 60 , a photo-diode detector 62 , and two photon detectors 64 and 66 .
The non down-converted pump pulse (P) photons and the down-converted signal (S) photons from source 10 are incident on first polarizing beam splitter 38 at receiver 20 . Polarizing beam splitter 38 reflects the vertically polarized pump pulse (P) photons and transmits the horizontally polarized signal (S) photons.
The pump pulse (P) photons enter an adjustable “mirror delay channel” ( 68 ), that includes corner reflector 44 and mirror 46 . After reflecting from mirror 46 , the pump pulse (P) photons are incident on the forty-five degree polarization rotator 54 . The polarization rotator rotates the polarization direction of almost all of the pump pulse (P) photons to an angle that is forty-five degrees from vertical.
The pump pulse (P) photons are next incident on the second polarizing beam splitter 40 . This beam splitter has its transmission axis set forty-five degrees from vertical so that almost all of the pump pulse (P) photons are transmitted through this beam splitter. A small number of the pump pulse (P) photons that do not have their polarization direction at forty-five degrees from vertical are reflected by beam splitter 40 and are absorbed by beam stop 56 .
The pump pulse (P) photons that have been transmitted through beam splitter 40 are reflected by directing mirror 48 to optical Kerr cell (OKC) 58 . The pump pulse (P) photons are incident on the OKC at a small angle from the normal to be further explained.
After passing through polarizing beam splitter 38 , the signal (S) photons enter nonlinear dispersion element (DE) 52 . The DE is an appropriately cut piece of dispersing material, for example, SF6 glass, and serves to enhance differences between signal photons that have been altered by the communications process and those that have not been, as will be further described.
After exiting element 52 , the signal photons (S) are reflected by directing mirror 50 and have near normal incidence on OKC 58 . There is approximately a 5 degree difference in angle between the signal (S) photon direction and the pump pulse (P) direction at OKC 58 . By providing this divergence, versus an alignment of the pump pulse and signal photon directions, the signal to noise ratio of the receiver is improved, as pump pulse (P) photons are ultimately prevented from reaching photon detectors 64 and 66 .
Both the pump pulse (P) and signal (S) photons pass through the optical Kerr cell 58 . The intensity in the pump pulse is great enough that it alters the birefringent properties of the liquid in the Kerr cell. In the absence of the pump pulse, the liquid molecules are randomly oriented, and the liquid is optically isotropic: it does not change the polarization direction of light passing through the cell.
In the presence of the intense pump pulse, the liquid molecules in the Kerr cell are aligned in the direction of the polarization of the pump pulse (P) photons (which is forty-five degrees from vertical). This alignment of the liquid molecules causes the liquid to become optically birefringent. If the liquid is, for example, Carbon Disulfide, this birefringence remains through the duration of the pump pulse (P) and for approximately 1.8 picoseconds after the pump pulse (P) exits the Kerr cell.
Signal (S) photons that pass through the Kerr cell while it is optically birefringent have their polarization direction rotated from horizontal to vertical. Signal (S) photons that pass through the Kerr cell while it is optically isotropic are not affected, and their polarization direction remains horizontal.
After passing through optical Kerr cell 58 , the pump pulse (P) photons are incident on photo-diode detector 62 , which along with its accompanying electronics is used to count the number of pump pulses and to measure the intensity of the pump pulses.
After passing through OKC 58 , the signal (S) photons pass through one (or more) color filters 60 . The color filter(s) transmit the low frequency signal (S) photons but absorb any pump pulse (P) or other “out of bandwidth” photons that may have entered the signal (S) photon path.
The signal (S) photons next reach the last polarizing beam splitter 42 . Signal (S) photons that have had their polarization direction rotated from horizontal to vertical in the optical Kerr cell 58 are reflected at polarizing beam splitter 42 and are incident on vertical photon detector 64 . Signal (S) photons that passed through OKC 58 while its liquid was optically isotropic maintain their original, horizontal polarization direction; these photons pass through polarizing beam splitter 42 and reach horizontal photon detector 66 . The sensitive photon detectors, with their associated electronics, are capable of photon counting.
The absolute time difference between the arrival of the pump pulse (P) at optical Kerr cell 58 and the arrival of any signal (S) photons at the cell 58 is controlled by the position of corner reflector 44 in the pump pulse (P) path of receiver 20 . The arrival time difference can be adjusted by translating the corner reflector.
The “filtering” properties of the Kerr cell in conjunction with the last polarizing beam splitter, pass or do not pass signal photon information depending on the cumulative time distributions of these photons as they correspond to signal photons that have not been altered by a collapse event in the transmitter (binary “zero”), and to signal photons that have been altered by such an event (binary “one”) as will be further explained.
Referring to FIGS. 2 and 3 , to send a binary “zero” from transmitter 22 to the receiver 20 , moveable mirror 24 of the transmitter is inserted into idler (I) photon beam path 32 . The idler (I) photons are reflected by mirror 24 and are detected by photon detector 26 . This detection does not measure the idler (I) photon energy. The properties of the idler (I) photons are not altered prior to their detection by photon detector 26 . Specifically, the center wavelength, bandwidth, and time width of each of the idler (I) photons are the same at the time of detection as they were when the photons were originally created in the down-conversion event in the nonlinear crystal of source 10 .
The detection of an idler (I) photon at transmitter 22 serves to “fix” the properties of its quantum-entangled partner, the signal (S) photon that is arriving at receiver 20 . Since the center wavelength, wide bandwidth, and short time width of each idler (I) photon were not changed prior to detection in transmitter 22 , each signal (S) photon that arrives at receiver 20 also has its original center wavelength, wide bandwidth, and short time width.
A slight uncertainty exists in the arrival time of a given signal (S) photon at the receiver. This is because the group velocity of the signal (S) photons is greater than the group velocity of the pump pulse (P) photons in the nonlinear crystal, and because the pump pulse has a non-zero time width. For the assumed case of a 200 femtosecond (FWHM) pump pulse and an 8 millimeter-long Beta Barium Borate (for example) nonlinear crystal, the arrival time uncertainty of a signal (S) photon at receiver 20 is slightly less than 2 picoseconds with respect to the arrival time of the pump pulse. It should be noted that other nonlinear crystal types besides Beta Barium Borate (BBO) are considered suitable, for example, a crystal of Potassium diHydrogen Phosphate or of Lithium Iodate are feasible.
Signal (S) photons that reach receiver 20 pass through polarizing beam splitter 38 and are then incident on nonlinear dispersion element 52 that has dispersive characteristics that enhance the differences between altered and unaltered signal photons. In this binary “zero” case, all signal (S) photons that arrive at nonlinear dispersion element 52 of receiver 20 have the same center wavelength. Consequently, the group velocity in the nonlinear dispersion element is the same for all of the signal (S) photons, and they all require the same amount of time, on average, to pass through element 52 .
Additionally, all signal (S) photons that arrive at receiver 20 have the same time width (˜44 femtoseconds, FWHM). Propagation through element 52 causes the time width of the signal (S) photons to increase. This increase is proportional to the inverse square of the initial time width. Assuming a total path length through SF6 glass of ˜1 meter, the very narrow initial time width of the signal (S) photons increases to ˜12.5 picoseconds (FWHM) after the nonlinear dispersion element.
Thus, with respect to the arrival time of the narrow pump pulse, any signal photons produced in the nonlinear crystal by that pump pulse arrive at the optical Kerr cell 58 with a Gaussian-shaped cumulative time distribution ˜14.5 picoseconds (FWHM), see distribution 70 of FIG. 4 .
The liquid in the optical Kerr cell is somewhat dispersive. However, a suitable optical Kerr cell is only about 1 cm in length. Thus the dispersion due to the Kerr cell has only a minor effect on the time properties of the photons passing through it.
By adjusting the position of corner reflector 44 of receiver 20 , the arrival time of the pump pulse at cell 58 can be set so that most signal photons pass through OKC 58 before the pump pulse reaches it. Consequently, most of the signal photons representing the binary “zero” case pass through the optical Kerr cell while the cell's liquid is optically isotropic; their polarization direction remains horizontal.
Corner reflector 44 is set so that in the binary “zero” case (no energy measurement at transmitter 22 and hence no collapse event), almost all of the signal (S) photons that reach polarizing beam splitter 42 are horizontally polarized. Consequently, almost all of the signal (S) photons pass through polarizing beam splitter 42 and are detected at photon detector 66 . In the binary “zero” case, very few signal photons are detected at photon detector 64 .
To send a binary “one” from transmitter 22 to receiver 20 , moveable mirror 24 of transmitter 22 is removed from idler photon beam path 32 . Idler (I) photons that reach transmitter 22 enter spectrometer 28 . Spectrometer 28 and detector array 30 are used to precisely measure the frequency (energy) of each incident idler (I) photon.
Each idler (I) photon is (irreversibly) annihilated in a detection event in one of the elements of detector array 30 of transmitter 22 . Thus, spectrometer 28 and detector array 30 restrict each idler (I) photon to a narrow spectral region before it is detected.
Each idler (I) photon is quantum entangled with the signal (S) photon that was created with it in the down-conversion event in nonlinear crystal 14 of source 10 ( FIG. 1 ). The two photons are entangled both in energy and linear momentum (as well as other entangled parameters), because the signal, idler, and pump photons must obey energy conservation and momentum conservation (phase-matching).
A precise measurement of the idler (I) photon's frequency (or wavelength) places a constraint on the allowed signal-photon-frequencies. The precise measurement of the idler (I) photon frequency at transmitter 22 causes an instantaneous “collapse” of the signal (S) photon's bandwidth and, for a majority of the signal photons, an accompanying change in the signal (S) photon's center wavelength. A wide variance in the center wavelength of signal photons experiencing the collapse condition thus occurs.
The source to receiver and source to transmitter distances are set so that this “bandwidth collapse” occurs just before the signal photon reaches the receiver.
The degree to which the signal (S) photon's bandwidth is reduced depends on the original pump pulse bandwidth, on the resolution of the idler frequency measurement, and on the thickness of the nonlinear crystal. The new center wavelength (after the collapse) will be some value falling within the original, “uncollapsed” signal (S) photon bandwidth. The original Gaussian profile of the bandwidth acts as a probability density function (pdf) for the new center wavelength.
Since the precise measurement of the idler (I) photon's frequency causes the bandwidth of the signal (S) photon to decrease, the time width of the signal (S) photon must increase (due to Heisenberg Uncertainty).
For example, by using a 200 femtosecond (FWHM) pump pulse and an 8 millimeter-long BBO crystal, measurement of the idler (I) photon wavelength to within one Angstrom resolution causes the time width of its entangled partner signal (S) photon to increase to a value of approximately 1.4 picoseconds. The time profile of the “collapsed” signal (S) photon depends on the time width of the pump pulse and on the new center wavelength of the signal (S) photon.
The time required for a “collapsed” signal photon to propagate through the nonlinear dispersion element (DE) is determined by the photon's center wavelength and by its time width. The dominant factor impacting this time is the center wavelength, which determines the group velocity of the signal photon in the material of the DE. The initial time width of the signal (S) photon is a secondary factor that controls the amount by which the photon's time width spreads in traveling through nonlinear dispersion element 52 . From an initial value of ˜1.4 picoseconds in the binary “one” case, the signal (S) photon time width increases to ˜1.8 picoseconds, after passing through nonlinear dispersion element 52 .
As noted above, the dominant factor in determining the time required for a signal (S) photon to propagate through the nonlinear dispersion element is the photon's center wavelength. The group velocity in the nonlinear dispersion element 52 is a nonlinear function of the center wavelength.
In the binary “one” case, wherein signal photons are altered by the “collapse” event, the center wavelength changes from one signal photon to the next. Because of this, after passing through the nonlinear dispersion element 52 , each series of signal photons associated with a pump pulse arrive at the OKC within a slightly skewed, Gaussian-shaped cumulative time distribution ˜22 picoseconds (FWHM). FIG. 4 shows an example distribution 72 representing signal photons of this binary “one” case.
Corner reflector 44 of receiver 20 is set so that, in the previously-described binary “zero” case, almost all signal photons pass through OKC 58 ahead of the pump pulse, while the cell liquid is optically isotropic, and their horizontal polarization direction is maintained. The binary “zero” case produces a much larger photon count rate at horizontal photon detector 66 than at vertical photon detector 64 .
In the binary “one” case, there is a greater overall cumulative “time spread” of the signal photons exiting nonlinear dispersion element 52 than exists in the binary “zero” case. Thus, there is a much larger probability that signal (S) photons will pass through OKC 58 at the same time as the pump pulse. Consequently, more signal (S) photons pass through the optical Kerr cell 58 while the cell liquid is birefringent. These signal (S) photons have their polarization direction rotated from horizontal to vertical, and they are subsequently reflected by polarizing beam splitter 42 and are detected at photon detector 64 .
In the binary “one” case, the photon count rate at photon detector 64 increases to well above the rate observed in the binary “zero” case. Additionally, the count rate at photon detector 66 in the binary “one” case decreases from the rate observed in the binary “zero” case, since the rate of production of signal and idler photon pairs (via parametric down-conversion in the nonlinear crystal) is the same in both the “zero” and “one” cases.
By observing the photon count rate at photon detector 64 versus the rate at photon detector 66 , an operator of the receiver can discern whether an operator at the transmitter is sending a binary “zero” or a binary “one”.
For sensing situations where there is not apriori information known regarding a specific transmitter, the “transmitter” becomes the media or atmosphere desired to be sensed. This media, which may be atomic, molecular, or of more dense composition, interacts with incident idler photons in an analogous manner to the spectrometer of the transmitter shown in FIG. 2 .
Interaction of an idler photon with the media is equivalent to the binary “one” case described above wherein a collapse event is present. Non-interaction of an idler photon with the media is equivalent to the binary “zero” as described above.
Such sensing may be performed by adding a second adjustable “mirror delay channel” to the “front end” of the receiver.
Referring to FIG. 5 , a modified receiver 20 ′ incorporating such a second mirror delay channel is shown. Such a second mirror delay channel 74 includes two optical mirrors ( 76 , 78 ) and a corner reflector 80 . The remainder of the receiver is as described in FIG. 3 .
The function of the additional mirror delay channel is to control the time at which signal photons and pump pulse photons reach first polarizing beam splitter 38 of receiver 20 ′.
If the time delay in the new mirror delay channel is set to a too small value, then signal and pump pulse photons arrive at and are detected in the receiver before any idler photons can reach the media to be sensed. This is equivalent to a binary “zero” condition described in regard to receiver 20 above in terms of detection of the signal photons at the receiver.
As the time delay in mirror delay channel 70 is increased, a point is reached where the optical path length from source 10 ( FIG. 1 ) to the media to be sensed is shorter than the optical path length from the source to the receiver. Idler photons will interact with the media to be sensed, before the signal and pump pulse photons reach polarizing beam splitter 38 of the receiver. This is equivalent to the binary “one” condition described in regard to receiver 20 above in terms of detection of the signal photons at the receiver.
In the sensor application, the system can determine whether the media to be sensed is present or absent, the amount of the media that is present—via the percentage of idler photons that interact with the media at a given distance, and the location of the media and its concentration as a function of position—via the translation of the additional corner reflector in the new mirror delay channel of the receiver.
Obviously, many modifications and variations of the invention are possible in light of the above description. It is therefore to be understood that within the scope of the claims, the invention may be practiced otherwise than as has been specifically described.
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A communication system employs quantum entanglement by projecting photons through a nonlinear crystal. Some become parametrically down-converted into signal and idler photon pairs. The signal photons are projected to a receiver and the idler photons to a transmitter. The transmitter operator can alter the time width and a majority of the center wavelengths of the idler photons via a collapse event in the transmitter. Because of quantum entanglement, a corresponding change in the time width and center wavelengths of the signal photons as received at the receiver results. The purposeful causation of the collapse event or a lack of such purposeful causation can be used for binary communication. In addition, the sensing of an atmospheric condition may be performed by equating changes in received signal photon characteristics with changes in collapse conditions in the atmosphere.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/800,374, filed May 15, 2006, which is fully incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention generally relates to an endoscope device having a shaft with a distal end that allows for blunt dissection, and more particularly relates to an endoscope device that utilizes a plurality of inflatable balloons circumferentially surrounding the distal end of the device's shaft to better position and maneuver the distal end as it advances through tissue planes and once it reaches a target working space or operative site.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] Endoscopes have been used for many years for viewing within a desired region of a patient's body through the patient's airway, other natural orifices, or a surgical incision. An endoscope typically has an elongated flexible shaft with a control head at its proximal end. The flexible shaft is equipped with one or more functional channels (e.g., instrument channels, air channels, irrigation channels, suction channels) that extend along the length of the flexible shaft from the distal end to the control head. The control head is connected to a light source, air/water supply and suction via an “umbilical” cord.
[0004] For fiber-optic endoscopes, the flexible shaft is also equipped with a channel holding optical fibers (i.e., an image guide) for carrying an image from the distal end of the shaft to the control head, where it can be viewed through an eyepiece by a physician.
[0005] For video-endoscopes, a Charge Coupled Device (CCD), which serves as an image-capturing means, is located at the distal end of the endoscope. Captured images are compressed and recorded on, for example, a hard disk, a removable memory device, an optical disk, or a magneto-optical (MO) disk.
[0006] The tip of the endoscope is controlled using pull wires attached at the tip just beneath the surface of the flexible shaft, and passing back through the length of the shaft to angling controls in the control head of the endoscope. Two angling wheels or knobs located on the control head for up/down and right/left movement incorporate a friction braking system, so that the tip can be fixed temporarily in any desired position.
[0007] Surgeons in the past have used blunt-tipped instruments as well as balloons in connection with endoscopic surgery to dissect tissue in order to develop a working space in the interior of the body. Balloon type surgical instruments have been developed to assist in this regard. Several of these prior art instruments are described below.
[0008] U.S. Pat. No. 5,762,604 describes a surgical instrument that utilizes an inflatable, transparent balloon. The instrument serves to dissect and form a dissected viewing space within the interior of the body to provide adequate depth of field for endoscopic viewing. The instrument includes a transparent tipped dissector-guide 5 having a guide member 10 with an interior lumen (cavity) 14 (dimensioned to accommodate a viewing scope or endoscope 22) as well as a working channel 34 (for an elongate trocar). The guide member 10 affords the surgeon contemporaneous vision through the far end of the guide 10 as the instrument navigates the interior of the body. Metal band 132 and balloon constraining sleeve 133 are employed to constrain balloon 120 in a first collapsed position around guide member 10. The constraining sleeve 133 is provided with a weakened, perforated surface that will give way and burst when an inflation medium is introduced into balloon chamber 122 allowing the balloon to deploy to the inflated position. As the balloon inflates, tissue is dissected by the balloon generally applying forces perpendicular to the tissue being dissected or separated. When balloon 120 is inflated, it is disposed in a “hot dog bun” shape around the guide 10, offering increased depth of field in all directions around lens 32 of endoscope 22. Procedures are described in this patent as being performed on an outer surface of the inflated balloon. See e.g., Cols. 7 to 8, lines 60 to 3, of the '604 patent.
[0009] U.S. Pat. Nos. 5,607,441 and 5,707,382 both describe a surgical instrument that includes an assembly 10 consisting of two primary components, namely, a balloon dissector 11 for the dissection of internal bodily tissue to form an operative space during a surgical procedure, and an endoscope 12 for providing simultaneous visualization during the surgical procedure as the dissector is advanced through tissue and the operative space is formed. The balloon dissector 11 basically comprises a conventional trocar cannula 13, an extension assembly 14 (with transparent tissue-contacting element 24), and an inflatable balloon 15. Tubular sleeve 17 connects trocar cannula 13 and extension assembly 14 and is sized to receive an endoscope. An endoscope would be inserted distally in assembly 10 through tubular sleeve 17 until it abuts ring 23 at the distal end of the extension assembly 14. Use of assembly 10 is described in Cols. 5 to 6, lines 55 to 19, of the '382 patent, and is shown in FIGS. 3 to 5, of this patent. To summarize, once the assembly 10 is positioned parallel to adjacent tissue layers with the aid of the endoscope, the balloon 15 is inflated to form an operative space. The balloon 15 is then deflated, and the assembly including the balloon dissector 11 removed and another trocar cannula 35 introduced into the operative space.
[0010] U.S. Pat. Nos. 5,938,585 and 6,277,065 both describe an anchoring and positioning balloon device shaped like a cradle that is deployed using a side-view type endoscope 10. Endoscope 10 includes an illumination device 20, a viewing device 22, and a working lumen or channel 24, all contained within window section 18. A cradle shaped inflatable balloon 30 is attached to the distal end section 12 of the endoscope 10. During operation of the endoscope 10 with the balloon 30 inflated, the cradle portion 34 spaces the window section 18 from the examining area, thus providing a good view of and a sufficient working space relative to the body cavity wall 27 (see Cols. 3 to 4, lines 59 to 7, of the '065 patent).
[0011] US 2005/0159645 A1 describes a sheath for use with a medical device such as an endoscope, that comprises: an elongated body having a proximal end and a distal end; a main lumen extending through the elongated body from the proximal end to the distal end; and one or more inflatable balloons mounted on an outside surface of the elongated body proximate to the distal end. Embodiments employing multiple balloons mount the balloons 16, 18, 52, 54, 56 in isolated fashion on the distal end of the elongated body (see FIGS. 1A, 1B, 1C), or along the length of the elongated body (see FIGS. 4A and 4B).
[0012] Unfortunately, the use of single balloons or multiple isolated balloons on the distal end of these prior art devices renders the positioning and advancement of the devices between/through natural tissue planes difficult to control.
[0013] It is therefore an object of the present invention to provide an endoscope device capable of blunt dissection that allows for improved control over the positioning of the distal end of the device's shaft between natural tissue planes (e.g., subcutaneous, subfascial, intraperitoneal, intrathoracic, intracranial tissue planes) and further allows for improved control over the shaft's advancement through these tissue planes.
[0014] The present invention therefore provides an endoscope device that comprises a shaft having a distal end and a plurality of separately inflatable balloons that alone or together with exterior functional channels (e.g., instrument channels, air channels, water channels, suction channels) circumferentially surround the distal end of the shaft.
[0015] In a preferred embodiment, the inventive endoscope device comprises: a shaft made up of a flexible or partially flexible tubular member having a distal end, and interior optical and inflation channels extending there through; functional channels adapted to extend along an outer surface of the tubular member; and a plurality of separately inflatable balloons, where the balloons together with the exterior functional channels circumferentially surround the distal end of the tubular member.
[0016] The present invention further provides a method of dissecting layers of tissue to form a working space between the tissue layers and then performing an endoscopic procedure within the newly formed working space, which method comprises:
providing an endoscope device as described hereinabove, wherein the balloons located on the distal end of the device's shaft are fully deflated; inserting the distal end of the shaft between the layers of tissue; advancing the distal end of the shaft between the tissue layers by sequentially inflating and deflating various balloons until a desired length of dissection has been completed; inflating all or some of the balloons to form a working space between the tissue layers; and repositioning the distal end of the shaft within the newly formed working space, as necessary, while performing an endoscopic procedure therein by inflating and deflating various balloons.
[0022] Other features and advantages of the invention will be apparent to one of ordinary skill from the following detailed description and accompanying drawings. 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. 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Particular features of the disclosed invention are illustrated by reference to the accompanying drawings, in which:
[0024] FIG. 1 is a perspective side view of a preferred embodiment of the shaft of the endoscope device of the present invention; and
[0025] FIG. 2 is an enlarged perspective view of the distal end of the shaft shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Although the shaft as described herein forms part of an endoscope device, it is not so limited. The inventive shaft may be used as a shaft for a catheter or other similar device, or it may constitute a jacket or sheath for such a medical or surgical device for adding protection and functionality thereto.
[0027] Moreover, although the ability of the inventive endoscope device to more effectively and efficiently perform blunt dissection of tissue planes will be emphasized herein, the device's balloons may be used for a number of other purposes, including, but not limited to, distending a body cavity (e.g., peritoneal cavity) in which an operation is to take place, thereby obviating the need for insufflation, facilitating intubation of, for example, the ampula of vater by acting as a scaffold against the duodenum wall, and blocking blood vessels to control bleeding/hemorrhaging. Moreover, and as will be readily appreciated by one skilled in the art, the device's balloons serve as a cushion to protect the mucosa during endoscopic procedures requiring the device's shaft to follow a tortuous path (e.g., endoscopic colon and rectal procedures), thereby decreasing iatrogenic injuries.
[0028] Referring now to the drawings in detail, a preferred embodiment of the shaft of the balloon endoscope device of the present invention is shown generally at 10 . Shaft 10 is part of an end-view type endoscope device that allows for blunt dissection of tissue planes, while providing an operator with an image (e.g., a charge-coupled image). As best shown in FIG. 1 , shaft 10 basically comprises: (a) a flexible or partially flexible tubular member 12 having a distal end 14 , and an interior optical channel 16 and four interior inflation channels (not shown) extending there through; (b) four functional channels 18 a , 18 b , 18 c , 18 d , adapted to extend along an outer surface 20 of the tubular member 12 ; and (c) four separately inflatable balloons 22 a , 22 b , 22 c , 22 d . In this embodiment, each interior inflation channel is in fluid communication with a different balloon or balloon chamber, and all such inflation channels are in further fluid communication with a control means, such as a handheld control dial, for separately inflating and deflating each balloon 22 a , 22 b , 22 c , 22 d.
[0029] As best shown in FIG. 2 , functional channels 18 a , 18 b , 18 c , 18 d , terminate in exit ports 24 a , 24 b , 24 c , 24 d , and together with balloons 22 a , 22 b , 22 c , 22 d , circumferentially surround the distal end 14 of the tubular member 12 . Opposing channels 18 b and 18 d are used to supply either irrigation fluid or suction, while opposing channels 18 a and 18 c are instrument channels, which may be used to deliver any surgical instrument adapted to contact, grasp or sever tissue including, but not limited to, forceps, scissors, knives, staplers, clip appliers, and other like devices. Although these channels are shown as circular in cross-section, their cross-section could be trapezoidal or any other suitable shape.
[0030] When balloons 22 a , 22 b , 22 c , 22 d , are fully deflated, their thickness approximates the outside diameter of the functional channels 18 a , 18 b , 18 c , 18 d , thereby forming a substantially uniform layer in terms of thickness about the distal end 14 of the tubular member 12 . It is noted that the use of a plurality of smaller-sized balloons on the distal end 14 of the shaft 10 eliminates the need to physically constrain these balloons during introduction of the shaft 10 into a body cavity. When balloons 22 a , 22 b , 22 c , 22 d , are all at least partially inflated, the balloons touch adjacent balloons and form a substantially continuous outer surface about the distal end 14 of the tubular member 12 .
[0031] As will be readily evident to one skilled in the art, in addition to allowing for improved control over its positioning and advancement through tissue planes, which will be described in more detail below, the inventive balloon endoscope device provides an operator with images (e.g., charge-coupled or video images) of the area being dissected as well as the ability to, among other things, apply clips, irrigate, apply suction and cut vessels as the shaft 10 is being advanced. Once a desired length of dissection has been completed, all or some of the balloons may be inflated to form a working space between the tissue layers, at which time necessary surgical instruments may be introduced through functional channels 18 a , 18 c , to perform the desired procedure(s).
[0032] The balloon endoscope shaft 10 of the present invention can be sized to render it suitable for performing a number of different medical or surgical procedures. By way of example, the inventive shaft 10 may be used for (1) plastic surgical procedures (e.g., cosmetic procedures such as brow lifts and facelifts), allowing subcutaneous tissue and fascial planes to be pulled up or elevated with only a very small incision, resulting in a beneficial decrease in the amount of scarring, (2) intracranial procedures such as evaluating and/or evacuating a hematoma using small bur holes in the skull, (3) harvesting veins without the need for long incisions that are susceptible to wound break down and infection, (4) general surgical procedures (e.g., endoscopic and laparoscopic gastrointestinal procedures including endoscopic colonoscopies), (5) thoracic surgical procedures, eliminating the need for single lung ventilation anesthesia (i.e., deflating and stopping ventilation to the lung involved in a procedure) and thereby allowing a patient, who typically has low pulmonary reserve and would not tolerate single lung ventilation, to continue to breathe from both lungs, and (6) bariatric surgical procedures. Preferred outside diameters for the inventive shaft 10 when used for the above-described medical or surgical procedures are set forth in Table 1 below.
TABLE 1 Medical or Surgical Procedure O.D. min 1 (mm) O.D. max 2 (mm) Plastic surgical procedures 3-5 15-20 Intracranial procedures 3-5 10-15 Vein harvesting 5-8 25-30 General surgical procedures 5-20 25->150 Thoracic surgical procedures 5-20 25-150 Bariatric surgical procedures 5-8 25-30 1 O.D. min - The outside diameter in millimeters (mm) when the balloons are fully deflated. 2 O.D. max - The outside diameter in mm when the balloons are fully inflated.
[0033] In addition to the benefits noted above, the inventive balloon endoscope device obviates the need for insufflation and thus the need for administering anesthesia or paralyzing agents to a patient, thereby allowing certain laparoscopic procedures, while still performed in an operating room, to be carried out more cost effectively and with reduced risk to the patient. The inventive endoscope device allows other laparoscopic procedures such as laparoscopic exploration and tissue biopsy of the peritoneal and retroperitoneal spaces to be performed bedside for critically ill and unstable patients.
[0034] The balloons used in the present invention may adopt any size and shape, but preferably are sized and shaped so as to collectively form a substantially continuous surface about the distal end 14 of the tubular member 12 when all are similarly inflated. In a preferred embodiment, and as best shown in FIG. 2 , each balloon 22 a , 22 b , 22 c , 22 d , has a trapezoidal cross-sectional shape. Each balloon may have one or more internal chambers and each has the ability to be expanded to a plurality of working sizes upon the application of given pressures through its respective inflation channel without bursting.
[0035] Balloons suitable for use in the present invention may be made using compliant materials, non-compliant materials, or a combination of complaint and non-compliant materials. As is well known to those skilled in the art, balloons made solely from compliant materials (e.g., polyethylene, polyolefin, polyurethane) expand and stretch with increasing pressure within the balloon, while balloons made solely from non-compliant materials remain at a pre-selected diameter as the internal balloon pressure increases beyond that required to fully inflate the balloon.
[0036] As will be readily evident to those skilled in the art, by inflating and deflating the various balloons 22 a , 22 b , 22 c , 22 d , the distal end 14 of the tubular member 12 of the endoscope shaft 10 can be moved either left or right, up or down, clockwise or counter-clockwise, thereby providing the operator with the ability to finely adjust the position of the distal end 14 of the tubular member 12 beyond that which is achievable by the angling controls in the control head of the endoscope.
[0037] The construction of the remaining parts or components of the endoscope shaft 10 (i.e., tubular member 12 , interior optical channel 16 , interior inflation channels, functional channels 18 a , 18 b , 18 c , 18 d , inflation/deflation control means), as well as, other parts or components of the endoscope (e.g., the control head, the light source(s), image guides or image-capturing/compressing/recording means, air/water/suction supply, etc.) are well-known in the art and do not form a part of this invention.
[0038] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the exemplary embodiments.
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A balloon endoscope device having a shaft with a distal end that allows for blunt dissection is provided. The shaft utilizes a plurality of separately inflatable balloons that alone or together with exterior functional channels (e.g., instrument channels, air channels, water channels, suction channels) circumferentially surround the distal end of the shaft to better position and maneuver the distal end as it advances through tissue planes and once it reaches a target working space or operative site.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for use in a vehicle speed controller and a method for controlling the speed of a vehicle.
2. Description of the Related Art
In high level water skiing competition events, the skier must be pulled through the ski run at a pre-set speed. If the time through a run indicates the speed was outside a pre-determined tolerance, the run is disqualified. It requires a high degree of skill on the part of the operator of the watercraft to meet the speed requirements.
U.S. Pat. No. 5,074,810 to Hobbs et al. describes a speed control system for a boat having particular utility for maintaining the speed of the boat during water skiing competition events. In Hobbs, after an operator adjusts the speed of a watercraft to a desired speed, a button is pressed which causes a control circuit to take over and maintain the desired speed of the boat by way of a speed control actuator positioned between the hand throttle and the engine throttle. The control circuit receives a pressure signal proportional to the speed of the craft from a pitot tube and pressure transducer. The control circuit compares the desired speed with the speed represented by the pressure signal and sends a control signal to an actuator connected to the engine throttle in order to make appropriate adjustments. In a second mode of operation, an operator may accelerate the boat to close to a speed stored in memory and then push a button to set the stored speed as the desired speed, whereupon the control circuit takes over to attain and maintain this speed.
A drawback with the Hobbs system is that an operator must focus on accelerating the boat to close to a desired speed and must also interact with the system prior to its activation, all at a time when there are .many demands on the operator. Furthermore, there is a risk of a runaway throttle condition should the actuator fail.
The subject of invention seeks to overcome drawbacks of other systems.
SUMMARY OF THE INVENTION
According to the present invent ion, there is provided apparatus for use in a vehicle speed controller, comprising: an actuator; a co-axial cable having an outer sheath for extending between a buttress and an engine throttle lever and an inner cable operatively associated with said actuator and extending through said sheath to a support positioned beyond said engine throttle lever; said outer sheath being relatively incompressible along its longitudinal axis and relatively flexible transversely of its longitudinal axis, said sheath having a length greater than the distance between said buttress and said engine throttle lever, at least when said engine throttle lever is in a closed throttle position; and a controller for receiving an input by a speed sensor and outputting a control signal to said actuator.
According to another aspect of the present invention, there is provided a method for controlling the speed of a vehicle, comprising the following steps: (a) accepting an operator input of a set speed when a current speed of said vehicle is less than said set speed; (b) after accepting an operator input of a set speed, refraining from controlling the current speed of said vehicle while said current speed of said vehicle remains less than said set speed; (c) when an engine throttle for said vehicle is opened by said operator and said vehicle reaches approximately said set speed, providing an indication to said operator; and (d) thereafter adjusting said engine throttle in order to maintain the speed of said vehicle within a pre-selected tolerance from said set speed.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which disclose an example embodiment of the invention,
FIG. 1 is a partially perspective view of a speed control system made in accordance with this invention, and
FIG. 2 is a flow diagram of the program control for the system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, a speed control system 10 made in accordance with this invention comprises an actuator in the nature of servo motor 12, a co-axial cable 14 having an outer sheath 16 and an inner cable 18, and a controller 20 operatively connected to the servo motor 12 by line 22. The controller receives an input from speed sensors 24 and 26 and from timer 32. The speed sensors may comprise pitot tubes and pressure transducers. The controller is connected for two-way communication with an input panel and display 30.
The outer sheath 16 of co-axial cable 14 extends between a buttress 36 on the housing of the servo drive 12 and a bracket 38 which is joined to the engine throttle lever 40. The outer sheath is relatively incompressible along its longitudinal axis 42 and is relatively flexible transversely of its longitudinal axis. This characteristic is typical of many commercially available co-axial cables wherein the outer sheath comprises an inner, helically wound, metal strip and an outer layer comprises a plastic covering.
When the engine throttle lever 40 is in a throttle closed position, as illustrated in FIG. 1, the length, L, of sheath 16 is greater than the distance D between the buttress 36 and the engine throttle lever 40. This is due to the curve in the sheath.
The inner cable 18 of co-axial cable 14 is operatively joined to the servo motor 12. The inner cable extends from the servo motor 12 through an opening in buttress 36, through outer sheath 16, and through an opening in bracket 38 to a nut 46 into which it is threaded. The nut 46 is an abutment which, for reasons which will become apparent hereinafter, acts as an adjustable stop.
A hand throttle is supported by a pivot 51. One end of an inner cable 52 of a co-axial cable 48 is joined to the hand throttle 50 proximate pivot 51. The other end of inner cable 52 is threaded to nut 46. The outer sheath 56 of the co-axial cable is fixed in position. A stop member 54 fixed on the hand throttle inner cable 52 limits the degree to which the hand throttle 50 may move the engine throttle lever 40 in a throttle opening direction, O. A spring 56 biases the engine throttle lever 40 to a throttle closed position.
Operation with the system 10 deactivated proceeds as follows. Should an operator pull back on hand throttle 50, the hand throttle inner cable 52 will slide in a forward direction such that stop member 54 and nut 46 move toward the sheath 56. Because one end of inner cable 18 of co-axial cable 14 is joined to nut 46, inner cable 18 is also pulled forwardly. However, the other end of cable 18 is joined to the inactive servo motor 12. The inactive servo motor will not pay out cable. Consequently, a stretching force is applied to cable 18 which will result in cable 18, and therefore sheath 16, between buttress 36 and bracket 38 becoming straighter. However, since the outer sheath 16 is relatively incompressible along its length, as the outer sheath straightens, it will push against bracket 38 to move the bracket, and therefore the engine throttle lever 40, in a throttle opening direction, O. Similarly, if the operator moves the hand throttle 50 in a throttle closing direction such that stop 54 moves away from sheath 48, cable 18 is relaxed so that sheath 16 is free to assume a more curved position. Consequently, sheath 16 will allow bracket 38 to move in a throttle closing direction under the influence of spring 56.
To explain the manner in which system 10 controls the speed of a watercraft in which it is installed, the operation of servo motor 12 is first addressed. Initially it is noted that pivot 51 is positioned sufficiently proximate inner cable 52 so that any tension applied to inner cable 52 by system 10 is insufficient to move hand throttle 50. Thus, for a given position of the hand throttle 50, if servo motor 12 is operated to draw in cable 18, a stretching force will be imparted to cable 18 since hand throttle 50 will act as a fixed support. This stretching force will cause cable 18 to straighten between the butt tess 36 and bracket 38 and consequently sheath 16 will straighten commensurately. This will result in sheath 16 pushing against bracket 38 to move the throttle lever 40 in a throttle opening direction, O. Conversely, if the servo 12 pays out cable 18, the cable 18 will be relaxed such that sheath 16 is free to increase its curvature and therefore allow bracket 38 to move in a throttle closing direction under the influence of spring 56.
In overview, system 10 controls the speed of a watercraft as follows. An operator activates system 10 from panel 30 and inputs a set speed to the controller from this panel; the operator may then accelerate the craft to close to the pre-set speed. During acceleration, the controller causes servo 12 to pay out some cable 18 in order to move abutment nut 46 to a pre-defined distance from bracket 38; this is felt by the operator as a lag in the acceleration. When the boat slightly exceeds the pre-set speed, the controller, which is input with an indication of the speed of the craft from sensors 24 and 26, sends the operator a signal it is taking over. Thereafter, the controller maintains the speed at the pre-set speed through appropriate signals to servo motor 12.
Water skiing competitions comprise the events of slalom, jump, and trick skiing. Slalom and jump skiing events mandate certain specific speeds for each run by the skier. Trick skiing does not have mandated speeds: the speed is instead at the elect ion of the skier and these runs are generally performed at much slower speeds than slalom or jump events. Each run is of a precise length and is divided into two segments. For slalom and jump events, the time through each segment is measured. If the times indicate that the speed through a segment is not within a certain tolerance, the run does not qualify. Furthermore, for a "record class" event, the tolerances are tighter. In major competitions, timing is accomplished with an on-board timer which responds to a magnetic buoy at the start, at the end of the first segment, and at the finish. For lesser competitions, "official" times may be obtained with a stop watch and, for on-board timing, an operator may need to press a button on the on-board timer when the boat passes a marker for the start, the end of the first segment, and the finish.
When system 10 is powered, the controller 20 loops through the software control program illustrated in block diagram form in FIG. 2. Referencing FIG. 2, as well as FIG. 1, during each loop of the software, the controller updates display 60 of panel 30 with any previously calculated indication of the current speed of the boat as well as with the last operator input set speed and the mode--i.e., slalom, jump, or trick and, for jump and slalom, regular or record class tolerances--(block 100). The controller then checks for a new set speed input by the operator (block 102). If the operator has switched the on/off button 62 to "off", the controller deactivates servo 12. If button 62 is switched to "on", the controller is enabled to control servo 12 (block 104). If the operator has pressed a certain selection of buttons 64, 66, and 68 to request re-calibration of the current set speed, the controller re-calibrates the set speed based on signals from timer 32 received during the previous run for that set speed (block 106). More particularly, a time signal is received by the controller from timer 32 at the end of each run segment. The controller has the regulation length of each segment available in memory. With this information, the controller may calculate the actual speed of the boat through the run. If this actual speed is different from the set speed, the controller applies a correction factor to the signals received from each speed sensor.
By pressing one of buttons 66 or 68, the operator may request a fine adjustment of the set speed, up or down, by 0.5 mph (block 108). Lastly, the operator may choose a new mode by an appropriate input via buttons 64, 66, and 68 (block 110). Since the mode determines the acceptable selections for the set speed as well as the speed tolerances, after the operator has input the mode and a particular set speed, the controller is ready to control the speed for the event (block 112).
When the current speed, as calculated by the controller, attains a pre-defined speed below the set speed (for example, 25 mph), the controller activates the servo motor to pay out cable 18 so that abutment nut 46 moves to a ready position a pre-defined distance from bracket 38 (block 114). The servo motor 12 allows the controller to accurately position the abutment nut 46 a known distance from bracket 38. The operator will sense the movement of the abutment nut 46 as a lag in acceleration as the hand throttle is pulled back.
When the boat has accelerated to a speed slightly greater than the pre-set speed, controller 20 senses an audible and/or visible indication to the operator indicating that it is now in control (block 116). This is a prompt to the operator to cease moving hand throttle 50. Utilising signals from the speed sensors 24, 26, the controller determines the current speed (block 118). Based on determinations of the current speed and signals from the timer 32 (which are recognised at block 134), the controller calculates the average speed for each segment of the present run (block 120). If the current speed deviates from the preset speed, or the average speed is outside of the necessary tolerances (block 122), the controller calculates the necessary servo changes to correct the speed errors (block 124). These changes are converted to control values for the servo (block 126) and sent to the servo to make the required adjustments (block 132).
The controller normally averages the signals received from the two speed sensors in determining the current speed. However, if the difference between these signals exceeds a pre-defined limit (indicating, for example, that one is clogged with seaweed), an error condition exists and the controller sends an error message to the display 60 (block 128).
The times for each of the two segments are measured by the controller 20 based upon start and stop timing signals from the timer 32. This timer can be either a manual push button or a magnetic buoy sensor. These times are displayed by the controller during execution of block 134. Once program control passes block 134, it returns to block 100. This program loop is executed several times per second.
When in control, controller 20 may cause the servo 12 to adjust the engine throttle lever 40 to a more open or more closed position. The maximum degree to which servo 12 may open throttle lever 40 is determined by the position of abutment nut 46. That is, once bracket 38 encounters the abutment nut, the servo 12 may not further move the engine throttle lever in a throttle opening position; thus the abutment nut acts as an adjustable stop. The abutment nut also allows an operator to overcome system 10 at any time by moving the hand throttle 50 toward a throttle closing position, as follows. Should hand throttle 50 be moved forward, servo 12 would attempt to compensate by closing the gap between bracket 38 and abutment nut 46. However, once this gap has closed, it is not possible for the servo 12 to compensate for further movement of the hand throttle 50 such that the operator may thereafter effectively close the throttle. Therefore, abutment nut 46 provides an important safety feature. Of course, an operator may also overcome system 10 by pressing the on/off button 62.
The rate at which servo 12 adjusts the engine throttle lever 40 depends upon the mode selected by the operator. Where jump mode is selected, speed corrections are very aggressive. This is due to the significantly larger forces on the boat imposed by the skier through a jump run.
While the present invention has been described in conjunction with its use with a water skier behind a boat, it will be appreciated that it also has application to other situations where it is desired to operate a boat at a constant speed. In addition, the system may be applied to other vehicles equipped with speed sensors.
Modifications will be apparent to those skilled in the art and, therefore, the invention is defined in the claims.
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A speed controller for vehicle comprises speed sensors which output to a controller which in turn outputs to a servo motor. The servo is connected to the inner cable of a co-axial cable, the outer sheath of which is lodged between a buttress and the engine throttle. The distance between the buttress and the engine throttle lever is, at least when the throttle is closed, shorter than the length of the outer sheath such that the outer sheath obtains a curved configuration. The inner cable extends beyond the engine throttle lever to a support. Accordingly, when the controller operates the servo to draw in the inner cable, the outer sheath is urged to straighten and, thereby, push against the engine throttle lever to open it. Conversely, when the inner cable is paid out, the outer sheath is relaxed to allow the engine throttle lever to close.
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This application is a divisional of U.S. patent application Ser. No. 08/465,439, filed Jun. 5, 1995, now U.S. Pat. No. 5,574,088, which in turn is a Continuation-In-Part of U.S. patent application Ser. No. 08/348,715, filed Dec. 2, 1994, now abandoned.
FIELD OF THE INVENTION
The invention relates to compositions for treating a porous self-supporting support carrier, particularly a support carrier of polyester or polyamide fibers, such as nylon, to increase their resistance to oxidizing agents, such as hydrogen peroxide and sodium hypochlorite, to methods of treating such support carrier using such compositions, to a support carrier treated with the composition, and to an improvement in a process of chemically oxidizing cellulosic fiber material such as wood pulp.
BACKGROUND OF THE INVENTION
Polyamide and polyester fibers have poor resistance to oxidizing agents, particularly to sodium hypochlorite. Polyester fibers and polyamide fibers, including all grades of nylon, lose strength after being in contact with sodium hypochlorite solution for a few hours.
In the manufacture of paper from cellulosic fiber wood pulp, the pulp is subjected to bleaching to increase the whiteness or brightness of the paper subsequently produced from the pulp. In this bleaching operation the pulp is exposed to oxidizing agents such as hydrogen peroxide and sodium hypochlorite and is thereafter conveyed to a paper-making operation. In these procedures the pulp is conveyed on a porous, self-supporting carrier sheet in the form of an elongate, continuous belt, and this carrier sheet, referred to in the paper-making art as a felt, is exposed to the oxidizing or bleaching chemical.
The exposure of the carrier sheet to the oxidizing or bleaching chemical substantially lowers the useful life of the felt.
These felts which typically may be 45 to 135 meters, in length, 7 meters wide and 3 to 5 mm thick are expensive typically costing several thousand dollars. The exposure of the felts to the bleaching or oxidizing agents, so degrades the felts that their useful life is not more than 40 days in continuous operation and frequently as short as 20 days. Various solutions have been tried to overcome this problem. One is to treat the felt with chlororesorcinol or chlororesorcinol formaldehyde, or a combination of chlororesorcinol and acid dyes. This improves the resistance of the felt to chlorine to a certain extent, but it does not have a useful effect against hydrogen peroxide. Another solution that has been tried is to apply melamine formaldehyde resin to the felt; however, this treatment makes the felt very stiff.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved process for chemically oxidizing or bleaching cellulosic fiber material, such as wood pulp, in which the fiber material is supported on a carrier sheet and the fiber material and carrier sheet are exposed to oxidizing or bleaching chemical.
It is a further object of this invention to provide a method of increasing the resistance of a polyamide fiber or polyester fiber carrier sheet to oxidizing or bleaching agents.
It is a still further object of this invention to provide a porous, self-supporting carrier sheet for use in conveying cellulosic fiber material, such as wood pulp.
It is still another object of this invention to provide a composition for increasing the resistance of polyamide or polyester fibers to oxidizing or bleaching chemical.
In particular a composition is provided for treating polyester and polyamide fibers, such as nylon, in the form of felts, to increase their resistance to oxidizing agents. The composition also renders the fibers soft and prolongs the useful life of felts used in paper-making.
In accordance with one aspect of the invention there is provided in a process of chemically oxidizing cellulosic fiber material in which the fiber material is supported on a porous, self-supporting carrier sheet and the fiber material and the carrier sheet are exposed to a chemical oxidizing agent, and in which the carrier sheet is of a material deleteriously affected by the oxidizing agent, the improvement wherein said carrier sheet is pretreated with a composition which increases the resistance of the material of the carrier sheet to the oxidizing agent, said composition comprising a) an organosiloxane modified with amino groups, b) a melamine formaldehyde resin, c) a catalyst for complexing said melamine formaldehyde resin; and d) water.
In accordance with another aspect of the invention there is provided a porous, self-supporting carrier sheet for use in conveying cellulosic pulp fibers in a paper manufacture, said carrier sheet being formed of polyester or polyamide fibers, said fibers of said sheet having a coating thereon derived from interaction of said fibers with a composition comprising a) an organosiloxane modified with amino groups, b) a melamine formaldehyde resin, c) a catalyst for complexing said melamine formaldehyde resin, and d) water.
In accordance with still another aspect of the invention there is provided a method of increasing the resistance of a polyamide fiber or polyester fiber porous, self-supporting carrier sheet to oxidizing agents comprising the steps of: (a) preparing a composition comprising (i) an organosiloxane modified with amino groups; (ii) a melamine formaldehyde resin; (iii) a catalyst for complexing said melamine formaldehyde resin; and (iv) water; (b) applying said composition to said carrier sheet and (c) drying and curing said composition on the fibers of said carrier sheet.
In accordance with yet another aspect of the invention there is provided a composition for increasing the resistance of polyamide fibers or polyester fibers to oxidizing agents, comprising: (a) an organosiloxane modified with amino groups; (b) a melamine formaldehyde resin; (c) a catalyst for complexing said melamine formaldehyde resin; and (d) water.
DETAILED DESCRIPTION OF THE INVENTION
Compositions according to the invention are prepared by dissolving the melamine formaldehyde resin, the catalyst for complexing the formaldehyde resin in water and dispersing an aqueous emulsion of the organosiloxane in the water. The pH of the composition is preferably adjusted to 7 or less, more preferably to pH 5 to 6.
The preferred melamine formaldehyde resin is methylated methylol melamine formaldehyde. The preferred concentration of melamine formaldehyde resin in the composition is 30-150 g/l.
The organosiloxane modified with amino groups is insoluble in water but can be emulsified in water.
The organosiloxane employed in the invention may be represented by formula (I): ##STR1## wherein each R, which may be the same or different is lower alkyl of 1 to 4 carbon atoms or phenyl, each R 1 is lower alkyl of 1 to 4 carbon atoms, phenyl or is selected from amino and lower alkoxy of 1 to 4 carbon atoms, and R 2 and R 3 , which may be the same or different are each selected from lower alkyl of 2 to 4 carbon atoms, phenyl, lower alkoxy of 1 to 4 carbon atoms or amino, provided that at least one of R 1 , R 2 and R 3 comprises amino.
The integers m and n are subject to wide variation and effectively determine the chain length of the organosiloxane. In particular the integers m and n are selected such that the modified organosiloxane is a fluid having a viscosity at 25° C. of 10 to 3500 cs, more especially 500 to 1000 cs, and a specific gravity at 25° C. of 0.95 to 1.05. Suitably the amine content calculated as g/mol.av. is 200 to 3000, preferably 400 to 2000.
One especially preferred class of organosiloxane in the invention is that of formula (II): ##STR2## in which each R 4 and R 5 , which may be the same or different is selected from amino and lower alkoxy of 1 to 4 carbon atoms, provided that at least some of the radicals R 4 are amino; preferably at least one of the radicals R 5 is amino and m and n are as defined previously.
Another preferred class of organosiloxane in the invention is that of formula (III): ##STR3## in which R 6 is amino and n is as defined previously.
It will be observed that the organosiloxanes of formula (II) may have amino or lower alkoxy modifying groups both as side chain members and as terminal groups of the chain, whereas in formula (III) the modifying amino is a terminal group.
The organosiloxane is preferably employed in the composition of the invention in a concentration of 10-150 g/l. It is employed as an emulsion in water preferably having a solids content of 20 to 50%, by weight.
The catalyst used is one which complexes the melamine formaldehyde. Its preferred concentration is 5-30 g/l of composition. It is preferably one of the following: salts of alkaline-earth metals; aluminum chloride solution; a solution of magnesium chloride and aluminum chloride.
The composition may optionally include a fluorochemical, i.e. a carbon-based polymer containing fluorine. The preferred concentration of fluorochemical in the composition is 5-50 g/l, more preferably 5-25 g/l. The preferred solids content of the fluorochemical is 15-40% by weight.
The composition may optionally include a combination of three acid dyes, namely Acid Yellow, Acid Red and Acid Blue. The Acid Yellow dye is preferably one of the following: Acid Yellow 10, 25, 169 and 219. The Acid Red dye is preferably one of the following: Acid Red 42, 57, 337 and 361. The Acid Blue dye is preferably one of the following: Acid Blue 25, 27, 72, 258, 277 and 294. The preferred concentration of acid dyes in the composition is 0.1-0.2 g/l Acid Yellow, 0.1-0.2 g/l Acid Red and 0.01-0.03 g/l Acid Blue.
The composition can further optionally include an antiprecipitant dispersing agent. Such agent is preferably ethoxylated fatty amine or ethoxylated fatty alcohol. Its preferred concentration in the composition is 1-10 g/l.
In the method of treating the carrier sheet polyester fibers or polyamide fibers, such as nylon felts, the carrier sheet or felt is preferably immersed in a bath of the composition until the carrier sheet or felt is thoroughly wetted. Preferably between 30-200% by weight of the composition is absorbed by the carrier sheet or felt, relative to the weight of the dry carrier sheet or felt. The carrier sheet or felt is then dried and is cured at an elevated temperature, preferably 330°-350° F. Drying and curing times depend on the weight, size and nature of the carrier sheet or felt and on the solution employed.
In one embodiment of the method, an aqueous solution of three acid dyes, Acid Yellow, Acid Red and Acid Blue is prepared. The preferred concentration of the acid dyes is 0.14 g/l Acid Yellow, 0.14 g/l Acid Red and 0.014 g/l Acid Blue. The felt is immersed in this solution, dried, and then immersed in a bath of the composition as described above. The felt is then dried and cured as described above.
The support carrier sheet may be woven or non-woven and is formed from polyester or polyamide fibers, usually polyamide fibers such as nylon.
The support carrier sheet is porous and will permit water to escape therethrough. In some woven support carrier sheets the weave is relatively open so that small openings between adjacent fibers or yarns of the weave are visible to the naked eye.
The carrier sheet or felt is self-supporting by which is to be understood that the sheet or felt is semi-rigid and maintains its generally planar configuration when supported at a single point, without bending or folding. On the other hand, the sheet or felt has sufficient flexibility that it can be manipulated manually, for example, it may be folded on itself, however, on removal of the manipulating force it resumes its original configuration or can be readily manipulated to restore the original configuration.
The sheet or felt is thus quite different in nature from a cloth or textile employed in garment manufacture.
The sheet or felt is relatively incompressible and typically has a length of at least 40 meters, suitably 45 to 135 meters, and a thickness of at least 2 mm, typically 3 to 5 mm.
Especially preferred open weave felts are of polyamide fiber, particularly Nylon 6 and are formed by 15 denier fibers grilion and have a weight of about 1400 gm/m 2 . Finer felts are of 3 to 4 denier fiber and weigh about 1200 g/m 2 .
In general the felts are of 3 to 15 denier fiber and have a weight of 1000 to 1500 g/m 2 .
In the invention amino groups of the modified organosiloxane react with hydroxyl groups of the polyester or polyamide providing a softening effect whereas the melamine formaldehyde resin produces cross-linking which results in rigidity. Amino groups of the polyester or polyamide may be blocked with the acid dyes.
The following examples describe testing of fibers treated with prior art compositions and with compositions according to the invention.
In these examples the organosiloxane employed was of the class of formula (II) hereinbefore having a viscosity at 25° C. of 750 cs, a specific gravity at 25° C. of 0.98 and having a function group equivalent of amino and lower alkoxy groups of 1,900.
EXAMPLE 1
A 15 denier fiber of Nylon 6 was tested for break point and for elongation using an Instron model 1130 (trademark) testing machine. The break point was determined to be 80 g and the elongation 59.7%.
The same fiber was immersed in 3% hydrogen peroxide solution for 75 hours at 175° F., then rinsed, dried and tested as above.
______________________________________Result:______________________________________BREAK 71.4 gELONGATION 47.5%RETAINED STRENGTH 89.2%RETAINED ELONGATION 79.5%______________________________________
The same fiber was immersed in a 10% sodium hypochlorite solution for 75 hours at 175° F., then rinsed, dried and tested as above.
______________________________________Result:______________________________________BREAK 32.6 gELONGATION 22.2%RETAINED STRENGTH 40.8%RETAINED ELONGATION 37.2%______________________________________
EXAMPLE 2
A fiber as in Example 1 was immersed in a solution containing 15 g/l Mesitol NBS (novolak resin) and 35 g/l chlororesorcinol. The pick-up (weight of solution absorbed to weight of dry fiber) was 50%. The fiber was rinsed and dried. The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 78.3 gELONGATION 52.9%RETAINED STRENGTH 97.8%RETAINED ELONGATION 88.6%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 28 gELONGATION 22%RETAINED STRENGTH 35%RETAINED ELONGATION 36.8%______________________________________
EXAMPLE 3
A fiber as in Example 1 was immersed in a solution containing three acid dyes: 0.14 g/l Acid Yellow, 0.14 g/l Acid Red and 0.014 g/l Acid Blue. The pH was adjusted to 5. The pick-up was 50%. The fiber was then immersed in a second bath as in Example 2. The pick-up was 50%. The fiber was rinsed and dried. The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 76.8 gELONGATION 46%RETAINED STRENGTH 96%RETAINED ELONGATION 77%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 28.7 gELONGATION 24.5%RETAINED STRENGTH 35.8%RETAINED ELONGATION 41%______________________________________
EXAMPLE 4
A fiber as in Example 1 was immersed in a bath containing 15 g/l Mesitol NBS and 35 g/l sulfonated resol resin. The pick-up was 50%. The fiber was dried.
The treated fiber was tested after immersion in hydrogen peroxide solution in accordance with Example 1.
______________________________________BREAK 67.5 gELONGATION 38.2%RETAINED STRENGTH 84.3%RETAINED ELONGATION 64%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution in accordance with Example 1.
______________________________________BREAK 34.6 gELONGATION 25.9%RETAINED STRENGTH 43.2%RETAINED ELONGATION 43.3%______________________________________
EXAMPLE 5
A fiber as in Example 1 was treated with the three acid dyes as in Example 3. It was then immersed in a bath containing 15 g/l Mesitol NBS and 35 g/l sulfonated resol resin at pH 5. Pick-up was 50%. The fiber was dried.
The treated fiber was tested after immersion in hydrogen peroxide solution in accordance with Example 1.
______________________________________BREAK 57 gELONGATION 34.7%RETAINED STRENGTH 71.2%RETAINED ELONGATION 58.1%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution in accordance with Example 1.
______________________________________BREAK 34 gELONGATION 27.5%RETAINED STRENGTH 42.5%RETAINED ELONGATION 46%______________________________________
EXAMPLE 6
A second sample of 15 denier fiber of Nylon 6 having the same break point and elongation as in Example 1 was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 72 gELONGATION 47%RETAINED STRENGTH 90%RETAINED ELONGATION 78.7%______________________________________
The fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 50 gELONGATION 32%RETAINED STRENGTH 62.5%RETAINED ELONGATION 53.6%______________________________________
EXAMPLE 7
A fiber as in Example 6 was immersed in a solution containing 35 g/l chlororesorcinol and 15 g/l sulfonated resol resin at pH 5. The pick-up was 50%. The fiber was dried.
The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 44 gELONGATION 30%RETAINED STRENGTH 55%RETAINED ELONGATION 50.2%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 81.6 gELONGATION 60.6%RETAINED STRENGTH 102%RETAINED ELONGATION 101.5%______________________________________
EXAMPLE 8
A fiber as in Example 6 was immersed in a bath containing 35 g/l chlororesorcinol and 15 g/l sulfonated resol resin. The fiber was dried and then immersed in a bath containing 100 g/l melamine resin, 20 g/l catalyst and 35 g/l fluorochemicals. It was then dried and cured at 350° F. for 90 seconds.
The treated fiber was tested in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 41 gELONGATION 28%RETAINED STRENGTH 51.2%RETAINED ELONGATION 46.9%______________________________________
The treated fiber was tested in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 74.4 gELONGATION 56.8%RETAINED STRENGTH 93%RETAINED ELONGATION 95.1%______________________________________
EXAMPLE 9
A third sample of 15 denier fiber of Nylon 6 having a break point of 75.6 g and an elongation of 72.6% was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 67.6 gELONGATION 63.0%RETAINED STRENGTH 89.4%RETAINED ELONGATION 86.7%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 56.8 gELONGATION 53.5%RETAINED STRENGTH 75.1%RETAINED ELONGATION 73.6%______________________________________
EXAMPLE 10
A fiber as in Example 9 was immersed in a solution of 100 g/l melamine resin and 20 g/l catalyst. The pick-up was 50%. The fiber was dried and cured at 330° F. for 90 seconds.
The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 71.6 gELONGATION 65.6%RETAINED STRENGTH 94.7%RETAINED ELONGATION 90.3%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 62.5 gELONGATION 52.2%RETAINED STRENGTH 82.6%RETAINED ELONGATION 71.9%______________________________________
EXAMPLE 11
A fiber as in Example 9 was immersed in a bath containing 70 g/l melamine resin, 20 g/l catalyst, 25 g/l fluorochemical and 50 g/l organosiloxane. It was dried and cured at 350° F. for 90 seconds.
The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 75 gELONGATION 82%RETAINED STRENGTH 99.2%RETAINED ELONGATION 112.9%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 65.6 gELONGATION 51.1%RETAINED STRENGTH 86.7%RETAINED ELONGATION 70.4%______________________________________
EXAMPLE 12
A fiber as in Example 9 was immersed in a bath containing three acid dyestuffs, 100 g/l melamine resin, and 20 g/l catalyst. Pick-up was 50%. The fiber was dried and then cured at 330° F. for 90 seconds. The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 74.9 gELONGATION 81.1%RETAINED STRENGTH 99.1%RETAINED ELONGATION 111.7%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 61 gELONGATION 45.2%RETAINED STRENGTH 80.6%RETAINED ELONGATION 62.2%______________________________________
EXAMPLE 13
A fiber as in Example 9 was immersed in a solution of acid dyes as in Example 3. It was then dried and immersed in a bath containing 100 g/l melamine resin, 20 g/l catalyst and 50 g/l organosiloxane. It was dried and then cured at 330° F. for 90 seconds. The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 72.8 gELONGATION 95.4%RETAINED STRENGTH 96.2%RETAINED ELONGATION 131.4%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 69.4 gELONGATION 70.7%RETAINED STRENGTH 91.7%RETAINED ELONGATION 97.3%______________________________________
EXAMPLE 14
A fourth sample of 15 denier fiber of Nylon 6 having a break point of 86 g and an elongation of 68% was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 78 gELONGATION 69%RETAINED STRENGTH 90.6%RETAINED ELONGATION 101.4%______________________________________
The same fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 52 gELONGATION 34%RETAINED STRENGTH 60.4%RETAINED ELONGATION 50%______________________________________
EXAMPLE 15
A fiber as in Example 14 was immersed in a bath containing 100 g/l melamine resin, 20 g/l catalyst, 35 g/l fluorochemicals and 50 g/l organosiloxane. The pick-up was 50%. The fiber was dried and cured. The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 76 gELONGATION 81%RETAINED STRENGTH 82.3%RETAINED ELONGATION 119.1%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 62 gELONGATION 50%RETAINED STRENGTH 72%RETAINED ELONGATION 73.5%______________________________________
EXAMPLE 16
A fiber as in Example 14 was immersed in a solution containing three acid dyes as in Example 3 at pH 4. The pick-up was 50%. The fiber was dried. The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 79.3 gELONGATION 68%RETAINED STRENGTH 92.2%RETAINED ELONGATION 100%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 45 gELONGATION 34%RETAINED STRENGTH 52.3%RETAINED ELONGATION 50%______________________________________
EXAMPLE 17
A fiber as in Example 14 was treated with three acid dyes as in Example 16. It was then dried and immersed in a bath containing 100 g/l melamine resin, 20 g/l catalyst, 25 g/l fluorochemicals and 50 g/l organosiloxane. The treated fiber was tested after immersion in hydrogen peroxide solution as in Example 1.
______________________________________BREAK 81.2 gELONGATION 88%RETAINED STRENGTH 94.4%.RETAINED ELONGATION 129.4%______________________________________
The treated fiber was tested after immersion in sodium hypochlorite solution as in Example 1.
______________________________________BREAK 72 gELONGATION 65%RETAINED STRENGTH 83.7%RETAINED ELONGATION 95.5%______________________________________
EXAMPLE 18
A polyester filament is treated in a bath as in Example 15. The fiber is dried and cured. It is tested after immersion in hydrogen peroxide solution and sodium hypochlorite solution as in Example 1, with good results.
It was observed from the tests that treating the nylon fiber with chlororesorcinol, sulfonated novolak resin or sulfonated resol resin, or combinations of these three products, or with the three acid dyes, did not give satisfactory results. It was also observed that treatment with melamine resin alone or with the addition of fluorochemicals increased the stiffness of the fibers, did not give optimum resistance to oxidizing agent, and also created some degree of water repellency on the nylon felt. The polyamide and polyester fibers treated with the compositions claimed herein had good resistance to hydrogen peroxide and sodium hypochlorite and were soft and elastic.
Carrier supports or felts treated with the composition of the invention still have a useful working life even after 180 days continuous operation, a marked improvement over the maximum of 40 days achieved in the prior art.
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A composition for increasing the resistance of polyamide fibers or polyester fibers to oxidizing agents comprising an organosiloxane modified with amino groups, melamine formaldehyde resin, a catalyst for complexing the melamine formaldehyde resin and water. The composition is used by applying it to the fibers so the fibers absorb the composition, and then drying and curing the composition on the fibers. The composition is employed to treat a polyester or polyamide felt employed to convey wood pulp which is to be bleached, prior to paper making operations, treatment of the felt with the composition significantly lengthens the useful life of the felt, exposed to bleaching chemicals.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to improvements in air filtration, and more particularly, but not by way of limitation, to improved fin structure for air filters having a centrifugal pre-cleaner stage.
2. Description of the Prior Art
It is well known in the prior art to provide air cleaner assemblies for internal combustion engines or the like which employ a cyclonic or centrifugal pre-cleaner stage prior to the introduction of the incoming air through the conventional paper filter element. In these assemblies, unitary molded plastic fin structures, of substantially cylindrical shape, are disposed about the cylindrical outer periphery of a conventional air filter element. These fin structures are further characterized by a plurality of circumferentially spaced, diagonal fins or vanes mounted on the cylindrical outer periphery thereof which extend across an annular space or chamber defined by the exterior of the filter element and the inner wall of the filter housing within which the filter element is mounted.
In the assembly of the prior art fin structures upon the corresponding filter elements, it is common for the molded plastic fin structures to crack or split in the event of misalignment between the fin structure and the filter element when the fin structure is forced over the end cap of the filter element. It is also virtually impossible to remove and reuse a prior art fin structure from a filter element upon which it as been assembled when the filter element must be renewed or replaced, thus increasing the cost of filter element replacement to the manufacturer and the consumer. It is also common for replacement filter elements, with prior art fin structures assembled thereto, to be mishandled between the manufacturer and time of installation in an air cleaner assembly to the extent that one or more fins may be broken from the filter element or, in more extreme cases, the fin structure may become split and thereby become permanently disengaged from the filter element, thus rendering the replacement filter element useless for its intended purpose.
The prior art fin structures are also relatively bulky to store in the manufacturer's warehouse thus increasing storage costs which cost increases must ultimately be borne by the consumer.
The various embodiments of the present invention overcome these deficiencies in the prior art and provide many advantages thereover.
SUMMARY OF THE INVENTION
The present invention contemplates an improved fin structure for installation about the substantially cylindrical outer periphery of an air filter element of the type having a radially outwardly extending rib formed about the outer periphery thereof. The fin structure comprises a substantially cylindrical body portion having a cylindrical outer surface, a cylindrical inner surface, an upper end face and a lower end face, with the inner and outer surfaces defining a relatively thin cylindrical wall. Fins extend radially outwardly from the outer surface of the body portion for directing the flow of air passing thereby. Bosses extend radially inwardly from the inner surface of the body portion for engaging the rib of the air filter element to limit longitudinal movement of the fin structure in one direction relative to the air filter element. At least one generally U-shaped aperture extends through the wall of the body portion thereby defining a corresponding resilient cantilevered lock tab having a radially inwardly extending lip on the free end thereof for engaging the rib of the air filter element to limit longitudinal movement of the fin structure in the opposite direction relative to the filter element.
In another form, the present invention contemplates a fin structure for installation about the cylindrical outer surface of a conventional air filter element in which the fin structure comprises a relatively thin strip having first and second parallel longitudinal edgs interconnecting opposite end portions thereof and having inner and outer side walls. The fin structure further includes a plurality of outwardly projecting fins formed on the outer side wall. Means are formed on the inner side walls for engaging the outer surface of the air filter element to secure the fin structure thereto. The fin structure further includes first and second coupling means formed respectively on the opposite end portions of the stip for mutually engaging the opposite end portions to secure the strip about the outer surface of the filter element with the fins extending radially outwardly therefrom.
An advantage of the present invention resides in the provision thereby of increased efficiency in air filtration.
Another advantage of the present invention resides in the provision thereby of simplified and trouble free installation of fin structures on filter elements.
A further advantage of the present invention resides in the provision thereby of a fin structure suitable for construction with economical materials.
A still further advantage of the present invention resides in the provision thereby of a fin structure which reduces manufacturing and storage costs.
Yet another advantage of the present invention resides in the provision thereby of a fin structure which is reusable on replacement filter elements.
Another advantage of the present invention resides in the provision thereby of a fin structure which is less susceptible to breakage during the assembly thereof on a filter element.
Other objects and advantages of the present invention will be evident from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a filter assembly with a centrifugal pre-cleaning stage showing portions of the housing, filter element and improved fin structure of the present invention broken away to more clearly illustrate the details of construction.
FIG. 2 is a side elevation view of an improved fin structure constructed in accordance with the present invention.
FIG. 3 is a top plan view of the fin structure of FIG. 2.
FIG. 4 is an enlarged partial cross-sectional view taken along line 4--4 of FIG. 3 illustrating the technique for releasing the lock tabs for removal of the fin structure from a filter element.
FIG. 5 is an enlarged partial cross-sectional view, similar to FIG. 4, illustrating the condition of the lock tabs relative to the filter element both during installation and removal of the fin structure therefrom.
FIG. 6 is a side elevation view of an alternate form of improved fin structure constructed in accordance with the present invention prior to its assembly into a substantially cylindrical configuration.
FIG. 7 is a top plan view of the fin structure of FIG. 6.
FIG. 8 is a partial top plan view of the fin structure of FIG. 6 assembled into a substantially cylindrical configuration.
FIG. 9 is partial side elevation view of the fin structure as shown in FIG. 8 illustrating the details of engagement between the opposite end portions thereof.
FIG. 10 is a partial top plan view of a fin structure similar to that illustrated in FIG. 8 showing another form of engagement between the opposite end portions thereof.
FIG. 11 is a partial top plan view similar to FIG. 10 illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 12 is a partial top plan view similar to FIG. 10 illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 13 is a partial top plan view similar to FIG. 10 illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 14 is a partial top plan view similar to FIG. 10 illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 15 is a partial top plan view similar to FIG. 10 illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 16 is a partial side elevation view illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 17 is a cross-sectional view taken along line 17--17 of FIG. 16.
FIG. 18 is a partial side elevation view illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 19 is a cross-sectional view taken along line 19--19 of FIG. 18.
FIG. 20 is a cross-sectional view similar to FIG. 19 illustrating a slight variation in structure.
FIG. 21 is a partial top plan view similar to FIG. 10 illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 22 is a partial side elevation view taken along line 22--22 of FIG. 21.
FIG. 23 is a partial side elevation view illustrating another form of engagement between the opposite end portions of the fin structure.
FIG. 24 is a cross-sectional view taken along line 24--24 of FIG. 23.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, the present invention is directed to improvements in air filters suitable for use with internal combustion engines. An important advance in the field of internal combustion air filter designs is embodied in the combination of a cyclone or centrifugal pre-cleaning stage prior to the introduction of the air through a conventional paper filter. One such apparatus typical of the combination of centrifugal pre-cleaning and paper filtration is illustrated in FIG. 1 and the apparatus is generally designated by the reference character 10.
The apparatus 10 includes an air inlet passage 12 and an air outlet passage 14 each communicating with a housing 16. The air inlet passage 12 communicates with an annular chamber or space 18 defined by the housing 16 and conventional cylindrically shaped paper filter element 20 positioned concentrically within the housing 16. The interior 22 of the filter element 20 communicates with the air outlet passage 14. An annular seal 24 provides sealing engagement between the filter element 20 and the entrance to the air outlet passage 14. The filter element 20 further includes an end cap 26 which is fixedly secured to one end of the perforated cylindrical outer wall 28 of the filter element adjacent the annular seal 24.
A dust cup 30 is removably secured to the housing 16 and is separated from the interior of the housing by means of a baffle plate 32. A slot or port 34 is formed in the baffle plate 32 and provides communication between the annular space 18 and the interior of the dust cup 30. A suitable valve 36 is mounted in the lower portion of the dust cup 30 to provide for removal of dust which has become deposited within the dust cup 30.
To provide for the centrifugal or cyclone pre-cleaning of air passing through the apparatus 10, a fin structure 40 is disposed about the filter element 20 in the annular space or chamber 18. The fin structure may be formed of any suitable material. It has been found that a plastic or synthetic resinous material is well adapted for this purpose, molded polypropylene being a preferred material.
The fin structure 40 is of novel construction and provides distinct advantages over known prior art fin structures. The fin structure 40 includes a substantially cylindrical body portion 42 having a substantially cylindrical outer surface 44, a substantially cylindrical inner surface 46, an upper end face 48 and a lower end face 50 as best shown in FIGS. 2, 3, 4 and 5. The inner and outer surfaces 46 and 44 define a relatively thin cylindrical wall.
A plurality of fins 52 extend radially outwardly from the outer surface 44 of the body portion 42 in circumferentially spaced relation adjacent the lower end face 50. The fins 52 are inclined at an angle to the longitudinal axis of the body portion 42 and extend across the annular space or chamber 18 in the housing 16 to direct the flow of air passing thereby into a high-speed rotation within the annular chamber 18 to thereby separate a large portion of any dust entrained in the air by centrifugal action. Such dust particles are directed toward the inside wall of the housing 16 and fall by gravity downwardly through the slot or port 34 into the dust cup 30.
The fin structure 40 further includes a plurality of circumferentially spaced, radially inwardly extending bosses 54 formed on the inner surface 46 adjacent the upper end face 48 of the body portion 42. The bosses 54 engage the upper end face of the end cap 26 of filter element 20 as shown in FIG. 4 to longitudinally position the fin structure 40 relative to the filter element 20 and prevent longitudinal displacement of the fin structure 40 downwardly relative to the filter element 20 as viewed in FIG. 4.
A plurality of circumferentially spaced U-shaped apertures 56 extend through the cylindrical wall of the body portion 42 along a line lying in a plane parallel to and intermediate the planes defined by the upper and lower end faces 48 and 50 of the body portion 42. Each aperture 56 defines an upwardly extending corresponding resilient cantilevered lock tab 58. The opposite ends of each U-shaped aperture 56 are preferably defined by an enlargement 60 having a diameter approximately two times the width of the remainder of the U-shaped aperture. The upper end portion of free end 62 of each lock tab 58 includes a radially inwardly extending lip 64 for engaging the lower edge of the end cap 26 of the filter element 20. The lip 64 is biased radially inwardly by the inherent spring action of the resilient lock tab 58 in the engagement of the lip 64 with the end cap 26, which cap essentially forms an annular rib about the cylindrical outer wall 28 of the filter element 20, and prevents any undesired longitudinal displacement of the fin structure 40 relative to the filter element 20 in an upward direction as viewed in FIGS. 1 and 4. The lip 64 comprises a radially inwardly extending ledge 66 and an inclined inner surface 68 extending between the inner edge 70 of the ledge 66 and the intermediate portion of the lock tab 58 at a distance from the ledge 66.
The novel configuration of the lock tabs 58 facilitates the quick and secure assembly of the fin structure 40 about the end cap 26 of a corresponding filter element 20. The inherent resilience of the lock tabs 58 permit the lock tabs to be deflected radially outwardly as shown in FIG. 5 to permit the passage of the end cap 26 thereby as the fin structure and filter element are moved longitudinally together about their coaxial cylindrical axes. When the lips 64 of the lock tabs 58 clear the lower edge of the end cap 26, the lock tabs 58 spring radially inwardly at which point the ledges 66 are properly positioned to prevent the inadvertent removal of the fin structure 40 from the filter element 20.
When it is desired to remove the fin structure 40 from a filter element 20 so that a new filter element can be installed and the old fin structure can be reused, it will be seen that by inserting the blade of a screwdriver or the like through the U-shaped aperture 56 adjacent the upper end portion 62 of the lock tab 58, the lip 64 can be pried radially outwardly until it will clear the end cap 26. By proceeding sequentially around the fin structure 40 to release each lock tab 58 as described, the fin structure 40 can be freed to slide upwardly in an unrestricted manner from engagement with the old filter element 20.
It should further be noted that the use of the improved fin structure 40 with the resilient lock tabs 58 eliminates the relative frequency of breakage of fin structures constructed in accordance with the prior art when installing them on filter elements, especially when installing them on filter elements of relatively small diameter. It will also be noted that this improved fin structure of the present invention permits the use of less expensive plastic or synthetic resin materials in the molding or forming of the fin structure since the elongation characteristics of the material employed in the construction of the fin structure of the present invention are not nearly as critical as they are in the prior art fin structures. The improved fin structure 40 is well adapted to be molded from the unitary mass of plastic or synthetic resin material, one such suitable material being polypropylene.
Referring now to FIGS. 6, 7 and 8, an alternate form of fin structure constructed in accordance with the present invention is shown therein which is generally designated by the reference character 40a. The fin structure 40a differs from the previously described fin structure 40 in that the fin structure 40a is constructed in the form of an elongated strip which is assembled into a generally cylindrical configuration at the end of installation of the fin structure 40a on the corresponding filter element 20. The previously described fin structure 40, in contrast, is initially molded in the generally cylindrical configuration described above and illustrated in FIGS. 2-5.
The fin structure 40a is preferably formed of a unitary mass of plastic or synthetic resin material such as polypropylene. The structure includes a relatively thin strip 72 having first and second parallel longitudinal edges 74 and 76 and opposite end portions 78 and 80. The strip 72 includes an inner side wall 82 and an outer side wall 84. A plurality of outwardly projecting diagonal fins 86 are formed on the outer side wall 84 adjacent the longitudinal edge 74 in spaced relation.
The fin structure 40a further includes a plurality of longitudinally spaced, outwardly extending bosses or tabs 88 formed on the inner side wall 82 adjacent the longitudinal edge 76 of the strip 72. A plurality of longitudinally spaced U-shaped apertures 90 extend through the strip 72 along a line substantially parallel to and intermediate the longitudinal edges 74 and 76. Each aperture 90 defines an upwardly extending corresponding resilient cantilevered lock tab 92. The opposite ends of each U-shaped aperture 90 are preferably defined by an enlargement 94 having a diameter proximately two times the width of the remainder of the U-shaped aperture. The upper end portion or free end 96 of each lock tab 92 includes a lip 98 which extends outwardly from the plane of the inner side wall 82 for engaging the lower end of the end cap 26 of the filter element 20 as will be described hereinafter. The lip 98 is biased into its outwardly extending portion by the inherent spring action of the resilient lock tab 92 in the engagement of the end cap 26. The lip 98 comprises an outwardly extending ledge 100 and an inclined inner surface 102 which extends between the outermost edge 104 of the ledge 100 and the intermediate portion of the lock tab 92 at a distance from the ledge 100.
The novel configuration of the lock tabs 92 is substantially identical to the lock tabs 58 described above for the fin structure 40 and facilitates the quick and secure assembly of the fin structure 40a about the end cap of a corresponding filter element 20 as will be described hereinafter.
The fin structure 40a is assembled for installation on an air filter element by bending the strip 72 into a cylindrical configuration as shown in FIG. 8 and mutually securing the end portions 78 and 80 of the strip 72 by suitable coupling means. One form of suitable coupling means is illustrated in FIGS. 6, 7 and 8 and comprises an outwardly extending rib 106 formed on the outer side wall 84 along the end portion 78 in substantially normal alignment with the longitudinal edges 74 and 76, and a corresponding groove 108 communicating with the inner side wall 82 along the end portion 80 in substantially normal alignment with the longitudinal edges 74 and 76. The rib 106 is substantially wedge-shaped in cross-section with the edges thereof diverging from the outer side wall 84 as best shown in FIGS. 7 and 8. The groove 108 is also wedge-shaped in cross-section with the edges thereof diverging from the inner side wall 82. The grooe 108 is sized and shaped to securely receive the rib 106 therein, as shown in FIG. 8, to retain the rib therein and to provide mutual engagement between the opposite end portions 78 and 80 of the strip 72 to retain the fin structure 40a in the assembled position as shown in FIG. 8.
When the fin structure 40a is assembled as shown in FIG. 8, the fin structure is then ready for assembly about the end cap 26 of a corresponding filter element 20. The inherent resilience of the lock tabs 92 permit the lock tabs to be deflected radially outwardly, in the same manner as described above and shown in FIG. 5, to permit the passage of the end cap 26 thereby as the fin structure 40a and the filter element 20 are moved longitudinally together about their coaxial cylindrical axes. When the lips 98 of the lock tabs 92 clear the lower edge of the end cap 26, the lock tabs 92 spring radially inwardly at which point the ledges 100 are properly positioned to prevent the inadvertent removal of the fin structure 40a from the filter element 20.
As with the previously described fin structure, when it is desired to remove the fin structure 40a from a filter element 20 so that a new filter element can be installed and the old fin structure can be reused, the previously described technique of inserting the blade of a screwdriver or the like through the U-shaped apertures 90 adjacent the upper end portions 96 of the lock tabs 92 to pry the lips 98 radially outwardly until they clear the end cap can be employed. It should further be noted that the use of the improved fin structure 40a with the resilient lock tabs 92 substantially eliminates the relative frequency of breakage of fin structures constructed in accordance with the prior art when installing them on filter elements. Also the improved fin structure 40a permits the use of less expensive plastic or synthetic resin materials in the molding or forming of the fin structure as noted above for the fin structure 40. An additional advantage of the fin structure 40a resides in the fact that required storage space for the various sizes of fin structures can be greatly reduced by storing the fin structues in the elongated, flat state illustrated in FIGS. 6 and 7.
FIGS. 10-24 illustrate a number of variations of coupling means which may be employed in the fabrication of the fin structure 40a to mutually secure the opposite end portions 78 and 80 to achieve the generally cylindrical configuration illustrated in FIG. 8. In FIG. 10, it will be seen that a first bight portion 110 is formed along the end portion 80 and is substantially C-shaped in cross-section and extends outwardly from the outer side wall 84 of the strip 72. A second bight portion 112 is formed along the opposite end portion 78 of the strip 72 and is also substantially C-shaped in cross-section and extends outwardly from the inner side wall 82 of the strip 72. The first and second bight portions 110 and 112 are sized and shaped to mutually engage one another as shown in FIG. 10 and thereby mutually engage the opposite end portions 78 and 80 of the strip 72. The bight portion 112 is preferably offset from the strip 72 proximate its line of mutual engagement with the first bight portion 110 to maintain the generally cylindrical configuration of the strip 72 as so assembled.
FIG. 11 illustrates a slight variation in coupling means which is substantially similar to that described above and shown in FIG. 10. The slightly modified first bight portion 110a and the slightly modified second bight portion 112a of FIG. 11 are additionally maintained in mutual engagement with one another by means of a resilient lip 114 also formed along the end portion 80 of the strip 72 and extending from the outer side wall 84 a distance beyond the first bight portion 110a. The lip 114 is sized and shaped to yieldably engage the outer surface of the second bight portion 112a when the first and second bight portions are mutually engaged to maintain the fin structure in assembled condition.
The coupling means illustrated in FIG. 12 is another variation of the coupling means described above and illustrated in FIG. 11. FIG. 12, the bight portion 110b is formed along the end portion 80 of the strip 72 and is substantially C-shaped in cross-section and extends in a direction substantially outwardly from the inner side wall 82 and curves in a counterclockwise direction as viewed in FIG. 12. The second bight portion 112b formed along the end portion 78 is also C-shaped in cross-section and extends outwardly from the outer side wall 84 and curves in a counterclockwise direction as viewed in FIG. 12. The coupling means of FIG. 12 further includes a resilient lip 114b formed along the end portion 80 and extending from the inner wall 82 a distance beyond the bight portion 110b, the resilient lip 114b being so sized and shaped as to yieldably engage the exterior surface of the bight portion 112b when the bight portions 110b and 112b are mutually engaged to maintain the fin structure in assembled condition.
The coupling illustrated in FIG. 13 is substantially identical to that previously described and illustrated in FIG. 11 with the exception that the mutually engaging surfaces of the slightly modified bight portions 110c and 112c are in the form of mutually engaged knife edges and the resilient lip is omitted.
The coupling means illustrated in FIG. 14 is characterized by a modified bight portion 110d formed on the end portion 80 which is substantially C-shaped in cross-section and extends outwardly from the inner side wall 82 while the slightly modified bight portion 112d formed along the end portion 78 is substantially C-shaped in cross-section and extends outwardly from the outer side wall 84. The mutually engaging surfaces of the bight portions 110d and 112d are in the form of oppositely directed knife edges.
The coupling means illustrated in FIG. 15 is a slightly modified version of the coupling means described above and illustrated in FIGS. 6, 7 and 8. A modified rib 106a is formed along the end portion 78 and extends outwardly from the outer side wall 84. The rib 106a is substantially cylindrical in cross-section. A corresponding modified groove 108a is formed along the end portion 80 and is sized and shaped to receive and retain the rib 106a therein to mutually interconnect the opposite end portions 78 and 80 to maintain the fin structure in assembled condition.
FIGS. 16 and 17 illustrate another form of coupling means. As illustrated therein, a pair of apertures 116 are formed in spaced relation through the strip 72 at the end portion 78 thereof. A corresponding pair of protuberances 118 are formed on the end portion 80 of the strip 72 and extends outwardly from the outer side wall 84. The protuberances 118 each include a conically shaped enlargement 120 formed on the outer end thereof. Mutual engagement is achieved between the end portions 78 and 80 by inserting the protuberances 118 into the corresponding apertures 116. The enlargements 120 prevent the retraction of the protuberances 118 from the apertures 116 after interconnection thereby maintaining the fin structure in the assembled condition. The end portions 78 adjacent the apertures 116 is preferably offset as shown in FIG. 17 to achieve a substantially cylindrical inner surface along the inner side wall 82. The use of relatively resilient plastic or synthetic resin material for the construction of the fin structure permits the temporary deformation of the apertures 116 and the enlargements 120 during the engagement process.
FIGS. 21 and 22 illustrate a variation of the coupling means described above and illustrated in FIGS. 16 and 17. The coupling means of FIGS. 21 and 22 includes a plurality of substantially rectangular apertures 116a formed through the strip 72 adjacent the portion 80. A corresponding plurality of protuberances 118a are formed along the end portion 78 and extend outwardly from the outer side wall 84. The protuberances 118a are substantially circular in horizontal cross-section and are preferably molded in the form of cylinders in substantial normal alignment with the longitudinal edges 74 and 76 of the strip 72. The vertical length of each aperture 116a is slightly greater than the vertical length of the corresponding protuberance 118a while the horizontal width of each aperture 116a is slightly less than the diameter of the corresponding cylindrically shaped protuberance 118a. It will be seen in FIG. 21 that the configuration of the protuberances results in an enlargement being formed thereby at a distance outwardly from the outer side wall 84. To assemble the fin structure, the protuberances 118a are engaged with and snapped into the corresponding apertures 116a, the diameter of each protuberance being in excess of the width of each corresponding aperture maintains the protuberances and apertures in mutual engagement thus retaining the fin structure in assembled condition.
FIGS. 23 and 24 illustrate another variation of the coupling means for securing the opposite ends 78 and 80 of the strip 72 in assembled condition. In this configuration, a pair of apertures 122 are formed through the strip 72 adjacent the end portion 80 thereof. A pair of wing-like diverging protuberances 124 extend outwardly from the inner side wall 82 adjacent the end portion 78 of the strip 72. The protuberances 124 are preferably lanced from the strip 72 and are relatively resilient. To interconnect the end portions 78 and 80, the protuberances 124 are squeezed together against their inherent resilience and inserted in the respective apertures 122. The protuberances are then released and allowed to spring back to their original position thereby securing the end portions 78 and 80 in mutual engagement thus placing the fin structure in assembled condition.
FIGS. 18 and 19 illustrate another variation in coupling means for mutually securing the opposite end portions 78 and 80. The coupling means includes three hook members 126 formed in spaced relation on and extending from the end portion 78 of the strip 72. Each hook member 126 includes a cavity 128 opening downwardly, as viewed in FIG. 18, in a direction substantially normal to the longitudinal edges 74 and 76 of the strip 72. Three corresponding protuberances 130 are formed on the end portion 80 and extend outwardly from the outer side wall 84. The cavities 128 of each hook member 126 and the protuberances 130 are so sized and shaped that each protuberance 130 is securely received within the corresponding cavity 128 to mutually engage one another and thereby mutually engage the opposite end portions 78 and 80 of the strip 72 to assemble the fin structure. The diameter of each protuberance 130 is preferably slightly greater than the downwardly directed opening of each corresponding cavity 128 to provide snap engagement between each protuberance and the corresponding cavity in which it is received. The hook members 126 are preferably offset as shown in FIG. 19 to provide a substantially cylindrical inner surface formed by the inner side wall 82 of the strip 72 when the fin structure is assembled.
FIG. 20 shows a slight variation of the coupling means described above and illustrated in FIGS. 18 and 19, differing only in the addition of an enlargement 132 formed on the outer end of each slightly modified protuberance 130a.
From the foregoing it will be seen that the present invention provides a number of forms of novel fin structure for installation on the filter element of an air filter assembly of the type which provides a cyclonic or centrifugal pre-cleaning stage prior to the introduction of the air through the filter element. The various forms of the invention described above and shown in the drawings provide distinct advantages over the prior art in economy of manufacture, material cost, storage cost, ease of assembly and reduction or breakage.
Changes may be made in the construction and arrangement of parts or elements of various embodiments as disclosed herein without departing from the spirit and scope of the invention as defined in the following claims.
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An improved unitary fin structure for installation on the filter element of an air pre-cleaner and final filter for an internal combustion engine or the like. The improved fin structure includes self-biased lock tab elements forming an integral part thereof for securing the fin structure to a conventional air filter element while providing means for the non-destructive removal thereof from the filter element. An alternate embodiment of the fin structure of the present invention provides for the manufacture of the fin structure in a substantially flat strip with coupling means on the opposite ends thereof for assembling the strip into a substantially cylindrical configuration at the time of installation on the filter element. Various forms of coupling means for engaging the opposite ends of the strip are also disclosed.
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[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/599,621 filed Jun. 22, 2000 which derives its priority from U.S. Provisional Patent Application Serial No. 60/148,556 filed Aug. 12, 1999.
FIELD
[0002] The present invention applies to fence and barrier systems; more particularly, the present invention applies to gate or door opening systems typically used with fences or barriers.
BACKGROUND
[0003] For as long as fences or barriers have been used to enclose spaces, there has been a need to include in the fence or barrier system a portal for gaining access to the enclosed space. For security and for many other reasons, the portal to which access to the enclosed space may be gained typically includes a movable closure. Such movable portal closures may be opened in a variety of different directions to include both horizontal (parallel to the earth's surface) and vertical (perpendicular to the earth's surface). The present invention pertains to portal closures whose movement is substantially horizontal, such horizontal movement being along either a linear or an arcuate path with respect to the fence or barrier system.
[0004] Numerous systems have been used over the years to open portal closures such as gates or doors. One of the most common systems is a chain-drive system wherein the teeth on a rotating, stationary mounted, sprocket are used to engage the openings in a chain, which chain is mounted to the portal closure. Such chain drive systems are slow, cumbersome, and prone to breakage. Such chain drive systems are also subject to the effects of weather; particularly the destructive effects of repeated exposure to moisture. Gates which open on an arcuate path typically use long arms—which long arms are prone to breakage.
[0005] There is therefore a need in the art to provide a system for opening a portal closure which will be fast operating, easy to use, and low in maintenance.
SUMMARY
[0006] A fast operating, easy to use, and relatively maintenance free system and method for moving a horizontally movable gate or door includes a stationary mounted linear induction motor, a magnetic stepper motor or a linear reluctance motor. A reaction piece, either a reaction plate or a reaction rod, is caused to move by the linear induction motor, the magnetic stepper motor or the linear reluctance motor. The movement of the reaction piece, which is mounted to the gate or door, is then used to control the opening and closing of the gate or door. When it is desired to open the gate or door, the linear induction motor the magnetic stepper motor, or the linear reluctance motor is activated. The activation of the motor causes the reaction plate or reaction rod to move with respect to the position of the motor. Because the reaction plate or reaction rod is mounted to the gate or door, the movement of the reaction plate or reaction rod causes the gate or door to move to an open position so that access to an enclosed space is permitted. Alternatively, the movement of the gate or door may be to a closed position so that the opening to the enclosed space is blocked.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0007] A better understanding of the system and method for moving a horizontally movable portal closure of the present invention will be had by reference to the drawing figures wherein:
[0008] [0008]FIG. 1 is a schematic front elevational view of the system of the present invention on a linearly horizontally moving portal closure;
[0009] [0009]FIG. 2 is a schematic front-elevational view of the system of the present invention on an arcuately horizontally movable portal closure;
[0010] [0010]FIG. 3 is a schematic diagram of the electrical connection of the various parts of the system;
[0011] [0011]FIG. 4A is a front elevational view of a reaction plate to be used with a linear reluctance motor; and
[0012] [0012]FIG. 4B is a top plan view of the reaction plate shown in FIG. 4A.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] As may be seen by reference to FIG. 1 and FIG. 2, the system and method of the present invention 10 , 110 is described with reference to the opening and closing of a gate 20 , 120 in a fence 100 . Those of ordinary skill in the art will understand that the present invention has applicability to any type of portal closure whose movement is substantially horizontal—either parallel or at an angle to the fence 100 . The portal may be formed in a gate, a wall, or any type of barrier which encloses a space.
[0014] In FIG. 1, a first embodiment of the system and method of the present invention 10 utilizes a linear induction motor system 30 of the type that is frequently used on amusement park rides, particularly roller coasters. In a roller coaster, such linear induction motor systems initiate the motion of the string of passenger cars up an incline at the top of which the coasting motion of the ride begins. Specifically, such linear induction motor systems include a reaction plate on the roller coaster passenger car. The reaction plate is constructed and arranged to be moved by a series of linear induction motors mounted between the rails on which the passenger cars roll. The reaction plates used in linear induction motor systems may be made of steel covered with a non-magnetic metal such as aluminum or copper, or they may be made from a solid non-magnetic metal such as aluminum or copper. Because of the magnetic fields applied by the linear induction motor to the reaction plate, the reaction plate is caused to be accelerated from a rest condition to a predetermined velocity past the linear induction motor.
[0015] In FIG. 1, the linear induction motor 35 imparts motion to the reaction plate 40 which causes the gate 20 to slide horizontally between open and closed positions. In FIG. 2, the linear induction motor 135 imparts motion to the reaction rod 145 which causes the gate 120 to swing on hinges 125 between open and closed positions.
[0016] Alternatively, a magnetic stepper motor may be used instead of a linear induction motor. When a magnetic stepper motor is used the reaction plate may include a plurality of steel ridges formed on a steel plate. The steel ridges on the steel plate electrically interact with the permanent magnets within the magnetic stepper motor. When a reaction rod is used, the steel rod may include a plurality of steel rings. The steel rings electrically interact with the permanent magnets in the stepper motor. The configuration and design of such ridges or rings is well known to those of ordinary skill in the art.
[0017] In yet another alternative embodiment a linear reluctance motor 535 may be used in place of the linear induction motor illustrated schematically in FIG. 1. When a linear reluctance motor 535 is used, the reaction plate is constructed differently. As shown in FIGS. 4A and 4B the reaction plate 540 constructed and arranged for use with a linear reluctance motor includes a plurality of substantially circular magnetic steel secondary segments 542 mounted on a non-magnetic material 544 . If the gate or door to be moved is also made from a magnetic steel then the secondary segments must be separated magnetically by a gap greater than the spacing between the secondary segments. One advantage to the use of the reaction plate 540 shown in FIGS. 4A and 4B with a linear reluctance motor 535 is the significant reduction in amperage needed to operate the horizontally movable portal closure system.
[0018] As is commonly experienced with motors such as linear induction motors, magnetic stepper motors or linear reluctance motors 35 , 135 , the acceleration of the reaction plate or reaction rod past the motor 35 or through the motor 135 can be quite rapid. Such rapid acceleration is particularly desirable in a situation where it is necessary to open and close a portal closure in a minimum amount of time--as in prisons or incarceration facilities.
[0019] When it is desired to move the portal closure 20 , 120 from a first closed or rest position, it is necessary to accelerate the portal closure 20 , 120 to a predetermined linear or arcuate speed. As the portal closure 20 , 120 nears the end of its travel path, it is then necessary to decelerate the portal closure 20 , 120 from its linear or arcuate speed to a second nonmoving or rest position. Such acceleration and deceleration of the portal closure 20 , 120 is easily governed by controlling the force and direction imparted on the reaction plate 40 or reaction rod 145 by the linear induction motor, the magnetic stepper motor or the linear reluctance motor 35 , 135 . For particularly heavy gates a second linear induction motor, a second magnetic stepper motor or a second linear reluctance motor may be placed alongside the first motor on the same side of the reaction plate or reaction rod or on the opposite side of the reaction plate or reaction rod.
[0020] While it is possible to program into the electronics 60 that control the linear induction motor, the magnetic stepper motor or the linear reluctance motor 35 , 135 , the amount of time needed to accelerate the portal closure 20 , 120 to its desired translational speed, then move the portal closure 20 , 120 at this desired translational speed for a predetermined period of time or travel distance, and then decelerate the movement of the portal closure 20 , 120 at the end of its travel path according to a selected time or travel distance, some applications may require more precise control of the position of the portal closure 20 , 120 . More precise control of the movement of the portal closure 20 , 120 may be obtained by the use of a position sensing system 50 (FIG. 3) which provides a signal indicative of the position of the portal closure 20 along its travel path. Such position sensors may be inductive, rotary, magnetic, or photoelectric. Such inductive, rotary, magnetic, or photoelectric position sensors 50 are well known to those of ordinary skill in the art.
[0021] As shown in FIG. 3, the signals obtained from the position sensors 50 may be electronically transmitted or coupled to an electronic control means 60 . The electronic control means 60 governs the force applied by the linear induction motor, the magnetic stepper motor or the linear reluctance motor on the reaction plate 45 or the reaction rod 145 so that the termination of the period of acceleration of the travel of the portal closure 20 , 120 to the translational speed may be governed by the actual position of the portal closure 20 , 120 , and the initiation of the deceleration of the motion of the portal closure 20 , 120 to the second or rest position may also be governed by the sensed position of the portal closure 20 , 120 .
[0022] As shown in FIG. 1, the portal closure 20 , may include one or more pressure sensitive switches 70 on its ends to cut off power to the motor 35 when the position of the portal closure 20 matches the first or second rest position of the portal closure or when an object appears in the path of travel of the moving portal closure 20 . A similar array of pressure sensitive switches may also be used on the embodiment shown in FIG. 2. Power may be supplied to the system from commercially available sources of electrical energy, or a solar power unit may be used to provide the necessary electrical energy to the system.
[0023] As shown in FIG. 2, the alternate embodiment of the system 110 of the present invention may be constructed so that it is operable with an arcuately pivotable gate or portal closure. Specifically, a reaction rod 140 is caused to pass through a linear induction motor, a magnetic stepper motor or a reluctance motor. This will cause the portal closure 120 to swing open or closed, pivoting on a pair of hinges 125 . Those of ordinary skill in the art will understand that a single long hinge may be used or a plurality of hinges may be used without detracting from the operability of the disclosed invention.
[0024] As shown in FIG. 1, the construction of the system and method for moving a movable portal closure of the present invention horizontally includes simply mounting the reaction plate 40 on a gate 20 which is movable along a horizontal path. This motion is typically governed by a wheel and track assembly, guideways or other systems well known to those of ordinary skill in the art.
[0025] The linear induction motor, the magnetic stepper motor, or the linear reluctance motor is located in close proximity to the travel path of the moving portal closure. Typically, the linear induction motor, the magnetic stepper motor or the linear reluctance motor is mounted in a stationary manner near the edge of the portal which is formed in the enclosure surrounding the space through which access through the portal is obtained.
[0026] While the foregoing disclosure enables those of ordinary skill in the art to make and use the disclosed invention, it will be understood that the foregoing disclosure will also enable those of ordinary skill in the art to make similar embodiments which include the principles of the disclosed invention. Such similar embodiments shall be included within the scope of the appended claims.
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A system and method for moving a horizontally sliding portal closure includes a linear reluctance motor or a magnetic stepper motor and a reaction piece. The reaction piece is attached to the portal closure such that activation of the stationary mounted linear induction or magnetic stepper motor causes movement of the reaction piece which, in turn, opens or closes the portal closure.
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This is a continuation of application Ser. No. 102,136, filed Sept. 29, 1987 and now abandoned.
BACKGROUND OF THE INVENTION
The present invention concerns a catalyst component for polymerization catalysts of α-olefines, such catalysts comprising an organoaluminum compound, an electron donor, and a solid catalyst component. More particularly, the solid catalyst component is obtained when a component or compound containing magnesium reacts with a titanium halogen compound. The present invention also concerns a method for producing these catalyst components as well as a method for polymerizing α-olefines, especially propylene, utilizing these thus-produced catalyst components.
High-activity catalysts which are produced from an aluminum alkyl compound, an electron donor, and a halogenated titanium compound on a solid carrier containing various magnesium compounds, are known for polymerizing α-olefines. The most commonly used magnesium compound is anhydrous magnesium chloride, either alone or together with other magnesium compounds, or organic magnesium compound manufactured by halogenating organic magnesium compounds with compounds containing chlorine. The magnesium compound may also be included in the solid carrier component for which silica is most commonly used.
In these types of polymerization catalysts, the properties of the solid carrier component have significant influence upon the properties of the final catalyst, e.g. on the activity thereof. These properties can be essentially influenced by the method of producing the carrier components.
It has been noted in the present invention, that when polymerizing α-olefines, especially propylene, it is possible to obtain considerably better yields and isotactic values, if magnesium silicate which has not been calcinated in advance by a heating treatment, is used as the solid carrier component.
The use of magnesium silicate in Ziegler-Natta catalysts, is known in and of itself. Thus, for example, according to the method presented in British patent publication No. 2,082,602, magnesium alkyl is dissolved or suspended into an inert hydrocarbon solvent, with magnesium silicate being added, after which the obtained solid catalyst compound is washed and treated with titanium tetrachloride. The thus-produced catalyst is used in the homopolymerization and copolymerization of ethylene.
In the method presented in DE patent publication No. 3,011,326, magnesium halide, e.g. magnesium chloride, is dissolved in ethanol, with magnesium silicate treated with a chlorinating agent being added into the produced solution. The magnesium halide is precipitated by adding the mixture into a hydrocarbon solvent, e.g. heptane, with the thus-obtained component being treated with titanium tetrachloride. The thus-produced catalyst has been also applied in the Polymerization of propylene, however the isotactic value obtained for the polymer in this method ranges between 92-93%.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to improve the polymerizing of α-olefines, especially propylene.
It is a mure specific object of the present to improve yield and isotactic value in the polymerizing of the α-olefines.
It is also an object of the present invention to provide a new and improved catalyst for the polymerizing of α-olefines, notably propylene.
It is an additional object of the present invention to provide a new and improved catalyst or carrier component for effecting polymerizing of the α-olefines.
These and other objects are attained by the present invention which is directed to a catalyst component for polymerizing α-olefines. The catalyst component is prepared by the steps of
(a) reacting a magnesium alkyl compound with a chlorinating compound,
(b) dissolving the thus-formed chlorinated magnesium alkyl compound in alcohol,
(c) adding magnesium silicate which has not been calcinated, to the thus-formed solution,
(d) adding the resulting mixture obtained in step (c) into a cold medium, thereby precipitating the chlorinated magnesium alkyl compound into and onto the magnesium silicate, and
(e) separating the obtained solid catalyst component. The present invention is also directed to a method for producing a catalyst component for polymerizing α-olefines, comprising steps (a)-(e) listed above.
The catalyst provided by the present invention is applied in manufacturing stereospecific polymers, especially polypropylene, so that the polymerizing yield and the isotactic value are high, as compared to catalysts prepared by previously-known technology. In particular, the catalyst component of the present invention is manufactured by reacting with a titanium halogen compound in the presence of an internal electron donor, a solid catalyst component which has been produced by the steps of
(a) reacting a magnesium alkyl compound with a chlorinating compound,
(b) dissolving the chlorinated magnesium alkyl compound in alcohol after optional washing,
(c) adding magnesium silicate which has not been calcinated, into the solution,
(d) adding the mixture obtained in step (c) into a cold medium, to precipitate the magnesium compound into and onto the magnesium silicate carrier, and
(e) separating the thus-obtained solid carrier component.
The present invention also concerns a method for producing catalyst: components for such polymerization catalysts of α-olefines which comprise an organoaluminum compound, an external electron donor, and a solid magnesium-containing catalyst component which has been produced when a solid carrier component containing magensium reacts with a titanium halogen compound. The method of the present invention for producing the catalyst component, comprises the steps of
(a) reacting a magnesium alkyl compound with a chlorinating compound,
(b) dissolving the chlorinated magnesium compound in alcohol (after possible washing),
(c) adding magnesium silicate which has not been calcinated, into the solution produced in step (b),
(d) adding the mixture obtained in step (c) into a cold medium, to precipitate the magnesium compound into and onto the magnesium silicate carrier,
(e) separating the obtained solid carrier component, and
(f) reacting the solid carrier component separated in step (e) with a titanium halogen compound in the present of an internal electron donor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The magnesium silicate used in step (c) when producing the catalyst component of the Present invention, is preferably a well-mixed mixture of silica and magnesium oxide, or a coprecipitate of silica and magnesium oxide. The manufacture of a coprecipitated silicon magnesium oxide (magnesium silicate) is well-known in the field. Coprecipitations of silica and magnesium oxide are commercially available. Silica and magnesium oxide can be effectively mixed by, e.g., grinding a mixture of these two oxides in a ball mill.
Another method for preparing a suitable magnesium silicate, is heating up of a mixture containing particles of silica or alkali metal silicate and a magnesium compound. When heated, these ingredients precipitate into magnesium silicate. Examples of magnesium compounds which can be heated up in this manner with silica or alkali metal silicate, include magnesium alkoxides, magnesium hydroxide, magnesium carbonate, magnesium sulfate, magnesium chloride, and magnesium nitrate. In the present invention, magnesium silicate precipitated from magnesium sulfate or magnesium chloride and sodium silicate, is preferably used as a carrier.
All reactants must be dry and treated with nitrogen (moisture and oxygen content <10 ppm) when preparing a carrier component according to the present invention.
The magnesium alkyl compound used as a reactant in the catalyst component of the present invention, is usually in the form of MgR' 2 or MgR'R" where R' and R" are either the same or different and contain alkyls from C 1 to C 20 , preferably C 2 -C 12 . The magnesium compound can be, for example, diethyl magnesium, ethyl-butyl magnesium, ethyl-hexyl magnesium, ethyl-octyl magnesium, dibutyl magnesium, butyl-hexyl magnesium, butyl-octyl magnesium, dihexyl magnesium, hexyl-octyl magnesium, dioctyl magnesium, etc. The most preferred of these magnesium alkyl compounds, is butyl-octyl magnesium.
The chlorinating agent may be selected from the group consisting of chlorine, hydrogen chloride, alkyl chloride (e.g. butyl-chloride), TiCl 4 , and mixtures thereof. The chlorination can be performed at a temperature of about -10° to 100° C., preferably at about 10°-60° C. After the chlorination, the reaction mixture can be treated with nitrogen for about 15-60 minutes to ensure complete chlorination.
The chlorinated magnesium alkyl compound can be treated with a small amount of alcohol, but even without the alcohol treatment the finished catalyst may prove highly active. The alcohol may be either allphatic or aromatic, and may contain one or several hydroxyl groups such as, e.g., methanol, ethanol, 2-ethyl hexanol. If the alcohol treatment is performed, the precipitate can be washed several times with a hydrocarbon solvent, and the surplus solvent evaporated off by means of a nitrogen flow. After this step, the precipitate is dissolved in ethanol and the magnesium silicate carrier is added to this solution. The carrier is allowed to impregnate in this solution at a temperature of about 60°-70° C. Normally, a treatment time of about 3-24 hours is sufficient.
The magnesium silicate carrier with its impregnation solution is siphoned into a cold (under about 0° C.) hydrocarbon solvent, in which the magnesium compound of the solution immediately precipitates into the pores and on the surface of the magnesium silicate carrier. The solvent temperature may vary between about -30° to -5° C. The obtained carrier component is washed several times with a hydrocarbon solvent. After the washing, the carrier component is treated with titanium tetrachloride by a method known in and of itself, in order to further produce a catalyst component.
The titanium treatment may take place, e.g. in a manner such that the solid carrier component is allowed to react with titanium tetrachloride either once or several times. The catalyst component may be additionally treated by means of an internal electron donor compound before, during, or after the titanium treatment. Titanium treatment should preferably take place in two stages so that in the first stage, an internal electron donor compound, usually of the amine, ether, or ester type, is added. A suitable donor, is, e.g., di-isobutyl phthalate.
In the first stage, a low temperature e.g. under about 0° C., preferably under about -20° C., is recommendably used. The temperature is raised during the titanium treatment to about 90°-110° C. The second titanium treatment is performed at a temperature of about 90°-100° C. for about 1-2 hours. The solid reaction product is separated from the liquid phase and washed with hydrocarbon solvent to remove impurities and derivatives. The catalyst component is dried with nitrogen gas at room temperature or at slightly higher temperature.
The catalyst component introduced by the present invention can be used to polymerize α-olefines by allowing the catalyst component to come into contact with an Al-compound and an external electron donor. Amines, ethers, esters (preferably alkyl or aryl esters of aromatic carboxyl acids) or silane compounds (aryl/alkyl silanes) such as methyl or ethyl esters of benzoic acid, toluene acid and phthalic acid, isobutyl esters of phthalic acid, triethoxy silane, etc., can be used, among others, as the external electron donor. The noted electron donors are compounds that are capable of forming complexes with Al-alkyls. These can be used to improve the stereospecific properties of the catalyst. The external electron donor and the Al-alkyl are mixed together with a molar ratio of electron donor and Al-alkyl being about 10-30, and the Al/Ti molar ratio is about 5-300 depending on the polymerization system.
The polymerization can be carried out either as slurry, bulk, or gas phase polymerization. Catalyst components and catalysts produced according to the present invention can be used in the polymerizing of α-olefines such as propylene, by slurry, bulk or gas phase methods.
The present invention will be further described by way of the following demonstrative examples:
EXAMPLES 1-9
60 ml. of magnesium alkyl (butyl-octyl magnesium as a 20% heptane solution) and heptane were measured into a five-necked flask which was provided with a mechanical stirrer, a reflux condenser, a gas supply valve and a thermometer. The suspension was treated with nitrogen and maintained under inert conditions throughout the manufacturing process. The mixture was then chlorinated with chlorine gas at a rate of 0.25 1/min. for 10-25 min.
After this, the mixture was treated with nitrogen for 30 min., and then heated up to 94°-98° C., with 20 ml. of ethanol being added, upon which the chlorinated precipitate thickened. The precipitate was twice washed with 250 ml of heptane, with excess solvent being evaporated by means of nitrogen flow after the washings. The precipitate was dissolved into ethanol at 80° C., with magnesium silicate that had not been calcinated being added to the solution.
The mixture was mixed at 70° C. overnight. The hot mixture was siphoned into cold (-20° C.) heptane, upon which the dissolved magnesium component precipitated into the pores and onto the surface of the magnesium silicate. The solid component was twice washed with heptane at room temperature, and was then cooled down to -25° C., with titanium tetrachloride being added at this temperature. After this, the temperature of the mixture was allowed to rise to room temperature, at which temperature di-isobutyl phthalate was added. The temperature was raised to 100°-110° C., and the mixture was stirred for 60 min.
After the precipitate had sedimented, the solution was removed by siphoning. The titanium tetrachloride treatment was repeated at 100°-110° C. for 60 min.
After the precipitate sedimented and the solution had been siphoned, the finished catalyst component was washed several times (5-6 times at a temperature of 80° C.) with heptane, and dried in a nitrogen flow.
EXAMPLE 10
The catalyst was produced as in Examples 1-9, however the first alcohol treatment with ethanol was left out, with the washing stage after this ethanol treatment also being omitted.
Table 1 lists the amount of reagents and solvents utilized in each of Examples 1-10.
The catalyst components produced in the above-described method were used in the polymerization of propylene by adding into a 2 1. polymerization reactor, a catalyst that had been prepared by mixing triethyl aluminum as aluminum alkyl and diphenyl dimethoxy silane as an external donor compound (Al/donor molar ratio 20) with 50 ml. of heptane, after five minutes, adding a catalyst component into this mixture so that the Al/Ti molar ratio was 200. The polymerization was performed under the following conditions: propylene partial pressure 9.0 bar, hydrogen partial pressure 0.3 bar, temperature 70° C. and polymerization time 3 h.
Ethylene was also polymerized with a catalyst utilizing the component of Example 9, in a manner such that a catalyst solution that had been prepared by using triethyl aluminum as the cocatalyst and a catalyst component so that the Al/Ti molar ratio was 5, was fed into a reactor that had been treated with nitrogen. The partial pressure of hydrogen bomb was adjusted to 7 bar. Ethylene was fed through so that the reactor total pressure was 15 bar. Polymerization temperature was 90° C. and Polymerization time 1 h.
1-butene was also polymerized with a catalyst utilizing a component prepared according to Example 8, in a manner such that a catalyst solution that had been prepared by using tri-isobutyl aluminum as the cocatalyst and diphenyl dimethoxysilane as the external donor compound was fed into the reactor that had been treated with nitrogen. After this, isobutane (300 g) serving as a medium was added into the reactor, as well as 1-butene (300 g) and the catalyst component of Example 8. Polymerization conditions were as follows: 1-butene partial pressure 0.1 bar, temperature 28° C. and polymerization time 4 h.
The polymerization results and the properties of the polymers are reported in Table 2. The catalyst activity is indicted with the value g of polymer/g of catalyst. The polymer isotacticity has been determined by means of a heptane extraction. Melt flow index (MFI) is determined according to standard ASTM D 1238 and bulk density according to standard ASTM D 1895-69.
COMPARATIVE EXAMPLE 1
The catalyst component was produced as in Example 9, however the magnesium silicate carrier of which 5.4 g was used, was calcinated before use by heating up for two hours at 600° C., and then cooling down under nitrogen. In connection with the first titanium treatment, 3 ml. of di-isobutyl phthalate was added as an internal electron donor compound. The polymerization activity of this catalyst was found to be 3.8 g PP/g cat. 3 h. The polymer isotacticity was 96.0% and bulk density 0.23 g/ml.
COMPARATIVE EXAMPLE 2
The catalyst component was produced as in Comparative Example 1, however the magnesium silicate used had been calcinated by heating up for 4 hours at 400° C. The catalyst polymerization activity was found to he 4.4 kg PP/g cat. 3 h. The polymer isotacticity was 96.4%, bulk density 0.25 g/ml and MFI 15.50 g/10 min/230° C./2.16 kg.
COMPARATIVE EXAMPLE 3
The catalyst component was produced as in Comparative Example 1, however the magnesium silicate used was calcinated by heating up at 200° C. for 4 hours and cooling down under nitrogen. The catalyst polymerization activity was found to be 5.6 kg PP/g cat. 3 h. The polymer isotacticity was found to be 96.3% and bulk density 0.23 g/ml, with MFI 16.53 g/10 min./230° C./2.16 kg.
The preceding description of the present invention is merely exemplary, and is not intended to limit the scope thereof in any way.
TABLE 1__________________________________________________________________________Production of catalystsCarrier R.sub.2 Mg Heptane Chlorination Alcohol TiCl.sub.4 DonorExampleg ml ml T/°C. t/min. ml ml T/°C. t/min. ml__________________________________________________________________________1 6.29 12 120 10-44 22 20 200 -20-110 60 3 45 200 110 60.sup. 2.sup.15.13 12 100 10-56 24 20 200 -20-110 60 3 45 200 110 603 5.39 8 140 13-56 40 14 200 -20-110 60 3 45 200 110 60.sup. 4.sup.25.44 12 100 18-60 28 20 200 -20-110 60 3 45 200 110 605 5.05 12 100 <0 80 20 200 -20-110 60 3 45 200 110 606 5.17 12 100 10-57 22 20 200 <-10 120 3 45 200 110 607 4.99 12 100 10-54 24 20 200 <-10 240 3 45 200 110 608 5.62 12 100 16-60 24 20 200 +20-110 60 3 45 200 110 60.sup. 9.sup.32.00 12 60 10-40 15 20 200 -20-110 60 -- 50 200 110 6010 4.79 24 60 10-65 45 45 200 -20-110 60 3 200 110 60__________________________________________________________________________ .sup.1 before the titanium treatment the surface layer and the bottom layer are separated from each other; further treatment is performed on th bottom layer .sup.2 after the carrier has been added, the mixture is mixed for 3 hours .sup.3 no donor
TABLE 2______________________________________Catalyst's polymerization activity andpolymer's properties MFI Isotac- 230° C. Activity ticity 2.16 kg BulkExample g polym./g cat. 3h % 10 min. density______________________________________1 4.2 (PP) 96.6 16.40 0.232 2.1 (PP) 98.8 19.79 0.273 2.6 (PP) 97.4 13.84 0.234 3.6 (PP) 97.7 12.07 0.315 3.1 (PP) 98.4 25.60 0.246 4.7 (PP) 97.4 11.97 0.217 2.4 (PP) 98.0 18.91 0.248 5.4 (PP) 98.4 18.96 0.37 0.3 (poly-l-butene) 96.1 -- 0.239 3.7 (PP) 86.4 -- 0.21 1.3 (PE) 13.62 0.36 (21.6 kg)10 9.3 93.0 4.14 0.38______________________________________
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A catalyst component for polymerization catalyst of α-olefines, the polymerization catalyst comprising an organoaluminum compound, an electron donor, as well as the solid catalyst component which is obtained when a compound containing magnesium reacts with a titanium halogen compound. A method for producing the catalyst component is also provided. The catalyst component is manufactured by reacting with a titanium halogen compound in the presence of an internal electron donor, a solid catalyst component which has been produced by the steps of
(a) reacting a magnesium alkyl compound with a chlorinating compound,
(b) dissolving the chlorinated magnesium alkyl compound in alcohol, after possible washing,
(c) adding into the solution, magnesium silicate which has not been calcinated,
(d) adding the mixture obtained in step (c) into a cold medium, to precipitate the magnesium compound into and onto the magnesium silicate carrier, and
(e) separating the thus-obtained solid carrier component.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to spring configurations and, more particularly, to a torsion spring configuration and a releasable casing using the same.
DESCRIPTION OF RELATED ART
[0002] A torsion spring is a mechanical element that reacts against torsion (twisting motion). A torsion spring is often made from a wire, ribbon, bar, or coil. Torsion Springs are widely used in automobiles, motorcycles, electrical appliances, telecommunication equipment, and other civil fields.
[0003] In operation, the more the torsion spring is twisted, the more force it needs to twist the torsion spring further. That is, the torsion spring is a kind of non-constant force provider.
[0004] Accordingly, to perform as a superior force provider, a need exists for a torsion spring configuration without the above disadvantages in the industry.
SUMMARY OF THE INVENTION
[0005] A releasable casing includes a base, a lid coupled to the base, a first torsion spring and a second torsion spring. The lid is rotatable around a rotating axis with respect to the base. The first torsion spring includes a first spring body, a first arm, and a second arm extending from the spring body. The first arm resists the lid toward an opening direction of the lid, and the second arm is fixed relative to the base. The first arm includes a first portion connected to the first spring body, an arc-shaped second portion extending from the first portion, and an arc-shaped third portion extending from the second portion. The first portion extends from the first spring body along a tangent direction thereof, and the second portion and the third portion bend oppositely. The second torsion spring includes a second spring body, and a third arm and a fourth arm extending from the second spring body. The third arm resists against the lid, and the fourth arm is fixed relative to the base.
[0006] A torsion spring assembly, which is used for opening a lid, includes a first spring and a second torsion spring. The first torsion spring includes a first spring body, a first spring arm configured for resisting against the lid, and a second spring arm configured for being fixed relative to the first spring body. The first and second spring arms extend from opposite ends of the first spring body. The first arm sequentially includes a first portion, a curved second portion, and a curved third portion. The third portion is deformable with respect to the first portion to apply a first force to prevent the lid from releasing. The second spring includes a second spring body, a third spring arm for resisting against the lid to apply a second force to release the lid, and a fourth spring arm for being fixed, the third and fourth spring arms extending from opposite ends of the second spring body.
[0007] A torsion spring includes a spring body wound by a helical wire, a first arm extending tangently from an end of the spring body, and a second arm extending from the other end of the spring body. The first arm includes sequentially a first portion extending from the spring body, a curved second portion bent toward a first direction from the first portion, and a curved third portion bent toward a different second direction from the second portion.
[0008] Other systems, methods, features, and advantages of the present torsion spring configuration and the present releasable casing with the torsion spring configuration will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present apparatus, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Many aspects of the present torsion spring configuration and the present releasable casing with the torsion spring configuration can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present device. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0010] FIG. 1 is an isometric view of a releasable casing with a torsion spring configuration in accordance with an exemplary embodiment mounted thereto, the releasable casing including a lid, a base, a first torsion spring, and a second torsion spring;
[0011] FIG. 2 is an exploded view of the releasable casing of FIG. I;
[0012] FIG. 3 is an isometric view of the lid of FIG. 1 , but viewed from an inverted aspect;
[0013] FIG. 4 is a schematic view showing a relationship of the first torsion spring and the lid in a closed state;
[0014] FIG. 5 is a schematic view showing a relationship of the first torsion spring and the lid in an intermediate state; and
[0015] FIG. 6 is a schematic view showing a relationship of the first torsion spring and the lid in an opened state.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Reference will now be made to the drawings to describe in detail, the preferred embodiments of the present torsion spring configuration and the present releasable casing with the torsion spring configuration.
[0017] Torsion springs are helical springs used to apply torque or store rotational energy. Torque by definition is a force that produces rotation. A torsion spring exerts a force of torque in a circular arc, and arms of the torsion spring rotate about a central axis thereof.
[0018] A typical torsion spring includes a cylindrical body constructed with a helical wire, two ends of the helical wire form a pair of arms extending from the body. In use, the body is typically sleeved on a rod, either one of the pair of arms is fixed, while the other arm (a free arm) is movable relative to the rod.
[0019] When a force is acted on the free arm at a distance from an axis of the torsion spring, the torque (a.k.a. moment), which is equal to the force multiplied by the arm of force (i.e. a distance of a point of contact of the arm), causes the free arm to rotate around the axis, thus, kinetic energy is transformed to potential energy.
[0020] When the torsion spring releases/exerts the potential energy stored, the free arm of the torsion spring rotates and returns to an initial position. A force acted from the free arm of the torsion spring gradually decreases as the free arm moves closer to the initial position. Supposing that the above torsion spring is utilized to release a lid of a releasable casing, a force applied to the lid by the torsion spring would gradually decreases. This results in that the lid rotates unevenly together with the free arm of the torsion spring during the releasing process.
[0021] As described above, it is difficult to choose an appropriate torsion spring for a given releasable casing. This is because in the given releasable casing, if the torsion spring thereof carries a relatively great torque, the lid would open and strike the releasable casing fiercely, resulting in undesired ricochets, shakes, or vibrations. Thus, the lid, or the releasable casing would be prone to damage. On the other hand, if the torsion spring carries a relatively small torque, the lid cannot open at a greatest releasing angle.
[0022] Hereinafter, a torsion spring configuration is described in detail to solve the above problem satisfactorily.
[0023] Referring to FIG. 1 and FIG. 2 , a releasable casing 100 with a lid 10 thereof released is illustrated. The releasable casing 100 includes a lid 10 and a base 20 pivotably attached together, further, a first torsion spring 30 and a second torsion spring 40 are used as force providers to provide a releasing force cooperatively, thus releasing the lid 10 . The lid 10 is rotatable around a rotating axis OO with respect to the base 20 , the position of the lid 10 with respect to the base 20 defines an opened state, a closed state, and a half opened state. The opened state is where the lid 10 is fully released from the base 20 at a largest opening angle, the closed state is where the lid 10 fully covers on the base 20 , and the half opened state is an intermediate state between the opened state and the closed state. The first torsion spring 30 and the second torsion spring 40 are utilized to provide the torque force that actuates the lid 10 .
[0024] The lid 10 includes a first supporting portion 12 and a second supporting portion 14 , both of which are in quadrant shapes. The first and second supporting portions 12 and 14 are formed near an edge of the lid 10 with axes thereof superposing each other and the rotating axis OO of the lid 10 . A positioning slot 16 perpendicular to the rotating axis OO of the lid 10 is defined beside the second supporting portion 14 . The first supporting portion 12 and the positioning slot 16 are respectively used to position the first torsion spring 30 and the second torsion spring 40 . The second supporting portion 14 forms a partial gear 142 to engage/mesh with a gear (not shown) positioned in the base 20 thus, slowing down the lid 10 during an opening procedure and dampening an impact between the lid 10 and the base 20 when reaching the largest opening angle.
[0025] The base 20 defines a first opening 22 , a second opening 24 , and a third opening 26 . The first opening 22 is defined near an edge of the base 20 corresponding to the first supporting portion 12 of the lid 10 allowing the first supporting portion 12 to extend therethrough. Similarly, the second opening 24 is defined near the edge of the base 20 corresponding to the second supporting portion 14 of the lid 10 allowing the second supporting portion 14 to extend therethrough. The third opening 26 is defined near the second opening 24 to allow an arm of the second torsion spring 40 to extend therethrough reaching the positioning slot 16 of the lid 10 .
[0026] The first torsion spring 30 includes a first body 32 spun in a coil, and a first arm 34 and a second arm 36 extending from the first body 32 . The first arm 34 extends from an end of the first body 32 forming an S-shape, and the second arm 36 extends tangently from an opposite end of the first body 32 . The second arm 36 is relatively a straight arm extending from the first body 32 , and the first arm 34 includes a first portion 342 extending relatively straight along an opposite direction to the second arm 36 , an arc-shaped second portion 344 , and an arc-shaped third portion 346 . The second portion 344 and the third portion 346 are end-to-end, and the bending directions thereof are opposite to each other. That is, a center point of an imaginary circle conformed to the second portion 344 and a center point of an imaginary circle conformed to the third portion 346 are respectively positioned at two opposite sides of the first arm 34 .
[0027] The second torsion spring 40 includes a second body 42 converted in coils, and a third arm 44 and a fourth arm 46 extending from the second body 42 . The third arm 44 and the fourth arm 46 are straight arms. The third arm 44 extends tangently from an end of the second body 42 , and the fourth arm 46 extends radially from another opposite end of the second body 42 .
[0028] The first body 32 and the second body 42 are sleeved on rods (not shown) formed in the base 20 correspondingly. The first arm 34 of the first torsion spring 30 and the third arm 44 of the second torsion spring 40 are fixed to the lid 10 of the releasable casing 100 , while the second arm 36 of the first torsion spring 30 and the fourth arm 46 of the second torsion spring 40 are fixed to the base 20 . Detailedly, the first arm 34 resists against the first supporting portion 12 of the lid 10 , and the third arm 44 is restricted in the positioning slot 16 defined on the lid 10 .
[0029] Referring to FIG. 3 together, the first supporting portion 12 defines a sliding channel 120 at a bottom thereof to allow the first arm 34 to be restricted therein and slide therealong.
[0030] Different states during an opening procedure of the lid 10 are respectively shown in FIG. 4 to FIG. 6 .
[0031] Firstly referring to FIG. 4 , a schematic view showing a relationship between the first torsion spring 30 and the lid 10 in the closed state is illustrated. In such a situation, the lid 10 fully covers the base 20 , and the first torsion spring 30 and the second torsion spring 40 are compressed. The first torsion spring 30 and the second torsion spring 40 carry great potential energy. The first portion 342 of the first torsion spring 30 is partially received in the sliding channel 120 , and the second portion 344 and the third portion 346 resist against the cambered surface 122 of the first supporting portion 12 . A contacting point X of the first arm 34 and the cambered surface 122 is on a conjunction of the second portion 344 and the third portion 346 . As a relative position of the third portion 346 and the first portion 342 is changed due to the first supporting portion 12 therebetween, the third portion 346 of the first arm 34 applies a restoration force through the contacting point X onto the first supporting portion 12 along a radial direction of the first supporting portion 12 . The restoration force holds the first supporting portion 12 onto the base 20 .
[0032] Subsequently referring to FIG. 5 , a schematic view showing a relationship between the first torsion spring 30 and the lid 10 in the half opened state is illustrated. As the lid 10 rotates relative to the rotating axis OO, a contacting point Y of the first arm 34 and the cambered surface 122 of the first supporting portion 12 gradually moves along the cambered surface 122 . The restoration force applied by the third portion 346 of the first arm 34 holding the first supporting portion 12 of the lid gradually decreases.
[0033] Finally referring to FIG. 6 , a schematic view showing a relationship between the first torsion spring 30 and the lid 10 in the opened state is illustrated. As the lid 10 rotates around the rotating axis OO to reach the largest opening angle, a contacting point Z of the first arm 34 of the first torsion spring 30 and the first supporting portion 12 gradually moves into the sliding channel 120 . In such a situation, the third portion 346 of the first arm 34 applies a supporting force to the first supporting portion 12 to support the lid 10 at the largest opening angle.
[0034] As described above, from the closed state to the half opened state, the first torsion spring 30 applies a first force onto the first supporting portion 12 holding the first supporting portion 12 in the opening procedure. Meanwhile, the second torsion spring 40 applies a second force onto the lid 10 releasing the lid 10 . During such a procedure, the first torsion spring 30 holds the lid 10 , and the second torsion spring 40 releases the lid, thus, a resultant force of the first force and a second force applied to the lid 10 releasing the lid 10 is adjusted. As the opening angle increases, the first force applied by the first torsion spring 30 decreases, and the second force applied by the second torsion spring 40 decreases. Therefore, the resultant force of the first force and the second force changes slightly or remains constant. From the half opened state to the opened state, the third portion 346 of the first arm 34 moves into the sliding channel 120 . The first force applied by the first torsion spring 30 disappears, and a third force is generated by the first arm 34 supporting the lid 10 , helping the lid 10 to reach and remain at the largest opening angle. The second force applied by the second torsion spring 40 decreases continuously. When the third portion 346 moves into the sliding channel 120 , the second force and the third force applied respectively by the first torsion spring 30 and the second torsion spring 40 together support the lid 10 , and keep the lid 10 at the largest opening angle.
[0035] A closing procedure is a reverse procedure of the above opening procedure.
[0036] It is clear that the first torsion spring 30 cooperates with the second torsion spring 40 to maintain the releasing force of lid 10 during the releasing procedure, and to support the lid 10 at the largest opening angle so as to eliminate/depress shakes of the lid 10 in the opened state. Such a configuration of the first torsion spring 30 and the second torsion spring 40 effectively resolves common problems of conventional torsion springs. The releasable casing 100 is superior to those by having a substantially constant releasing force on the lid 10 and a long work life thereof due to depressed/eliminated strikes. This torsion spring configuration can be utilized in many electronic devices, such as a game player, a disc player, a tool box, or even a dressing case, etc.
[0037] It should be emphasized that the above-described embodiments of the present invention, including any preferred embodiments, are merely possible examples of implementation of the principles of the invention, and are merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments of the invention without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention and be protected by the following claims.
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A torsion spring includes a spring body wound by a helical wire, a first arm extending tangently from an end of the spring body, and a second arm extending from the other end of the spring body. The first arm includes sequentially a first portion extending from the spring body, a curved second portion bent toward a first direction from the first portion, and a curved third portion bent toward a different second direction from the second portion. A torsion spring assembly and a releasable casing using the torsion spring are also disclosed.
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DESCRIPTION
Background of Prior Art
This invention is directed to an improved manufacturing method for the manufacture of sandwich-like panels of prestressed concrete. Specifically, it is directed to an improvement in the method wherein such sandwich panels are formed in factories as slab bodies of great length and are ultimately cut to individual desired panel lengths after completion of the formation and curing of the slab.
Concrete sandwich panels are well known products and have come into considerable use for wall panel members in building construction due to their improved resistance to the transmission of heat over that of ordinary concrete panels. Essentially, a sandwich panel in accordance with the term as used herein comprises a primary structural body of concrete in a substantially flat slab configuration that may or may not have hollow cores, depending upon intended usage. Immediately in contact with one face of the primary concrete layer is an insulating layer which is typically a panel of foam product such as polystyrene. Overlying the insulating layer is a second layer of concrete, usually thin relative to the primary layer, which covers the insulation to provide a weather and abrasion resistant outer surface for the panel. The outer layer of concrete is held in fixed relationship to the primary layer of concrete through the use of pin members. The pins extend through the insulating layer and are bonded to the primary and secondary concrete layers.
Desired manufacturing procedure for such panels involves forming them in slabs of great length and utilizing accelerating curing conditions by means of applied heat. Unfortunately, as a result of accelerated curing, there is a differential rate at which the relatively thick primary or supporting layer of concrete cures over the rate at which the relatively thin secondary or outer layer of the concrete cures. This is due to several factors, but is largely due to the fact that the insulating layer performs its function well and prevents a uniform flow of heat through the two separated layers of concrete so that they cannot cure at the same rates. Because of such differential heating rates between the layers of concrete, and the resultant curing thereof at different rates, the concrete layers exhibit different expansion and contraction relative to each other. This causes stress in the thinner secondary body resulting in a tendency to form stress cracks therein. Such cracks, while not harming the strength of the concrete or of the overall panel to any major extent, do produce a highly undesirable cosmetic effect, particularly when the secondary layer is frequently used as the outer decorative face of the panels.
Brief Summary of the Invention
In accordance with the present invention, while the slab is being formed or immediately thereafter, the concrete of the secondary or outer layer is indented transversely at pre-selected cutting locations. This is done while the concrete is still in the fluid state by forming a transverse indentation, such as a groove, across the concrete. Such indentations are generally referred to as contraction joints in the art. As a result, any stresses which build up due to differential curing and expansion rates find relief by producing a crack in the weakest area of the concrete i.e., in the groove or indentation. The grooves are positioned at the locations in the slab at which it is to be cut transversely to form individual panel lengths. Consequently, cracks are not present in the finished product.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be best understood with respect to the drawings wherein
FIG. 1 is a cross-sectional perspective view of an end of a prestressed slab (hollow core type).
FIG. 2(a) is a cross-sectional view of a section of slab along line 2--2 of FIG. 1 during manufacture, showing the primary layer of concrete and insulation in place.
FIG. 2(b) is a cross-sectional view similar to that of FIG. 2(a) with the outer concrete layer in place and showing an indenting tool schematically for providing a transverse groove in the concrete.
FIG. 2(c) shows the slab of FIG. 2(b) after curing.
FIG. 3 is an enlarged sectional view of an indented portion showing a stress crack extending down to the foam layer.
DETAILED DESCRIPTION OF INVENTION
Referring to the drawings it will be seen that, in each of the Figures, like parts bear the same numerical designation. In FIG. 1 there is shown in cross-sectional perspective of an end view of a hollow core concrete sandwich slab 10 of conventional type and great length. While the invention is described with respect to hollow core slabs and panels it should be understood that the invention is equally applicable to the formation of sandwich panels without the hollow cores. The number, shape and arrangement of the cores may vary. The same is true of prestressing. That is, prestressing strands or other reinforcing cables or rods may be included and may vary in number, size and arrangement.
FIG. 1 illustrates the bottom primary or support layer of concrete 11 which includes rectangular openings 12 produced therein. Such hollow core slabs and panels can be produced by a variety of processes. One such process is shown in U.S. Pat. No. 3,217,375. The process for producing the hollow cores forms no direct portion of the present invention nor does the prestressing of the slabs. For present purposes it suffices that a concrete body 11 of considerable continuous length is to be joined to a layer of an insulating foam material 13 and an outer or secondary layer or skin 14 of concrete. Reinforcing strands or the like may also be included in layer 14. However, they would be of relatively small diameter or cross-section suitable for the thickness of layer 14. Typically such factory cast bodies are cast in great lengths in excess of 400 feet and are subsequently sawed by concrete saws into desired lengths. Layer 13 of the thermally insulating material is typically a polystyrene. While the thickness of polystyrene layer 13 may vary over a considerable range, it is typically in the range of about 1-6 inches thick, 21/4 inches being frequently used. Insulating material 13 has essentially zero abrasion resistance and tends to weather rapidly upon exposure to the elements. Therefore, it is standard practice to include the secondary or top, outer layer of concrete 14 to provide protection against the elements. Outer layer 14 may be either a smooth flat surface of concrete or it may be shaped into various ornamental configurations during the course of casting. As these additional features form no direct part of the present invention, they will not be elaborated on further here. As can be seen from the Figures, concrete layer 11 is preferably relatively thick compared to concrete layer 14.
In the process of casting body 10 of FIG. 1, a flat casting bed having a pallet 15 is utilized. Pallet 15 provides a substantially horizontal working surface. Not shown are side forms which define the outer edges of the cast concrete. Pallet 15 is underlined by support members such as I-beams 16. Also typically, the pallet has joined to the underside thereof, some means for providing heat to accelerate the rate of curing of the concrete lying on the pallet. In FIGS. 2 this is illustrated as steam pipe 17 which delivers live steam at desired temperature, accelrating the curing process. Heat passes from pipe 17 through the bottom of pallet 15 and into lower layer 11 of the concrete. Usually there is provided a canopy or other suitable enclosure (not shown) over the entire body at the time the accelerated curing is taking place. However, the large majority of heat that enters body 10 does so by passing into concrete body 11 after passing through pallet 15 rather than being introduced into body 10 by convection from heated air lying above and below the pallet in the enclosure.
Other means of accelerated heating may be used. For example, it is well known in the art to use hot oil rather than steam in pipe 17 and it is also well known to use electrical heating elements attached to the bottom of the pallet in place of pipe 17 to provide the desired heat for curing.
Referring to FIG. 2(a), there are illustrated hairpin shaped members 18 which are utilized to hold insulation layer 13 onto the surface of the still wet, and uncured concrete layer 11. Layer 11 is typically on the order of about 8 inches in thickness. The hairpin members are inserted through the insulation 13 and penetrate into the still uncured concrete 11 as illustrated with a top portion of the hairpin projecting above layer 13. Onto the structure of FIG. 2(a) there is poured the additional layer of concrete 14. This layer of concrete flows around the upper edges of the hairpins 18 and ultimately upon curing, locks onto hairpins 18 which in turn are locked into layer 11, thus holding layer 14 fixed in relationship to layer 11 whereby the sandwich structure is formed with the insulation layer carried therebetween.
After the sandwich structure has been formed, as above, the curing thereof is accelerated by means of heat applied primarily through base layer 11. The differential rate at which the heat is absorbed into layer 14 relative to layer 11 brings about differential expansion between the two layers during the heating cycle and during the cooling cycle after accelerated curing is completed. This introduces the aforementioned stresses into the top relatively thin layer 14 which may form undirected or haphazard stress cracks due to the differential expansion and contraction of layers 11 and 14. Illustrated in FIG. 2(b) is a blade or other suitably shaped tool member 19 which extends transverse to the length of the bed pallet and the continuous concrete body. It is utilized to indent the outer, still uncured layer 14 of concrete as shown at 20 by depressing it into the concrete to provide a transverse notch, groove or other suitable indentation therein. While the fluidity of outer layer 14 of concrete will not permit a complete cut-through of the concrete layer 14 by indentation therein of tool 19, retention of the groove or indentation does occur. This provides sufficient weakening at that point in the structure so that any differential expansion and contraction of layers 14 and 11 results in the generation of a transverse crack at the groove as illustrated in FIG. 2(c) and FIG. 3 at 21. Crack 21 in most instances extends completely through layer 14 down to the adjacent surface of foam 13. Thus, it can be seen that preferential or directed cracking can be made to occur at predetermined preferred locations in the continuous concrete sandwich structure.
In the process of the invention, spaced indentations are provided in the structure at the various locations where a saw cut is to be made in order to form the individual panels of desired length for ultimate use in the field. Thus, most cracks which form are at points where saw cuts will obliterate them and the finished panel lengths are relatively crack-free at their outer surface. Sawing is accomplished in any manner as is well known in the art.
Having described the preferred embodiment of the invention, it is to be defined by the following claims.
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A method of manufacture in which the formation of unsightly stress cracks in sandwich-like panels of prestressed concrete are prevented by the formation of a "contraction joint" at selected locations in the panel's outer layer of concrete during its manufacture.
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BACKGROUND OF THE INVENTION
The present invention relates generally to an optical sensor and a method of operation thereof and in particular to a method of enhancing sensor accuracy.
Optical sensors are commonly used for a variety of functions including detecting skewed or double picked notes within the note transport mechanism of an Automated Teller Machine.
A variety of different prior art detectors have been utilized to detect note skew in ATMs. These include both electromechanical and optical detectors. However, they all have certain features in common. In particular, they all rely on a pair of sensors, each of which is located at a predetermined position along the transport path within the ATM. Also as the detector is arranged to determine skew perpendicular to the direction of travel along the transport path, both sensors and light sources must be located within the transport path, thus making assembly and serviceability of the detectors difficult. For example, cables must be laid into both sides of the transport path to connect to the sensors.
In addition, changes in LED power and sensor sensitivity throughout the lifetime of a sensor have also caused problems when attempting to use optical sensors for note detection in an ATM.
A further problem with the use of optical sensors is the large variation in the opacity of notes used today. Also, some bank notes have relatively transparent windows. With prior art optical sensors these windows are seen as holes.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an optical sensor that ameliorates the aforementioned problems.
It is a further object of the present invention to produce an improved note skew detector.
It is a still further object of the present invention to provide an optical sensor that can operate accurately while utilizing a relatively inexpensive phototransistor-as opposed to an expensive photo-diode.
According to a first aspect of the present invention there is provided an optical detector adapted to measure the opacity of media, comprising a light means and a light sensor, arranged so as to have a media path there between, the light source having a drive means which is actively adjustable, during use, for detecting media of different opacities, so as to maintain a substantially constant sensor output.
Preferably, the optical sensor is a single optical sensor.
Most preferably, the light source and optical sensor are optically coupled via two distinct optical paths, which are formed in part by optical light guides.
Preferably the detector comprises a control means arranged to make determinations as to the degree of skew of a note based on the signal produced from the sensor.
Preferably, when in use, the detector is arranged such that the sensor receives light via each optical path, the output of the sensor being dependent on whether or not a note is present in either or both optical paths.
According to a second aspect of the present invention there is provided an Automated Teller Machine (ATM) having an optical detector as described above.
According to a third aspect of the present invention there is provided a method of detecting the opacity of media utilizing a detector comprising a sensor, a light source and associated drive means arranged to provide a media path therebetween, the method comprising
a) passing media therebetween, b) adjusting the current to the light source in order to maintain the output of the sensor at a substantially constant level, and c) measure the current required as a measure of opacity of the media being detected.
According to a fourth aspect of the present invention there is provided a method of detecting skew in a bank note, being transported along the transport path of a note transport mechanism, utilizing an optical detector comprising a light source and an optical sensor, which are optically coupled via light guides arranged to transmit light from the source to the sensor via two distinct optical paths, comprising detecting the actively adjustable input to the light source, required during use, for media of different opacities, so as to maintain a substantially constant sensor output an output at the sensor corresponding to both the first and second optical paths.
According to a fifth aspect of the present invention there is provided a method of detecting double picked bank notes in an ATM transport mechanism, utilizing an optical detector comprising a light source and an optical sensor, which are optically coupled via light guides arranged to transmit light from the source to the sensor via two distinct optical paths, comprising detecting the actively adjustable input to the light source, required during use, for media of different opacities, so as to maintain a substantially constant sensor output an output at the sensor corresponding to both the first and second optical paths.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 ; is a schematic illustration of a note skew or double pick detector in accordance with the present invention;
FIG. 2 is a schematic illustration of the detector of FIG. 1 in the transport mechanism of an Automated Teller Machine (ATM) in accordance with the present invention;
FIG. 3 is a graphical representation of the variable output of a prior art detector, during the detection of a bank note;
FIG. 4 is a graphical representation of the detector output produced to maintain a substantially constant sensor output when zero, one or more media pass through the detector;
FIG. 5 is a schematic representation of the drive circuitry of a sensor in accordance with the present invention; and
FIG. 6 a is an illustration of the output of a sensor in accordance with the present invention when a single note is detected; and
FIG. 6 b is an illustration of the output of a sensor in accordance with the present invention when two notes are detected.
DETAILED DESCRIPTION
FIG. 1 illustrates a skew note detector 10 , including an optical sensing means 12 , for use in a note transport mechanism 14 of an Automated teller Machine (ATM) (not shown). The detector 10 comprises a light source 16 and a single optical sensor 18 , optically coupled via a pair of optical wave-guides 20 A, 20 B. The wave-guides are arranged to have an air gap 22 there between, so as to provide a note transport path between the said wave-guides. The wave-guides are further arranged to provide a first optical path 24 A and a second, distinct, optical path 24 B between the light source 16 and the sensor 18 . In this way the output of the sensor 18 is dependent on the light transmitted via the wave-guides 20 A, 20 B to the detector 18 , over both optical paths 24 A, 24 B. The output of the sensor 18 is fed to a control means 25 arranged to make determinations as to the degree of skew of a note based on the output of the sensor 18 , as will be discussed in more detail below, with reference to FIGS. 2 & 3 .
FIG. 2 illustrates the use of the detector 10 in the transport mechanism 14 . In addition it illustrates the flexibility of the detector which, in addition to note skew detection can also provide information on double picked notes. The cash transport mechanism of FIG. 2 is part of an ATM cash dispensing mechanism, comprising a currency cassette 26 arranged to contain a stack of currency notes 28 of the same pre-determined denomination supported on their long edges. The cassette 26 is associated with a pick mechanism 30 . When one or more currency notes are to be dispensed from the cassette 26 in the course of a cash dispensing operation, the pick mechanism 30 draws out notes one by one from the stack 28 , and each note is fed by feed rollers 32 , 34 , 36 via guide means 38 to feed rollers 40 . The direction of feed of the notes is at right angles to their long dimensions. It should be understood that the cash dispensing mechanism 14 could include more than one cassette each associated with a pick mechanism, but in the present embodiment only one cassette and pick mechanism will be described.
Each picked note is passed through the sensing station 12 by the feed rollers 40 and by further feed rollers 42 . If a multiple note is detected by the optical system 10 , in a manner to be described in more detail below, then a divert gate 44 diverts the multiple note via rollers 46 into a reject bin 48 , in a manner known to a skilled person.
If a single note is detected then the note passes on to a stacking wheel 50 to be loaded on to stationary belt means 56 . The stacking wheel 50 comprises a plurality of stacking plates 52 spaced apart in parallel relationship along the shaft 51 of the stacking wheel 50 . When the required number of notes have been loaded on to the belt means 56 , the belt means 56 transports the notes to a cash delivery slot (not shown), again in a manner known to a skilled person, which will not therefore be described further herein.
The detector 10 is positioned within the transport mechanism 14 , such that the first and second wave-guides 20 A, 20 B lie on opposite sides of the transport path. Thus one or more bank notes being transported by the mechanism will pass through the air gap 22 between the wave-guides 20 A, 20 B. As the source 16 and sensor 18 are arranged at the same side of the transport path all necessary wiring can be located at the one side making assembly and repair considerably easier than in prior art detectors. Hence there is no need to feed wiring into the body of the transport mechanism, as with prior art skew and double pick detectors.
FIG. 3 illustrates the output of a prior art non-compensated detector. To obtain maximum contrast between zero, one and two notes the light is set and fixed to an intensity that gives maximum sensor output with no notes present i.e. close to ground or supply. When a note is introduced the light reaching the sensor is reduced, generally from 100% to 5%. The output is now close to the signal noise level. By introducing a further note a similar (20 times) reduction will take place. Output is now 0.25% and cannot be easily discriminated from noise. Thus it can only be said that there is more than one note. Such a system will fail with more opaque media such as Thin Film media.
Also, changes in operation of the light sources or sensors used in such detectors during their lifetime can cause comparable changes in output from detectors leading to false readings.
FIG. 4 illustrates a detector output in accordance with the present invention in which the output of the sensor is maintained at a constant level by adjusting the supply voltage of the light source when one or more notes is detected.
When no notes are present the output of the detector is maintained at a fixed, low level, say 300 mV by applying a current of 0.12 mA to the light source within the detector. In order to maintain the same sensor output, when a note is placed in the optical path between the light source and the sensor, the current supplied to the light source must be raised, say to 8.0 mA. If a second, superposed note is located between the light source and sensor the input must be raised again, to say 30 mA, in order to maintain the same output from the sensor.
Thus the change in input from zero to one note is almost a 7-fold increase and the increase from one to two notes is more than 4-fold. Thus these increases are much more easily determined than with prior art methods. Thus measuring the input to the light source instead of the output from the sensor provides an improved detector.
With more powerful light sources these current levels would be greater and more linear, therefore, allowing the detection of extremely opaque media.
FIG. 5 illustrates the feedback circuit required to enable the maintenance of a constant sensor output, in the detector in accordance with the present invention.
The Compensated Opacity Schematics
The Loop Reaction Speed Depends On:
(1) The charge current delivered from the driver circuit to the charge capacitor
(2) The efficiency of the LED. Higher efficiency demands less current and thus speeds up the charge of the charge capacitor as well as it demands less change in a given situation and thus speeds up the loop reaction.
(3) The phototransistor load resistor. A smaller load resistor (greater load) depletes the base region of the phototransistor faster and allows for a faster turn off.
(4) The load of the charge capacitor. The smaller the two resistors R 3 and R 4 are the faster the charge capacitor can be depleted.
(5) The charge capacitor. A smaller capacitor is charged and depleted faster.
(6) The inductor. A larger inductor increases the drive current.
Closed Loop
The LED (D 4 ) and the phototransistor (U 2 ) are physically positioned such that U 2 receives light from D 4 . This light path, together with the FB input of U 1 , creates a closed loop. The loop balances when the voltage U FB to GND is approximately 0.252 [V].
Reduction of Light
By reducing the photo current in U 2 (reduction of light received by U 2 ) the voltage U FB is reduced. This result in a current increase delivered by U 1 and thus (over time) a voltage increase across C 1 which in turn results in a current increase in D 2 , D 3 , D 4 , R 4 and R 3 . A current increase in D 4 (white LED) gives a rise in the light produced and equilibrium is restored. As this results in a current increase in R 3 the output voltage increases with the light increase.
Over voltage protection and maximum current
U 1 has a built-in over voltage protection circuit, which prevents the voltage across C 1 from rising beyond 27.5 [V].
The maximum current that can pass through D 4 is thus given by
I D4max =( U OVP −U D2+D3+D4 )/( R 3 +R 4 )=(27.5−(0.7+0.7+4))/(68+270)=65 [mA]
Maximum Output Voltage
The maximum output voltage is given by the maximum current through R 3 .
U o — max =I D4max *R 3 =0.065*68=4.42 [V]
Avoiding closed loop oscillations
If U 1 is capable of charging C 1 faster than U 2 can change the photo current then the feed back voltage (U FB ) will change too slowly and a U C1 overshoot will be the result which in turn gives excess D 4 current and thus excess light.
The rise time created by U 2 and its load resistor (R 2 ) must be so much smaller than the charging of C 1 that the resultant overshoot can be accepted. The actual speed with which C 1 is charged by U 1 depends on a set of factors which depends on the efficiency of the boost converter formed by U 1 /L 1 . Experiments are needed to obtain these data. A good result is achieved for R 2 =100 k, L 1 =5.6 uH and C 1 =10 uF.
LED On Time
When a more opaque media is introduced into the light path the feed-back loop increases the LED current to compensate for the measured light loss. The LED ON time depends on the speed with which the driver can increase the drive voltage (charge the charge capacitor) and thus the LED current. This in turn depends on the maximum drive current and the size of the charge capacitor.
A larger capacitor reduces the ON time at the delivered current and vice versa.
The current being delivered depends on the inductor. A larger inductor increases the current. The driver is limited to handle inductors below 27 uH.
By using over current (70 mA versus 20 mA) the LED On Time is reduced. The total light path must be so efficient that a common bill results in a LED current of 20 [mA] or less. The light path should not permanently be obstructed as this will lead to decreased lifetime.
The higher the LED efficiency is the less current is used to create light and similarly more current is available to charge the charge capacitor.
LED Off Time
The speed with which the light output will be reduced depends on the capacity of C 1 given that U 1 can switch off in a few microseconds.
The C 1 discharge path depends on R 3 and R 4 assuming that the forward voltages of the diodes are reasonably constant.
τ= R*C= (68 +270)*10 u=3.38 [ms]
This is too slow. A τ of less than 0.3 [ms] is wanted.
This can be achieved by increasing max current. A higher max current will result in smaller resistors. However a higher max current stresses the LED! This also demands a faster phototransistor/resistor pair as C 1 will charge faster.
Modifications may be incorporated without departing from the scope of the present invention.
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An optical detector is disclosed, which is adapted to measure the opacity of media. The detector comprises a light means and a light sensor, arranged so as to have a media path there between. The light source has a drive means, which is actively adjustable, during use, for detecting media of different opacities, so as to maintain a substantially constant sensor output.
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TECHNICAL FIELD
[0001] Embodiments described herein generally relate to a measuring apparatus and a measuring method for metallic microstructures or material properties and those using ultrasonic waves energized by a pulse laser beam.
BACKGROUND ART
[0002] There has been a wide-spread use of ultrasonic wave for measurements of metallic microstructures or material properties. For instance, in the PTL 1 below, there is disclosed a grain size measuring apparatus for measuring grain sizes in a steel plate, using the principle that energized ultrasonic waves, transmitted through a steel plate, have different attenuation characteristics depending on grain sizes in the steel plate.
[0003] It is known that grain sizes, attenuated ultrasonic waves, and ultrasonic frequencies generally follow a scatter law to be defined (by expression 1), such that:
[0000]
[
Math
1
]
D
=
(
K
-
1
·
α
·
f
-
n
)
1
n
-
1
(
expression
1
)
[0004] Here, denoted by a is an attenuation rate (dB/mm) of an ultrasonic wave, D is a grain size (mm), f is a frequency (MHz) of the ultrasonic wave, and n is a coefficient representing a scatter mode, typically within 1 to 4 or near.
[0005] In other words for ultrasonic waves scattered at crystal grains, the attenuation due to the scattering is promoted as the frequency becomes high. This tendency has an increased significance as the grain size increases. Accordingly, resultant differences in the attenuation rate can be based on to measure qualities of a metallic material, including the grain size, for instance.
[0006] For use to energize ultrasonic waves in a material to be measured, there are available known methods including a method employing a piezoelectric vibrator (as a first method), a method employing electromagnetic forces (as a second method), and a method employing a pulse laser beam (as a third method). Among them, the first method needs to closely attach the piezoelectric vibrator to the material to be measured, with an intervening medium (liquid) having a matched acoustic characteristic. Moreover, energized ultrasonic waves need to have frequencies typically about a few MHz or less. The second method permits ultrasonic waves to be energized in a non-contact manner, with a limited spacing (a stand-off distance) typically about a few mm from the material to be measured. Besides, this measuring material has to be a magnetic body. Namely, the second method is inapplicable to inspections such as that of a carbon steel (having a hot austenite structure) in a hot processing, that is a non-magnetic body, or of a stainless steel that also is a non-magnetic body.
[0007] In comparison with them, the third method is wide-spread because of advantages permitting non-contact measurements, large standoff distances (several 100 mm), and measurements of non-magnetic bodies.
CITATION LIST
Patent Literature
[0008] PTL 1: JP2006-84392 A
SUMMARY
Technical Problem
[0009] However, in the measurement of grain size, for instance, if energized ultrasonic waves have excessively high frequencies, the attenuation due to scattering at crystal grains develops at excessively high rates. As a result, energized ultrasonic waves become faint before reaching a detection point, where detected ultrasonic waves have worsened signal-to-noise ratios causing a debased measurement precision. On the other hand, if energized ultrasonic waves have excessively low frequencies, they undergo significant attenuation due to their diffusion irrelevant to the grain size, still constituting a difficulty in the measurement
[0010] Accordingly, for measurements of metallic microstructures or material properties, energized ultrasonic waves should have frequencies selected as necessary.
[0011] In the meanwhile, according to the third method, energized ultrasonic waves have a frequency distribution typically depending on equipment-specific factors including the pulse width of a pulse laser beam in use. They are subject to the structure of a pulse laser oscillator; and hard to change. In a real sense, it was difficult to energize ultrasonic waves of adequate frequencies in accordance with an object of measurement.
[0012] For instance, there is a Q-switched solid-state pulse laser oscillator, stable in the performance and wide-spread for industrial use, which can output a pulse laser beam with a pulse width, typically in a range of several nanoseconds or more. When a material to be measured is irradiated with such a pulse laser beam, there appear ultrasonic waves energized as pulse ultrasonic waves of a half wave length, having their frequency components distributed over a range of 10 to 100 (MHz), with principal peaks within a range of 20 to 50 (MHz) or neat Detected waveforms can be processed to take out specific frequency components, using one of techniques for frequency analyses, such as a Fourier transform or a wavelet transform, as well known. However, those techniques tend to have a lower frequency resolution, as a shorter time is taken for recording phenomena being the targets to be analyzed. Pulse ultrasonic waves of the half wave length are recorded within a very short time, and provide lowered frequency resolutions. Therefore, it was difficult to avoid mixing frequency components else.
[0013] Moreover, in particular for high frequency components, their amplitudes as intensities are small, so they provide low signal-to-noise ratios. For such reasons, resultant precision was occasionally insufficient for measurements of metallic microstructures or material properties, in particular for measurements of grain sizes in a metallic material, as an issue.
[0014] Further, in order for pulse laser beams to be output with a pulse width of 1 nanosecond or less, there is a short pulse laser oscillator available in the market, which however is adapted to output a pulse laser beam with a very small light energy per pulse. In a use of a pulse laser beam from the short pulse laser oscillator, energized ultrasonic waves were faint, failing to provide detection signals with sufficient intensities, giving debased signal-to-noise ratios. Resultant precision was occasionally insufficient for measurements of metallic microstructures or material properties, in particular for measurements of grain sizes in a metallic material, as an issue.
[0015] Embodiments herein have been devised in view of the problem described. It is an object of embodiments herein to provide a measuring apparatus and a measuring method for metallic microstructures or material properties. They are to be adapted for use of a pulse laser oscillator having a typical pulse width, to energize ultrasonic vibrations sustainable over durations of one and half wavelengths or more, involving desirable frequency components more than ever. This adaptation allows for measurements of metallic microstructures or material properties, in particular for more highly precise measurements to be made of grain sizes in a metallic material within a grain size range of several micrometers or less.
Solution to Problem
[0016] To achieve the object, according to embodiments herein, there is provided a measuring apparatus for metallic microstructures or material properties including in a first aspect thereof a pulse laser oscillator, a beam splitter, optical paths, a condenser, a laser interferometer, and a waveform analyzer. The pulse laser oscillator is made up to output a first laser beam. The beam splitter is made up to split the output first laser beam into split beams. The optical paths are made up to propagate light of split beams split by the beam splitter, respectively, taking different times for light propagation thereof. The condenser is made up to superimpose light of split beams propagated through the optical paths, respectively, on an identical spot of a measuring material, for irradiation therewith. The laser interferometer is made up to irradiate the measuring material with light of a second laser beam, and have light intensity variations resulted from interferences between reference light and light of the second laser beam reflected or scattered from the measuring material, as bases to detect ultrasonic waves energized by light of the first laser beam and transmitted in the measuring material. The waveform analyzer is made up to calculate a metallic microstructure or a material property of the measuring material based on ultrasonic waves detected by the laser interferometer.
[0017] According to embodiments herein, the measuring apparatus for metallic microstructures or material properties further includes in a second aspect thereof an optical path length changer made up to change a difference in optical path length at one or more of the optical paths in the first aspect
[0018] According to embodiments herein, the measuring apparatus for metallic microstructures or material properties includes in a third aspect thereof a high refractive index material provided on an optical path at one or more of the optical paths in the first aspect
[0019] According to embodiments herein, the measuring apparatus for metallic microstructures or material properties has a fourth aspect, wherein among the optical paths in the first aspect, a first optical path and a second optical path requiring a longer light propagation time than that have a length difference in between, different from a length difference between the second optical path and a third optical path requiring a longer light propagation time than this.
[0020] According to embodiments herein, there is provided a measuring method for material properties including in a first aspect thereof splitting a first laser beam into split beams, propagating light of the split beams through optical paths having different light propagation times, respectively, irradiating an identical spot of a measuring material with light of split beams propagated through the optical paths, respectively, irradiating the measuring material with light of a second laser beam, having light intensity variations resulted from interferences between reference light and light of the second laser beam reflected or scattered from the measuring material, as bases to detect ultrasonic waves energized by light of the first laser beam and transmitted in the measuring material, and analyzing detected waveforms of the ultrasonic waves, calculating a metallic microstructure or a material property of the measuring material.
Advantageous Effects
[0021] As will be seen from the foregoing, according to embodiments herein, there is an adaptation achieved for use of a pulse laser oscillator having a typical pulse width, to energize ultrasonic vibrations sustainable over durations of one and half wavelengths or more, involving desirable frequency components more than ever, thereby allowing for measurements of metallic microstructures or material properties, in particular for more highly precise measurements to be made of grain sizes in a metallic material within a grain size range of several micrometers or less.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 is a diagram showing a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 1 of embodiments herein.
[0023] FIG. 2 is a diagram showing a configuration of a laser interferometer in the measuring apparatus for metallic microstructures or material properties according to the example 1 of embodiments.
[0024] FIG. 3 includes part (A) as a graph showing an example of a sequence of pulse laser beams derived from a pulse laser oscillator in the measuring apparatus for metallic microstructures or material properties according to the example 1 of embodiments, and part (B) as a graph showing an example of a sequence of ultrasonic waves energized by the measuring apparatus for metallic microstructures or material properties according to the example 1 of embodiments.
[0025] FIG. 4 is a diagram showing a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 2 of embodiments herein.
[0026] FIG. 5 is a diagram showing a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 3 of embodiments herein.
[0027] FIG. 6 gives illustrations showing examples of a half mirror 25 in the measuring apparatus 3 for metallic microstructures or material properties according to the example 3 of embodiments.
[0028] FIG. 7 is a diagram showing a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 4 of embodiments herein.
[0029] FIG. 8 is a diagram showing a configuration of a laser interferometer 33 in the measuring apparatus for metallic microstructures or material properties according to the example 4 of embodiments.
[0030] FIG. 9 is a diagram showing a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 5 of embodiments herein.
[0031] FIG. 10 is a diagram showing a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 6 of embodiments herein.
[0032] FIG. 11 is a diagram showing a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 7 of embodiments herein.
[0033] FIG. 12 includes part (A) as a graph showing an example of a sequence of pulse laser beams derived from a pulse laser oscillator in the measuring apparatus for metallic microstructures or material properties according to the example 7 of embodiments, and part (B) as a graph showing an example of a sequence of ultrasonic waves energized by the measuring apparatus 7 for metallic microstructures or material properties according to the example 7 of embodiments.
DESCRIPTION OF EMBODIMENTS
[0034] There will be described examples of embodiments herein, with reference to the drawings.
EXAMPLE 1
[0035] Description is now made of a measuring apparatus for metallic microstructures or material properties taken as an example for energizing ultrasonic waves to measure grain sizes in a metallic material, according to an example 1 of embodiments herein.
[0036] <<Configuration of the Measuring Apparatus for Metallic Microstructures or Material Properties>>
[0037] FIG. 1 shows in a diagram a configuration of the measuring apparatus for metallic microstructures or material properties according to the example 1 of embodiments.
[0038] As shown in FIG. 1 , the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments includes a pulse laser oscillator 11 , a half wave plate 12 , a first polarizing beam splitter 13 , a combination of reflecting mirrors 14 and 15 , a second polarizing beam splitter 16 , a condensing lens 17 , a laser interferometer 30 , an oscilloscope 31 , and a waveform analyzing computer 32 .
[0039] The pulse laser oscillator 11 is provided with a Q-switched solid-state pulse laser light source employing an Nd:YAG (neodymium-doped yttrium-aluminum-garnet), and adapted to output a pulse laser beam 201 with a pulse width within degrees ranging a few nanoseconds to a dozen nanoseconds. It is noted that the pulse laser light source employed may be, for instance, a semiconductor-excited solid-state pulse laser light source, a pulse gas laser light source, a fiber laser light source, a semiconductor laser light source, or a flash lamp, or any one of those light sources combined with a laser amplifier or the like. Further, embodiments herein are applicable not simply in the case using a Q-switched solid-state pulse laser, of which output is linearly polarized, but even in cases in which the state of polarization is different as will be described later on.
[0040] The half wave plate 12 is an optical element for rotating the direction of polarization of linearly polarized light The half wave plate 12 is operable to revolve about an optical axis of the pulse laser beam 201 output from the pulse laser oscillator 11 , causing the direction of polarization to be rotated by twice the revolved angle. Here, it is fixed at an angle to have a ratio of 1:1 set up between an amount of light of a first split beam 202 and an amount of light of a second split beam 203 , as they are established as splits by the first polarizing beam splitter 13 to be described below
[0041] The first polarizing beam splitter 13 is an optical element adapted to be permeable for a set of horizontal polarized (i.e. parallel-to-paper polarized) components of the pulse laser beam 201 to transmit as the first split beam 202 , and reflective for a set of vertical polarized (i.e. normal-to-paper polarized) components of the pulse laser beam 201 to go as the second split beam 203 along an optical path oriented in a perpendicular direction relative to the above-noted optical axis.
[0042] The reflecting mirrors 14 and 15 are arranged in positions for reflecting the second split beam 203 having been reflected at the first polarizing beam splitter 13 , to make it incident to the second polarizing beam splitter 16 to be described below.
[0043] The reflecting mirrors 14 and 15 are arranged to delay the time elapsed for the second split beam 203 to travel after being split to reach a measuring material 100 , so that ultrasonic waves energized when the measuring material 100 is irradiated with light of the first split beam 202 overlap in part with ultrasonic waves energized when the measuring material 100 is irradiated with light of the second split beam 203 . It is noted that the measuring material 100 , not limited to a metallic material, may be a non-metallic material such as a glass, ceramics, or rigid plastic.
[0044] The second polarizing beam splitter 16 works to combine the first split beam 202 and the second split beam 203 with each other.
[0045] The condensing lens 17 condenses light of the first split beam 202 and the second split beam 203 combined by the second polarizing beam splitter 16 , on an identical spot on the measuring material 100 . This creates plasma at a surface of the measuring material 100 , having ultrasonic waves energized in the measuring material 100 . Then, energized ultrasonic waves travel inside the measuring material 100 , reaching an opposing surface, where they appear in the form of micro vibrations. The measuring material 100 being irradiated with light of the first split beam 202 and light of the second split beam 203 thus has micro vibrations produced thereon, which can be detected in the form of electric signals by the laser interferometer 30 .
[0046] The oscilloscope 31 is operable to display waveforms in accordance with electric signals detected by the laser interferometer 30 .
[0047] The waveform analyzing computer 32 is adapted for operations to calculate grain sizes in the measuring material 100 based on electric signals detected by the laser interferometer 30 . For instance, the waveform analyzing computer 32 is operable on waveforms detected by the laser interferometer 30 , for extracting therefrom waveforms of reflection echoes in a repetition of longitudinal ultrasonic waves, followed by applying thereto a continuous wavelet transform, to determine vibration powers by frequencies. Then, the waveform analyzing computer 32 is operable on vibration powers of longitudinal echoes, for their fitting using logarithmic functions, to determine attenuation rates a by frequencies. These values provide a basis for use of the relationship shown (in the expression 1), to calculate grain sizes.
[0048] FIG. 2 shows in a diagram a configuration of the laser interferometer 30 in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0049] As shown in FIG. 2 , the laser interferometer 30 includes a narrow line-width laser light source 101 , a beam splitter 102 , a combination of condensing lens 103 , 104 , and 106 , a photorefractive crystal 105 , and a photodiode 107 .
[0050] The narrow line-width laser light source 101 is a light source operable to output a narrow line-width laser beam 211 with a high-wave number stability and a favorable coherency.
[0051] The beam splitter 102 works to split a laser beam 211 output from the narrow line-width laser light source 101 , into two, having either transmitting as a detecting beam 211 toward the condensing lens 103 , the other being refracted to go as a pump beam 213 to be incident to the photorefractive crystal 105 .
[0052] The condensing lens 103 condenses light of the detecting beam 211 on a surface of the measuring material 100 opposing the surface irradiated with light of the first split beam 202 and light o the second split beam 203 .
[0053] The condensing lens 104 condenses light of the detecting beam 211 reflected by the measuring material 100 , to make it strike into the photorefractive crystal 105 .
[0054] The photorefractive crystal 105 is made up to work when irradiated with rays of light, as a crystal responsive to their being light or dark by having charges moved in accordance therewith, inducing changes in refraction indices.
[0055] There are rays of light of the detecting beam 211 and rays of light of the pump beam 213 incoming to the photorefractive crystal 105 , where they intersect each other, creating interference fringes. Then, the photorefractive crystal 105 has distributions of refraction indices produced therein in fringe shapes according to light and dark contrasts of the interference fringes. They each act as a diffractive gating, where part of light of the pump beam 213 is diffracted toward light of the detecting beam 212 . In such a situation, the measuring material 100 is vibrated at a high speed. This provides the detecting beam 212 with a varied optical path, causing rays of light of the detecting beam 212 to be deviated in phases relative to distributions of refraction indices, with resultant variations in amounts of light diffracted from light of the pump beam 213 to light of the detecting beam 212 .
[0056] The photodiode 107 is operable to convert fractions of light it has received into electric signals, affording to detect, as electric signals, variations in amounts of light diffracted from light of a pump beam 213 to light of a detecting beam 212 that represent a high-speed vibration on a measuring material.
[0057] <<Operations of the Measuring Apparatus for Metallic Microstructures or Material Properties>>
[0058] Description is now made of operations of the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments, with reference to FIG. 1 and FIG. 2 .
[0059] The pulse laser oscillator 11 outputs a pulse laser beam 201 , which is split by the first polarizing beam splitter 13 into a first split beam 202 and a second split beam 203 . The first split beam 202 , transmitted across the first polarizing beam splitter 13 , transmits across the second polarizing beam splitter 16 , too, before it arrives at a measuring material 100 .
[0060] On the other hand, the second split beam 203 , reflected by the first polarizing beam splitter 13 , is further reflected by the reflecting mirrors 14 and 15 and still by the second polarizing beam splitter 16 , before it arrives at the measuring material 100 .
[0061] The first split beam 202 and the second split beam 203 thus travel different optical paths after being output from the pulse laser oscillator 11 until their arrivals at the measuring material 100 , so that the second split beam 203 is delayed from the first split beam 202 to reach the measuring material 100 .
[0062] FIG. 3(A) shows in a graph an example of a sequence of pulse laser beams derived from the pulse laser oscillator 11 in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments. FIG. 3(B) shows in a graph an example of a sequence of ultrasonic waves energized by the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0063] FIG. 3(A) illustrates intensities of light of a first split beam 202 having reached a measuring material 100 , being maximized at a point of time t 1 , and intensities of light of a second split beam 203 having reached the measuring material 100 , being maximized at a point of time t 3 .
[0064] Then, FIG. 3(B) illustrates amplitudes of an ultrasonic wave energized at the point of time t 1 with light of the first split beam 202 having reached the measuring material 100 , being maximized at a point of time t 2 , and amplitudes of an ultrasonic wave energized at the point of time t 3 with light of the second split beam 202 having reached the measuring material 100 , being maximized at a point of time t 4 .
[0065] Such being the case, there is a first split beam 202 combined with a second split beam 203 delayed therefrom to reach a measuring material 100 , so that ultrasonic waves energized when the measuring material 100 is irradiated with light of the first split beam 202 overlap in part with ultrasonic waves energized when the measuring material 100 is irradiated with light of the second split beam 203 . Accordingly, there can be energized ultrasonic waves much involving specific frequency components.
[0066] Here, the first split beam 202 and the second split beam 203 have their arrival times at a surface of the measuring material 100 , with a difference Δt in between, which is representative (by expression 2), letting f be a frequency of energized ultrasonic waves, such that:
[0000] Δ t=k/f (expression 2),
[0000] where k is a correction factor in consideration of characteristics at rising and falling edges of a pulse laser beam, within degrees ranging 0.5 to 2.
[0067] The first split beam 202 and the second split beam 203 have their optical path lengths, with a difference ΔL in between as necessary to establish the arrival time difference Δt, which is representative (by expression 3), such that:
[0000] Δ L=c 0 ·Δt (expression 3),
[0000] where c 0 is the speed of light in the air, approximately 3×10 8 m/s.
[0068] Therefore, the reflecting mirrors 14 and 15 may well be arranged in position to make the optical path length difference between the first split beam 202 and the second split beam 203 equal to ΔL (i.e. in position substantially at a distance of ΔL/2).
[0069] In the meanwhile, if the above-noted Δt is excessively long relative to the pulse width of the pulse laser beam, ultrasonic waves energized with light of the first split beam 202 and ultrasonic waves energized with light of the second split beam 203 individually travel, respectively, failing to overlap, thus missing the effect of having energized ultrasonic waves much involve desirable frequency components.
[0070] Accordingly, between the times elapsed for the first split beam 202 and the second split beam 203 to arrive at a surface of the measuring material 100 , the difference Δt may well conform to a relationship to a pulse width t p of the pulse laser beam that is defined (by expression 4), such that:
[0000] Δ t<a·t p (expression 4),
[0000] where a is a constant that may well be set generally within degrees about 5 for ensured overlaps between ultrasonic waves energized with light of the first split beam 202 and ultrasonic waves energized with light of the second split beam 203 .
[0071] Such being the case, given an optical path length difference ΔL calculated using (expression 2) through (expression 4), the reflecting mirrors 14 and 15 can be arranged in position to have a resultant optical path length difference equal to the ΔL (i.e. in position substantially at a distance of ΔL/2), allowing for ultrasonic waves to be energized in a measuring material 100 , much involving specific frequency components. As will be seen from the foregoing, according to the example 1 of embodiments, the measuring apparatus 1 for metallic microstructures or material properties employs a first split beam 202 combined with a second split beam 203 travelling an optical path requiring a longer light travel time than that, with a resultant difference between their arrival times at a surface of a measuring material 100 , permitting energized ultrasonic waves to much involve specific frequency components in accordance therewith. This allows for measurements of metallic microstructures or material properties, in particular for well precise measurements to be made of grain sizes in the metallic material 100 .
[0072] Moreover, according to the example 1 of embodiments, the measuring apparatus 1 for metallic microstructures or material properties includes a combination of reflecting mirrors 14 and 15 arranged to delay the time elapsed for the second split beam to travel after being split to reach the measuring material 100 , so that ultrasonic waves energized when the measuring material 100 is irradiated with light of the first split beam overlap in part with ultrasonic waves energized when the measuring material 100 is irradiated with light of the second split beam. However, this configuration is not restrictive. There may well be a configuration including prisms or retro-reflectors substituting for the reflecting mirrors 14 and 15 .
[0073] Further, according to the example 1 of embodiments, the measuring apparatus 1 for metallic microstructures or material properties includes a laser interferometer 30 of a two-wave mixing system provided with a photorefractive crystal 105 . However, this configuration is not restrictive. There may well be a configuration including, instead of the laser interferometer 30 , a Fabry-Perot interferometer adapted to measure high-frequency vibrations even on a rough surface of a measuring material 100 , or a Michelson interferometer adapted to measure high-frequency vibrations on a mirror-finished surface of a measuring material 100
[0074] In the example 1 of embodiments described, the measuring apparatus 1 for metallic microstructures or material properties is taken as an example adapted to measure grain sizes in a measuring material 100 that has material properties else. It is noted that this example is not restrictive. There may well be an adaptation to measure a tensile strength, yield strength, or formability of the measuring material 100 , a crystalline orientation in the measuring material, or the like.
EXAMPLE 2
[0075] In the example 1 of embodiments described, the measuring apparatus 1 for metallic microstructures or material properties is taken as an example employing a pair of beam splitters to provide a difference in length between an optical path for a first split beam 202 and an optical path for a second split beam 203 , whereas this example is not restrictive.
[0076] Description is now made of a measuring apparatus for metallic microstructures or material properties taken as an example employing a single beam splitter to provide a difference in length between an optical path for a first split beam 202 and an optical path for a second split beam 203 , according to an example 2 of embodiments herein.
[0077] FIG. 4 shows in a diagram a configuration of a measuring apparatus for metallic microstructures or material properties according to the example 2 of embodiments.
[0078] As shown in FIG. 4 , the measuring apparatus 2 for metallic microstructures or material properties according to the example 2 of embodiments includes a pulse laser oscillator 11 , a half wave plate 12 , a polarizing beam splitter 22 , a condensing lens 17 , a combination of reflecting mirrors 18 and 19 , a combination of quarter wave plates 20 and 21 , a laser interferometer 30 , an oscilloscope 31 , and a waveform analyzing computer 32 .
[0079] Among those constituent components, the combination of reflecting mirrors 18 and 19 , the combination of quarter wave plates 20 and 21 , and the polarizing beam splitter 22 will be described. For each of the other components not to be described, refer to description of a component designated by an identical reference sign, as it is identical in configuration, in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0080] The quarter wave plate 20 is an optical element for changing a linear polarization to a circular polarization, and a circular polarization to a linear polarization. The quarter wave plate 20 has properties acting on linear polarized light, to rotate the direction of polarization by 90 degrees when the light is twice transmitted across the plate 20 . The quarter wave plate 21 has a similar configuration to the quarter wave plate 20 .
[0081] There is a first split beam 202 reflected by the first polarizing beam splitter 13 , and circularly polarized by the quarter wave plate 20 . The reflecting mirror 18 reflects this first split beam 202 toward the first polarizing beam splitter 13 .
[0082] There is a second split beam 203 transmitted across the first polarizing beam splitter 13 , and circularly polarized by the quarter wave plate 21 . The reflecting mirror 19 reflects this second split beam 203 toward the first polarizing beam splitter 13 .
[0083] The polarizing beam splitter 22 is adapted to be permeable for a set of horizontal polarized (i.e. parallel-to-paper polarized) components of a pulse laser beam 201 to transmit as a second split beam 203 , and reflective for a set of vertical polarized (i.e. normal-to-paper polarized) components of the pulse laser beam 201 to go as a first split beam 202 along an optical path oriented in a perpendicular direction relative to the afore-mentioned optical axis. The polarizing beam splitter 22 is further adapted to combine a first split beam 202 reflected by the reflecting mirror 18 and a second split beam 203 reflected by the reflecting mirror 19 , with each other.
[0084] Therefore, in the measuring apparatus 2 for metallic microstructures or material properties according to the example 2 of embodiments, the reflecting mirror 19 or 18 is arranged in position to make the optical path length difference between the first split beam 202 and the second split beam 203 equal to ΔL (i.e. in position substantially at a distance of ΔL/2), like the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0085] As will be seen from the foregoing, according to the example 2 of embodiments, the measuring apparatus 1 for metallic microstructures or material properties employs a single beam splitter to provide a difference between an optical path for a first split beam 202 and an optical path for a second split beam 203 . The optical path difference serves to provide a difference between arrival times at a surface of a measuring material 100 , which permits energized ultrasonic waves to much involve specific frequency components in accordance therewith. This allows for measurements of metallic microstructures or material properties, in particular for well precise measurements to be made of qualities of a metallic material 100 , including grain sizes among others.
EXAMPLE 3
[0086] In the example 1 of embodiments described, the measuring apparatus 1 for metallic microstructures or material properties is taken as an example including a pulse laser oscillator 11 for outputting a pulse laser beam of linear polarized light, to provide a difference in length between an optical path for a first split beam 202 and an optical path for a second split beam 203 , the split beams being split from the pulse laser beam of linear polarized light. It however is noted that the pulse laser beam, in no way limited to a linear polarization, may well be non-polarized.
[0087] FIG. 5 shows in a diagram a configuration of a measuring apparatus for metallic microstructures or material properties according to an example 3 of embodiments herein.
[0088] As shown in FIG. 5 , the measuring apparatus 3 for metallic microstructures or material properties according to the example 3 of embodiments includes a pulse laser oscillator 24 , a half mirror 25 , a combination of condensing lens 17 and 27 , a combination of reflecting mirrors 14 , 15 , and 26 , a laser interferometer 30 , an oscilloscope 31 , and a waveform analyzing computer 32 .
[0089] Among those constituent components, the pulse laser oscillator 24 , the half mirror 25 , the reflecting mirror 26 , and the condensing lens 27 will be described. For each of the other components not to be described, refer to description of a component designated by an identical reference sign, as it is identical in configuration, in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0090] The pulse laser oscillator 24 is adapted to output a pulse laser beam 201 that is a non-polarized laser beam having a pulse width within degrees ranging a few nanoseconds to a dozen nanoseconds.
[0091] The half mirror 25 is a mirror reflector for splitting the pulse laser beam 201 output from the pulse laser oscillator 24 into a first split beam 202 and a second split beam 203 .
[0092] FIG. 6 shows in illustrations in part (A) and part (B) thereof examples of the half mirror 25 in the measuring apparatus 3 for metallic microstructures or material properties according to the example 3 of embodiments.
[0093] As shown in FIG. 6(A) , the half mirror 25 is formed as a combination of a permeable plate 301 adapted to transmit light of a pulse laser beam 201 output from the pulse laser oscillator 24 , and a set of reflective elements 302 fixed thereon. The reflective elements 302 are made to occupy a total area, whereby the permeable plate 301 has a total area retained to be 1:1 thereto.
[0094] The half mirror 25 may well have a configuration illustrated in FIG. 6(B) .
[0095] FIG. 6(B) shows an example in which the half mirror 25 is provided as a combination of a reflecting mirror 303 adapted to reflect light of a pulse laser beam 201 output from the pulse laser oscillator 24 , and a set of holes 304 formed therein. The holes 304 are formed to occupy a total area, whereby the reflecting mirror 303 has a total area retained to be 1:1 thereto.
[0096] There is a second split beam 203 reflected by the reflecting mirror 15 . This split beam 203 is reflected by the reflecting mirror 26 toward the condensing lens 27 .
[0097] A measuring material 100 is set. On a surface of the measuring material 100 , there is a spot on which light of the first split beam 202 is condensed. For the second split beam 203 reflected by the reflecting mirror 26 , the condensing lens 27 is arranged to condense its light on substantially the same spot as that spot, for irradiation therewith.
[0098] Therefore, in the measuring apparatus 3 for metallic microstructures or material properties according to the example 3 of embodiments, the reflecting mirrors 14 , 15 , and 26 are arranged as necessary to make the optical path length difference between the first split beam 202 and the second split beam 203 equal to ΔL (i.e. in a position or positions substantially at a distance of ΔL/2), like the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0099] As will be seen from the foregoing, according to the example 3 of embodiments, the measuring apparatus 3 for metallic microstructures or material properties is operable, even in a situation using light of a pulse laser beam that is non-polarized for irradiating a measuring material 100 , to make use of a combination of a first split beam 202 and a second split beam 203 travelling an optical path requiring a longer light travel time than that This combination serves to provide a difference between arrival times at a surface of the measuring material 100 , which permits energized ultrasonic waves to much involve specific frequency components in accordance therewith. This allows for measurements of metallic microstructures or material properties, in particular for well precise measurements to be made of qualities of a metallic material 100 , including grain sizes among others.
[0100] According to the example 3 of embodiments, the measuring apparatus 3 for metallic microstructures or material properties has a configuration including a half mirror 25 . However, there may well be a configuration including, instead of the half mirror 25 , a non-polarized beam splitter adapted to split a non-polarized laser beam.
EXAMPLE 4
[0101] In the example 1 of embodiments described, the measuring apparatus 1 for metallic microstructures or material properties is taken as an example including a laser interferometer 30 adapted to use light of a laser beam 211 for irradiating a surface of a measuring material 100 opposing a surface irradiated with light of a first split beam 202 and light of a second split beam 203 . The laser interferometer 30 is further adapted to have light intensity variations resulted from interferences between reference light and light of the laser beam 211 reflected from the measuring material 100 , as bases to detect ultrasonic waves energized by light of the first split beam 202 and light of the second split beam 203 and transmitted in the measuring material. It however is noted that this example is not restrictive.
[0102] Description is now made of a measuring apparatus 4 for metallic microstructures or material properties taken as an example including a laser interferometer adapted to use light of a laser beam 211 for irradiating an identical surface of a measuring material 100 irradiated with light of a first split beam 202 and light of a second split beam 203 , and have light intensity variations resulted from interferences between reference light and light of the laser beam 211 reflected from the measuring material 100 , as bases to detect ultrasonic waves energized by light of the first split beam 202 and light of the second split beam 203 and transmitted in the measuring material, according to an example 4 of embodiments herein.
[0103] FIG. 7 shows in a diagram a configuration of a measuring apparatus for metallic microstructures or material properties according to the example 4 of embodiments.
[0104] As shown in FIG. 7 , the measuring apparatus 4 for metallic microstructures or material properties according to the example 4 of embodiments includes a pulse laser oscillator 11 , a half wave plate 12 , a first polarizing beam splitter 13 , a combination of reflecting mirrors 14 and 15 , a second polarizing beam splitter 16 , a condensing lens 17 , a laser interferometer 33 , an oscilloscope 31 , and a waveform analyzing computer 32 .
[0105] Among those constituent components, the laser interferometer 33 will be described. For each of the other components not to be described, refer to description of a component designated by an identical reference sign, as it is identical in configuration, in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0106] FIG. 8 shows in a diagram a configuration of the laser interferometer 33 in the measuring apparatus 4 for metallic microstructures or material properties according to the example 4 of embodiments.
[0107] As shown in FIG. 8 , the laser interferometer 33 includes a narrow line-width laser light source 101 , a beam splitter 102 , a combination of condensing lens 103 , 104 , and 106 , a photorefractive crystal 105 , a photodiode 107 , and a wavelength selecting filter 108 . Among those constituent components, the wavelength selecting filter 108 will be described. For each of the other components not to be described, refer to description of a component designated by an identical reference sign, as it is identical in configuration, in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0108] As shown in FIG. 8 , the laser interferometer 33 is made up to use light of a detecting beam 211 split from a laser beam 211 to irradiate a surface of a measuring material 100 irradiated with light of a first split beam 202 and light of a second split beam 203 , and condense light of the detecting beam 211 reflected on the surface of the measuring material 100 , to provide as incident light to the photorefractive crystal 105 .
[0109] In this situation, the wavelength selecting filter 108 , installed on an optical path of light of the detecting beam 211 , works to keep light of the first split beam 202 and the second split beam 203 reflected on the surface of the measuring material 100 , from striking into the photorefractive crystal 105 .
[0110] As will be seen from the foregoing, according to the example 4 of embodiments, the measuring apparatus 4 for metallic microstructures or material properties is operable to use light of a laser beam 211 to irradiate a surface of a measuring material 100 irradiated with light of a first split beam 202 and light of a second split beam 203 , thereby having light intensity variations resulted from interferences between reference light and light of the laser beam 211 reflected from the measuring material 100 , as bases to detect ultrasonic waves energized by light of the first split beam 202 and light of the second split beam 203 and transmitted in the measuring material 100 .
EXAMPLE 5
[0111] In the example 1 of embodiments described, the measuring apparatus 1 for metallic microstructures or material properties is taken as an example including a combination of reflecting mirrors 14 and 15 fixed in position so that ultrasonic waves energized with light of a first split beam 202 and ultrasonic waves energized with light of a second split beam 203 overlap with each other. However, there may well be employed a combination of reflecting mirrors 14 and 15 arranged to be movable.
[0112] Description is now made of a measuring apparatus 1 for metallic microstructures or material properties taken as an example including a combination of reflecting mirrors 14 and 15 arranged to be movable so that ultrasonic waves energized with light of a first split beam 202 and ultrasonic waves energized with light of a second split beam 203 overlap with each other, according to an example 5 of embodiments herein.
[0113] FIG. 9 shows in a diagram a configuration of a measuring apparatus for metallic microstructures or material properties according to the example 5 of embodiments.
[0114] As shown in FIG. 9 , the measuring apparatus 5 for metallic microstructures or material properties according to the example 5 of embodiments includes a pulse laser oscillator 11 , a half wave plate 12 , a first polarizing beam splitter 13 , a combination of reflecting mirrors 14 and 15 , a second polarizing beam splitter 16 , a condensing lens 17 , a laser interferometer 33 , an oscilloscope 31 , and a waveform analyzing computer 32 . It further includes an optical path length calculator 41 , a driver 42 , a motor 43 , a revolving shaft 44 , and a mirror cabinet 45 .
[0115] Among those constituent components, the optical path length calculator 41 , the driver 42 , the motor 43 , the revolving shaft 44 , and the mirror cabinet 45 will be described. For each of the other components not to be described, refer to description of a component designated by an identical reference sign, as it is identical in configuration, in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments. Here, the optical path length calculator 41 , the driver 42 , the motor 43 , the revolving shaft 44 , and the mirror cabinet 45 constitute a section, which is referred to as an optical path length changer.
[0116] The optical path length calculator 41 serves when a frequency of an ultrasonic wave to be energized is input in accordance with the user's operation, to calculate an optical path length for a second split beam 203 , as necessary, to energize ultrasonic waves of the input frequency.
[0117] The driver 42 is adapted to generate a drive signal to establish the optical path length for the second split beam 203 , as it is calculated by the optical path length calculator 41 .
[0118] The motor 43 follows the drive signal generated by the driver 42 to make the revolving shaft 44 revolve, thereby causing the mirror cabinet 45 to move in either direction X 1 or X 2 , carrying the combination of reflecting mirrors 14 and 15 accommodated therein.
[0119] As will be seen from the foregoing, according to the example 5 of embodiments, the measuring apparatus 5 for metallic microstructures or material properties is operable to make use of a combination of a first split beam 202 and a second split beam 203 travelling an optical path requiring a longer light travel time than that, in the manner of rendering variable the difference between arrival times at a surface of a measuring material 100 . This permits energized ultrasonic waves to much involve specific frequency components, as necessary, along with the context of measurement, thus affording to change ultrasonic frequency components available for the measurement, in an adequate manner complying with the context of measurement. This allows for measurements of metallic microstructures or material properties, in particular for well precise measurements to be made of grain sizes in the metallic material 100 .
[0120] According to the example 5 of embodiments, the measuring apparatus 5 for metallic microstructures or material properties employs a motor to be driven to displace a mirror cabinet 45 in either direction X 1 or X 2 . However, this is not restrictive. There may well be use of a hydraulic or pneumatic cylinder to move a mirror cabinet 45 in either direction X 1 or X 2 .
EXAMPLE 6
[0121] In the example 1 of embodiments described, the measuring apparatus 1 for metallic microstructures or material properties is taken as an example including a combination of reflecting mirrors 14 and 15 arranged in position so that ultrasonic waves energized with light of a first split beam 202 and ultrasonic waves energized with light of a second split beam 203 overlap with each other. However, there may well be a high refractive index material installed in an optical path of a second split beam, to make the second split beam travel a shorter optical path to arrive at a measuring material 100 .
[0122] Description is now made of a measuring apparatus for metallic microstructures or material properties taken as an example including a high refractive index material installed along an optical path of a second split beam, according to an example 6 of embodiments herein.
[0123] FIG. 10 shows in a diagram a configuration of a measuring apparatus for metallic microstructures or material properties according to the example 6 of embodiments.
[0124] As shown in FIG. 10 , the measuring apparatus 6 for metallic microstructures or material properties according to the example 6 of embodiments includes a pulse laser oscillator 11 , a half wave plate 12 , a first polarizing beam splitter 13 , a combination of reflecting mirrors 14 and 15 , a second polarizing beam splitter 16 , a condensing lens 17 , a laser interferometer 30 , an oscilloscope 31 , a waveform analyzing computer 32 , and a combination of high refractive index materials 51 and 52 .
[0125] Among those constituent components, the combination of high refractive index materials 51 and 52 will be described. For each of the other components not to be described, refer to description of a component designated by an identical reference sign, as it is identical in configuration, in the measuring apparatus 1 for metallic microstructures or material properties according to the example 1 of embodiments.
[0126] The high refractive index material 51 is installed along a course of an optical path of a second split beam 203 extending between the first polarizing beam splitter 13 and the reflecting mirror 14 . The high refractive index material 52 is installed along a course of the optical path of the second split beam 203 extending between the reflecting mirror 15 and the second polarizing beam splitter 16 .
[0127] The high refractive index materials 51 and 52 are each formed by using a medium that has a higher refractive index than the air, so that the optical path of the second split beam 203 has a contracted length.
[0128] In the meanwhile, in the high refractive index materials 51 and 52 , that is, in the medium having a higher refractive index than the air, light has a slower speed c 1 than in the air, which is representative (by expression 5), such that:
[0000] c 1 =c 0 /n (expression 5),
[0000] where n is a refractive index of the high refractive index materials 51 and 52 . Therefore, according to the example 6 of embodiments, the measuring apparatus 6 for metallic microstructures or material properties has a length difference ΔL′ between an optical path of a first split beam 202 and the optical path of the second split beam 203 which is representative (by expression 6), such that:
[0000] Δ L′=c 1 ·Δt=c 0 ·t/n (expression 6).
[0129] Accordingly, the optical path of the second split beam 203 can be cut down in length, for instance, by approximately 31% when the high refractive index materials 51 and 52 are made of a quartz glass that has a refractive index n equal to 1.45.
[0130] It is noted that the high refractive index materials 51 and 52 each have an input end face and an output end face for the second split beam 203 to strike in and out. It is preferable to apply an AR (anti-reflective) coat to each end, to suppress losses in light amount due to reflection at the end faces.
[0131] As will be seen from the foregoing, according to the example 6 of embodiments, the measuring apparatus 6 for metallic microstructures or material properties includes a high refractive index material set installed on an optical path of a second split beam 203 . Accordingly, even in a situation suffering from constraints, such as those due to an installation space of equipment, in which the optical path of the second split beam 203 might otherwise have failed to save a sufficient length as the high refractive index material set is unused, it is still possible for the measuring apparatus 6 to employ a first split beam 202 combined with the second split beam 203 travelling the optical path requiring a longer light travel time than that, with a resultant difference between their arrival times at a surface of a measuring material 100 , permitting energized ultrasonic waves to much involve specific frequency components in accordance therewith. This allows for measurements of metallic microstructures or material properties, in particular for well precise measurements to be made of grain sizes in a metallic material.
EXAMPLE 7
[0132] In the example 3 of embodiments described, the measuring apparatus 1 for metallic microstructures or material properties is taken as an example including a pulse laser oscillator 24 adapted to output a pulse laser beam as a non-polarized laser beam, and having a first split beam 202 and a second split beam 203 split from the pulse laser beam, providing a length difference between their optical paths.
[0133] Description is now made of a measuring apparatus 1 for metallic microstructures or material properties taken as an example including a pulse laser oscillator 24 adapted to output a pulse laser beam as a non-polarized laser beam, and having a first split beam 202 , a second split beam 203 , and a third split beam split from the pulse laser beam, providing length differences among their optical paths, according to an example 7 of embodiments herein.
[0134] FIG. 11 shows in a diagram a configuration of a measuring apparatus for metallic microstructures or material properties according to the example 7 of embodiments.
[0135] As shown in FIG. 11 , the measuring apparatus 7 for metallic microstructures or material properties according to the example 7 of embodiments includes a pulse laser oscillator 24 , a combination of condensing lens 17 , 27 , and 64 , a combination of reflecting mirrors 14 , 15 , 26 , 62 , and 63 , a combination of non-polarizing beam splitters 60 and 61 , a laser interferometer 30 , an oscilloscope 31 , and a waveform analyzing computer 32 .
[0136] Among those constituent components, the condensing lens 64 , the reflecting mirrors 62 and 63 , and the non-polarizing beam splitters 60 and 61 will be described. For each of the other components not to be described, refer to description of a component designated by an identical reference sign, as it is identical in configuration, in the measuring apparatus 3 for metallic microstructures or material properties according to the example 3 of embodiments.
[0137] There is a pulse laser beam 201 output from the pulse laser oscillator 24 , and split at the non-polarizing beam splitter 60 into a first split beam 202 and a fourth split beam 205 . The first split beam 202 is transmitted across the non-polarizing beam splitter 60 . The fourth split beam 205 is reflected by the non-polarizing beam splitter 60 toward the non-polarizing beam splitter 61 . The non-polarizing beam splitter 60 is made up to give the first split beam 202 an amount of light to be 1:2 in the ratio to an amount of light it gives the fourth split beam 205 .
[0138] The fourth split beam 205 , split at the non-polarizing beam splitter 60 , enters the non-polarizing beam splitter 61 , where it is split into a second split beam 203 and a third split beam 204 . The second split beam 203 is reflected by the non-polarizing beam splitter 61 toward the reflecting mirror 62 . The third split beam 204 is transmitted across the non-polarizing beam splitter 61 . Here, the non-polarizing beam splitter 61 is made up to give the second split beam 203 an amount of light to be 1:1 in the ratio to an amount of light it gives the third split beam 204 .
[0139] The second split beam 203 , split at the non-polarizing beam splitter 61 , is reflected by the reflecting mirrors 62 and 63 toward the condensing lens 64 .
[0140] A measuring material 100 is set. On a surface of the measuring material 100 , there is a spot on which light of the first split beam 202 is condensed. For the second split beam 203 reflected by the reflecting mirrors 62 and 63 , the condensing lens 64 is arranged to condense its light on substantially the same spot as that spot, for irradiation therewith.
[0141] The non-polarizing beam splitters 60 and 61 , the reflecting mirrors 26 , 62 , and 63 , and the condensing lens 64 are arranged in positions to establish an optical path for the second split beam 203 , such that ultrasonic waves energized when the measuring material 100 is irradiated with light of the first split beam 202 overlap in part with ultrasonic waves energized when the measuring material 100 is irradiated with light of the second split beam 203 .
[0142] Further, the non-polarizing beam splitters 60 and 61 , the reflecting mirrors 14 , 15 , and 26 , and the condensing lens 27 are arranged in positions to establish an optical path for the third split beam 204 , such that ultrasonic waves energized when the measuring material 100 is irradiated with light of the second split beam 203 overlap in part with ultrasonic waves energized when the measuring material 100 is irradiated with light of the third split beam 204 .
[0143] As will be seen from the foregoing, according to the example 7 of embodiments, the measuring apparatus 7 for metallic microstructures or material properties is operable to employ, among others derived from an output pulse laser beam, a combination of a first split beam 202 and a second split beam 203 travelling an optical path requiring a longer light travel time than that, with a resultant difference between their arrival times on a surface of a measuring material 100 , and a combination of the second split beam 203 and a third split beam 204 travelling an optical path requiring a longer light travel time than that, with a resultant difference between their arrival times on the surface of the measuring material 100 , in the manner of rendering the differences different from each other. This permits a single shot of pulse laser beam to energize two kinds of ultrasonic waves with different frequency components, allowing for measurements of metallic microstructures or material properties, in particular for well precise measurements to be made of grain sizes in a metallic material.
[0144] FIG. 12(A) as a graph showing an example of a sequence of pulse laser beams derived from a pulse laser oscillator in the measuring apparatus for metallic microstructures or material properties according to the example 7 of embodiments. FIG. 12(B) shows in a graph an example of a sequence of ultrasonic waves energized by the measuring apparatus 7 for metallic microstructures or material properties according to the example 7 of embodiments.
[0145] FIG. 12(A) illustrates intensities of light of a first split beam 202 having reached a measuring material 100 , being maximized at a point of time t 11 , intensities of light of a second split beam 203 having reached the measuring material 100 , being maximized at a point of time t 13 , and intensities of light of a third split beam 204 having reached the measuring material 100 , being maximized at a point of time t 15 .
[0146] Then, FIG. 12(B) illustrates amplitudes of an ultrasonic wave energized at the point of time t 11 with light of the first split beam 202 having reached the measuring material 100 , being maximized at a point of time t 12 , amplitudes of an ultrasonic wave energized at the point of time t 13 with light of the second split beam 203 having reached the measuring material 100 , being maximized at a point of time t 14 , and amplitudes of an ultrasonic wave energized at the point of time t 15 with light of the second split beam 204 having reached the measuring material 100 , being maximized at a point of time t 16 .
[0147] Such being the case, there is a first split beam 202 combined with a second split beam 203 delayed therefrom to reach a measuring material 100 , so that ultrasonic waves energized when the measuring material 100 is irradiated with light of the first split beam 202 overlap in part with ultrasonic waves energized when the measuring material 100 is irradiated with light of the second split beam 203 .
[0148] Further, the second split beam 203 is combined with a third split beam 204 delayed therefrom to reach the measuring material 100 , so that ultrasonic waves energized when the measuring material 100 is irradiated with light of the second split beam 203 overlap in part with ultrasonic waves energized when the measuring material 100 is irradiated with light of the third split beam 204 .
[0149] Accordingly, a single shot of pulse laser beam can serve to energize two kinds of ultrasonic waves with different frequency components, allowing for measurements of metallic microstructures or material properties, in particular for well precise measurements to be made of grain sizes in a metallic material.
[0150] It is noted that according to the example 7 of embodiments, the measuring apparatus 7 for metallic microstructures or material properties may well have a set of high refractive index materials installed on an optical path of a second split beam 203 and an optical path of a third split beam 204 , like the measuring apparatus 6 for metallic microstructures or material properties according to the example 6 of embodiments.
INDUSTRIAL APPLICABILITY
[0151] Embodiments herein are applicable to quality measurements of rolling materials in hot rolling mills.
REFERENCE SIGNS LIST
[0000]
1 , 2 , 3 , 4 , 5 , 6 , or 7 . . . a measuring apparatus for metallic microstructures or material properties
11 or 24 . . . a pulse laser oscillator
12 . . . a half wave plate
13 . . . a first polarizing beam splitter
14 , 15 , 18 , 19 , 26 , 62 , or 63 . . . a reflecting mirror
16 . . . a second polarizing beam splitter
17 , 27 , or 64 . . . a condensing lens
20 or 21 . . . a quarter wave plate
22 . . . a polarizing beam splitter
25 . . . a half mirror
30 or 33 . . . a laser interferometer
31 . . . an oscilloscope
32 . . . a waveform analyzing computer
41 . . . an optical path length calculator
42 . . . a driver
43 . . . a motor
44 . . . a revolving shaft
45 . . . a mirror cabinet
51 or 52 . . . a high refractive index material,
60 or 61 . . . a non-polarizing beam splitter
60 . . . a non-polarizing beam splitter
100 . . . a measuring material
101 . . . a narrow line-width laser light source
102 . . . a beam splitter
103 , 104 , or 106 . . . a condensing lens
105 . . . a photorefractive crystal
107 . . . a photodiode
108 . . . a wavelength selecting filter
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A pulse laser oscillator ( 11 ) outputs a first laser beam, a beam splitter splitting the first laser beam into split beams, optical paths ( 12, 13, 14, 15, 16 ) propagating light of split beams split, respectively, taking different times for light propagation thereof, a condenser superimposing light of split beams propagated through the optical paths, respectively, on an identical spot of a measuring material ( 100 ), for irradiation therewith, a laser interferometer ( 30 ) irradiating the measuring material ( 100 ) with light of a second laser beam, having light intensity variations resulted from interferences between reference light and light of the second laser beam reflected or scattered, as bases to detect ultrasonic waves energized by light of the first laser beam and transmitted in the measuring material ( 100 ), a waveform analyzer ( 32 ) calculating a metallic microstructure or a material property of the measuring material ( 100 ) based on ultrasonic waves.
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BACKGROUND
[0001] 1. Field of the Disclosure
[0002] The disclosure refers to a manually guided press device for connecting two work pieces. In particular, the press device of the disclosure is suited for connecting a pipe with a press fitting by pressing. The disclosure further relates to manually guided press devices for pressing cable lugs.
[0003] 2. Discussion of the Background Art
[0004] Such manually guided press devices comprise a pressing tool with a plurality of pressing jaws. With a pressing tool for pipe connections, the pressing jaws embrace the press fitting slipped over the pipe. By closing the pressing jaws the press fitting and the pipe are deformed or pressed. With pressing tools for cable lugs, the same are pressed by closing pressing jaws, the cable lug being positioned between at least two pressing jaws. In this case, one of the pressing jaws may be stationary. For the generation of the necessary high pressing forces, the pressing tool is connected to a converting device, typically an electrohydraulic or electromechanic converting device. The converting device is generally driven by an electric motor with the interposition of a transmission. A hydraulic converting device comprises a hydraulic pump, usually a piston pump or a gear pump. The pump is driven by a brush motor. Due to their construction, the pumps employed, which have to generate a high torque, require a rather low drive speed, typically about 2,000 to 5,000 rotations per minute. However, since the brush motor is operated at much higher speeds, a reduction gearing is arranged between the motor and the pump. With a hydraulic converting device, the hydraulic medium conveyed by the pump displaces a working piston. The working piston is connected with the pressing jaws so that high pressing forces can be transmitted to pressing jaws by the working piston. Upon reaching the set or predetermined maximum pressing force, the pressure chamber provided for the actuation of the working piston is opened by means of a valve, typically in the form of a needle valve, so that a sudden pressure reduction occurs in the pressure chamber. The pressure reduction causes an increase in the pump speed that is detected via a rotational speed sensor and causes an automatic deactivation of the electric motor. A return spring thereafter pushes back the working piston and the pressing jaws are thereby opened.
[0005] Such manually guided press devices have to be maintained at regular intervals. Studies have shown that the component determining the maintenance interval is the brush motor. Due to the frequent starting under load and to the provision of stop functions in which a short circuit is produced via the brush, the brushes of the brush motor are subjected to extensive wear.
[0006] It is an object of the disclosure to provide a manually guided press device for which longer maintenance intervals are realized.
SUMMARY
[0007] The manually guided press device of the disclosure for connecting a pipe with a press fitting by pressing comprises a pressing tool with a plurality of pressing jaws. The pressing tool is driven by an electric motor with the interposition of a converting device. In particular, the converting device is an electrohydraulic or an electromechanic converting device. According to the disclosure the electric motor is a brushless motor. It is a significant advantage of a brushless electric motor over the brush motors used in the known pressing tools that no wearprone brushes are provided. The use of a brushless electric motor allows omitting the brushes that are subject to extensive wear due to high loads. Thereby, it becomes possible to extend the maintenance cycles significantly. Specifically, the number of pressing operations that can be performed between two maintenance checks can at least be doubled or even tripled.
[0008] Further, the use of a brushless electric motor, as contemplated by the disclosure, has the advantage that the maintenance costs are reduced, since no replacement of the brushes or the entire brush motor is required.
[0009] The electric motor is an external or internal rotor motor. Preferably, the electric motor is a brushless external rotor motor. Compared to brushless internal rotor motors, external rotor motors have the advantage that, for the same overall dimensions, they rotate slower and have a higher torque. For example, a sevenpole external rotor motor comprises a stator with twelve grooves, with every second groove being wound. As a consequence, the filed rotates by 60° when the phase changes. In this example, the bell or the external rotor surrounding the stator has fourteen magnets or seven pole pairs distributed over 360°. When changing the phase, the external rotor moves seven times slower than the field so that the outer rotor rotates by only 8.57° when the field rotates by 60°. Thereby, a lower rotational speed is realized for the outer rotor.
[0010] In a particularly preferred embodiment the brushless electric motor is directly connected with the converting device. In this preferred development of the present disclosure a reduction gearing, ultimately necessary when using brush motors, can be omitted. When an electrohydraulic converting device is used, it is therefore particularly preferred that the output shaft of the electric motor is connected directly with the hydraulic pump, i.e. with the drive shaft of the hydraulic pump. Due to the omission of the gearing, possible in this embodiment, costs can be reduced. In particular, the necessary structural space can be reduced significantly. It is a particular advantage of the use of a brushless motor, in which the reduction gearing is omitted or drastically simplified, that the efficiency can be improved significantly. Losses occur in particular due to the friction within the gearing, which losses can be reduced significantly by a drastic simplification or even a complete omission of the gearing. Omitting the gearing, which is possible when a brushless motor is used, allows an increase in efficiency of, in particular, more than 20% and, more preferred, more than 25%. This has the advantage that the operating time can be extended significantly if the same accumulator is used, or that, for the same operating time, a smaller and thus lighter accumulator can be used. Another advantage of simplifying or omitting the gearing is a significantly reduced generation of noise. Further, the vibrations occurring, as well as the heat generated are reduced.
[0011] Preferably, the output shaft of the electric motor is arranged such that it is coaxial with the drive shaft of the hydraulic pump. Thus, a simple connection of the shafts can be realized with a small structural space required.
[0012] The use of a brushless electric motor for operating the press device has a particular advantage in that a brushless electric motor or the control device of the brushless electric motor allows realizing additional functions in a simple manner.
[0013] In a particularly preferred embodiment of the disclosure, a control device connected with or integrated in the electric motor is used not only to control the rotational speed required to generate a desired torque or a desired pressing force, but also to determine the current rotational speed. For example, it is possible to conclude on the motor speed from the voltage induced into the windings. This allows a simple detection of the fact that the motor speed increases. A sudden increase in motor speed occurs when the pressure valve is opened, i.e. as soon as the required pressing force is reached. This rise in the rotational speed of the motor can be determined in a simple manner through the control device and can be used to deactivate the electric motor. The rotational speed sensor required in known press devices and ultimately necessary to determine the rise in rotational speed when the valve opens, can be omitted because of the use of a brushless electric motor as contemplated by the disclosure. This allows for a reduction of manufacturing costs. In particular, this has the advantage that a component important to the function of the press device is replaced by the control device and that significantly more reliable determination of the rotational speed is thereby achieved. The rotational speed sensor that might result in considerably damage to the press device can no longer occur.
[0014] In another preferred embodiment, the determination or calculation of the motor torque and/or the pressing force generated by the pressing jaws is done directly from the parameters of the brushless electric motor. Thereby, an automatic deactivation of the electric motor upon reaching the desired or set pressing force can be realized in a simple manner. In particular, it is possible to omit or at least drastically simplify the valve that opens the pressure chamber in conventional press devices. The valve, which in known press devices is opened when the pressing force is reached, can be simplified in this preferred embodiment at least such that it merely is an emergency valve that prevents damage to the press device upon a failure of the control device.
[0015] Another advantage of using a brushless electric motor, especially in combination with a control device already existing or connected with the electric motor, is that upon reaching the set pressing force or upon the occurrence of malfunctions the motor can be decelerated by corresponding control commands or by software. It is thereby possible to avoid the extensive wear occurring with brush motors when the motor is decelerated by the short circuit produced.
[0016] Still another advantage of using a brushless electric motor is that a sensor-less commutation is possible. Thus, it is no longer necessary to provide failure-prone rotational speed sensors to monitor the pressing force or to control operation.
[0017] In a preferred development of the press device a setting device is provided. Using the setting device, it is possible, for example, to enter pressing parameters in a simple manner via keys and a display. The same are transmitted to the control device of the electric motor so that a direct simple control of the electric motor and thus of the entire press device is possible. Depending on the configuration of the control device and the parameters determined by the control device, it is thus possible that the desired pressing force merely has to be entered via the setting device. An adaptation in the mechanics, by which, for example the pressure point at which the valve opens is varied, is not required. In this respect, the structure of the press device is significantly simplified. Further, mechanical components are omitted which, especially due to the great forces occurring, could be damaged or are at least more maintenance-intensive.
[0018] In a particularly preferred development of the disclosure the setting device allows, for example, entering the type of press device used. This is advantageous in that a manually guided press device can be provided in which the pressing tool is exchangeable. Thus, a troublesome adaptation of the press device to the pressing tool is no longer required. It is only necessary to enter an ID number of the pressing tool, for example. In a particularly preferred development the type of pressing tool is detected automatically by the press device. This may be done by means of an identification of the type of the pressing tool which is detected, in particular automatically, by control device. Thus, the user can change the pressing tool and does not have to pay attention to an adaptation of the corresponding pressing parameters. Thereby, it is avoided, for example, that the maximum allowed pressing force of a particular pressing tool is exceeded.
[0019] In another preferred embodiment of the disclosure a signal output device is connected with the control device of the brushless electric motor. By means of the signal output device the finishing of the pressing can be signaled in a simple manner. The occurrence of malfunctions or the requirement of maintenance can be signaled by the signal output device. The signal output device may be an acoustic and/or tactile (vibration) signal output device. The in particular acoustic signal output may in this case be realized directly by the control device. In addition, the signal output device may also have a display.
[0020] According to the disclosure, the manually guided press device in a preferred embodiment is operated such that the control device connected with the electric motor is used, as described above, to determine the rotational speed and/or the torque and/or other pressing parameters. In addition, the control device can also be used to control a signal output device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The following is a detailed description of preferred embodiments with reference to the accompanying drawings.
[0022] In the Figures:
[0023] FIG. 1 is a schematic sectional view of an embodiment of a manually guided press device for connecting a pipe with a press fitting by pressing, in accordance with the disclosure, and
[0024] FIG. 2 is a schematic side elevational view of an embodiment of a manually guided press device for pressing cable lugs, in accordance with the disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The manually guided press device for connecting pipes by pressing a press fitting ( FIG. 1 ) comprises a brushless electric motor 10 whose output shaft 12 is connected with an eccentric 14 . A pump piston 16 is driven via the eccentric 14 . Further, for being supplied with power, the brushless electric motor 10 is connected to a non-illustrated rechargeable battery, such as an accumulator, or a power supply unit or the mains.
[0026] Hydraulic fluid is supplied to a chamber 20 via a control valve 18 . By pumping the hydraulic fluid into the chamber 20 , a working piston 22 is moved to the left in the drawing. The left end of the working piston 22 in the drawing is connected to the pressing jaws 24 of the pressing tool 26 . By increasing the pressure in the chamber 20 and by a resulting displacement of the working piston 22 to the left, the pressing jaws 24 are closed. The pressing jaws 24 embrace the non-illustrated pipe as well as the press fitting surrounding the pipe, which are both situated in an opening 25 .
[0027] The press device illustrated thus has three main components, i.e. the pressing tool 26 , a converting device 28 and the electric motor 10 .
[0028] In the embodiment illustrated a needle valve 30 is provided that opens the chamber 30 upon reaching the pressing force, so that the pressure in the chamber decreases abruptly. Due to this pressure reduction in the chamber 20 the rotational speed of the motor increases significantly. This increase in rotational speed is detected by a control device 32 connected to the brushless electric motor 10 and leads to a deactivation of the electric motor 10 . As soon as the electric motor 10 is deactivated, a spring 34 pushes the working piston 22 back into its initial position illustrated in FIG. 1 .
[0029] Further, the control device 32 may be connected to a setting device 34 that is in particular provided at the non-illustrated housing of the press device. Via the setting device 34 , which may comprise a display 36 and input keys 38 , it is possible to preset pump parameters, pressing forces etc. Further, the brushless electric motor provided by the disclosure can be used as a signal output device. This may be an acoustic signal output, a tactile signal output, such as the generation of vibrations, or an optical signal output via a display. Of course, the already existing display 36 of the setting device could be used for signal outputting purposes.
[0030] In another preferred embodiment of a press device, the press device is a press device for cable lugs ( FIG. 2 ). The press device for cable lugs schematically illustrated in FIG. 2 is illustrated in non-sectional side elevation, the functioning corresponding to that of the pressing tool described with reference to FIG. 1 . In particular, according to the disclosure, a brushless electric motor 10 is provided also in this case, which is also connected to an eccentric. Thus, the same components as illustrated in FIG. 1 are arranged in the housing 41 . Only the generally cylindrical intermediate part 42 ( FIG. 1 ) provided to receive the pressing jaws is omitted. Instead, pressing jaws 44 ( FIG. 2 ) are connected to the working piston 22 ( FIG. 1 ). The pressing jaws 44 are arranged within a pressing jaw head 46 . The pressing jaw head 46 has an opening 48 into which the cable lug to be pressed is inserted.
[0031] For the rest, the structure of the pressing tool illustrated in FIG. 2 corresponds to the pressing tool described with reference to FIG. 1 , in particular with respect to the design of the drive for the pressing jaws.
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A manual press device for connecting two work pieces by means of embossing, comprising a press tool, a converting device, and an electric motor. The electric motor is designed as a brushless electric motor, and preferably connected directly to a hydraulic pump without interconnecting a transmission.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of application Ser. No. 10/080,785 filed on Feb. 22, 2002, now U.S. Pat. No. 7,547,345, which is a continuation of application Ser. No. 09/499,174 filed on Feb. 7, 2000, now abandoned.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates in general to explosive shaped charges and, in particular to, high performance powdered metal mixtures for use as the liner in a shaped charge, particularly a shaped charge used for oil well perforating.
BACKGROUND OF THE INVENTION
[0003] Without limiting the scope of the invention, its background is described in connection with perforating oil wells to allow for hydrocarbon production, as an example. Shaped charges are typically used to make hydraulic communication passages, called perforations, in a wellbore drilled into the earth. The perforations are needed as casing is typically cemented in place with the wellbore. The cemented casing hydraulically isolates the various formations penetrated by the wellbore.
[0004] Shaped charges typically include a housing, a quantity of high explosive and a liner. The liner has a generally conical shape and is formed by compressing powdered metal. The major constituent of the powdered metal was typically copper. The powdered copper was typically mixed with a fractional amount of lead, for example twenty percent by weight, and trace amount of graphite as a lubricant and oil to reduce oxidation.
[0005] In operation, the perforation is made by detonating the high explosive which causes the liner to collapse. The collapsed liner or jet is ejected from the shaped charge at very high velocity. The jet is able to penetrate the casing, the cement and the formation, thereby forming a perforation.
[0006] The penetration depth of the perforation into the formation is highly dependent upon the design of the shaped charge. For example, the penetration depth may be increased by increasing the quantity of high explosive which is detonated to propel the jet. It has been found, however, that increasing the quantity of explosive not only increase penetration depth but may also increase the amount of collateral damage to the wellbore and to equipment used to transport the shaped charge to depth.
[0007] Attempts have been made to design a liner using a powdered metal having a higher density than copper. For example, attempts have been made to design a liner using a mixture of powdered tungsten, powdered copper and powdered lead. This mixture yields a higher penetration depth than typical copper-lead liners. Typical percentages of such a mixture might be 55% tungsten, 30% copper and 15% lead. It has been found, however, the even greater penetration depths beyond that of the tungsten-copper-lead mixture are desirable.
[0008] Therefore a need has arisen for a shaped charge that yields improved penetration depths when used for perforating a wellbore. A need has also arisen for such a shaped charge having a liner that utilizes a high performance powdered metal mixture to achieve improved penetration depths.
SUMMARY OF THE INVENTION
[0009] The present invention disclosed herein comprises a liner for a shaped charge that utilizes a high performance powdered metal mixture to achieve improved penetration depths during the perforation of a wellbore. The high performance powdered metal mixture includes powdered tungsten and powdered metal binder. The powdered metal binder may be selected from the group consisting of tantalum, molybdenum, lead, copper and combination thereof. This mixture is compressively formed into a substantially conically shaped liner. The mixture may additionally include graphite intermixed with the powdered tungsten and powdered metal binder to act as a lubricant. Alternatively or in addition to the graphite, an oil may intermixed with the powdered tungsten and powdered metal binder to decrease oxidation of the powdered metal.
[0010] Tantalum and molybdenum are the preferred components of the binder as optimal performance of a shaped charge comes from the use of powdered metals that have not only a high density, but also, a high sound speed. The product of these two properties is called the acoustic impedance of the material. It has been determined that it is the acoustic impedance of the powdered metal in the shaped charge liner that best determines penetration depth, a higher value being more desirable. Thus, rather than simply increasing the density of the powdered metal mixture, it is more important to increase to acoustic density of the mixture to achieved better shaped charge performance.
[0011] In one aspect, the present invention is directed to a liner for a shaped charge that is compressively formed into a substantially conically shaped rigid body from a mixture of approximately 92 to 99 percent by weight of powdered tungsten and approximately 8 to 1 percent by weight of powdered metal binder. In one embodiment, the powdered metal binder consists essentially of lead and molybdenum. In another embodiment, the powdered metal binder consists essentially of lead, molybdenum and tantalum. In a further embodiment, the powdered metal binder consists essentially of lead, molybdenum and copper. In yet another embodiment, the powdered metal binder consists essentially of lead, molybdenum, tantalum and copper.
[0012] In another aspect, the present invention is directed to a shaped charge including a housing, a quantity of high explosive inserted into said housing and a liner inserted into the housing so that the high explosive is positioned between the liner and the housing. The liner is compressively formed into a substantially conically shaped rigid body from a mixture of approximately 92 to 99 percent by weight of powdered tungsten and approximately 8 to 1 percent by weight of powdered metal binder. In one embodiment, the powdered metal binder consists essentially of lead and molybdenum. In another embodiment, the powdered metal binder consists essentially of lead, molybdenum and tantalum. In a further embodiment, the powdered metal binder consists essentially of lead, molybdenum and copper. In yet another embodiment, the powdered metal binder consists essentially of lead, molybdenum, tantalum and copper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings of which:
[0014] FIG. 1 is a schematic illustration of a shaped charge having a liner according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
[0016] Referring to FIG. 1 , a shaped charge according to the present invention is depicted and generally designated 10 . Shaped charge 10 has a generally cylindrically shaped housing 12 . Housing 12 may be formed from steel or other suitable material. A quantity of high explosive powder 14 is disposed within housing 12 . High explosive powder 14 may be selected from many that are known in the art for use in shaped charges such as the following which are sold under trade designations HMX, HNS, RDX, HNIW and TNAZ. In the illustrated embodiment, high explosive powder 14 is detonated using a detonating signal provided by a detonating cord 16 . A booster explosive (not shown) may be used between detonating cord 16 and high explosive powder 14 to efficiently transfer the detonating signal from detonating cord 16 to high explosive powder 14 .
[0017] A liner 18 is also disposed within housing 12 such that high explosive 14 substantially fills the volume between housing 12 and liner 18 . Liner 18 of the present invention is formed by pressing, under very high pressure, powdered metal mixture. Following the pressing process, liner 18 becomes a generally conically shaped rigid body that behaves substantially as a solid mass.
[0018] In operation, when high explosive powder 14 is detonated using detonating cord 16 , the force of the detonation collapses liner 18 causing liner 18 to be ejected from housing 12 in the form of a jet traveling at very high velocity toward, for example, a well casing. The jet penetrates the well casing, the cement and the formation, thereby forming a perforation.
[0019] The production rate of fluids through such perforations is determined by the diameter of the perforations and the penetration depth of the perforations. The production rate increases as either the diameter or the penetration depth of the perforations increase. The penetration depth of the perforations is dependent upon, among other things, the material properties of liner 18 . Based upon the test data presented below, it has been determined that penetration depth is not only dependent upon the density of the powdered metal mixture of liner 18 but also upon the sound speed the powdered metal mixture of liner 18 . More particularly, it is the acoustic impedance, which is the product of the density and the sound speed, of the powdered metal mixture which determines the penetration depth of perforations created using liner 18 . Thus, to maximize the penetration depth, the acoustic impedance of liner 18 should be maximized.
[0000]
TABLE 1
Density
Sound Speed
Acoustic
Element
(g/cc)
(km/sec)
Impedance
Tungsten
19.22
4.03
77.45
Copper
8.93
3.94
35.18
Lead
11.35
2.05
23.27
Tin
7.29
2.61
19.03
Tantalum
16.65
3.41
56.78
Molybdenum
10.21
5.12
52.28
[0020] Table 1 lists the density, the sound speed and the acoustic impedance of several metals which may be used in the fabrication of liner 18 of the present invention. In theory, liner 18 could be made from 100% tungsten as this would yield the highest acoustic impedance for the powdered metal mixture of liner 18 . Manufacturing difficulties, however, prevent this from being practical. Because tungsten particles are so hard they do not readily deform, particle-against-particle, to produce a liner with structural integrity. In other words, a liner made from 100% tungsten crumbles easily and is too fragile for use in shaped charge 10 . Attempts have been made to strengthen such liners by adding a malleable material such as lead or tin as a binder. As can be seen from table 1, these materials have both low densities and low sound speeds resulting in low acoustic impedances compared to tungsten. Thus, the resulting penetration depth of a liner made from a combination of tungsten and either a lead or tin binder is not optimum.
[0021] Liner 18 of the present invention replaces some or all of the lead or tin with one or more high performance materials which is defined herein as a material having an acoustic impedance greater than that of copper. These high performance materials typically have both a high density and a high sound speed, thereby resulting in a high acoustic impedance, and also have suitable malleability in order to give strength to liner 18 .
[0022] The powdered metal mixture of liner 18 of the present invention comprises a mixture of powdered tungsten and one or more powdered high performance materials. For example, the powdered metal mixture of liner 18 of the present invention may comprises a tungsten-tantalum mixture, a tungsten-molybdenum mixture, a tungsten-tantalum-molybdenum mixture, a tungsten-tantalum-lead mixture, a tungsten-molybdenum-lead mixture, a tungsten-tantalum-molybdenum-lead mixture, a tungsten-tantalum-copper mixture, a tungsten-molybdenum-copper mixture, a tungsten-tantalum-molybdenum-copper mixture, a tungsten-tantalum-lead-copper mixture, a tungsten-molybdenum-lead-copper mixture or a tungsten-tantalum-molybdenum-lead-copper mixture. In each of the above mixtures, the tungsten is typically in the range of approximately 50 to 99 percent by weight. The tantalum is typically in the range of approximately 1 to 30 percent by weight. The molybdenum is typically in the range of approximately 1 to 30 percent by weight. The copper is typically in the range of approximately 1 to 30 percent by weight. The lead is typically in the range of approximately 0 to 20 percent by weight. The powdered metal mixture of liner 18 may additionally include graphite to act as a lubricant. Alternatively or in addition to the graphite, an oil may be mixed into the powdered metal mixture to decrease oxidation of the powdered metal. Using the mixtures of the present invention for liner 18 , the penetration depth of shaped charge 10 is improved, compared with the penetration depths achieved by shaped charges having liners of compositions known in the art.
[0023] More specifically, liner 18 of the present invention may contain approximately 50 to 90 percent by weight of tungsten, approximately 0 to 20 percent by weight of the lead, approximately 1 to 30 percent by weight of the tantalum and approximately 1 to 30 percent by weight of the molybdenum. Alternatively, liner 18 of the present invention may contain approximately 50 to 90 percent by weight of tungsten, approximately 0 to 20 percent by weight of the lead, approximately 1 to 30 percent by weight of the tantalum and approximately 1 to 30 percent by weight of the copper. As another alternative, liner 18 of the present invention may contain approximately 50 to 90 percent by weight of tungsten, approximately 0 to 20 percent by weight of the lead, approximately 1 to 30 percent by weight of the molybdenum and approximately 1 to 30 percent by weight of the copper. Liner of the present invention may alternatively contain approximately 50 to 90 percent by weight of tungsten, approximately 0 to 20 percent by weight of the lead and approximately 1 to 30 percent by weight of the tantalum. Likewise, liner 18 of the present invention may contain approximately 50 to 90 percent by weight of tungsten, approximately 0 to 20 percent by weight of the lead and approximately 1 to 30 percent by weight of the molybdenum.
[0024] The following results were obtained testing various powdered metal mixtures for liner 18 of shaped charge 10 of the present invention.
[0000]
TABLE 2
Mixture
Penetration Depth
(Component Weight %)
(in.)
55%W—27%Ta—18%Pb
8.24
55%W—45%Ta
6.11
55%W—20%Cu—15%Pb—10%Ta
8.72
55%W—20%Cu—15%Pb—10%Ta
7.64
55%W—20%Cu—15%Pb—10%Ta
7.74
55%W—10%Cu—10%Pb—20%Ta
7.09
[0025] All of the embodiments described above contain tungsten in combination with a high performance material to provide liner 18 with increased penetration depth when the jet is formed following detonation of shaped charge 10 . As explained above, use of tungsten alone to form liner 18 would result in a very brittle and unworkable liner. Therefore, tungsten is combined with other materials to give the tungsten based liner the required malleability. The present invention achieves this result without sacrificing the performance shaped charge 10 by combining the powdered tungsten with high performance materials such as tantalum and molybdenum. In addition, these mixtures may also contain copper, lead or both.
[0026] While this invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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A liner ( 18 ) for a shaped charge ( 10 ) that utilizes a high performance powered metal mixture to achieve improved penetration depths during the perforation of a wellbore is disclosed. The high performance powdered metal mixture includes powdered tungsten and powdered metal binder. The powered metal binder may be selected from the group consisting of tantalum, molybdenum, lead, cooper and combination thereof. This mixture is compressively formed into a substantially conically shaped liner ( 18 ).
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[0001] This utility patent application claims the benefit of provisional application No. 60/267,311, filed Feb. 8, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to lines, leaders, tippet material, or tapered leaders (for sake of brevity hereinafter called “fishing line or lines”), used in various types of fishing applications and, more particularly, is concerned with an enhanced fishing line having a unique combination of properties in terms of breaking strength, elongation, knot breaking strength, breaking toughness, and flexibility stiffness.
[0004] 2. Description of the Prior Art
[0005] Synthetic monofilament fishing lines, comprised of synthetic polymeric materials such as polyamides, polyesters, polyethylenes, or fluoropolymers, have long been used in fishing applications. The synthetic monofilament fishing lines employed in the prior art have traditionally attempted to achieve the highest possible breaking strength with the smallest possible diameter. The objective of creating fishing lines with the smallest possible diameter is to make the fishing line as inconspicuous as possible so as to increase the potential for attracting the fish to the bait or fly, while also providing as high a strength as possible in order to hook-up and land the larger fish.
[0006] This traditional way of making fishing lines has several disadvantages associated with it that have not yet been overcome in the design and construction of fishing lines. Due to the nature of the polymeric materials used to make the monofilament fishing lines, the material becomes increasingly stiffer in order to achieve a high ultimate breaking strength. The stiffness of the material is related to its elongation, or the ratio of the extension of the material to the initial length of the material prior to stretching. The increased stiffness of the material results in the line becoming less flexible which tends to make tying knots in the line more difficult and also tends to dramatically reduce the breaking strength of the line at the knot.
[0007] In addition, stiffer, stronger lines have less capacity to resist shock or rapid impact loading conditions before breaking, such as when a fish is hooked-up and rapidly swims in a direction away from the rod and reel to place a rapid loading on the line. The capacity to resist rapid loading conditions is referred to as the breaking toughness of the line. Lines that have a high breaking strength will generally have a lower ultimate elongation and a correspondingly low breaking toughness. The lower breaking toughness is what causes the instantaneous breakage of the line under the rapid impact conditions. Since the line breaks almost instantaneously, the fisherman does not have ample time to react and relieve the pressure in the line by either raising the tip of the rod or allowing the line to come off the reel. Therefore, more fish are lost after the initial hook-up due to breaking of the line from these rapid loading conditions as a result of its lower breaking toughness.
[0008] By observing and studying prior art fishing lines and statements that are made with regard to the benefits of the so-called high-performance fishing lines, one concludes that current state-of-the-art practices employed to improve performance of fishing lines primarily involve making fishing lines that have higher ultimate breaking strength and correspondingly thinner diameters. The apparent intent is to achieve a higher ultimate knot breaking strength while the critical property of breaking toughness is ignored.
[0009] Tests conducted on prior art fishing lines demonstrate this assertion. The so-called high performance fishing lines do generally have higher ultimate breaking strength and thinner diameters. However, there is generally only a marginal benefit, if any, in terms of a higher ultimate knot breaking strength. They also have relatively lower ultimate elongation, significantly lower breaking toughness and significantly less flexibility by virtue of their higher flexibility stiffness.
[0010] The test equipment used to measure the aforesaid properties of fishing lines is a conventional universal testing machine, such as those under the Instron name, and the tests are conducted in accordance with test procedures outlined in ASTM D-2101-91 where a constant rate of extension of ten inches per minute and a specimen gauge length of 10 inches were used.
[0011] As referred to herein, the various properties are defined as follows. The Ultimate Breaking Strength is defined as the force required to break the line divided by its cross sectional area, whose value is presented with units of pounds per square inch (also referred to as psi herein). The Ultimate Knot Breaking Strength is defined as the force required to break the line divided by its cross sectional area, with an overhand knot tied into the line, whose value is presented with units of pounds per square inch. The Ultimate Elongation is defined as the ratio of the extension of a material at the breaking point, to the length of the material prior to stretching, whose value is presented as a percentage. The Breaking Toughness is defined as the actual work per unit volume of material that is required to break the material, whose value is presented with units of inch-pounds per cubic inch. The Flexibility Stiffness is defined as the stiffness of the material measured between 5% and 10% elongation and is determined by subtracting the stress in the monofilament at which 5% elongation is achieved from the stress in the monofilament at which 10% elongation is achieved, and dividing this difference by the 5% difference in elongation. The lower the Flexibility Stiffness, the more flexible the monofilament.
[0012] Due to the adverse effects on performance from the tradeoffs associated with prior art fishing lines, there exists a need for an enhanced fishing line having a unique combination of the aforementioned properties which improves performance.
SUMMARY OF THE INVENTION
[0013] The present invention provides an enhanced fishing line designed to satisfy the aforementioned need. The enhanced fishing line of the present invention is adapted for use in various types of fishing applications and provides a product having superior properties over those presently on the market which improves performance. In particular, the enhanced fishing line of the present invention has a unique combination of ultimate breaking strength and ultimate elongation properties so as to provide a fishing line with a significantly higher breaking toughness and with an optimal ultimate knot breaking strength, and lower flexibility stiffness, so as to provide a fishing line with significantly higher performance.
[0014] Accordingly, the present invention is directed to a fishing line which comprises: (a) a monofilament made of a polymer, such as a polyamide, such as nylon 6, nylon 66, nylon 612, nylon 11, and nylon 12; or a fluoropolymer, such as polyvinylidene fluoride; or a polyolephine, such as polypropylene; (b) the monofilament having an ultimate breaking strength of a minimum of about 150,000 psi, an ultimate elongation of a minimum of about 30%, an ultimate knot breaking strength of a minimum of about 130,000 psi, a breaking toughness of a minimum of about 25,000 inch-pounds per cubic inch, and a flexibility stiffness of no greater than about 500,000 pounds per square inch.
[0015] More particularly, the monofilament has a diameter of between about 0.003 inches to 0.045 inches, and is manufactured by an extrusion process followed by a drawing process, such that the monofilament has an extruded diameter between about 1.1 and 1.4 times the finished diameter after drawing.
[0016] Further, the ultimate breaking strength of the monofilament is within a range of about 150,000 to 180,000 psi. The ultimate elongation of the monofilament is within a range of about 30% to 100%. The ultimate knot breaking strength of the monofilament is within a range of about 130,000 to 170,000 psi. The breaking toughness of the monofilament is within a range of about 25,000 to 35,000 inch-pounds per cubic inch. Also, the monofilament has a flexibility stiffness of about 225,000 to 500,000 pounds per square inch.
[0017] These and other features and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The enhance fishing line of the present invention is a monofilament made of a polymer, preferably a polyamide, such as nylon 6, nylon 66, nylon 612, nylon 11, and nylon 12; or a fluoropolymer, such as polyvinylidene fluoride; or a polyolephine, such as polypropylene. The monofilament has a finished diameter of between about 0.003 inches to 0.045 inches.
[0019] The monofilament preferably is made by an extrusion process, followed by a drawing process where the extruded diameter is between 1.1 and 1.4 times the diameter of the finished monofilament after stretching or drawing. Specifically, in a set of representative examples, a quantity of the polymer, as described above, is extruded using conventional extruding equipment to provide an extruded monofilament of between 1.1 and 1.4 times the finished diameter of the monofilament. The extruded monofilament is then subjected to a drawing process where the monofilament is stretched out along its length and results in a corresponding reduction in the diameter of the monofilament until the finished diameter is achieved. The drawing process aligns the molecular chains in a direction parallel to the long axis of the monofilament thereby increasing the ultimate breaking strength of the material along with its stiffness. After the drawing process, the monofilament is heat treated to relieve the high stresses, which can exist near the surface of the monofilament as a result of the drawing process. This heat treatment subjects the monofilament to a temperature range of between 40 and 150 degrees Celsius for a time period of between 30 minutes and 4 hrs. After heat treating the monofilament can further be subjected to an irradiation process, wherein the monofilament is exposed to gamma irradiation or electron beam to achieve an accumulation of 0.5 to 100 mega rads of exposure. The irradiation process promotes cross linkage of the molecules and results in lower flexibility stiffness and greater ultimate elongation while maintaining a high ultimate breaking strength.
[0020] The aforementioned extrusion, drawing, treatment processes are set to instill the enhanced fishing line with a unique combination of properties which include the following. The enhanced fishing line will generally have a minimum ultimate breaking strength of 150,000 psi (pounds per square inch) or within a range of about 150,000 to 180,000 psi, a minimum ultimate elongation of 30% or within a range of about 30% to 100%, a minimum ultimate knot breaking strength of 130,000 psi or within a range of about 130,000 to 170,000 psi, a minimum breaking toughness of 25,000 inch-pounds per cubic inch or within a range of about 25,000 to 35,000 inch-pounds per cubic inch, and a flexibility stiffness of no more than 500,000 psi or within a range of about 225,000 to 500,000 psi, based on averaging the test results for a total of five specimens from the same production lot being tested using a universal testing machine in accordance with test procedures outlined in ASTM D-2101-91 at a constant rate of extension of ten inches per minute and a specimen gauge length of 10 inches.
[0021] Following the aforementioned steps of the extrusion and drawing processes, samples were made of monofilament fishing line having the minimum ultimate breaking strength of 150,000 psi and the minimum ultimate elongation of 30% that resulted in the line having the ultimate knot breaking strength of more than 130,000 psi, a breaking toughness of more than 25,000 inch-pounds per cubic inch, and a flexibility stiffness of less than 500,000 psi.
[0022] [0022]FIG. 1 presents a table of Fishing Line Test Data which includes data for the enhanced monofilament fishing line samples along with data for prior art fishing line samples that were available in the market. Column (1) presents the diameter values of the fishing line samples in inches. Column (2) presents the ultimate breaking strength values of the fishing line samples in pounds per square inch. Column (3) presents the ultimate elongation values of the fishing line samples in %. Column (4) presents the ultimate knot breaking strength values of the fishing line samples in pounds per square inch. Column (5) presents the breaking toughness values of the fishing line samples in inch-pounds per cubic inch. Column (6) presents the flexibility stiffness values of the fishing line samples in pounds per square inch. Rows (A) through (C) present the test data for the enhanced fishing line samples according to the current invention. Rows (D) through (M) present the test data for typical prior art lines.
[0023] Observing the test data for the enhanced lines according to the present invention, one can readily observe that the combination of ultimate breaking strength greater than 150,000 psi and ultimate elongation greater than 30% produce levels of ultimate knot strength greater than or equal to 130,000 psi, breaking toughness greater than or equal to 25,000 in-pounds per cubic inch, and flexibility stiffness less than or equal to 500,000 psi. In the case of prior art samples such as the samples in rows (F), (G), (H), (I), (J), (L), and (M), the ultimate breaking strength is greater than 150,000 psi, however, the ultimate elongation is considerably less than 30% for each of these samples, resulting in low ultimate knot strength values of less than 130,000 psi, low breaking toughness values of less than 25,000 in-pounds per cubic inch, and flexibility stiffness greater than 500,000 psi. In the case of the prior art sample in row (E), the ultimate elongation is higher at 30.385%, however, the ultimate breaking strength is considerably less than 150,000 psi, and the ultimate knot strength is also considerably less than 130,000 psi. Therefore, one can readily observe from the data in FIG. 1 that the unique combination of high ultimate breaking strength (at least 150,000 psi) and high ultimate elongation (at least 30%) produces enhanced performance with regard to greater ultimate knot breaking strength (at least 130,000 psi), greater breaking toughness (at least 25,000 in-pounds per cubic inch) and reduced flexibility stiffness (no greater than 500,000 psi) which results in greater flexibility.
[0024] Field testing of these fishing line samples, which were made in the form of tippet material for fly fishing, has confirmed the unique, positive benefits of the improved fishing line having the unique combination of properties mentioned previously. The additional benefit of increased flexibility was also realized as demonstrated by the ease with which knots were able to be tied and by the natural way in which the tippet material presented the fly.
[0025] It is thought that the present invention and its advantages will be understood from the foregoing description and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely preferred or exemplary embodiment thereof.
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An enhanced fishing line has a unique combination of breaking strength and elongation properties to provide a high level of flexibility, a high ultimate knot breaking strength, and a high level of breaking toughness that is defined as the actual work per unit volume of material required to break the material. The line is a monofilament construction made of a synthetic polymeric material such as a polyamide, polyester, polyethylene, or fluropolymer and manufactured by an extrusion process followed by a drawing process where the extruded diameter is between 1.1 and 1.4 times the diameter of the finished line after drawing.
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BACKGROUND
[0001] The present invention relates to a tool management system and particularly to a system providing control of reticle stocking and sorting operations in a semiconductor fabrication system.
[0002] Depending on the type of IC device being manufactured, a wafer may be subjected to several photolithography processes as layers are formed successively to form the device. To perform the various photolithography processes, a semiconductor plant has a photolithography area comprising a number of steppers that utilize a cataloged library of reticles. The number of reticles that need to be readily available can easily exceed one thousand, due to the number of different products that can be manufactured in one facility, with each reticle having a replacement cost of about $1,500. The reticles are usually stored in a reticle storage system, centrally located within the photolithography area, and are cataloged by reticle identification number. The reticle(s) are transported via a conveyor system to the particular stepper awaiting a certain reticle. One problem with managing reticles is that they are very delicate structures and can be easily damaged in handling. They are also routinely inspected to ensure that they are still viable for use.
[0003] These reticles have not only high replacement cost, but also high maintenance cost. Reticles occupy storage and substantial floor space, creating considerable traffic congestion in the fabrication system.
[0004] The reticles are generally owned by customers rather than a fabrication plant. The fabrication plant bears the responsibility of maintaining the reticles, and lack authority to phase out or scrap reticles without customer permission.
[0005] FIG. 1 is a schematic view showing a conventional method of reticle management. Reticles are stored in online reticle storage 11 , offline reticle storage 13 , or reticle outlet 15 . The reticles are then transported by transport devices 12 , 14 , and 16 . The current position and other related information is stored in a reticle management center 17 . When reticles are conventionally utilized in a fabrication process within a fabrication system 10 , they are stored in online reticle storage 11 awaiting transport to a processing area. These reticles lie idle in the online reticle storage 11 not in use. When idle time of the reticles exceeds a preset time period, manual intervention is required to move these idle reticles from the online reticle storage 11 to the offline reticle storage 13 . These reticles are moved back to the online reticle storage 11 when needed for fabrication processes. Generally, the activation of the idle reticles is initiated by a product order pertaining to these reticles. When the idle reticles stay in the offline reticle storage 13 longer than a preset time period, they should be moved from the offline reticle storage 13 to the reticle outlet 15 . At the same time, a customer engineer 18 of the fabrication system 10 checks the reticle idle state from a reticle management center 17 , informs the owner 19 (customer) of the reticles in this idle state and requests disposition of the reticles. If the customer wishes to take possession of the idle reticles, the reticles are returned. If the customer declines to take possession, the reticles are scraped shortly thereafter.
[0006] Such conventional reticle management system has several disadvantages.
[0007] First, the conventional system leads to redundant reticle transport among the online reticle storage 11 , the offline reticle storage 13 , and the reticle outlet 15 . In the conventional system, idle reticles are moved from online to offline reticle storage when the idle time of the reticles exceeds a preset time period, and are returned to the online reticle storage 11 when required by any fabrication process. The transport of reticle from the online reticle storage 11 to the offline reticle storage 13 is executed manually, with idle time the sole factor impacting transport decisions. Thus, reticles can be characterized as idle and returned to the offline reticle storage, even though a pertinent process operation, requiring their use, may resume as soon as one day later. After the reticles reach the offline reticle storage, they are restored to the online reticle storage when the process operation resumes. This round trip in a short time consumes transport capacity of the fabrication system, and requires an excess of manual attention, lowering overall efficiency of the fabrication system.
[0008] Second, considerable communication is required when querying customers for disposition instructions for the reticles. Since reticles have high replacement cost and are of major importance in the fabrication process, disposition is deployed carefully, with erroneous disposition resulting in serious consequences. Generally, a decision regarding reticle disposition only follows repeated discussion and confirmation through complex paperwork and processes.
[0009] Third, there is no flexibility in setting the time limit for different customers and products. All reticles in the online reticle storage have the same idle time limits, as do the reticles in the offline storage, despite the fact that reticles may belong to different customers and pertain to different products, all with discrete needs and practices. Some customers may order frequently, some infrequently, and others sporadically. Similarly, different products are characterized by different order patterns. The conventional system assigns a single idle time limit to all reticles and passes over the above-mentioned differences without due attention.
[0010] Hence, there is a need for a reticle management system that addresses the inefficiency arising from the existing technology.
SUMMARY
[0011] It is therefore an object of the invention to provide a system and method of reticle management reducing redundant reticle transport.
[0012] It is another object of the invention to provide a system and method of reticle management reducing communication required by inquiry and confirmation of reticle disposition.
[0013] It is still another object of the invention to provide a system and method of reticle management with flexible time limit setting capability.
[0014] To achieve these and other objects, the present invention provides a demand-based reticle management mechanism.
[0015] According to one embodiment of the invention, a reticle management system is provided within a fabrication system. The reticle management system comprises first reticle storage, second reticle storage, third reticle storage, and a host system.
[0016] The first reticle storage stores a first reticle currently in use. The second reticle storage stores a second reticle not currently in use. The third reticle storage stores a third unused reticle temporarily before it is disposed of. The host system is adapted to rearrange the first, second, and third reticles among the first, second, and third reticle storages, based on demand data pertaining to a product requiring least one reticle during fabrication.
[0017] According to another embodiment of the invention, a method is provided for managing the reticles among the three storage locations mentioned. The method rearranges the first, second, and third reticles among the first, second, and third storages according to demand data for a product. The product's manufacture requires at least one of the reticles, and the demand data is order or order prediction data. In order to manage the first reticle stored in the first storage, a first time limit is determined. Next, a first idle time of the first reticle is calculated. The first idle time is reset when demand data of the product corresponding to the first reticle is received. When the first idle time exceeds the first time limit, a first transfer command is issued to move the first reticle from the first storage to the second storage. Similarly, in order to manage the second reticle stored in the second storage, a second time limit is determined. Next, a second idle time of the second reticle is calculated. When demand data of the product requiring the second reticle is received, a first return command is issued to move the second reticle from the second reticle storage to the first reticle storage. When the second idle time exceeds the second time limit, a second transfer command is issued to move the second reticle from the second storage to the third storage. When demand data of the product corresponding to the third reticle is received, a second return command is issued to move the third reticle from the third storage to the second storage. This method may take the form of program code embodied in a tangible media. When the program code is loaded into and executed by a machine, the machine becomes an apparatus for practicing the invention.
[0018] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0020] FIG. 1 is a schematic view showing a conventional operation of reticle management;
[0021] FIG. 2 is a schematic view showing the operation of reticle management according to the present invention;
[0022] FIGS. 3A and 3B are flowcharts of the reticle management operation of the system in FIG. 2 ; and
[0023] FIG. 4 is a diagram of a storage medium storing a computer program providing the reticle management method.
DETAILED DESCRIPTION
[0024] The present invention will now be described with reference to FIGS. 2 to 4 , which in general relate to a reticle management system within a fabrication system. While the preferred embodiment of the invention operates with semiconductor fabrication systems, it is understood that the type of article processed by the fabrication system is not critical to the present invention, and any fabrication system using tools owned by customers (such as reticles) may utilize the present invention.
[0025] FIG. 2 is a schematic view showing the operation of reticle management according to the present invention. A fabrication system 20 is a semiconductor fabrication system comprising online reticle storage 21 , offline reticle storage 23 , reticle outlet 25 , a reticle management center 27 , and an order database 28 .
[0026] The online reticle storage stores a first reticle currently in use in a fabrication process. The offline reticle storage stores a second reticle not currently in use. The reticle outlet serves as an outlet of a third reticle, which will be sent to a scrap mill 291 or returned to its owner, customer 29 . A transport device 22 , linked with the online reticle storage 21 and the offline reticle storage 23 , transports reticles therebetween. A transport device 24 , linked with the offline reticle storage 23 and the reticle outlet 25 , transports reticles therebetween. A transport device 261 transports reticles between the reticle outlet 25 and a reticle storage of the customer 29 . A transport device 265 transports reticles from the reticle outlet 25 to the scrap mill 291 .
[0027] The reticle management center 27 is adapted to relocate the first, second, and third reticles among the online and offline storages, and the reticle outlet, based on demand data pertaining to a product, which uses at least one of the reticles during its fabrication process. The demand data, retrieved from an order database, is order or order prediction data determined by the customer 29 . The order database 28 is connected with the customer 29 through a network 295 . The customer 29 uploads the order or order prediction data to the database 28 through a GUI and the network 295 .
[0028] FIGS. 3A and 3B are flowcharts showing the operation of reticle management of the present invention. The reticle management method showed in FIG. 3A and 3B manages the reticles in the fabrication system described above and shown in FIG. 2 .
[0029] Using FIG. 3A as an example, a first time limit is set in step S 311 . The first time limit is the maximum allowable idle time for the first reticle in the online reticle storage. The first time limit can be determined different ways. According to this embodiment, the first time limit is based primarily on a customer's specification, and is further modified by an operator in the fabrication plant.
[0030] Next, a first idle time of the first reticle is calculated by an internal counter of the reticle management center 27 (step S 313 ). It is determined if any demand data of the product corresponding to the first reticle has been sent to the order database 28 and transferred to the reticle management center 27 (step S 315 ), and if so, the first idle time is reset to 0 , otherwise the method proceeds to step S 317 . In step S 317 , it is determined whether the first idle time exceeds the first time limit, and if so, a first transfer command is issued to move the first reticle from the online reticle storage to the offline reticle storage (step S 319 ).
[0031] Referring to FIG. 3B , a second time limit is set in step S 331 . The second time limit is the maximum allowable idle time for the second reticle in the offline reticle storage. The second time limit can be determined different ways. According to this embodiment, the second time limit is based primarily on a customer's specification, and is further modified by an operator in the fabrication plant.
[0032] Second, a second idle time of the second reticle is calculated by an internal counter of the reticle management center 27 (step S 333 ). In step S 335 , it is determined if any demand data corresponding to the second reticle has been sent, and if so, the method proceeds to step S 336 , otherwise the method proceeds to step S 337 . In step S 336 , a first return command is issued, directing the transport device 22 to return the second reticle from the offline reticle storage to the online reticle storage. In step S 337 , it is determined whether the second idle time exceeds the second time limit, and if so, a second transfer command is issued, directing the transport device 24 to transfer the second reticle from the offline reticle storage to the reticle outlet (step S 339 ).
[0033] When the second reticle is sent to the reticle outlet 25 , it is classified as a third reticle and sent to the scrap mill 291 or return the reticle storage of the customer 29 according to prior agreement. When demand data of the product corresponding to the third reticle is received, a second return command is issued to move the third reticle from the reticle outlet to the online reticle or offline storage.
[0034] The method of the present invention, or certain aspects or portions thereof, may take the form of program code (i.e. instructions) embodied in a tangible media, such as floppy diskettes, CD-ROMS, hard drives, or any other machine-readable storage medium, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. The methods and apparatus of the present invention may also be embodied in the form of program code transmitted over some transmission medium, such as electrical wiring or cabling, through fiber optics, or via any other form of transmission, wherein, when the program code is received and loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. When implemented on a general-purpose processor, the program code combines with the processor to provide a unique apparatus that operates analogously to specific logic circuits.
[0035] FIG. 4 is a diagram of a storage medium storing a computer program providing the reticle management method according to the present invention. The computer program product comprises a computer usable storage medium having computer readable program code embodied in the medium, the computer readable program code comprising computer readable program code 41 receiving first and second time limits, computer readable program code 43 counting a first idle time and resetting the first idle time when a demand data of a product corresponding to the first tool is received, computer readable program code 45 issuing a first transfer command to move the first tool from a first tool storage to a second tool storage when the first idle time exceeds the first time limit, computer readable program code 47 counting a second idle time and resetting the second idle time when a demand data of the product corresponding to the second tool is received, computer readable program code 48 issuing a return command, and computer readable program code 49 issuing a second transfer command to move the second tool from the second tool storage to a third tool storage when the second idle time exceeds the second time limit.
[0036] While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A reticle stocking and sorting system. The reticle management system comprises first reticle storage, second reticle storage, third reticle storage, and a host system. The first reticle storage stores a first reticle currently in use. The second reticle storage stores a second reticle not currently in use. The third reticle storage stores a third unused reticle temporarily before it is disposed of. The host system is adapted to rearrange the first, second, and third reticles among the first, second, and third reticle storages, based on demand data pertaining to a product requiring least one article during fabrication.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a cleaning, descaling and corrosion inhibiting composition and a process for employing same.
[0003] 2. Description of the Prior Art
[0004] Equipment used in power plants, chemical and petrochemical plants, paper mills, sugar mills, pipelines, air conditioners in large buildings and many other industrial environments are subject to the formation of scale, either by circulating water or by process compounds. This includes all types of heat exchangers, boilers, vessels, piping and other equipment. Precipated solids reduce the heat transfer efficiency and oftentimes cause tube failure due to overheating which may result in plugging or fouling of the equipment. To prevent interference with industrial processes, cleaning of the metal surfaces of the equipment employed therein is required. The water-formed precipitates are generally inorganic in nature, especially precipitates formed in hot closed systems, for example, in steam generators or heat exchangers. Common deposits which are found include iron oxides (magnetite and hematite), sulfides, alkaline earth carbonates, sulfates, and silicates.
[0005] Hydrochloric acid is widely used for the chemical cleaning of structural steel from which heat transfer and piping systems are fabricated. Hydrochloric acid forms soluble products which serve to dissolve calcium or magnesium carbonates. Hydrochloric acid, does not, however, dissolve sulfates or silicates. Therefore, other chemicals must be mixed or incorporated with the hydrochloric acid. It is also well known that hydrochloric acid is highly corrosive. In addition, if copper salts are present in the scale, they will dissolve and reprecipitate on iron surfaces causing severe localized corrosion.
[0006] It is an object of the present invention to provide a non-toxic, industrial descaling and cleaning composition which is effective in removing scales and oxides from the surfaces of the process equipment used in various industries while avoiding corrosion to the equipment.
SUMMARY OF THE INVENTION
[0007] A highly effective industrial cleaning composition which is effective in descaling without causing corrosion has now been found which comprises a mixture of hydrochloric acid, hydrofluoric acid, one or more chelating agents, a surfactant, a copper complexing agent, and a non-toxic inhibitor which serves to block the anodic and cathodic sites on the steel surfaces of the process equipment.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The composition of the present invention includes as the non-toxic inhibitor from 40 to 200 parts per million, preferably from 60 to 100 parts per million, and most preferably 80 parts per million of acridine orange. The chemical formula for acridine orange is N,N,N′N′-tetramethyl-3,6-acridinediamine monohydrochloride. The use of this compound has been found to inhibit or block the anodic and cathodic site in structural steel of the type that is commonly used in the fabrication of a variety of pieces of process equipment
[0009] The benefits of using acridine orange (AO) are multifaceted and are as follows:
[0010] 1. AO has fast and direct protonation when added to acidic solutions. The protonation process is a charge transfer process, viz., flow independent.
[0011] 2. The AO inhibitor molecules bind strongly to metal surfaces.
[0012] 3. The free flat aromatic rings having a surface area of 38 A°, are bound in a plane which is parallel to the metal surface, such that the position of the positively charged hydrogen ring in AO is close to the predominant negatively charged electric layer on the metal surface.
[0013] The composition includes from about 5% to about 15%, by weight, hydrochloric acid, preferably from 5% to 10%, and most preferably 8% acid, which serves to remove most calcium, magnesium and iron oxides.
[0014] The composition also preferably includes 1% to 5%, by weight, preferably 1.5% of hydrofluoric acid, which aids in the removal of silicate containing scales. The conjoint use of hydrochloric acid and hydrofluoric acid serves to accelerate the dissolution of many very hard and complex scale formations.
[0015] While various chelating agents can be employed in the composition and process of the present invention, such as EDTA, citric acid, HEDTA, etc., it has been found that a mixture of 2% citric acid and 2% EDTA is preferred since it is extremely effective in dissolving iron oxide deposits and also deposits containing copper oxides. In point of fact, even sulfate-containing deposits will be dissolved when this mixture of chelating agents is employed.
[0016] The inclusion of from about 50 to about 200 parts per million (ppm), preferably 100 ppm of thiourea, will insure the maintenance of any dissolved copper in a soluble state. In the absence of such a copper complexing agent, copper oxides which are present in any scale, will dissolve and then plate out as metallic copper causing severe pitting of the industrial process equipment and the piping systems.
[0017] In addition, while it is optional, it has been found to be beneficial if the descaling composition includes about 0.1 grams/liter of a neutral emulsifying agent, such as alkyl benzene sulfonate.
[0018] It has also been found that the benefits of the process of the present invention can best be achieved by employing a temperature of about 300° K or above for a period of about one (1) to about ten (10) hours, with eight (8) hours being preferred.
[0019] For a fuller understanding of the nature and objects of this invention, the following specific examples are given. These examples, however, are not to be construed as limiting the invention in any manner.
EXAMPLE 1
[0020] A series of 5.0 cm×2.5 cm mild steel specimens were prepared by cutting them from a single sheet of cold-rolled 1020 steel. The specimens were then polished under running tap water using a series of silicon carbide emery paper of 100, 400 and 600 grit, respectively, and then washed with distilled water and thereafter degreased with benzene and weighed on a Mettler AJ 100 electronic balance.
[0021] One group of prepared steel specimens were fully immersed in 500 cc of a cleaning and descaling solution containing 8% hydrochloric acid, 1.5% hydrofluoric acid, 80 ppm of acridine orange, 2% citric acid, 2% EDTA, 0.1 g/l of alkyl benzene sulfonate, 100 ppm thiourea and 80 PPM of acridine orange. This is referred to herein as the “inhibited solution”.
[0022] Another group of steel specimens were also immersed in the foregoing cleaning and descaling solution except for the fact that the composition did not contain any acridine orange. This is referred to herein as the “uninhibited solution”
[0023] Potentiostatic polarization studies were carried out for both inhibited and uninhibited solutions under isothermal conditions at 303°, 313°, and 323° K and under controlled conditions of flow at 600, 1000 and 1400 rpm employing a potentiostat (Model 553-AMEL-Italy). The iron electrode was polarized from −900 mV to −100 mV (vs. saturated calomel electrode) at a sweep rate of 20 mV/min.
[0024] Another series of potentiostatic polarization studies were conducted for the heat transfer set of conditions, with a potential of −1000 mV being applied until a steady state heat flux was attained as indicated by the constant temperature reading from the thermocouples. Then the full polarization was carried out under isothermal conditions.
[0025] The duration of each of the weight loss experiments was eight (8) hours. At the conclusion of the test, the specimens were withdrawn, rinsed with water, then dried and reweighed. The percentage inhibitor efficiency was calculated by the following equation:
I %= W u −W I /W u ×100.
EXAMPLE 2
Performance of the Inhibitor (AO) under Controlled Conditions of Heat and Mass Transfer Cathodic Region
[0026] The effect of fluid flow, bulk temperature and heat transfer on the cathodic current density at a given cathodic potential of 0.1 V below the corrosion potential are shown in Tables 1, 2, and 3.
TABLE 1 The Cathodic Current Density mA/cm 2 for Uninhibited Chemical Cleaning Solution I c,u and Inhibited Solution I c,I and the Inhibition Efficiency I % under Isothermal Conditions. (Inhibitor Concentration 60 PPM) Temperature ° K 303 313 323 RPM I c, u I c, I I % I c, u I c, I I % I c, u I c, I I % 0 15 1.6 89 39 5.5 86 57 8.8 85 600 4.6 0.5 89 14 1.6 88.6 36 3.3 90.8 1000 4.6 0.46 90 14 1.6 88.6 34 3.0 91 1400 4.8 0.51 89.4 15 1.7 88.7 34 3.5 89.7
[0027]
TABLE 2
The Cathodic Current Density, mA/cm 2 , of Uninhibited Chemical
Cleaning Solution Under 60 kW/m 2
Heat transfer (The Interfacial temperatures are Bracketed).
Bulk Temperature, ° K
RPM
303
313
323
600
8
(322.7)
19 (330.5)
40 (339.9)
1000
7.3
(315.9)
17 (324.3)
39 (333.7)
1400
6.5
(312.3)
16 (321.6)
37 (331.4)
[0028]
TABLE 3
The Cathodic Current Density I C,I , MA/cm 2 , for Inhibited Chemical
Cleaning Solution, under Heat Flux of 60 kW/m 2 . I % is the Inhibitor
Efficiency. Interfacial
Temperature values are the same as in Table 2.
Bulk Temperature, K
303
313
323
RPM
I C,I
I %
I C,I
I %
I C,I
I %
600
0.65
92
2.3
88
4.2
89.5
1000
0.60
92
1.9
89
3.2
91.8
1400
0.58
91.1
1.7
89.4
2.8
92.4
[0029] It can be seen from Tables 1, 2 and 3 that the cathodic current density values are independent of the flow rate, while the increase in temperature (bulk or interfacial) has a significant effect in stimulating the cathodic process. This confirms the activation energy control of the cathodic reaction of hydrogen as the predominant reaction, as well as the lack of mass transfer effect on the adsorption processes of the inhibitor.
[0030] The increase in temperature (bulk or interfacial) has no significant effect on the inhibition efficiency, viz. the increase in temperature has no effect on the orientation of the adsorbed molecules or their geometry.
[0031] The high efficiency values are attributed to the ability of the inhibitor, acridine orange, to block the cathodic areas on the metal surface, leading to a significant reduction in hydrogen evolution.
EXAMPLE 3
[0032] Acridine orange (AO) also showed high performance in blocking the anodic sites, as shown in the data presented in Tables 4, 5 and 6 for both isothermal and heat transfer conditions.
TABLE 4 The anodic Current Density, mA/cm 2 , for uninhibited Chemical Cleaning Solution I a , U, Inhibited Solution I a, I , and the Inhibitor Efficiency, I %, Under Isothermal Conditions Temperature, K 303 313 323 RPM I a, u I a, I I % I a, U I a, I I % I a, U I a, I I % 0 29 1.8 94 46 2.5 97 97 16 83.5 600 7 1.3 81 14 2.3 93.6 40 5.7 86 1000 6.8 1.3 81 15 2.0 86.7 36 4.8 87 1400 7.1 1.3 81.7 15 2.7 82 38 3.5 91
[0033]
TABLE 5
The anodic Current Density, mA/cm 2 , for uninhibited Chemical Cleaning
Solution under 60 kW/m 2
Heat Transfer Rate. (The Interfacial Temperatures are bracketed).
Bulk Temperature K
RPM
303
313
323
600
13 (322.7)
23
(330.5)
63
(339.9)
1000
12 (315.9)
23
(324.3)
58
(333.7)
1400
11 (312.3)
20
(321)
48
(331)
[0034]
TABLE 6
The Anodic Current Density I aI , mA/cm 2 , for Inhibited Chemical
Cleaning Solution and the Inhibitor Efficiency I %, under 60 kW/m 2 ,
Heat Transfer Rate
Bulk
Temperature, K
303
313
323
RPM
I a, I
I %
I a, I
I %
I a, I
I %
600
1.8
86
4.1
82
12
81
1000
1.6
87
3.7
84
7.8
87
1400
1.4
87
3.3
83
6.0
87
[0035] The inhibition of the anodic sites (Tables 4-6) and cathodic sites (Tables 1-3) confirm the mixed effect of the inhibitor.
[0036] The invention is not limited to the embodiments described above. The detail involved in the description of these embodiments is for illustrative purposes only. Reasonable variations and modifications of this invention will be apparent to those skilled in the art without departing from the spirit and scope thereof.
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The present invention is directed to a composition, and a process employing same, for descaling, cleaning and inhibiting the corrosion of process equipment made of steel by including an inhibitory effective amount of acridine orange in the composition.
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[0001] This application claims the benefit of and claims priority to Application Ser. No. 60/743,140 filed on Jan. 18, 2006 and is incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to nozzles for a shower pipe to spray wash liquid onto a pulp mat.
[0003] Pulp is typically processed in mills by soaking or mixing wood pieces in tanks with chemicals that convert the wood pieces into pulp, and then bleaching pulp. The processing typically involves repeated stages of mixing the pulp with liquid and drawing the liquid out of the pulp by allowing the pulp to form mats on cylindrical vacuum drums. The pulp mats are washed by spraying wash liquid onto the mats. The wash liquid cleans chemicals out of the pulp mat. The wash liquid is sprayed from nozzles attached to liquid pipes spanning the width of the vacuum drums. There is a long felt need for liquid pipes and nozzle assemblies that uniformly spray wash liquid onto the mat and are inexpensive to manufacture and operate.
SUMMARY
[0004] A shower pipe and nozzle assembly for spraying a wash liquid on a pulp including: apertures in the pipe extending a length of the pipe spanning a width of the pulp mat, are laterally aligned along two or more rows such that adjacent apertures are in different rows, and the nozzle assembly includes a nozzle, a mounting block and a lip wherein the nozzle includes a hollow stem that attaches to the aperture and secures the nozzle assembly to the pipe, the block has a face that conforms to the pipe surface surrounding the aperture, an opposite face supporting the lip and an opening for the nozzle stem which is offset from a center of the block, and the lip includes a curved fan for turning wash liquid from the nozzle towards the pulp mat, a mounting surface abutting the opposite face of the block and a corner fitting over an edge of the block. The wash liquid flows through the pipe, the hollow stem of the nozzle and out of the nozzle as a stream that is generally tangential to the lip. The fan of the lip gradually turns the water towards the pulp mat and spreads the stream such that the water is sprayed uniformly on the mat. The multiple rows of apertures and nozzles project wash liquid towards the mat at different directions.
[0005] A nozzle assembly for spraying a wash liquid onto a pulp mat, the assembly comprising: a fastener-nozzle having an internal conduit for the wash liquid, an external fastener structure for attaching to an aperture in a wash liquid pipe and an outlet to the internal conduit for discharging the wash liquid, and a curved lip having a curved surface mounted to the pipe by the fastener-nozzle extending from the outlet to the internal conduct, the curved surface having an expanding width to convert a stream of wash liquid from the outlet to a sheet of wash liquid directed to the mat. A mounting block may be included in the assembly between the pipe and lip, wherein the block has an offset opening to receive the fastener-nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a side view of a shower pipe and nozzle assembly, and a section of a pulp mat on a cylindrical dryer.
[0007] FIG. 2 is a cross-sectional view of the shower pipe and nozzle assembly, showing just one nozzle assembly.
[0008] FIG. 3 is a top view of the lip of the nozzle assembly.
[0009] FIG. 4 is an enlarged cross-sectional view of the nozzle assembly showing the hollow nozzle stem attached to an aperture in the pipe, a mounting block for the nozzle assembly, and a portion of the lip of the nozzle assembly.
[0010] FIG. 5 is a cross-sectional view of the shower pipe and nozzle assembly taken along line 5 - 5 in FIG. 1 and showing a side view of a portion of the pulp mat and cylindrical dryer.
[0011] FIG. 6 is an exploded isometric view of the nozzle assembly and a portion of the pipe.
DETAILED DESCRIPTION
[0012] FIG. 1 shows a shower pipe 10 that sprays a wash liquid 12 onto a pulp mat 14 . The mat (shown by dotted lines) forms on a rotating cylindrical vacuum drum 16 . The liquid wash is sprayed evenly and uniformly on the mat in one, two or more wash liquid sheets. The shower pipe 10 is positioned near the surface of the mat 14 and drum 16 . The shower pipe may be an extended cylinder spanning the width (W) of the vacuum drum. The pipe may be circular in cross-section, but may be rectangular, curvilinear or have some other cross-sectional shape. The pipe is preferably hollow and has an interior closed conduit 26 through which flows the wash liquid. A source 18 of liquid wash is connected to one or both ends of the pipe.
[0013] Wash liquid nozzle assemblies 20 are arranged along the length of the pipe 10 . The nozzle assemblies may be aligned in one, two or more rows extending laterally along the pipe. In the embodiment shown in FIG. 1 , the nozzle assemblies are arranged along a first row 22 and a second row 24 . The rows may be angularly offset by an angle (A in FIG. 5 ) that may be in a range of 3 degrees to 20 degrees. The nozzle assemblies 20 may be arranged to alternate between the rows along the length of the pipe. The nozzle assemblies may be equally spaced along the pipe and the spacing may be determined to provide a relatively uniform spray of wash liquid on the pulp mat 14 . The dotted lines in FIG. 1 between the nozzle assemblies and the mat 14 indicate a uniform flow of two sheets of wash liquid being sprayed onto the mat. Preferably, the sprays from two adjacent nozzle assemblies on the same row (and separated by at least one other nozzle assembly on another row) do not overlap.
[0014] FIG. 2 is a cross-sectional view of the pipe 10 and a single nozzle assembly 20 . The interior surface of the pipe defines a wash liquid passage 26 . Along each row in the pipe are a series of equally spaced apertures 28 that receive a nozzle-fastener 30 of the nozzle assembly. The apertures 28 may be threaded to receive a threaded stem portion of the nozzle fastener. The apertures 28 may be tapered to ease insertion of the fastener. Wash liquid flows through a hollow passage 32 of the stem of the nozzle-fastener. This hollow passage has an inlet open to the liquid passage 26 and an outlet 34 for projecting wash liquid relatively tangentially to a lip 36 of the nozzle assembly. The nozzle-fastener also secures the nozzle assembly to the pipe, and extends through openings in the lip 36 and in the mounting block 46 ( FIG. 4 ).
[0015] As show in FIG. 3 , the lip 36 may have a curved surface 38 that has a radially inward section (near the pipe) that is relatively tangent to the circumference of the pipe and perpendicular to the stream of wash liquid flowing from the nozzle. The lip includes a radially outward portion that both curves into the wash liquid stream and expands laterally. The lip may be a generally thin metal or plastic plate having a curved surface 38 , a mounting section 48 and a corner 50 . The mounting section 48 is a flat planar section that abuts an outside face 51 of the mounting block 46 . The corner 50 is a right angled lip that fits over an outside edge 52 of the mounting block. In top view ( FIG. 3 ), the curved surface of the lip is relatively narrow near the nozzle outlet 34 and expands into a fan-like shape. The curved surface 38 of the lip causes the water stream to spread out into a fan shaped liquid spray that flows to the pulp mat.
[0016] FIG. 4 is an enlarged view of a nozzle assembly 20 attached to the pipe 10 . The nozzle-fastener 30 includes a threaded stem 42 that screws into a threaded aperture 28 in the pipe. The head 44 of the nozzle-fastener may be a hexed bolt head. In one embodiment, the nozzle-fastener is a bolt having a hollow passage 32 that provides a wash fluid conduit from the liquid passage 26 in the pipe to the nozzle outlet 34 . The nozzle-fastener secures the nozzle assembly to the pipe.
[0017] The nozzle assembly may also include a mounting block 46 that is generally rectangular and has a first side that conforms to and abuts an outer surface of the pipe. The mounting block includes a second side, opposite to the first side, that is generally planar and provides a support surface for a planar mounting section 48 of the lip. An opening 54 through the mounting block receives the stem of the nozzle-fastener, but may not be threaded. The opening 54 in the block may be offset (see difference of lines D and C) from a center of the block. The offset allows the outlet 34 of the fastener-nozzle to be in close proximity to the radially inward portion of the curved surface 38 of the lip 36 . The second side of the mounting block abuts against the planar mounting section 48 of the lip 36 , when the nozzle-fastener secures the assembly 20 to the pipe. The corner 50 of the lip is a narrow strip that forms a 90-degree corner with respect to the mounting section 48 of the lip. When fitted to the mounting block, the corner 50 folds over an edge 52 of the mounting block and thereby assists preventing the lip from rotating about the mounting block and nozzle-fastener.
[0018] FIG. 5 shows wash liquid jetting from the outlet 34 of the passage 32 through the nozzle-fastener and flowing onto the curved surface 38 of the lip 36 . The lip spreads the water stream and turns the water stream towards a tangent of the pulp mat 14 and cylindrical drum 16 . Preferably, the spray of wash liquid from each row 22 , 24 of nozzle assemblies is a generally uniform across the width of the mat. The angle (E, F) between the wash spray and mat depends on the row of the nozzle assembly and the amount of curvature in the lip. In the embodiment shown in FIG. 5 , two sheets of wash liquid 55 , 56 flow onto the pulp mat, where each sheet is from one of the two rows of nozzle assemblies.
[0019] FIG. 6 is an exploded view of the pipe 10 and a nozzle assembly 20 . A nozzle-fastener 30 is inserted through an opening in the mounting section 48 of the lip 36 and an opening 54 in the mounting block 46 . The stem 42 of the nozzle-fastener screws into a threaded aperture 28 of the pipe to secure the mounting block to the pipe and the lip to the mounting block. The corner 50 of the lip fits around an edge of the mounting block to prevent rotation of the lip.
[0020] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A nozzle assembly for spraying a wash liquid towards a pulp mat, the assembly including an integral fastener-nozzle having a conduit for the wash liquid, an outlet to the conduit for discharging the wash liquid and an attachment to secure the fastener-nozzle to an aperture in a wash liquid pipe, and a wash liquid direction device extending outwardly from the pipe and adapted to direct the wash liquid from the outlet towards the pulp mat.
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[0001] This application claims the benefit of U.S. Provisional Application No. 60/480,246, filed Jun. 20, 2003.
FIELD OF THE INVENTION
[0002] The invention relates to the use of peptides having bradykinin-antagonistic action for the production of pharmaceuticals for the treatment of degenerative joint diseases.
BACKGROUND OF THE INVENTION
[0003] In degenerative joint diseases such as osteoarthrosis, a slowly progressing destruction of the joint takes place, which is caused in particular by the proteolytic degradation of collagen by collagenases. Collagenases belong to the superfamily of the metalloproteinases (MP) or matrix metalloprotein-ases (MMPs). MMPs are capable of degrading fibrillar and nonfibrillar collagen and proteoglycans, which are all important constituents of the cartilaginous matrix. MMP 3 is involved in the biological degradation of the extracellular matrix and is found in increased levels in patients with osteoarthrosis, which is why particular importance is ascribed to MMP 3 in the degradation of the joint matrix in osteoarthrosis (Manicourt et al. (1994) Arthritis and Rheumatism 37:1774-83).
[0004] Bradykinin is a naturally occurring nonapeptide that has some pharmacological effects that lead to inflammation and pain. Peptides having bradykinin-antagonistic action have already been described in European patent EP 0 370.453 B1. It is further known that peptides having bradykinin-antagonistic action can be employed in the treatment of osteoarthritis or rheumatoid arthritis (AU 638 350). Osteoarthritis and rheumatoid arthritis are joint diseases having severe inflammatory phases in the course of the disease. Lemer et al. (Arthritis and Rheumatism (1987), 30, 530-540) report that, in the context of rheumatoid arthritis, bradykinin may actually enhance bone resorption, but does not stimulate the degradation of the cartilaginous matrix itself.
[0005] In the attempt to find active compounds for the treatment of degenerative joint diseases, it has now been found that the peptide employed according to the invention inhibits the release of MMPs such as MMP-3 (and MMP-1 and MMP-13). As a result, the matrix degradation can be inhibited significantly more effectively than only by the inhibition of MMPs themselves that have already been released or formed in the tissue.
SUMMARY OF THE INVENTION
[0006] The invention therefore relates to the use of the compound of the formula I,
[0000] A-B-X-E-F-K-(DYTIC-G-M-F′-I (I)
[0000] for the production of pharmaceuticals for the treatment of degenerative joint diseases, in which:
[0007] A
a 1 ) is a hydrogen atom, (C 1 -C 8 )-alkyl; (C 1 -C 8 )-alkanoyl, (C 1 -C 8 )-alkoxycarbonyl or (C 1 -C 8 )-alkylsulfonyl, in which in each case 1, 2 or 3 hydrogen atoms are optionally replaced by 1, 2 or three identical or different radicals from the group consisting of carboxyl, amino, (C 1 -C 4 )-alkyl, (C 1 -C 4 )-alkylamino, hydroxy, (C 1 -C 3 )-alkoxy, halogen, di-(C 1 -C 4 )-alkylamino, carbamoyl, sulfamoyl, (C 1 -C 4 )-alkoxycarbonyl, (C 6 -C 12 )-aryl and (C 6 -C 12 )-aryl-(C 1 -C 5 )-alkyl, or in which in each case 1 hydrogen atom is optionally replaced by a radical from the group consisting of (C 3 -C 8 )-cycloalkyl, (C 1 -C 4 )-alkylsulfonyl, (C 1 -C 4 )-alkylsulfinyl, (C 6 -C 12 )-aryl-(C 1 -C 4 )-alkylsulfonyl, (C 6 -C 12 )-aryl-(C 1 -C 4 )-alkylsulfinyl, (C 6 -C 12 )-aryloxy, (C 3 -C 9 )-heteroaryl and (C 3 -C 9 )-heteroaryloxy and 1 or 2 hydrogen atoms are replaced by 1 or 2 identical or different radicals from the group consisting of carboxyl, amino, (C 1 -C 4 )-alkylamino, hydroxy, (C 1 -C 4 )-alkoxy, halogen, di-(C 1 -C 4 )-alkylamino, carbamoyl, sulfamoyl, (C 1 -C 4 )-alkyloxycarbonyl, (C 6 -C 12 )-aryl and (C 6 -C 12 )-aryl-(C 1 -C 5 )-alkyl, a 2 ) is (C 3 -C 8 )-cycloalkyl, carbamoyl, which can optionally be substituted on the nitrogen by (C 1 -C 6 )-alkyl or (C 6 -C 12 )-aryl, (C 6 -C 12 )-aryl, (C 6 -C 12 )-aroyl, (C 6 -C 12 )-arylsulfonyl or (C 3 -C 9 )-heteroaryl or (C 3 -C 9 )heteroaroyl, where in the radicals defined under a 1 ) and a 2 ) heteroaryl, aroyl, arylsulfonyl and heteroaroyl in each case is optionally substituted by 1, 2, 3 or 4 different radicals from the group consisting of carboxyl, amino, nitro, hydroxy, cyano, (C 1 -C 4 )-alkylamino, (C 1 -C 4 )-alkyl, (C 1 -C 4 )-alkoxy, halogen, di-(C 1 -C 4 )-alkylamino, carbamoyl, sulfamoyl and (C 1 -C 4 )-alkoxycarbonyl, or a 3 ) is a radical of the formula II,
[0000]
[0000] where
[0010] R(1) is defined as A under a 1 ) or a 2 ),
[0011] R(2) is a hydrogen atom or methyl,
[0012] R(3) is a hydrogen atom or (C 1 -C 6 )-alkyl, where alkyl is unsubstituted or monosubstituted by amino, substituted amino, hydroxy, carbamoyl, guanidino, substituted guanidino, ureido, mercapto, methylmercapto, phenyl, 4-chlorophenyl, 4-fluorophenyl, 4-nitrophenyl, 4-methoxyphenyl, 4-hydroxy-phenyl, phthalimido, 4-imidazolyl, 3-indolyl, 2-thienyl, 3-thienyl, 2-pyridyl, 3-pyridyl or cyclohexyl, where substituted amino is a moiety —NH-A′- and substituted guanidino is a moiety —NH—C(NH)—NH-A′-, in which A′ is as defined under a 1 ) or a 2 );
[0013] B is Arg, Lys, Orn, 2,4-diaminobutyroyl or an L-homoarginine radical,
where in each case the amino or the guanidino group of the side chain can be substituted by an A as described under a 1 ) or a 2 );
[0015] X is a compound of the formula IIIa or IIIb
[0000] G′-G′-Gly (IIIa)
[0000] G′-NH-(CH 2 ) n —CO (IIIb)
[0000] in which G′ independently of one another is a radical of the formula IV
[0000]
[0000] in which R(4) and R(5) together with the atoms carrying these is a heterocyclic mono-, bi- or tricyclic ring system having 2 to 15 carbon atoms, and n is 2 to 8;
[0016] E is the radical of phenylalanine,
which is optionally substituted by halogen in the 2-, 3- or 4-ring position, or is tyrosine, 0-methyltyrosine, 2-thienylalanine, 2-pyridyl-alanine or naphthylalanine;
[0018] F independently of one another is the radical of a neutral, acidic or basic aliphatic-or aromatic amino acid, which can be substituted in the side chain,. or is a covalent bond;
[0019] (D)-Tic is the radical of the formula V
[0000]
[0020] G is G′ or a covalent bond;
[0021] F′ is the radical of a basic amino acid Arg or Lys in the L or D form or a covalent bond, where the guanidino group or amino group of the side chain can be substituted by A as defined under a,) or a2), or is a radical —NH—(CH 2 ) n — where n is 2-8, or a covalent bond;
[0022] I is —OH, -NH 2 or NHC 2 H 5 ;
[0023] K is the radical —NH—(CH 2 ) x —CO where x is 1 to 4 or a covalent bond;
[0024] M is defined as F, and its physiologically tolerable salts.
DETAILED DESCRIPTION OF THE INVENTION
Definition of Terms
[0025] As used above, and throughout the description of the invention, the following terms, unless otherwise indicated, shall be understood to have the following meanings.
[0026] The term “(C 1 -C 8 )-alkyl” is understood as meaning hydrocarbon radicals whose carbon chain is straight-chain or branched and contains 1 to 8 carbon atoms, for example methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tertiary-butyl, pentyl, isopentyl, neopentyl, hexyl, 2,3-dimethylbutyl, heptyl, neohexyl or octyl.
[0027] The term “halogen” is understood as meaning fluorine, chlorine, bromine or iodine.
[0028] The term “(C 3 -C 8 ) -cycloalkyl” is understood as meaning radicals such as moieties that are derived from 3- to 8-membered monocycles such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl.
[0029] The term “(C 6 -C 12 )-aryl” is understood as meaning aromatic hydrocarbon radicals having 6 to 14 carbon atoms in the ring. —(C 6 -C 12 )-aryl radicals are, for example, phenyl, naphthyl, for example 1-naphthyl, 2-naphthyl, biphenylyl, for example 2-biphenylyl, 3-biphenylyl and 4-biphenylyl, anthryl or fluorenyl. Biphenylyl radicals, naphthyl radicals and in particular phenyl radicals are preferred aryl radicals.
[0030] The term “(C 3 -C 9 )-heteroaryl” is to be understood as meaning radicals such as acridinyl, azetidinyl, benzimidazolyl, benzofuranyl, benzothiofuranyl, benzothiophenyl, benzoxazolyl, benzothiazolyl, benzotriazolyl, benzo-tetrazolyl, benzisoxazolyl, benzisothiazolyl, benzimidazalinyl, carbazolyl, 4aH-carbazolyl, carbolinyl, chromanyl, chromenyl, cinnolinyl, decahydro-quinolinyl, 2H,6H-1,5,2-dithiazinyl, dihydrofuran[2,3-b]-tetrahydrofuran, furanyl, furazanyl, imidazolidinyl, imidazolinyl, imidazolyl, 1H-indazolyl, indolinyl, indolizinyl, indolyl, 3H-indolyl, isobenzofuranyl, isochromanyl, isoindazolyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxadiazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazinyl, pyroazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyridooxazolyl, pyridoimidazolyl, pyridothiazolyl, pyridothiophenyl, pyridinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, 2H-pyrrolyl, pyrrolyl, quinazolinyl, quinolinyl, 4H-quinolizinyl, quinoxalinyl, quinuclidinyl, tetra-hydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, 6H-1,2,5-thia-diazinyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,3,4-thia-diazolyl, thianthrenyl, thiazolyl, thienyl, thienothiazolyl, thienooxazolyl, thienoimidazolyl, thiophenyl, triazinyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1,2,5-triazolyl, 1,3,4-triazolyl and xanthenyl. The preferred examples are pyridyl; such as 2-pyridyl, 3-pyridyl or 4-pyridyl; pyrrolyl; such as 2-pyrrolyl and 3-pyrrolyl; furyl; such as 2-furyl and 3-furyl; thiophenyl, thienyl; such as 2-thienyl and 3-thienyl; imidazolyl, pyrazolyl, oxazolyl, isoxazolyl, thiazolyl, isothiazolyl, tetrazolyl, pyridazinyl, pyrazinyl, pyrimidinyl, indolyl, isoindolyl, benzofuranyl, benzothiophenyl, 1,3-benzodioxolyl, indazolyl,:benzimid-azolyl, benzoxazolyl, benzothiazolyl, quinolinyl, isoquinolinyl, chromanyl, isochromanyl;.cinnolinyl, quinazolinyl, 20- quinoxalinyl, phthalazinyl, pyrido-imidazolyl, pyridopyridinyl, pyridopyrimidinyl, purinyl and pteridinyl.
[0031] Patient includes both human and other mammals.
[0032] Pharmaceutically effective amount means an amount of the compound according to the invention effective in producing the desired therapeutic effect.
[0033] Preferred or Particular Embodiment
[0034] A particular embodiment of the invention is the use according to the invention of the compound of the formula I, wherein: B is Arg, Orn or Lys,
where the guanidino group or the amino group of the side chain is unsubstituted or can be substituted by (C 1 -C 8 )-alkanoyl, (C 6 -C 12 )-aroyl, (C 3 -C 9 )-heteroaroyl, (C 1 -C 8 )-alkylsulfonyl or (C 6 -C 12 )-arylsulfonyl, where the aryl, heteroaryl, aroyl, arylsulfonyl and hetero-aroyl radicals can be substituted as described above under a 2 ) by optionally 1, 2, 3 or 4 identical or different radicals;
[0036] E is phenylalanine, 2-chlorophenylalanine, 3-chlorophenyl-alanine, 2-fluorophenylalanine, 3-fluorophenylalanine, 4-fluorophenylalanine, tyrosine, O-methyltyrosine or β(2-thienyl)alanine;
[0037] K is a covalent bond; and
[0038] M is a covalent bond.
[0039] A more particular embodiment of the invention is the use according to the invention of the compound of the formula I, wherein:
[0040] A is a hydrogen atom, (D)- or (L)-H-Arg, (D)- or (L)-H-Lys or (D)- or (L)-H-Orn;
[0041] B is Arg, Orn or Lys, where the guanidino group or the amino group of the side chain can be substituted by a hydrogen atom, (C 1 -C 8 )-alkanoyl, (C 6 -C 12 )-aroyl, (C 3 -C 9 yheteroaroyl, (C 1 -C 8 )-alkylsulfonyl or (C 6 -C 12 )-arylsulfonyl, where the aryl, heteroaryl,-aroyi, arylsulfonyl and heteroaroyl radicals can optionally be substituted by 1, 2, 3 or 4 identical or different radicals from the group consisting of methyl, methoxy and halogen;
[0042] X is Pro-Pro-Gly, Hyp-ProGly or Pro-Hyp-Gly;
[0043] E is Phe or Thia;
[0044] F is Ser, Hser, Lys, Leu, Val, Nle, lle or Thr;
[0045] K is a covalent bond
[0046] M is a covalent bond
[0047] G is the radical of a heterocyclic ring system of the formula IV, selected from the radicals of the heterocycles pyrrolidine (A), piperidine (B), tetrahydroisoquinoline (C), cis- or trans-decahydroisoquinoline (D), cis-endo-octahydroindole (E), cis-exo-octahydroindole (E), trans-octahydroindole (E), cis-endo-, cis-exo-, trans-octahydrocyclopentano[b]pyrrole (F), or hydroxyproline (V);
[0048] F′ is Arg; and
[0049] I is OH.
[0050] A further particular embodiment of the invention is the use according to the invention of a compound of the formula I, .which is selected from the group:
[0000]
H-(D)-Arg-Arg-Pro-Hyp-Gly-Thia-Ser-(D)-Tic-Oic-
Arg-OH,
H-(D)-Arg-Arg-Pro-Pro-Gly-Thia-Ser-(D)-Tic-Oic-
Arg-OH,
H-(D)-Arg-Arg-Pro-Hyp-Gly-Phe-Ser-(D)-Tic-Oic-Arg-
OH,
H-(D)-Arg-Arg-Hyp-Pro-Gly-Phe-Ser-(D)-Tic-Oic-Arg-
OH
and
H-(D)-Arg-Arg-Pro-Pro-Gly-Phe-Ser-(D)-Tic-Oic-Arg-
OH.
[0051] A further particular embodiment of the invention is the use according to the invention of a compound of the formula I, which the compound of the formula I is D-arginyl-L-arginyl-L-prolyl-L-prolylglycyl-3-(2-thienyl)-L-alanyl-L-seryl-(3R) -1,2,3,4-tetrahydro-3-isoquinolinecarbonyl-(2S,3aS,7aS)octahydro-1H -indole-2-carbonyl-L-arginine, also known under the name HOE 140.
[0052] The peptides employed according to the invention are prepared as described in EP 0 370 453 B1.
[0053] On account of the pharmacological properties, the compounds according to the invention are suitable for the selective prophylaxis and therapy of degenerative joint diseases such as osteoarthrosis; spondylosis or cartilage atrophy after immobilization such as after joint trauma or relatively long immobilization of a joint after meniscus or patella injuries or torn ligaments. The term “osteoarthrosis” is understood as meaning a disease which chiefly develops in connection with a disparity between the strain on and the load capacity of the individual joint components and joint tissues, which is associated with increasing destruction of the cartilage and which is in the main not inflammatory. Damage to the joint cartilage, such as fraying, demedullation and hyalinization, followed by reactive changes in the subchondral bone, and also capsule changes, is prominent in the pathology. The term “spondylosis” is understood as meaning an arthrosis of the vertebral bodies, with this arthrosis being characterized by a noninflammatory loss of cartilage from the vertebral bodies and intervertebral disks.
[0054] The pharmaceuticals according to the invention can be administered by inhalative or transdermal administration or by subcutaneous, intraarticular, intraperitoneal or intravenous injection. Intraarticular administration or topical application is preferred.
[0055] Suitable solid or pharmaceutical preparation forms are, for example, suspensions, emulsions, or injectable solutions, and preparations having protracted release of active compound, in whose preparation customary excipients are used.
[0056] Preferably, the pharmaceutical preparations are prepared and administered in dose units, each unit containing as active constituent a certain dose of the compound of the formula I according to the invention. In the case of injection solutions in ampoule form, this dose can be up to approximately 300 mg, but preferably approximately 10 to 100 mg, in the case of injection solutions for intraarticular treatment up to approximately 300 micrograms, preferably 100 micrograms.
[0057] For the treatment of an adult patient, depending on the activity of the compound according to formula I, daily doses of approximately 0.01 mg/kg to 10 mg/kg of active compound are indicated in the case of systemic administration, in the case of the administration of injection solutions daily doses of 0.001 mg/kg to 0.005 mg/kg of active compound are indicated and in the case of topical or inhalative administration, daily doses of 0.01 mg/kg to 5 mg/kg of active compound are indicated. Under certain circumstances, however, higher or lower daily doses may also be appropriate. The daily dose can be administered either by single administration in the form of an individual dose unit or else a number of smaller dose units or by multiple administration of subdivided doses at specific intervals.
EXAMPLES
[0058] The invention is illustrated below with the aid of examples.
[0059] The abbreviations used for the amino acids correspond to the three-letter code customary in peptide chemistry, as is described in Europ. J. Biochem. 138, 9 (1984). Further abbreviations used are listed below.
Oic octahydro-1H-indole-2-carbonyl Thia 2-thienylalanyl Tic 1,2,3,4-tetrahydroisoquinolin-3-ylcarbonyl
[0063] HOE 140 was prepared as described in EP 0 370 453 B1.
Pharmacological Examples
[0064] For the analysis of the disease-modifying action of HOE140 in a cell culture model relevant to cartilage, the MMP3 expression was analyzed in the chondrosarcoma cell line SW1353 (ATCC: HTB 94). For the experiments, SW1353 cells were cultured under standard conditions (37° C., 5% CO 2 ) in DMEM-Glutamax with 10% of fetal calf serum (FCS) in plastic culture bottles. After detrypsinization of the cells, 50,000 cells were inoculated per well of a 96-well flat-bottom plate in medium without FCS and preincubated with the compound HOE140 in an incubator. After one hour, the cells were stimulated by addition of human IL1-β(0.1 ng/mL, Roche) in a total volume of 300 μL. After incubation for 24 hours under standard conditions, the cell culture supernatant was taken off, centrifuged for 5 minutes and frozen at −20° C. until further analysis. The MMP3 expression in the cell culture supernatants was then analyzed by means of a commercial MMP3 ELISA test system (Amersham) according to the instructions of the manufacturer. In parallel to this, a WST cytotoxicity test was carried out with the remaining cells. For this, the commercial test system of Roche was used and the measurement was carried out according to the instructions of the manufacturer's protocol. Table 1 below shows the results. Bradykinin increases the MMP3 release by more than 30%. This increased release of MMP3 was inhibited by HOE140 in a dose-dependent manner.
[0000]
TABLE 1
MMP- 3 release from SW cells
MMP-3 release
Relative values
MW
based on
Stimulation parameter
(OD 450 nm)
SD
starting value
unstimulated
93
20
IL1α (0.05 ng/mL)
328
17
100
IL1α + bradykinin
433
32
132.0
(0.1 μM)
IL1α + bradykinin (0.1 μM) +
458
50
139.6
0.05 μM HOE140
IL1α + bradykinin (0.1 μM) +
371
8
113.1
0.1 μM HOE140
IL1α + bradykinin (0.1 μM) +
309
18
94.2
0.5 μM HOE140
IL1α + bradykinin (0.1 μM) +
306
27
93.3
1 μM HOE140
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Peptides having bradykinin-antagonistic action are suitable for the production of pharmaceuticals for the prophylaxis and therapy of diseases in whose course an increased activity of matrix metalloproteinases is involved. These include diseases such as degenerative joint diseases, for example osteoarthrosis, spondylosis and chondroporosis after joint trauma or relatively long immobilization of a joint after meniscus or patella injuries or torn ligaments. The invention therefore relates to the use of a compound of the formula I,
A-B-X-E-F-K-(D)-TIC-G-M-F′-I (I)
for the production of pharmaceuticals for the treatment of degenerative joint diseases, wherein A, B, X, E, F, K, (D)-TIC, G, M, F′ and I are as defined herein.
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REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Application No. 61/612,684 filed on Mar. 19, 2012 the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of clothing, and more particularly to a garment that can be worn in a variety of styles and fashions.
[0004] 2. Description of Related Art
[0005] The item described herein represents a unique product because it is convertible and compact. It is cost effective and rather easy to put on, take off and wear in general. This invention has appeal for all ages and while primarily designed for use by women can also be worn by men. The varying ways in which this product can be worn lends itself to multiple uses as well as functionality. For example:
[0006] 1. When worn as a head dress it has appeal to persons of both religious and non religious practices.
[0007] 2. Within certain regions of the world there is uncertainty as to the weather and temperature conditions. Since this sometimes poses a problem with preparation and readiness for most people use of said device has the essential functionality to provide warmth and protection without sacrificing style, compatibility, flexibility, availability, storage and cost.
[0008] 3. The travel industry has forced people to be more conscience of the items they pack and wear. Thus traveling to and from different climates bring about different needs. The hat and scarf worn in the morning may need to be converted to a light jacket or cape by the afternoon or in a cool airplane or restaurant. This invention allows for such versatility all in one garment.
[0009] The needs and uses of said garment are evident and described in detail within this patent. The invention is appealing, simple, comfortable, convertible, light weight, cost-efficient to manufacture, and provides warmth, style, as well as affordable fashion for any person regardless of their location in the world.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a garment which is appealing, comfortable, simple, cost efficient to manufacture.
[0011] A further object of the present invention is to provide a garment which can be worn as top wear, pants, a shawl, a shrug, a scarf, a turban, a body wrap, etc.
[0012] The present invention is unique in its design and function, it can be worn by any adult and fashioned into several types of apparel ranging from a hat and scarf to a pair of gaucho pants. Because the garment does not have buttons or snaps, it can be easily utilized by persons with handicaps or disabilities. It can be worn as a head and shoulder shawl, a hat and neck scarf, a top wear, a light jacket, a shrug, and pants. It can be worn underneath or over a coat, or with or without other garments.
[0013] Another unique feature is that it can be used by men all over the world as either head turban and/or shoulder cover.
[0014] The garment according to the present invention comprises a shawl or panel portion, two sleeves/tube portions, and a body portion between the two tube portions. The garment can be made with either wide bell (or straight) shaped sleeves or tapered sleeves, which does not change the function ability of the garment.
[0015] The unique design is created using one cut and a two sewn seam pattern which is used in the creation of a bell sleeve type garment out of a light weight stretchable fabric. There are no hooks, Velcro, zippers or buttons needed in the creation of this device. For creating a tapered sleeve type garment, an additional cut is necessary. All this leads to a cost efficient model for manufacture.
[0016] The dimensional and construction features described in this application are cited as examples only for illustrative purposes and are not to be considered as limiting the scope of this invention. Fabrics that can be used includes but is not limited to the following:
[0017] stretch polyester fleece,
[0018] jersey knit,
[0019] or any combination of directional stretch fabrics.
[0020] This invention will take a variety of shapes and forms while remaining within the scope of coverage.
[0021] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0022] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0023] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0024] The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.
[0026] FIG. 1 is a plan view of said invention described hereinafter wherein a long flat panel is connected to a tubular triangular shaped bottom section;
[0027] FIG. 2A is a plan view of a sheet of fabric 152 cm×127 cm which is used to make the convertible garment of the present invention;
[0028] FIG. 2B illustrates that the fabric is folded in half along the vertical axis;
[0029] FIG. 2C is a plan view of the folded fabric having a first cutline;
[0030] FIG. 3 is a plan view of the unfolded fabric having two first cut lines;
[0031] FIG. 4 is a plan view of the fabric with the second horizontal edge brought up to the first cut lines and sewn to the first cut lines, creating the pattern for the garment with wide bell shaped (or straight) sleeves.
[0032] FIG. 5 is a plan view of the folded fabric with the first cutline and the second cutline for making a garment with tapered sleeves;
[0033] FIG. 6 is a plan view of the unfolded fabric with the two first cut lines and two second cut lines for making a garment with tapered sleeves;
[0034] FIG. 7 is a plan view of the garment with tapered sleeves wherein the second horizontal edge of the fabric is sewn to the two second cut lines respectively to create tapered sleeves/tubes;
[0035] FIG. 8A is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment opens toward the front and the panel is around the neck line and used as a shawl or scarf to drape in front;
[0036] FIG. 8B is a rear view of the embodiment in FIG. 8A ;
[0037] FIG. 8C is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment opens toward the front and the panel is around the neck line and a portion of the panel is tossed over one shoulder;
[0038] FIG. 8D is a rear view of the embodiment in FIG. 8C ;
[0039] FIG. 9A is a front view of another embodiment of the convertible garment worn as a top wear and head covering wherein the garment opens toward the front and the panel is around the neck line and used as a head covering;
[0040] FIG. 9B is a rear view of the embodiment in FIG. 9A ;
[0041] FIG. 9C is a front view of another embodiment of the convertible garment worn as a top wear and hooded wrap wherein the garment opens toward the front and the panel is around the neck line and used as a hooded wrap;
[0042] FIG. 9D is a rear view of the embodiment in FIG. 9C ;
[0043] FIG. 10A is a front view of another embodiment of the convertible garment worn as a top wear and cowl neck collar wherein the garment opens toward the front and the panel is around the neck line and used as a cowl neck collar;
[0044] FIG. 10B is a rear view of the embodiment in FIG. 10A ;
[0045] FIG. 11A is a front view of another embodiment of the convertible garment worn as an oriental style wrap wherein the garment opens toward the front and the panel is around the neck line and crisscrossed over mid chest and tied in back;
[0046] FIG. 11B is a rear view of the embodiment in FIG. 11A ;
[0047] FIG. 11C is a front view of another embodiment of the convertible garment worn as a knot shrug shawl wherein the garment opens toward the front and the panel is around the neck line and tied in a knot;
[0048] FIG. 11D is a rear view of the embodiment in FIG. 11C ;
[0049] FIG. 12A is a front view of an embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the front and the panel is around the hip level;
[0050] FIG. 12B is a rear view of the embodiment in FIG. 12A ;
[0051] FIG. 13A is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the front and the panel is around the hip level, creating a full top that can be worn with or without another top;
[0052] FIG. 13B is a rear view of the embodiment in FIG. 13A ;
[0053] FIG. 14A is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the front and the panel is around the hip level;
[0054] FIG. 14B is a rear view of the embodiment in FIG. 14A ;
[0055] FIG. 14C is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the front and the panel is around the hip level;
[0056] FIG. 14D is a rear view of the embodiment in FIG. 14C ;
[0057] FIG. 15A is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the front and the panel is around the hip level;
[0058] FIG. 15B is a rear view of the embodiment in FIG. 15A ;
[0059] FIG. 16A is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the front and the panel is around the hip level;
[0060] FIG. 16B is a rear view of the embodiment in FIG. 16A ;
[0061] FIG. 17A is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the back and the panel is around the hip level;
[0062] FIG. 17B is a rear view of the embodiment in FIG. 17A ;
[0063] FIG. 17C is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the back and the panel is around the hip level;
[0064] FIG. 17D is a rear view of the embodiment in FIG. 17C ;
[0065] FIG. 17E is a front view of another embodiment of the convertible garment worn as a top wear wherein the garment is inverted and opens toward the back and the panel is around the hip level;
[0066] FIG. 17F is a rear view of the embodiment in FIG. 17E ;
[0067] FIG. 18A illustrate an additional embodiment as utilized as a turban type hat and neck shawl.
[0068] FIG. 18B is a rear view of the embodiment in FIG. 18A ;
[0069] FIG. 19A is a front view of another embodiment of the convertible garment which is worn as a neck shawl or scarf;
[0070] FIG. 19B is a rear view of the embodiment in FIG. 19A ;
[0071] FIG. 20A is a front view of another embodiment of the convertible garment which is worn as a gaucho wrap pants wherein the garment opens toward the front, the tubes are worn as pants' legs and the panel is around the hip and waste area;
[0072] FIG. 20B is a rear view of the embodiment in FIG. 20A .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0073] Referring to FIG. 1 , the overall shape of said invention can be seen. The device consists of a top portion 400 which is comprised of a flat rectangular shaped cloth. Said 400 rectangular shaped cloth is attached to a lower portion tubular and somewhat rectangular shaped cloth structure 100 . At the point of attachment 60 there is an opening 86 . There are also openings at the lower left and lower right of the triangular structure point 62 and point 76 . It is the combination of both this flat section along with the tube like section that lends itself to being used in a vast majority of ways by an individual looking to wear the garment.
[0074] In still referring to FIG. 1 , there is disclosed a convertible garment according to the first embodiment 10 of the present invention of which the tubes are in tapered shape.
[0075] The convertible garment 10 comprises a body portion 100 having an inner layer 52 and an overlapping exterior layer 54 of fabric of an equal size, both said layers having a first 56 , 66 and second 58 , 68 vertical edges, a first 46 and second 61 , 60 horizontal edges, both said layers 52 , 54 are only connected on the first horizontal edge 46 , and not connected on the second horizontal edges 61 , 60 , leaving an opening 86 for a person to extend his/her hands/legs through.
[0076] The convertible garment 10 further comprises a first tube portion 200 having a first layer 62 and an overlapping second layer 64 of fabric of an equal size, the first layer 62 is connected to and perpendicularly extending from the first vertical edge 56 of the inner layer 52 of the body portion 100 , the second layer 64 is connected to and perpendicularly extending from the first vertical edge 66 of the exterior layer 54 of the body portion 100 , both said layers 62 , 64 of the first tube portion 200 are connected together to form a tube shape with an opening on the distal end 70 ; and a second tube portion 300 having a first layer 74 and an overlapping second layer 76 of fabric of an equal size, the first layer 74 is connected to and perpendicularly extending from the second vertical edge 58 of the inner layer 52 of the body portion 100 , the second layer 76 is connected to and perpendicularly extending from the second vertical edge 68 of the exterior layer 54 of the body portion 100 , both said layers 74 , 76 of the second tube portion 300 are connected together to form a tube shape with an opening on the distal end 78 . The opening 86 between the two tube portions 300 , 200 allows a person to extend his/her hands/legs into tube portions 300 , 200 and exit out of the openings 70 , 78 , respectively.
[0077] The garment 10 further comprises a panel portion 400 which has one layer of fabric. The panel portion 400 is generally rectangular in shape having two vertical edges 14 , 16 , a first horizontal edge of which only the middle is connected to the second horizontal edge 60 of the exterior layer 54 of the body portion 100 , and a second horizontal edge 12 which is not connected to any other portion of the garment 10 , thus the two ends of the panel portion 400 hang freely like flaps 82 , 84 .
[0078] The connections between the panel portion 400 and body portion 100 , the connection between the two layers of body portion 100 , and the connection between the body portion 100 and the tube portions 200 , 300 may be integrally connected or sewn or seamed together. If the garment 10 is made out of one sheet of fabric, these components are integrally connected; they are parts of the fabric. The method of making the garment 10 out of one sheet of fabric will be discussed later.
[0079] The body portion 400 and the tube 100 are sizably dimensioned to allow a person to wear the garment 10 on the upper body with the two tube openings 76 , 62 being worn as arm sleeves and on the lower body with the two tube openings 76 , 62 being worn as pants legs. A person may extend his/her hands or legs through opening 86 into the sleeves/pants' legs 200 , 300 and beyond the openings 70 , 78 .
[0080] In other embodiment, the tube sections 200 , 300 may be in different shapes including but not limited to a straight shape, and wide bell shape which does not change the function ability of the garment.
[0081] The garment 10 may be made out of one sheet of generally rectangular light weight directional stretchable fabric having an inner surface, an outer surface, two horizontal edges, and two vertical edges. The sheet of fabric may include stretch polyester fleece, jersey knit, polyester/cotton, and any combinations thereof. The sheet of fabric is dimensioned such that the dimension measured between the two vertical edges is greater than the dimension measured between the two horizontal edges. The sheet of fabric is stretchable between two vertical edges and not stretchable between its horizontal edges.
[0082] A method of making the convertible garment with wide bell or straight shaped sleeves/tubes according to the present invention comprises the following steps:
[0083] First, obtaining one sheet of rectangular shaped fabric 1 having a first 12 and second 61 horizontal edge with a dimension L, and a first 16 and second 14 vertical edge with a dimension W, referring to FIG. 2A for a plan view of such a sheet of fabric. For easy comprehension, the four corners of the fabric are designated as A, B, C, and D, respectively. The preferred dimensions for the sheet of fabric 1 are about 60 inches (L) by 50 inches (W). The fabric 1 is stretchable between the two vertical edges 16 , 14 but is not stretchable between the two horizontal edges 12 , 61 .
[0084] Secondly, fold the fabric 1 in half parallel to the vertical edge 14 creating a sheet of two layered rectangular shaped fabric with a dimension of a half of L in a horizontal direction and a dimension of W in a vertical direction. FIG. 2B illustrates fabric folded in half creating a folded line 63 , wherein corners A and B are overlapped and corners C and D are overlapped.
[0085] Thirdly, FIG. 2C , make a first cutline at about three tenths of the dimension away from the first horizontal edge 12 in a horizontal direction starting from the overlapping vertical edges 14 , 16 towards the vertical fold line 63 , the first cutline is about one third of the dimension. FIG. 2C illustrates the folded fabric has a first cutline 18 , 20 .
[0086] Next, referring to FIG. 3 , unfolding the sheet of fabric 1 which has two first cut lines 18 , 20 , each located around three tenth of the dimension from the first horizontal edge 12 extending from the vertical edge 16 , 14 towards center of the sheet of fabric 1 . Each cut line 18 , 20 is about one third of the dimension of the length of the sheet 1 . FIG. 3 illustrates the pattern for the bell (or straight or wide) shaped tube/sleeve type garment before sewing the device together. Once the two cuts are made, the panel portion 400 which is on the top portion above the first cut lines 18 , 20 in this figure is completed. This is the same top portion that can be seen in FIG. 1 on the completed embodiment of the invention.
[0087] Continuing with the development of the device refer to FIG. 4 . Therein, bring up the second horizontal edge 61 to the two first cut lines 20 , 18 , creating a fold line 46 . Stitch (Sew) together part of the second horizontal edge 61 to each of the first cut lines 20 , 18 respectively to create two straight (or wide bell) shaped tubes 300 , 200 with two openings on the terminal ends 78 , 70 , respectively which can be worn as arm sleeves or pants' legs. FIG. 4 illustrates the garment for the bell (or straight or wide) shaped tube/sleeve type garment.
[0088] The stitching (sewing) seam for creating the tube/sleeve portions are indicated in dashed line within FIG. 4 . The region between the two tube portion openings 70 , 78 is designated as a hollow body portion 100 which has two layers of fabric and has an opening 86 for a person to extend his/her hands/legs through and into the tube body portion 100 and out the left and right side openings 70 , 78 .
[0089] In a preferred embodiment, the sheet of fabric 1 is about 60 inches (L) by 50 inches (W); each of the tube sections 200 , 300 is about 19 inches by 17.5 inches; the panel portion 400 is about 60 inches by 15 inches; the body portion 100 is about 22 inches by 17.5 inches.
[0090] For creating a tapered sleeve type garment 10 , an additional cut is necessary. A method of making the convertible garment 10 with tapered shaped sleeves/tubes according to the present invention comprises following the first three steps of the method of making a wide bell or straight shaped sleeves/tubes garment. Refer to the foregoing paragraphs and FIGS. 2A , 2 B, 2 C for the first three steps of making a garment with tapered shaped sleeve/tubes garment.
[0091] Next referring to FIG. 5 , the second horizontal edge 61 of the fabric 1 is brought to the first cut line 20 , 18 , creating a fold line 46 . Thereafter a second cutline is created—the second cutline starting from the vertical edges 14 , 16 towards the vertical fold line 63 and forming an acute angle 65 with the first cutline 18 , 20 . Said FIG. 5 illustrates this second cut on the folded fabric performed to create a tapered tube or tapered sleeve effect. The preferred angle 65 between the first and second cut lines is between 25 to 45 degrees.
[0092] After this cutting process depicted in FIG. 5 , to continue creating the garment, FIG. 6 , one needs to unfold the sheet of fabric 1 .
[0093] FIG. 6 illustrates the fabric 1 unfolded and prepared for stitching or sewing. The fabric 1 has two first cut lines 20 , 18 and four second cut lines wherein two of the second cut lines 21 , 19 are connected to the two first cut lines 20 , 18 respectively, and the other two of the second cut lines 25 , 23 are connected to the shortened second horizontal edge 61 . The portion above the first cut lines 20 , 18 is designated as panel portion 400 .
[0094] Subsequently, and referring to FIG. 7 , the second horizontal edge 61 has been brought upward to align with the two first cut lines 20 , 18 ; thereafter this section has been stitched or sew whereby the overlapped second cut lines 21 and 25 come together. Additionally the process of stitching or sewing the overlapped second cut lines 19 and 23 is also done to create two tapered shaped tube like portions 300 , 200 with openings on the distal ends 78 , 70 respectively, which can be worn as arm sleeves or pants' legs. The region between the two tube portions 300 and 200 as indicated is designated as body portion 100 which has been created by overlapping two layers of fabric. Said tube section has an opening 86 for a person to extend his/her hands/legs into the tube like structure 300 , 200 .
[0095] FIG. 7 further illustrates the garment with tapered tubes/sleeves. The stitched or sew seams have created the two tube like sections 300 , 200 .
[0096] In a preferred embodiment, the sheet of fabric 1 is about 60 inches (L) by 50 inches (W); each of the tubes 200 , 300 is about 19 inches by 17.5 inches, the tapered sides of the tubes 21 , 25 , 19 , 23 may be about 22 inch, the angle 65 between the first cutline and second cutline is about 30 degrees; the panel portion 400 is about 60 inches by 15 inches; the body portion 100 is about 22 inches by 17.5 inches.
[0097] The present invention is unique in its design and function, it can be worn by any adult and fashioned into several types of apparel ranging from a hat and scarf to a pair of gaucho pants. Versatility of the product can provide various functionalities.
[0098] When the garment 10 is worn on the upper body the garment can be worn in a variety of styles/fashions. The garment can be inverted and worn in a way that the panel portion 400 is on the top of the garment 10 and the body portion 100 is on the bottom of the garment 10 . With the body portion 100 being worn on one's back, the two tubes 200 , 300 being worn as arm sleeves, the panel portion 400 being up around ones neckline and worn as a shawl, scarf, cowl neck collar, head covering or wrap, there are many styles/fashions that can be created as shown in FIGS. 8A-11D . In these styles/fashions, the garment opens towards the front.
[0099] FIG. 8A illustrates an embodiment of the present invention. The garment opens towards the front; the body portion 100 is on one's back, arms are placed into tube portions 200 , 300 , and the panel portion 400 is up at neck line and is used as the shawl or scarf portion to drape in front.
[0100] FIG. 8B illustrates the back view of FIG. 8A embodiment.
[0101] FIG. 8C illustrates an additional embodiment where the garment opens towards the front; tubes 200 , 300 are worn as arm sleeves and one flap 82 or 84 at neck line is tossed over one shoulder.
[0102] FIG. 8D illustrates the back view of the aforementioned embodiment.
[0103] FIG. 9A illustrates an additional embodiment of the present invention where the garment opens toward the front; the panel portion is at the neck line and is used as a head covering, placed loosely around the head and tossed over each shoulder. The body portion and tube portions are used as sleeves, shoulders and back of the garment.
[0104] FIG. 9B illustrates the back view of said embodiment.
[0105] FIG. 9C illustrates an additional embodiment where the garment opens to the front; arms are placed into the tube portions 200 , 300 and the panel portion 400 is at the neck line and is wrapped loosely around the head and face, tied into a knot and tucked under in the front. Alternatively, flaps 82 , 84 of the panels 400 can also be brought around to the back and tied. This feature is important for women that utilize head covering as part of daily life.
[0106] FIG. 9D illustrates the back view of such embodiment. Pane portion 400 is seen as a hood like feature around the back of the head.
[0107] FIG. 10A illustrates an additional embodiment where the garment opens to the front; arms are placed into tube portions 200 , 300 as sleeves. The left and right flaps 82 , 84 are at neck line and wrapped across the front and back of the neck in a circular fashion to create a cowl neck collar. The end of panel portion 100 is tucked under the collar, creating a continuous look.
[0108] FIG. 10B illustrates the back view of the same embodiment.
[0109] FIG. 11A illustrates an additional embodiment of the invention where the garment opens toward the front; arms are place in tube portions as sleeves. The flaps of the panel portion are at neck line, crisscrossed over mid chest, taken to the back of the body, and the corners of panel portion is tied and tucked under the back of the garment to create an oriental style wrap.
[0110] FIG. 11B illustrates the back view of the embodiment. The tube portions 200 , 300 are seen as the sleeves of the garment in this view.
[0111] FIG. 11C Illustrates an additional embodiment where the garment opens towards the front, arms are placed into tube portions 200 , 300 as sleeves and the flaps 82 , 84 of panel portion 100 are tied in front with a low hanging knot.
[0112] FIG. 11D illustrates the back view of FIG. 11C .
[0113] Alternatively, the garment 10 can be worn in a way that the garment is inverted and opens towards the front. The body portion 100 is on the top of the garment 10 and the panel portion 400 is on the bottom of the garment 10 . In this way, the body portion 100 is being worn on one's back, the two tubes 200 , 300 are being worn as arm sleeves, the panel portion 400 is being wrapped around ones hip level. This usage lends itself to a vast variety of styles/fashions most of which are shown in FIGS. 12A-16B . In these styles/fashions, the garment is inverted and opens toward the front.
[0114] FIG. 12A illustrates an embodiment wherein the garment 10 is inverted and opens toward the front; arms are placed into tube portions 200 , 300 as sleeves; flaps 82 , 84 of panel portion 400 are draping down at hip level and are intended to hang loosely as flaps in the front.
[0115] FIG. 12B illustrates the back view of this free flowing hanging garment style.
[0116] FIG. 13A illustrates an additional embodiment. In a fashion, similar to the previous embodiment presented in FIG. 12A , the garment 10 herein is inverted and opens towards the front; body portion 100 is worn on one's back; arms are placed into tube portions 200 , 300 as sleeves. Flaps 82 , 84 of the panel portion 400 are draping at hip level. The left flap is crossed over the font of the body and tucked into the right sleeve of the tube portion. The right flap is also crossed over the top of other panel and tucked into the left sleeve of the tube portion. This approach Creates a full top that can be worn with or without another top.
[0117] FIG. 13B illustrates the back view of said embodiment FIG. 13A .
[0118] FIG. 14A illustrates an additional embodiment wherein the garment is inverted and opens towards the front; the body portion 100 is worn on one's back; one's arms are placed into tube portions 200 , 300 as sleeves. Flaps 82 , 84 of panel portions 400 are draping down at the hip level and are tied in front to create a diamond shape front, to accent any additional garments the user may choose to wear in conjunction with said invention.
[0119] FIG. 14B illustrates the back view of FIG. 14A .
[0120] FIG. 14C illustrates an additional embodiment wherein arms are placed into the tube portions 200 , 300 as sleeves. Flaps 82 , 84 of the panel portion 400 are draping downward at hip level and tied off low down to one side.
[0121] FIG. 14D illustrates the back view of FIG. 14C .
[0122] FIG. 15A illustrates an additional embodiment wherein said garment is inverted and opens towards the front. Arms are placed into tube portions 200 , 300 as sleeves. Flaps 82 , 84 of panel portion 400 are draping downward at hip level and are crisscrossed around the waistline wherein they are tied off in the back. Panel portion 400 can be adjusted up to cover more of the frontal area.
[0123] FIG. 15B illustrates the back view of FIG. 15A .
[0124] FIG. 16A illustrates an additional embodiment wherein the garment is inverted and opens toward the front. Arms are placed into tube portions 200 , 300 as sleeves. Flaps 82 , 84 of panel portion 400 are draping downward at one's hip level. One flap 82 or 84 of the panel portion is crossed over the front of the body and tucked into one of the tube portions 200 or 300 , creating a top with a hanging flap.
[0125] FIG. 16B illustrates the back view of FIG. 16A .
[0126] Similar to the aforementioned fashions/styles wherein the garment 10 can be worn with the body portion 100 being on the top and the panel portion 400 being on the bottom of the garment, another usage is where the body portion 100 in these styles/fashions is worn on one's chest. In this usage the garment is inverted and opens towards the back. These styles/fashions are illustrated in FIGS. 17A-17E .
[0127] FIG. 17A illustrates an additional embodiment wherein the garment is inverted and worn with the opening towards the back and the body portion 100 worn in the front; arms are placed into tube portions 200 , 300 . The panel portion 400 is hanging down in the back. The top neckline of garment 10 may be adjusted to fit comfortably around the neck. Flaps 80 or 82 of panel portion 400 are crisscrossed at the back, brought around to the front of the body and tied in the center front.
[0128] FIG. 17B illustrates the back view of FIG. 17A .
[0129] FIG. 17C illustrates an additional embodiment wherein the garment is inverted and opens towards the back. Arms are placed into tube portions 200 , 300 backwards, with panel section 400 hanging off from the back. The top of garment is adjusted to fit comfortably around the neck. The flaps 80 , 82 of panel section 400 are crisscrossed around the waistline and tied low to the side of the body.
[0130] FIG. 17D illustrates the back view of FIG. 17C .
[0131] FIG. 17E illustrates an additional embodiment; the garment is inverted and opens towards the back. Arms are placed into tube portions 200 , 300 , with panel portion 400 hanging off at the back. The top of the garment is adjusted to fit comfortably around the neck. The flaps 82 , 84 of panel portion 400 are tied into a knot at the back and fan out as desired.
[0132] FIG. 17F illustrates the back view of FIG. 17E .
[0133] FIG. 18A illustrate an additional embodiment as utilized as a turban type hat and neck shawl. The panel portion 400 is centered around the shoulders and neck in even proportions on each side like a shawl. One flap 82 or 84 is place over the crown of the head to create a base for the hat. Holding the panel portion 400 in place over the crown of the head, twisting the remaining portion of the flap to the end and wrap around the lowest part of the base part of panel portion 400 in a clockwise direction and tuck under itself. Twist the remaining flap 84 or 82 of the panel portion 400 across the back in the opposite direction and tuck, creating a rim for the hat or turban portion or it can be left to hang down at the back. The tube portions 200 , 300 can be folded upward to create a scarf effect or downward to create a shawl effect, thus eliminating the draft that results when a separate hat and scarf are worn. This style can be worn inside or outside of a coat and can be worn by men as a turban and women as head dress and coverings.
[0134] FIG. 18B illustrates the back view of FIG. 18A .
[0135] FIG. 19A illustrates an additional embodiment as utilized as a neck shawl or scarf. Panel portion 400 is centered around the shoulders and the neck in even proportions on each side. The panel portion 400 , tube portions 200 , 300 , and body portion 100 can be tied or twisted in front to create a variety of looks and shawls.
[0136] FIG. 19B Illustrates the back view of FIG. 19A .
[0137] As illustrated in FIGS. 20 A and 20 B, and in another embodiment, the garment 10 can be worn as the gaucho wrap pants. Legs are placed into tube portions 200 , 300 with the garment's opening towards the front. The body portion 100 is pulled up to the middle of the abdominal waist area to secure that the front and hip area is covered. Additionally, this is further achieved by pulling the first flap 82 of panel portion 400 across the hip and waist area and around the top of body portion 100 . Thereafter, one would also pull the second flat 84 of panel portion 400 across the other side, overlapping body portion 100 and the other flap 82 of panel portion 400 . To secure said garment into place for a comfortable fitting pant garment and tie it in place a knot can be tied in the front or in the back.
[0138] FIG. 20A is a front view and FIG. 20B is a back view of the garment worn as the gaucho wrap pants.
[0139] The figures do not limit the possibilities of the garment as any variations of these functionalities can be modified to taste to create even more styles.
[0140] While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled.
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The present invention is unique in its design and function, it can be worn by any adult and fashioned into several types of apparel ranging from a hat and scarf to a pair of gaucho pants. Because the garment does not have buttons or snaps, it can be easily utilized by persons with handicaps or disabilities. It can be worn as a head and shoulder shawl, a hat and neck scarf, a top wear, a light jacket, a shrug, and pants. The unique design is the one cut and two sewing seams creation of the bell sleeve type garment out of a light weight stretchable fabric. There are no hooks, Velcro, zippers or buttons. For creating a tapered sleeve type garment, an additional cut is made. Because of its simplicity, the garment of the present invention is cost efficient to manufacture.
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FIELD OF THE INVENTION
[0001] The present invention relates to an improved and convenient process for the preparation of 3-Ethoxy-4-(alkoxy carbonyl)-phenyl acetic acid, which can be represented by formula (Ia) where R 1 represents ethyl or methyl. Specifically the present invention relates to an improved process for the preparation of compound of formula (Ia), which is the key intermediate for Repaglinide of formula (I), by the process, which involves non-hazardous raw materials with an easy handling, and cost effective process
[0002] Repaglinide is a known oral anti-diabetic drug used for the treatment of diabetes, called Type-2 diabetes. It may be used alone or with metformin.
BACKGROUND OF THE INVENTION
[0003] In Journal of Medicinal Chemistry 1998 Vol.41, No.26,5219 the process for the preparation of hypoglycemic benzoic acid derivatives was disclosed. Specifically disclosed the process for the preparation of 3-Ethoxy-4-(ethoxy carbonyl)-phenyl acetic acid. The process of the preparation of 3-Ethoxy-4-(ethoxy carbonyl)-phenyl acetic acid comprises of reacting 2-Hydroxy-4-methyl-benzoic acid with ethyl bromide in the presence of K 2 CO 3 in acetone at 150° C. for 30 hrs in autoclave to give Ethyl-2-ethoxy-4-methyl-benzoate. The obtained compound was reacted with NBS in the presence of 2,2 1 -azo-bis-(isobutyronitril) in CCl 4 to yield Ethyl-4-bromomethyl-benzoate. And this 4-bromomethyl ester is reacted with NaCN in the presence of N-benzyl-tri-n-butylammonium chloride in water and dichloromethane at 20° C. for 43 hrs to give Ethyl-4-cyanomethyl-2-ethoxy-benzoate. The cyano methyl ester was treated with gaseous HCl in ethanol at reflux to yield Ethyl-2-ethoxy-4-ethoxycarbomethyl-benzoate. The obtained diester was hydrolyses with 2N NaOH in ethanol at 23-25° C. for 1.5 hr to yield 3-Ethoxy-4-(ethoxy carbonyl)-phenyl acetic acid.
[0004] The above process described for the preparation of 3-Ethoxy-4-(ethoxy carbonyl)-phenyl acetic acid has some disadvantages to perform in large scale as it involves lacrimetic chemicals like ethyl bromide, which is difficult to handle in commercial scale. The usage of carbon tetra chloride as a solvent is yet again set back in the process, since it is class-I solvent, and usage of ethanol as a solvent is also a set back in the process as the recovery and reuse of said solvent is not feasible in scale up. And the process has another disadvantage is all the reactions have longer hour maintenance, higher temperature and HCl gas passing at refluxing temperature. Still the process has another disadvantage is the formation of diacid impurity during the preparation of formula IV and I. Hence, the process renders with high cost and is not suitable for commercial production.
[0005] WO 01/35900 A2 describes the process for the preparation of 3-ethoxy-4-(ethoxy carbonyl) phenyl acetic acid. This process comprises of reacting 4-methyl salicylic acid with ethylbromide in dimethyl sulfoxide at 35-40° C. to give ethyl-2-ethoxy-4-methyl benzoate. The obtained compound was reacted with n-butyl lithium in a solution of diisopropyl amine in tetra hydrofuran and hexamethyl phosphoramide, then reacted with carbon dioxide at −75° C. to give 3-ethoxy-4-(ethoxy carbonyl) phenyl acetic acid.
[0006] The above said patent process for the preparation of 3-ethoxy-4-(ethoxy carbonyl) phenyl acetic acid has some disadvantages to perform in large scale as it involves lacrimatic chemicals like ethyl bromide, moisture sensitive and fire hazardous chemicals like n-butyl lithium. And the process has another disadvantage is operational bottleneck like −75° C. temperature. Still the process has another disadvantage is the usage of tetrahydrofuran and dimethylsufoxide as the recovery and reuse of said solvents is not feasible in scale up. The said process mentioned in WO 01/35900 A2 is suffering with scale up operations, so there is need to develop to overcome the above said disadvantages.
[0007] These forgoing problems, directed us towards the present invention, which is the convenient and economic process for the preparation of compound of the formula (Ia), which is the key intermediate for the preparation of Repaglinide of the formula (I), is a known oral anti-diabetic drug used for the treatment of diabetes. The present invention involves a cheaper and easy handling chemicals like diethyl sulfate instead of ethyl bromide, cyclohexane (class-II) solvent instead of CCl 4 (class-I), cheaper solvent methanol instead of ethanol, cheaper phase transfer catalyst tetra butyl ammonium bromide instead of N-benzyl-tri-n-butylammonium chloride and dry HCl gas passing also avoided as mentioned in the prior art. The present process an advantageous over prior art references that all stages are obtained with good yield and purity.
[0008] The product obtained in the present process is having high yield than prior art and the process is cost effective, Eco-friendly and easily scalable.
SUMMARY OF THE INVENTION
[0009] The present invention relates to an improved and convenient process for the preparation of 3-Ethoxy-4-(alkoxy carbonyl)-phenyl acetic acid of formula (Ia), which is the key intermediate for preparation of Repaglinide of formula (I) is used for the treatment of anti diabetes.
[0010] The process of the present invention comprises the esterification and etherficaton of (2-Hydroxy-4-methyl) benzoic acid of formula (II) with diethyl sulfate using potassium carbonate in toluene as a solvent to give Ethyl-2-ethoxy-4-methyl-benzoate of formula (III). Which on allylic bromination with NBS in the presence of AIBN as a catalyst in cyclohexane resulted Ethyl-4-bromo methyl-2-ethoxy-benzoate of formula (IV). The bromo methyl compound on cyanation with sodium cyanide in the presence of tetra butyl ammonium bromide as a phase transfer catalyst in dichloro-methane and water as a solvent afforded Ethyl-4-cyanomethyl-2-ethoxy-benzoate of formula (V). Which on hydrolysis in the presence of sodium hydroxide in water resulted (4-carboxy-3-ethoxy-phenyl) acetic acid of formula (IV). The obtained diacid compound on esterfication in the presence of trimethyl amine in toluene afforded the Alkyl-2-ethoxy-4-alkoxy carbonyl methyl-benzoate of formula (III), the di ester compound selectively hydrolyses with sodium hydroxide in methanol to give 3-Ethoxy-4-(alkoxy carbonyl)-phenyl acetic acid of formula (Ia).
[0011] The process of the present invention is cost effective and eco-friendly over prior art procedures.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Accordingly, the present invention provides an improved and convenient process for the preparation of 3-Ethoxy-4-(alkoxy carbonyl)-phenyl acetic acid of formula (Ia).
[0013] The process of the present invention is schematically represented as follows.
[0014] The present invention provides a process for the preparation of compound of formula (Ia) as shown in the above scheme, which comprises.
[0015] Preparation of compound of formula (III) from compound of formula (II) by esterification and etherification with diethyl sulfate.
[0016] Transforming the compound of formula (III) into compound of formula (IV) involves allylic bromination with NBS in the presence of AIBN.
[0017] Transforming the compound of formula (IV) into compound of formula (V) involves cyanation with NaCN.
[0018] Preparation of compound of formula (VI) from compound of formula (V) by hydrolysis.
[0019] Preparation of compound of formula (VII) from compound of formula (VI) by esterification.
[0020] Conversion of compound of formula (VII) into compound of formula (Ia) by selective hydrolysis of ethoxy carbonyl methyl group.
[0021] Another aspect of the process of present invention includes preparation of intermediate described by general formula (VI)
[0022] The process to prepare compound of formula (III) includes, reacting the carboxy and hydroxy groups of compound of formula (II) with diethylsulfate in the presence of suitable base such as potassium carbonate, sodium carbonate, triethyl amine, potassium-t-butoxide and like in suitable solvent such as C 1 -C 4 ketone, toluene, benzene, cyclohexane and like. The temperature ranges from 80-110° C., preferably 100-110° C.
[0023] The reagents used in the above process may range from equimolar to 5 mole ratio. The duration of reaction may range from 15-35 hr, preferably from 20-30 hrs.
[0024] Preparation of compound of formula (IV) involves allylic bromination of compound of formula (III) with suitable allylic brominating reagents like N-bromo succinimide, dibromo dimethyl hydentoin in the presence suitable free radical initiators such as 2,2 1 -azo-bis-(isobutyronitrile), di benzoyl peroxide and like in suitable solvents. Such as chloroform, CCl 4 , cyclohexane and dichloromethane, preferably in cyclohexane. The temperature ranges from 25° C. to reflux temperature of the solvent used preferably 75-85° C. The duration of the reaction may range from 3 hr to 10 hr, preferably 3 hr to 5 hr. The reagents used in the process may range from 1 mole to 2 mole ratio.
[0025] Transformation of compound of formula (IV) into compound of formula (V) involves cyanation with sodium cyanide in suitable solvent. Such as mixture of water and organic solvents like dichloromethane, toluene, benzene, chloroform ethyl acetate, in the presence of suitable phase transfer catalyst such as tetra butyl ammonium halide, benzyl trimethyl ammonium halide, N-benzyl-tri-n-butyl ammonium halide and the like, where halide represents chlorine, bromine or iodine.
[0026] The quantity of water may range from 0.5 times to 4 times and quantity of solvent may range from 3 times to 10 times.
[0027] In preparation of compound of formula (VI) includes, hydrolysis of cyano ester compound of formula (V) with suitable acidic reagents such as hydrochloric acid, hydrobromic acid, sulfuric acid and the like, suitable basic reagents such as sodium hydroxide, potassium hydroxide, sodium hydride, potassium hydride, preferably in sodium hydroxide and the like, in suitable solvent. Such as water, C 1 -C 4 alcohol, dichloromethane, chloroform, acetonitrile and the like at suitable temperature may range from 25° C. to reflux temperature of the solvent used, preferably 80° C. to 100° C.
[0028] The reagents used in the above process may range from 2 moles to 4 mole ratio, preferably 3 mole ratio.
[0029] Preparation of compound of formula (VII), involves esterification with suitable reagents such as ethyl bromide, ethyl chloride, diethyl sulfate, methyl bromide, methyl chloride, dimethyl sulfate and the like. In the presence of suitable base such as potassium carbonate, sodium carbonate, sodium bicarbonate, potassium bicarbonate, triethyl amine and the like in suitable solvent such as toluene, C 1 -C 4 ketone, cyclohexane, benzene and the like.
[0030] The reagents used in the above process may range from 1 mole to 4 mole ratio, preferably 3 mole ratio. The temperature may ranges from 25° C. to reflux temperature of the solvent used, preferably 90-110° C.
[0031] The process for the preparation of compound of formula (Ia) includes, selective hydrolysis of compound of formula (VII) with suitable reagents, may be acidic or basic. Acidic reagents such as hydrochloric acid, hydrobromic acid, sulfuric acid, acetic acid and the like, basic reagents such as sodium hydroxide, potassium hydroxide, sodium hydride, potassium hydride, and the like, in suitable solvent. Such as, C 1 -C 4 alcohol, acetonitrile, C 1 -C 4 ketone and the like or mixture of water and organic solvents like C 1 -C 4 alcohol, acetonitrile, C 1 -C 4 ketone, preferably mixture of water and methanol, at suitable temperature may range from 0° C. to reflux temperature of solvent used, preferably 10° C. to 15° C.
[0032] The reagents used in the above process may range from 0.8 moles to 1.2 mole ratio, preferably equimolar ratio, the duration of the reaction may range from 1 hr to 20 hr preferably 1 hr to 2 hr.
[0033] The above process, includes isolation of compound by pH adjustment with suitable acidic reagents such as hydrochloric acid, hydrobromic acid, sulfuric acid and the like, preferably hydrochloric acid. The pH may range from 1 to 6, preferably 1 to 3.
[0034] The process described in the present invention is demonstrated in examples illustrated below. These examples are provided an illustration only and therefore should not be construed as limitation to the scope of invention.
EXAMPLE 1
Preparation of Ethyl-2-ethoxy-4-methyl benzoate (III)
[0035] Added 260 ml (3.0 mol) of diethyl sulfate to the mixture of 1000 ml of toluene, 272.5 g (3.0 mol) of potassium carbonate and 100 g (1.0 mol) of 2-Hydroxy-4-methyl-benzoic acid at 25-45° C. for 1 hr to 1 hr 30 min. Heated the reaction mass to azeotropic reflux for 20-30 hr. Cooled the reaction mixture to 25-35° C. and collected the unwanted material by filtration, washed the unwanted material with 500 ml of toluene. Combined filtrate was washed with water (1×1000 ml and 1×500 ml) at 80-85° C. Total organic layer was concentrated to residue under vacuum at below 70° C. The yield of the title compound is 128 g (94.11%).
[0036] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
EXAMPLE 2
Preparation of Ethyl-4-bromo methyl-2-ethoxy benzoate (IV)
[0037] To the suspension of 700 ml of cyclo hexane, 86 g (1.0 mol) of N-bromo succinimide and 3 g (0.03 mol) of AIBN was added 100 g (1.0 ml) of Ethyl-2-ethoxy-4-methyl benzoate. Heated the resulted mass to reflux and stirred for 3-5 hr. Cooled to 50-60° C. and charged 200 ml of water, then stirred for 10-15 min. Separated the aqueous phase and organic phase. The organic phase was washed with 200 ml of 5% hydrose followed by water (200 ml) at 50-60° C. Total organic phase was distilled completely under vacuum at below 60° C. Cooled to 25-35° C. and the title compound was isolated from residue with 100 ml n-Heptane at 0-5° C. The obtained compound was recrystallised from 400 ml of n-Heptane. Dried the compound under reduced pressure at 45-50° C. The yield of the recrystallised compound is 59.2 g (43%).
[0038] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
EXAMPLE 3
Preparation of Ethyl-4-cyanomethyl-2-ethoxy benzoate (V)
[0039] A solution of 350 ml of dichlro methane and 50 g (1.0 mol) of Ethyl-4-bromo methyl-2-ethoxy benzoate was added slowly to a suspension of 30 ml of water, 13 g (1.5 mol) of sodium cyanide and 2.5 g of tetra butyl ammonium bromide at temperature of 10-15° C. Then raised the reaction mass temperature to 25-35° C. and stirred for 25-35 hr. After completion of reaction separated the aqueous phase and organic phase. Washed the organic phase with water (1×100 ml and 1×50 ml). Distilled off the organic phase under reduced pressure at below 45° C. The titled compound was isolated from residue with 100 ml of isopropyl alcohol at a temperature of 0-5° C. Dried the compound under reduced pressure at 35-40° C. The yield of the obtained product is 32.7 g (80.3%).
[0040] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
EXAMPLE 4
Preparation of (4-Carboxy-3-ethoxy-phenyl) acetic acid (VI)
[0041] Charged 50 g (1.0 mol) of Ethyl-4-cyanomethyl-2-ethoxy benzoate to a solution of 250 ml of water and 26 g (3.0 mol) of sodium hydroxide. The resulted reaction mixture was heated to reflux for 1½ hr to 2 hr. Cooled the reaction mass to 25-35° C. and adjust the pH to around 2 with hydrochloric acid at 25-35° C., stirred for 45-60 minutes. Filtered the compound and washed with 100 ml of water. Dried the product at 70-80° C. The yield of the title compound is 46.1 g (96%).
[0042] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
EXAMPLE 5
Preparation of Ethyl-2-ethoxy-4-ethoxy carbonyl methyl benzoate (VII)
[0043] Added 94 ml (3.0 ml) of triethylamine and 88 ml (3.0 ml) of diethyl sulfate to a suspension of 250 ml of toluene and 50 g (1.0 mol) of (4-carboxy-3-ethoxy-phenyl) acetic acid at temperature of 25-35° C. The resulted reaction mass was heated to reflux for 1-2 hr. Charged 500 ml of water into reaction mass at 80-85° C., and stirred for 15-30 minutes. Separated the aqueous phase and organic phase. Washed the organic phase with 250 ml of water at 80-85° C. and distilled under reduced pressure at below 70° C. Cooled to 25-35° C. and unloaded the residue. The yield of the obtained product is 58 g (92.8%).
[0044] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
EXAMPLE 6
Preparation of 3-Ethoxy-4-(ethoxy carbonyl)-phenyl acetic acid (VI)
[0045] A solution of 15 ml of water and 1.4 g (0.98 mol.) of sodium hydroxide was added slowly to a slowly to a solution of 25 ml of methanol and 10 g (1.0 mol) of Ethyl-2-ethoxy-4-ethoxy carbonyl methyl benzoate at a temperature of 10-15° C. Stirred for 1-2 hrs at 10-15° C., then the solvent was distilled off from reaction solution under reduced pressure at below 60° C. Cooled to 25-35° C. and charged 20 ml of water and 20 ml of toluene. Then stirred for 15-30 min, separated the aqueous phase and organic phase. Washed the aqueous phase with 20 ml of toluene. Aqueous layer pH was adjusted to 34 with hydrochloric acid at temperature of 0-5° C. Product was extracted with toluene (2×30 ml) from acidified aqueous layer at temperature of 50-60° C. Washed the total organic phase with water (3×30 ml), and concentrated under reduced pressure at below 70° C. The title compound was isolated from residue with 20 ml of cyclohexane at a temperature of 10-15° C. Dried the product at 45-50° C. The yield is 7 g (77.8%).
[0046] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
EXAMPLE 7
Preparation of Methyl-2-ethoxy-4-methoxy carbonyl methyl benzoate (VII)
[0047] Charged 30 g (1.0 mol) of (4-Carboxy-3-ethoxy-phenyl) acetic acid to a suspension of 300 ml of toluene, 39 ml (3.0 mol) of dimethyl sulfate and 55.8 g (3.0 mol) of potassium carbonate. Resulted reaction mass was heated to reflux for 1 hr to 2 hr and charged 300 ml of water into reaction mass at 80-85° C., stirred for 15-30 min. Separated the aqueous phase and organic phase. Washed the organic phase with 150 ml of water at 80-85° C. Organic phase was distilled under reduced pressure at below 70° C. The yield of the title product is 31.8 g (94.2%).
[0048] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
EXAMPLE 8
Preparation of 3-Ethoxy-4-(methoxy carbonyl)-phenyl acetic acid (Ia)
[0049] Charged 20 g (1.0 mol.) of methyl-2-ethoxy-4-methoxy carbonyl methyl benzoate and 50 ml of methanol to a solution of 30 ml of water and 3 g (0.95 mol) of sodium hydroxide at temperature of 25-35° C. Stirred the reaction mass for 1 hr to 2 hr at 25-35° C. Distilled off the solvent from reaction solution under reduced pressure. Cooled to 25-35° C. and charged 40 ml of water and 40 ml of toluene then stirred for 15-30 minutes. Separated the aqueous phase and organic phase. Washed the aqueous phase with 40 ml of toluene. Aqueous layer pH was adjusted to 3-4 with hydrochloric acid at a temperature of 25-35° C. Product was extracted with toluene (2×40 ml) from acidified aqueous layer at a temperature of 30° C. Washed the total organic phase with water (2×40 ml), and concentrated under reduced pressure. The title compound was isolated from residue with 40 ml of cyclohexane at a temperature of 25-35° C. Dried the product at 45-50° C. The yield is 10 g (53%).
[0050] The obtained product was characterised by analytical techniques like IR, Mass and 1 H-NMR
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The present invention relates to an improved and convenient process for the preparation of 3-Ethoxy-4-(alkoxy carbonyl)-phenyl acetic acid, which can be represented by formula (Ia) where R 1 represents ethyl or methyl. Specifically the present invention relates to an improved process for the preparation of compound of formula
(Ia), which is the key intermediate for Repaglinide of formula (I), by the process, which involves non-hazardous raw materials with an easy handling, and cost effective process
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This non-provisional application claims priority under 35 U.S.C. § 119(a) on patent application Ser. No. 1021012 filed in The Netherlands on Jul. 5, 2002, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of controlling an inkjet printer containing at least two substantially closed ducts in which ink is present, comprising:
actuating an electro-mechanical transducer whereby the pressure in a first duct is increased and a pressure change in another duct is also generated by the actuation. The present invention also relates to an inkjet printhead suitable for the use of this method and an inkjet printer provided with such a printhead.
2. Background Art
A method of this kind is known from EP 0 790 126. The known method is used in a printhead for an inkjet printer wherein the printhead comprises a duct plate in which a number of parallel grooves are formed in the longitudinal direction, each groove terminating in an exit opening or nozzle. The duct plate is covered by a flexible plate so that the grooves form a plurality of substantially closed ink ducts. A number of electro-mechanical transducers are provided on the flexible plate at the ducts so that each duct is confronted by one or more of the transducers. The transducers, in this case piezo-electric transducers, are provided with electrodes. When a voltage is applied in the form of an actuation pulse across the electrodes of a piezo-electric transducer of this kind, the result is a sudden deformation of the transducer in the direction of the associated duct, resulting in the pressure in the duct being suddenly increased. As a result, a drop of ink is ejected from the nozzle.
On the side remote from the duct plate, the transducers are supported by a carrier member. The printhead is also provided with a number of connecting elements which connect the carrier member via the flexible plate to the duct plate. These connecting elements serve to increase the mechanical strength of the printhead so that an applied actuation pulse will also always result in the required pressure rise and thus the required drop ejection, i.e. a drop ejection with which the drop, for example, has a previously known size and/or a previously known speed.
The known method, however, has a significant disadvantage. Despite the rugged construction, it is not possible to completely prevent the actuation of a piezo-electric transducer of a first duct from also having an influence on the position in another duct, particularly a neighboring duct. The reason for this is that the actuation causes the piezo-electric transducer to expand, so that mechanical forces are transmitted to the carrier member. Since the carrier member is, in turn, connected to the piezo-electric transducers of the other ducts, these forces will be transmitted to these transducers. This mechanical actuation of these transducers will result in a pressure change in the other ducts, and this pressure change is particularly noticeable in neighboring ink ducts. In many cases, this pressure change increases the closer a neighboring duct is to the duct where the first piezo-electric transducer is electrically actuated. The result of this pressure change is that the drop ejection process in another duct of this kind is adversely influenced. This is also termed cross-talk and may be manifested in a deviant drop size, drop speed, ejection time, and so on. Such deviations will finally result in print artefacts or irregularities, which are visible in varying degrees depending on the nature of the deviation.
SUMMARY OF THE INVENTION
The object of the present invention is to obviate the above-described problems by deforming an electro-mechanical transducer as a result of the pressure change, which generates an electrical signal, and measuring the electric signal.
The method according to the present invention makes use of the fact that a pressure change in the other duct will result in the deformation of an electro-mechanical transducer operatively connected to the duct. In actual fact, this transducer is then used as a sensor in order to record the pressure change in a duct as a result of actuation of another duct. This “sensor” transducer could, for example, be the same electro-mechanical transducer present for normal control of the neighboring duct. The deformation of the sensor transducer will result in the generation of an electrical signal by said transducer. It is precisely this signal which is measured by the method according to the present invention. This signal gives clear information as to the degree of cross-talk. If the signal is very strong, then the effect of the cross-talk is considerable. This could have the effect, for example, that the other duct does not print so that print artefacts might occur. If the signal is only very weak, this means that there is practically no influence, if any, on the other duct, so that printing can be carried out ordinarily with such duct. By using the method according to the present invention cross-talk can at all times be reduced to a non-perceptible level so that there is no adverse influence on the print quality.
European Patent Application EP 1 013 453 discloses a method in which the electro-mechanical transducer is used as a sensor to measure the state of an ink duct. In this method, after the end of the actuation pulse, the transducer is used as a sensor to measure the pressure waves in the same duct. This known method is used to check the state of the controlled duct so that it is possible to decide whether any repair action is to be carried out. However, it has never been known to measure the pressure change in another duct after actuation of an electro-mechanical transducer in a specific duct.
In one embodiment of the method of the present invention, a time suitable for ejecting an ink drop from a neighboring duct is determined on the basis of the measured signal. It has been found that on the basis of the measured signal it is possible to find a time suitable for ejecting a drop from the neighboring duct. The pressure change in a neighboring duct has the form of a pressure wave, possibly similar to a damped sine wave. Thus the influence of the pressure change in the neighboring duct on any drop ejection process in that duct is not constant. Such influence varies with time and finally is reduced to zero if the pressure wave is completely damped. It has been found that before the pressure wave is completely damped there are one or more times at which the influence of the pressure change is such that it does not result in visible artefacts in the printed image. These times are suitable for ejecting an ink drop from the neighboring duct. These times can be determined by experiment. This can be done simply by initiating cross-talk, for example by ejecting a drop from a neighboring duct and then at a specific time thereafter ejecting a drop from the actual duct. The influence of cross-talk can also be determined by analysing the printed ink drop. By repeating this a number of times, the effective influence of cross-talk as a function of the measured electrical signal can be determined. By storing this in a memory it is always possible to establish the time at which the measured signal may be expected to have no appreciable influence from cross-talk.
In the following embodiment, a time is selected such that the pressure change in the neighboring duct does not appreciably influence the drop formation in that duct. This embodiment makes use of the fact that one or more of the previously mentioned times are “zero-crossings”, i.e. times at which the pressure change does not appreciably influence the drop formation. This means that the essential characteristics of the drop, particularly the drop speed, the drop size, the drop shape and the time at which the drop is formed (with respect to the time of actuation of the transducer), are not noticeably influenced. This results in an actuation at a time in the pressure ejection process in which no noticeable print artefacts are expected. A zero-crossing of this kind can be determined by simple experiments, for example by measuring each of the essential characteristics of an ink drop as a function of the time of actuation with respect to actuation of a neighboring duct (to induce cross-talk).
In one embodiment of the present method, a separate electro-mechanical transducer is used at each of the ducts. A method of this kind is advantageous because each duct can be actuated by its own electro-mechanical transducer and, if required, measured with the same electro-mechanical transducer. This simplifies actuation of the individual ducts and measurement of the electric signals generated by the transducers in response to a pressure change in a duct.
It should be noted that cross-talk can occur not only when the pressure is raised in a duct to such an extent as to lead to ejection of an ink drop. A pressure change in another duct can also result from a different type of actuation not directed to the ejection of an ink drop but, for example, at repairing an ink duct, or checking the action of the electro-mechanical transducer, or filling a duct with ink, and so on. This may in turn have a noticeable influence on the drop ejection process in the other duct so that there is nevertheless cross-talk.
Cross-talk incidentally is not restricted to neighboring ducts but, depending on the construction of the inkjet printer, may also be noticeable over longer times. For example, it has been found that inkjet printheads having several rows of nozzles, each row being controlled separately, do exhibit an influence of the control of ducts in one row on the control of ducts in another row. By using the method according to the present invention it is also possible to reduce or even eliminated the effect of this influence.
The method according to the present invention can be implemented in various ways. For example, during the production of an inkjet printer it is possible to carry out measurements according to the present invention and determine specific times suitable for reducing the effect of cross-talk. It is also possible to regularly repeat such measurements for an existing inkjet printer, for example after specific printer loading or at times when the printer is undergoing maintenance. A gradual change of the printer, for example due to ageing of the materials from which the printer is made, may have the result that the times at which cross-talk has no effect will be different. By regularly determining these times it is possible to make optimal use of the method according to the present invention at all times. In another embodiment, the effect of the actuation of one duct in a neighboring duct is measured and at the same time a time is determined which is suitable for ejecting an ink drop from the neighboring duct. Real-time implementation of this kind can be carried out by using a closed loop control as is adequately known from the prior art.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a diagram showing an inkjet printer;
FIG. 2 is a diagram showing an inkjet printhead;
FIG. 3 shows a diagram with which the method according to the present invention can be applied; and
FIG. 4 shows the result of cross-talk on drop speed.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 diagrammatically illustrates an inkjet printer. In this embodiment, the printer includes a roller 1 which supports a receiving medium 2 . Four printheads 10 move across the receiving medium. The roller 1 is rotatable about its axis as indicated by arrow A. A carriage 3 carries the four printheads 10 , one for each of the colors cyan, magenta, yellow and black, which can be moved in reciprocation in the directions indicated by the double arrow B, parallel to the roller 1 . In this way the printheads 10 can scan the receiving medium 2 . The carriage 3 is guided on rods 4 and 5 and is driven by suitable means (not shown). In the embodiment as shown in the drawing, each printhead 10 comprises eight ink ducts, each with its own exit opening 14 , which form an imaginary line perpendicular to the axis of the roller 1 . In a practical embodiment of the printing apparatus, the number of ink ducts per printhead 10 is many times greater. Each ink duct is provided with a piezo-electric transducer (not shown) and associated actuation and measuring circuit (not shown) as described in connection with FIG. 3 . Each of the printheads also contains a control unit for adapting the actuation pulses, i.e., the time when the pulse takes place. In this way, the ink duct, transducer, actuation circuit, measuring circuit and control unit form a system serving to eject ink drops in the direction of the roller 1 . It is not essential for the control unit and/or for example all the elements of the actuation and measuring circuit to be physically incorporated in the actual printheads 10 . It is also possible for these elements to be located, for example, in the carriage 3 or even in a more remote part of the printer, there being connections to components in the printheads 10 themselves. In this way, these elements nevertheless form a functional part of the printheads without actually being physically incorporated therein. If the transducers are actuated image-wise, an image forms which is built up of individual ink drops on the receiving medium 2 .
FIG. 2 diagrammatically illustrates a printhead. The printhead 10 illustrated comprises a duct plate 12 defining a row of exit openings 14 and a number of parallel ink ducts 16 . Only one of the ink ducts 16 is visible in FIG. 2 . The exit openings 14 and the ink ducts 16 are formed by milling grooves in the top surface of the duct plate 12 . Each exit opening 14 is in communication with an associated ink duct 16 . The ink ducts are separated from one another by dams 18 .
The exit openings 14 and ink ducts 16 are covered at the top by a thin flexible plate 20 rigidly connected to the dams of the duct plate. A number of grooves 22 are formed in the top surface of the plate 20 and extend parallel to the ink ducts 16 and are separated from one another by ribs 24 . The ends of the grooves 22 adjoining the exit openings 14 are somewhat offset from the edge of the plate 20 .
A row of elongate fingers 26 , 28 is so formed on the top surface of the plate 20 that each finger extends parallel to the ink ducts 16 and is connected at the bottom end to one of the ribs 24 . The fingers are grouped in triplets, each triplet consisting of one central finger 28 and two lateral fingers 26 . The fingers of each triplet are connected at the top and are formed by a block of piezo-electric material in one piece 30 . Each of the fingers 26 belongs to one of these ducts 16 and is provided with electrodes (not shown) to which a voltage can be applied in accordance with a print signal. These fingers 26 are piezo-electric transducers which serve as actuators which in response to the applied voltage expand and contract in the vertical direction so that the corresponding part of the plate 20 is bent towards the inside of the associated ink duct 16 . As a consequence, the ink (for example aqueous ink, solvent ink or hot melt ink) present in the ink duct is compressed, so that an ink drop is ejected from the exit opening 14 . The central fingers 28 are disposed above the dams 18 of the duct plate and serve as support elements which take the reaction forces of the actuators 26 . If, for example, one or both actuators 26 belonging to the same block 30 expand, they exert an upward force on the top part of block 30 . This force is largely compensated by a tensile force of the support element 28 , the bottom end of which is rigidly connected to the duct plate 12 via rib 24 of the plate.
At the top, the blocks 30 bear flat against one another and are covered by a carrier member 32 which is formed by a number of longitudinal bars 34 extending parallel to the ink ducts 16 , and by transverse bars 36 which interconnect the ends of the longitudinal bars 34 (only one transverse bar is shown in FIG. 1 ).
Since the support elements 28 inevitably have a specific elasticity, expansion of one or both actuators 26 of one of the blocks 30 will also cause a slight expansion of the support elements 28 so that a slight bending of the carrier member 32 occurs. This bending force will be transmitted to the adjoining blocks 30 and thus parasitic acoustic waves (cross-talk) will form in the neighboring ink ducts. Cross-talk of this kind can cause problems, particularly if a large number of actuators in neighboring blocks 30 are actuated simultaneously. However, since carrier member 32 consists of separate bars 34 interconnected only at the parallel sides by the cross-bars 36 , the bending forces are mainly restricted to the block 30 , from which they come. In this way cross-talk can be suppressed but may nevertheless still occur. By the application of the method according to the present invention, as described in connection with FIG. 3 (not shown in FIG. 2 ), the effect of cross-talk can be further reduced or even completely eliminated.
FIG. 3 is a diagram with which the method according to the present invention can be used. FIG. 3 shows a first piezo-electric transducer 26 operatively connected to a first ink duct (not shown). This transducer can be controlled by pulse generator 40 . A second piezo-electric transducer 26 ′ is also shown, and is operatively connected to another ink duct (not shown), for example the duct directly adjoining the first ink duct. The piezo-electric transducer 26 ′ is connected via line 41 to resistor 42 and A/D converter 43 . The latter is in turn connected to the control unit 44 provided with a processor (not shown). Control unit 44 is connected to D/A converter 45 , which can deliver signals to pulse generator 47 . The control unit is connected via line 46 to other parts of the printer (not shown), particularly a central processor.
The following takes place when the method according to the invention is applied. First of all, piezo-electric transducer 26 is controlled via pulse generator 40 to eject an ink drop from a first ink duct. As a result of the energization of transducer 26 , a pressure change also takes place in the neighboring ink duct, which pressure change will result in a deformation of piezo-electric transducer 26 ′. As a result of this deformation, transducer 26 ′ generates a current which will flow to earth via measuring resistor 42 . The voltage thus available across measuring resistor 42 is fed to A/D converter 43 , which transmits this voltage as a digital signal to control unit 44 . This control unit analyses the signal and in this embodiment determines one or more zero-crossings of the cross-talk signal by reference to a model stored in its memory (not shown). This zero-crossing is remembered and taken into account in the control of transducer 26 ′ when an ink drop must be ejected from this neighboring duct. The control of transducer 26 ′ is initiated by control unit 44 which transmits a signal to D/A converter 45 which transmits the signal in analogue form to pulse generator 47 . Finally, this pulse generator sends a pulse to transducer 26 ′ suitable to actuate the latter so that an ink drop is ejected from the corresponding duct. Thus transducer 26 ′ is provided with a measuring circuit, via line 41 , and a control circuit, which in this embodiment partially overlap one another.
In this embodiment, not only is transducer 26 ′ provided with its own measuring circuit, but all the piezo-electric transducers of corresponding printheads have a circuit of this kind. In order to maintain clarity, the other measuring circuits and piezo-electric transducers have not been shown. This embodiment enables real-time decisions to be taken as to whether cross-talk is to be taken into account and how this effect can be compensated.
In another embodiment, the printhead comprises just one or a few measuring circuits for the many tens or hundreds of transducers. In this embodiment, it is possible to check all the transducers at regular intervals, for example automatically when servicing of the printer, in order to determine the effect of cross-talk on individual transducers. This information can then be taken into account in the printing of an image.
In another embodiment, the printer itself does not contain a measuring circuit but measurement according to the present invention is carried out when the printer is produced. In certain cases, in fact, a single measurement of the influence of cross-talk can yield sufficient information adequately to reduce or even eliminate the effect of cross-talk during the life of the printhead.
FIG. 4 , which is made up of FIGS. 4 a and 4 b , shows the possible effect of cross-talk on a drop characteristic, in this case the speed at which an ink drop is ejected from a duct. FIG. 4 a shows the exit speed in meters per second against time (in arbitrary units) for a specific ink duct K (not shown). This curve is obtained by ejecting drops of ink from this duct at a high frequency, in this case 15 kHz, for a time t=0 to t=t E . The speed of the drops can be measured using a stroboscope as generally known from the art. In the case of FIG. 4 a , the drops are ejected always at a speed of about 10 ms between t=0 and t=t E . This means that there is no noticeable influence of the actuation of other ducts.
The curve of FIG. 4 b gives the drop ejection speed of the same duct K. In this case, however, a directly neighboring duct is also actuated for a shorter or longer time after duct K has been actuated. The x-axis shows the time t between actuation of the duct K and actuation of the neighboring duct. This time t is also termed the delay. If both ducts are actuated at the same time (t=0) then there is a considerable effect on the drop ejection speed of duct K. This is the result of parasitic acoustic waves in this duct, i.e. cross-talk. With increasing delay, the influence of the actuation of the neighboring duct decreases. In this case, the drop speed as a function of the delay will be a sinusoidal curve which is completely damped at t=t E . There is then no longer any noticeable influence of the actuation of the neighboring duct. The drop ejection process is then apparently completely concluded so that actuation of the neighboring duct cannot have any further effect. It can be seen that at certain times, namely t 1 to t 6 , there is, in fact, no noticeable effect of the cross-talk, at least with respect to the drop ejection speed: at these times the ejection speed is of course equal to the speed applicable when there is no cross-talk whatever. These times are termed zero-crossings. The position of these times can be take into account during printing. By ejecting a drop at a zero-crossing of this kind there is in fact no noticeable influence of cross-talk and hence no print artefact need form. Account should be taken of the fact that the zero crossing or crossings of other drop characteristics (for example drop size, drop shape, etc) need not be at the same place. If that is the case, then cross-talk will still always have an effect. However, by jetting at a zero-crossing of the most dominant characteristic, i.e. the drop speed for example in a specific application, the noticeable effect of cross-talk can be practically completely or even entirely eliminated.
It should be noted that there are probably still times outside the zero-crossings t 1 to t 6 at which no visible print artefacts occur due to cross-talk. These times can be determined by analysis of a printed image itself in relation to the measured electrical signal.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A method of controlling an inkjet printer containing at least two substantially closed ducts in which ink is present, which includes actuating an electro-mechanical transducer whereby the pressure in a first duct is increased, and a pressure change in another duct is also generated by said actuation, whereby an electro-mechanical transducer is deformed as a result of the pressure change, said electrical transducer generating an electrical signal, and measuring the electric signal.
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[0001] This application claims the benefit of prior provisional patent application Ser. No. 60/217613 filed Jul. 11, 2000.
TECHNICAL FIELD
[0002] The present invention relates generally to a an ejector arrangement for a work machine, and more specifically to a mounting apparatus used to couple an ejector blade to a hydraulic cylinder.
BACKGROUND
[0003] Work machines are used in earth moving operations to move material, such as dirt and rocks, from one location to another. An example of the aforementioned type of work machine is the ejector truck often advantageously utilized in those applications in which space constraints limit or prohibit the raising of a truck bed such as is required for a conventional dump truck. Typically, the bed portion of an ejector truck remains attached to the bed portion chassis. An ejector blade is moveably mounted within the truck bed and is coupled to a hydraulic ram or cylinder comprising a plurality of sequentially extendable and retractable individual segments. The cylinder is typically coupled to the ejector blade by two trunniuns or pivot pins disposed on opposite sides of the cylinder and co-linearly oriented, thereby allowing rotation of the ejector blade, relative to the cylinder, about an axis generally parallel with the floor of the bed.
[0004] One drawback of prior art ejector-type work machines is the potential damage to the aforementioned trunnions caused by either an uneven load in the bed portion or, during ejector blade retraction, an obstruction contacting the ejector blade causing a tendency of the ejector blade to rotate about a substantially vertical axis substantially located at the point of attachment of the ejector blade with the hydraulic cylinder. To assist in preventing the aforementioned rotation, adjustable yaw rollers are typically provided on the ejector blade-mounted carriage portion to slidably engage the side walls of the truck bed. However, damage to the aforementioned trunnions and/or cylinder may result upon improper yaw roller adjustment requiring the trunnions to bear these loading conditions until the improperly adjusted yaw roller or rollers engage the side walls of the truck bed, thereupon transferring these loads to the truck bed. The present invention is directed to overcome one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
[0005] In one aspect of the present invention, there is provided an ejector arrangement for a work machine of the type having a receptacle. The ejector arrangement includes an ejector blade, a cylinder, and a coupler pivotally coupled to the cylinder and pivotally coupled with the ejector blade.
[0006] In another aspect of the invention, a method of attaching a cylinder to an ejector blade in a work machine is provided. The method consists of pivotally attaching a first coupler member to a cylinder about a first longitudinal axis. The method also consists of providing a second coupler member attached with the ejector blade and pivotally attached to the first coupler member about a second longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a diagrammatic elevation view, in partial cut-away, of a work machine having the arrangement of this invention.
[0008] [0008]FIG. 2 is a diagrammatic elevation view of the ejector arrangement of this invention.
[0009] [0009]FIG. 3 is a diagrammatic sectional view taken along lines 3 - 3 of FIG. 2.
[0010] [0010]FIG. 4 is a diagrammatic sectional view taken along lines 4 - 4 of FIG. 3.
[0011] [0011]FIG. 5 is a diagrammatic sectional view taken along lines 5 - 5 of FIG. 3.
DETAILED DESCRIPTION
[0012] With reference now to the Figures, a work machine is shown generally at 100 having an attached receptacle or bed portion 101 for holding materials to be transported to another location for unloading. To assist in removing the material from the bed portion 101 , the work machine 100 is provided with an ejector arrangement 102 of the present invention which includes an ejector blade 104 coupled to the bed portion 101 by a multi-stage hydraulic ram or cylinder 105 which moves the ejector blade 104 relative to the bed portion 101 . The ejector blade 104 is typically supported adjacent its bottom portion 108 by at least one roller 109 which moves across the floor 112 of the bed portion 101 . The overall shape of the ejector blade 104 is such that it substantially conforms to the shape of the bed portion 101 .
[0013] The ejector blade 104 is further attached to a carriage assembly 113 which slidably engages the side walls 114 of the bed portion 101 in response to movement of the cylinder 105 . A pair of yaw rollers 115 , attached to opposing sides of the carriage assembly 113 , assists in maintaining proper orientation of the ejector blade 104 within the bed portion 101 by slidably engaging the side walls 114 in response to any tendency of the ejector blade 104 to pivot about an axis substantially normal to the bed portion 101 . Activation of the cylinder 105 of the type described herein initiates a sequential elongation of the cylinder 105 causing a forcible contact between the materials deposited into the bed portion 101 and the ejector blade 104 , with a continual elongation of the cylinder 105 resulting in the ejection of the materials from the bed portion back end 117 , typically through a tailgate 120 . Upon the ejection of the materials from the bed portion 101 , the cylinder 105 may be reversibly operated causing retraction of the ejector blade 104 to bed loading position substantially as shown in FIG. 1.
[0014] The cylinder 105 is secured at one end 123 to a bracket 124 which is pivotally carried on the bed portion 101 for pivotal movement in a vertical plane in response to the extension and retraction of the cylinder 105 . The ejector arrangement 102 of the present invention includes a coupler 125 used to couple the ejector blade 104 with the cylinder 105 . As shown best in FIG. 2, the coupler 125 of the present invention consists of a first coupler member 200 pivotally attached to the cylinder 105 , and a second coupler member 201 pivotally attached to the first coupler member 200 and attached with the ejector blade 104 .
[0015] With reference now to FIG. 3, the first coupler member 200 comprises an upper member 300 and a lower member 301 both fixedly connected to two side members 304 spaced a sufficient distance apart to accommodate the cylinder 105 therebetween. A mounting flange 305 is preferably fixedly attached to the upper and side members 300 , 304 on opposing sides of the first coupler member 200 . The first coupler member 200 is pivotally attached to the cylinder 105 by use of a pair of substantially co-linear first pivot pins 308 , each preferably fixedly attached with the cylinder 105 , both of which define a first longitudinal axis designated herein by reference numeral 309 . As will be apparent to those skilled in such art, providing the aforementioned pivotal attachment allows for rotation of the ejector blade 104 , relative to the cylinder 105 , in the general direction of arrows 312 , 313 . Each first pivot pin 308 is secured to a respective side member 304 by a removable bushing cap 316 preferably attached to each side member 304 by the use of preferably two fasteners 317 .
[0016] Each of the upper and lower members 300 , 301 are provided with substantially co-linear second pivot pins 320 , both defining a generally vertical second longitudinal axis designated herein by reference numeral 321 . Each respective second pivot pin 320 is used to pivotally attach the second coupler member 201 to the first coupler member 200 , thereby allowing for rotation of the ejector blade 104 relative to the cylinder 105 in the general direction of arrows 324 , 325 . It is preferred that each respective axis 309 , 321 be substantially orthoganally oriented, relative to one another, thereby allowing the ejector blade 104 to pivot, relative to the cylinder 105 , about both the vertical and horizontal axis 321 and 309 .
[0017] As should be apparent to those skilled in such art, an advantage of providing the ejector blade 104 with the ability to rotate, relative the cylinder 105 , about the second longitudinal axis 321 is that potentially damaging stresses which would otherwise be borne by the fist pivot pins 308 due to, for example, improper adjustment of one or more yaw rollers 115 are minimized until such time as ejector blade 104 rotation causes the yaw rollers 115 to engage the side walls 114 , thereby transferring the aforementioned stresses to the side walls 114 .
[0018] With reference now to FIG. 4, the second coupler member 201 preferably comprises an upper bearing assembly 400 and a lower bearing assembly 401 each pivotally mounted to a respective second pivot pin 320 . As shown, the ejector blade 104 of the type described herein typically comprises a plurality of lateral support members with two such adjacent lateral support members designated herein as upper lateral support member 404 and lower lateral support member 405 . Each respective bearing assembly 400 , 401 is preferably fixedly attached to, respectively, the upper and lower lateral support members 404 , 405 by use of mechanical fasteners 408 .
[0019] With reference now to FIG. 5, a bottom view of the coupler 125 is shown attached to the cylinder 105 and ejector blade 104 with the lower lateral support member 405 removed for clarity. As shown, the first coupler member 200 is preferably resiliently mounted to the ejector blade 104 by use of preferably a pair of resilient mounting structures 500 . Each resilient mounting structure 500 comprises a fastener 501 , having a head portion 504 , preferably threadably attached to a vertical ejector blade support structure 505 . Each respective fastener 501 is structured and arranged for reciprocative placement within an aperture 508 provided in each respective mounting flange 305 . An upper resilient member 509 , preferably comprising a resilient bushing made of rubber or other elastomeric type material, is concentrically placed about the fastener 501 substantially between each mounting flange 305 and head portion 504 . Also provided is a lower resilient member 512 also preferably comprising a resilient bushing made of rubber or other elastomeric type material. As shown, the lower resilient member 512 comprises an enlarged portion 513 , substantially interposed between the mounting flange 305 and the ejector blade 104 , and a reduced portion 514 interposed between the fastener 501 and aperture 508 .
[0020] To add increased stability to the resilient mounting structures 500 , a substantially rigid sleeve 516 may be concentrically placed between the fastener and each respective resilient member 509 , 512 . In addition, a washer 517 may be provided as shown and coupled to the fastener 501 preferably between the head portion 504 and upper resilient member 509 . Furthermore, shims 518 may be placed between the lower resilient member 512 and the vertical ejector blade support structure 505 in order to assist in properly aligning the coupler 125 , cylinder 105 , and ejector blade 104 .
[0021] As should be appreciated by those skilled in such art, upon either ejecting materials unevenly loaded in the bed portion 101 or the ejector blade 104 encountering an obstacle (not shown) in the bed portion 101 offset from the cylinder centerline 521 , the ejector blade 104 may yaw or rotate about the second longitudinal axis 321 which, if undamped or otherwise compensated for, may create a noisy and potentially damaging resonant yaw effect.
[0022] Industrial Applicability
[0023] With respect to the drawings and in operation, the ejector arrangement 102 of the present invention includes an ejector blade 104 , movably mounted within the bed portion 101 , by use of the cylinder 105 . A coupler 125 pivotally couples the ejector blade 104 to the cylinder 105 about two substantially orthogonal axis of rotation 309 , 321 . The horizontal or first longitudinal axis 309 advantageously permits the ejector blade 104 to remain at substantially the same orientation, relative to the bed portion 101 , despite any potential changed in orientation of the longitudinal axis of the cylinder 105 during cylinder 105 extension and retraction.
[0024] As should be appreciated by those skilled in such art, the introduction of the aforementioned second longitudinal axis 321 allows the ejector blade 104 to rotate about second longitudinal axis 321 , relative to the cylinder 105 , thereby transferring to the side wall 114 , via the yaw rollers 115 , any resultant stresses, forces and moments which otherwise would be placed on the first pivot pins 308 .
[0025] The resilient mounting structures 500 assist in eliminating any potential resonant rotation of the ejector blade 104 about the second longitudinal axis 321 and/or the potential tendency of the ejector blade 104 to “walk” as it is being extended/retracted along the bed portion 101 . Ejector blade-attached fasteners 501 are positioned in such manner as to pass through the apertures 508 provided in the mounting flanges 305 and to reciprocally move thereat in response to rotations of the ejector blade 104 about the second longitudinal axis 321 . Dampening of the aforementioned potential resonant effects, each mounting flange 305 in sandwiched between an upper and lower resilient member 509 , 512 each concentrically placed about the fastener 501 . Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims.
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In the operation of work machines having an ejector blade pivotally coupled to a cylinder by cylinder-attached pivot pins, it has been a problem reducing the stress acting on the pivot pins caused by, for one example, improperly set yaw rollers. The present invention provides for an ejector arrangement for a work machine in which a coupler is pivotally coupled to the cylinder and pivotally coupled with the ejector blade.
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This application is a continuation of U.S. patent application Ser. No. 97/372,211, filed May 1, 1989, which is a continuation of U.S. patent application Ser. No. 115,944, filed Nov. 2, 1987 both now abandoned.
The invention concerns a container for distributing doses of treatment fluid.
BACKGROUND OF THE INVENTION
There are numerous embodiments for containers for distributing doses of treatment fluid, comprising a dosing device mounted in the neck of the container, the container being intended to function with the neck pointed towards the bottom, alternatively immersed in and taken out of a mass of water, in particular a toilet tank.
In the first embodiment, which has numerous variations, the dosing device comprises a float suspended under the neck of the container, fixed to one or two mobile valves operating together with one or two fixed seats accommodated in the neck of the container (patents: French 2 572 749, European 182 671, U.S. Pat. Nos. 4,346,483, 4,285,074, 3,778,850, 3,774,808, 3,698,021, 2,722,394, 2,967,310, 3.908,209, 3,841,524, 4,189,793, 4,131,958, 2,726,406, 4,036,407, 4,066,187, 3,965,497). This first embodiment is based on the principle that the variation of the water level in the water tank causes ascending or descending vertical slide of the float which itself causes the opening and closing of the valve or valves, which are of a mechanical or air type. According to certain variations, the valves, the seats and the neck of the container are put together to create the dosage chambers, with the aim of issuing defined doses of treatment fluid. Containers with dosing devices according to this first embodiment have the disadvantages that their functioning is linked to the movement of the float with all resulting imprecisions; that the halting of the flow is very random; that the mechanical-type closures are rather weak; and finally numerous pieces are required.
In a second embodiment, a discharge hole is accommodated in a transverse wall distanced from the free edge of the neck accomodating an air chamber. The container is only partially filled with the maintenance fluid. This second embodiment is based on the principle that the rise in the water level in the water tank above the free edge of the neck traps a mass of air in the air chamber. Then, when the level continues to rise, this mass of air is compressed and, when there is sufficient excess pressure, partially ejected into the container above the treatment fluid or it causes a certain excess pressure in relation to the external atmosphere. When the level of water in the water flush goes down to below the free edge of the neck, the excess pressure which exists in the air chamber disappears, as a result of its contact with the external atmosphere. The excess pressure existing in the container causes the expulsion of the treatment fluid until there is an equilibrium of pressure again on both sides of the discharge hole. This second embodiment is described in U.S. Pat. Nos. 3,806,965, 3,787,904, 3,864,763, 2,688,754, 3,073,488 and English patents 710 796, 2 094 846. This second embodiment has two advantages over the previously described first embodiment. On one hand, a "hydraulic" function resulting from the single variation of pressure in the time following the filling and emptying of the water tank and the resulting difference in pressure between one side of the discharge hole and the other, this functioning being theoretically continuous in contrast to the "mechanical" functioning operating the drive of a float commanding one or more valves which eventually jam causing functioning to be forcably discontinued. Meanwhile, the forms of execution of this second embodiment have the disadvantage that, from the functioning principle, the quantity of maintenance fluid issued is not invariable in the period, as soon as the container is emptied itself. In effect, as soon as the container is emptied, on one hand, the hydrostatic pressure exerted by the maintenance fluid on the discharge hole reduces and, on the other hand, the volume of air in the container which must have excess pressure to evacuate the maintenance fluid, increases.
SUMMARY OF THE INVENTION
The invention comprises a container for distributing doses of treatment fluid, to issue invariable doses of maintenance fluid, whatever the superficial tension of the fluid of the liquid which one wishes to distribute.
The invention therefore proposes, firstly and in the first variation, a container for distributing doses of treatment fluid comprising a dosing device mounted in the neck, the container being intended to function with the neck of the container, pointed towards the bottom, alternatively immersed in and taken out of a mass of water, in particular a toilet water tank, the dosing device being of a type essentially comprising a transverse wall extending from the free edge of the neck and so creating a chamber of air and a hole for evacuating treatment liquid punched in the wall, the dosing device functioning in a first phase by the creation of excess air pressure in the container when the water level rises above the level of the neck, as a result of the formation in the chamber of a mass of air separated from the atmosphere by the mass of water, then its compression and finally expulsion into the container via the evacuation hole, and in a second phase, at the lowering of the water level below the level of the neck by evacuating part of the treatment liquid via the evacuation hall which is ejected on the exterior of the container following the excess pressure created previously in this, as a result of connecting the air chamber with the atmosphere, until the pressure in the container returns to a value corresponding to that the of the atmospheric air thus causing a halt in the flow of treatment fluid, characterised in that the dosing device comprises a mechanical, adjusting mechanism which functions essentially by gravity, with functions, on one hand, to reduce the opening of a passage leading to a discharge hole at the second phase of the lowering of the water level and discharge of treatment fluid and, on the other hand, to reduce the variation related to the total weight of the adjusting mechanism and the treatment fluid column which it supports, given the approriate weight of the adjusting mechanism, this adjusting mechanism being intended for regulation of doses distributed as soon as the container is empty.
The invention proposes a container for distributing doses of treatment fluid comprising a dosing device mounted in the neck characterised in that it comprises an adjusting mechanism comprising a mounted mobile piece with a passage into a skirt attached to the tranverse wall, placed in the air chamber, terminated at the side of the free edge of the neck, normally lower, by the discharge hole and on the opposite side, that is towards the container, normally higher, by the evacuation hole.
The invention proposes finally and in a second variation a container to distribute doses of treatment fluid comprising a dosing device mounted in the neck, the dosing device being of the type comprising an upper transverse wall extending from the lower free edge of the neck of the container, creating a chamber of air and punched in the hole for evacuating the treatment fluid; a fixed lower transverse return extending from the lower free edge of the neck and punched in the treatment fluid discharge hole at an axial distance from the evacuation hole; a fixed lateral skirt connecting the transverse wall and the lower return; a passage for the treatment fluid between the evacuation hole and the discharge hole, along the skirt; and a part forming an axially movable valve needle cooperating with the discharge hole, characterised in that the part forming the valve needle, belonging to a device essentially situated between the transverse wall and the lower return, is mobile between the extreme lower position at which it corresponds with the lower tranverse return forming a seat to close the discharge hole and an upper position at which it is distanced from the lower return to open the discharge hole at least partially; and on which a vertical descending force is exerted which is, on one hand, greater than the maximum force exerted by the treatment liquid on the evacuation hole and, on the other hand, less than the force exerted on the discharge hole as a result of there being water in the full water tank via the chamber of air; in such a way that, in the first place, when the tank is full, the part forming the valve needle may be in the extreme lower position as a result of the force which is exerted on it; in the second place, when the water tank is empty, this part forming the valve needle first passes from its extreme lower position to a higher position as a result of this force being less than the force exerted in the opposite direction by the excess air pressure in the container above the treatment fluid and by the treatment fluid itself, until a dose of treatment fluid flows through the discharge hole and this part forming the valve needle then passes from this upper position to the extreme lower position when the force exerted in the opposite direction to the force which is exerted on this valve needle forming part is less than this latter force; and, in the third place, when the tank fills, this valve needle forming part first passes from its extreme lower position to this higher position as a result of the force exerted by the water in the tank being greater to that exerted in the opposite direction by the treatment fluid, which causes the transfer of air from the air chamber to the inside of the container above the treatment fluid via the discharge hole, the passage and the evacuation hole thus creating said excess air pressure and this valve needle forming part then being passed from this upper position to its extreme lower position as a result of the force which is exerted on said valve needle forming part, when the excesses in air pressure within the container above the treatment fluid and within the air chamber are substantially the same.
Other characterstics and advantages of the invention will be shown in the following description which refers to appended drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing the method of assembly of a container according to the first variation of the invention in a toilet water tank, both the container and the tank being filled.
FIG. 2A and 2B are two partial schematic views, on a larger scale, of the first possible embodiment of the first variation of the invention in two different functioning states, empty and full tank, respectively.
FIGS. 3 and 4 are two partial schematic views, on a larger scale, of second and third possible embodiments of the first variation.
FIGS. 5 and 6 are two sectional schematic views through an axial plane of the dosing device according to the second variation of the invention which is partially shown (the water tank not being shown) and according to two embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention concerns a container 1 for distributing doses of a treatment fluid 2, principally for a toilet water tank 3.
The fluid 2 is for colouring, perfuming, disinfecting, or other. The qualification "treatment" therefore covers all desired functions, this fluid generally contains surface-active products and, for this reason, has a superficial tension very clearly greater than that of water.
The container 1 comprises a lateral wall 4, a base 5 and a neck 6 bordered by a free edge 7 defining an opening 8.
The container 1 can have a general, normally vertical axis 1a. It can be cylindrical or, preferably flattened with a transverse cross-section more or less pseudo-rectangular. The container 1 is rigid so as not to be substantially distorted by depression or excess pressure inside.
Initially the treatment fluid 2 fills the container 1 only partially, for example to 2/3 of its volume, so as to leave the amount of air 9 necessary to the functioning inside.
The container 1 can have for example a height of approximately 15 cm and a total volume of approximately 300 cm 3 .
Before use, for storage and transportation, a cork (not shown) is screwed, ratched or otherwise onto the neck 6 to close the opening 8. In this situation, the container 1 generally rests on its base 5, the neck 6 being pointed towards the top.
The container 1 comprises a dosing device 10 mounted in the neck 6, of a type essentially comprising a transverse wall 11 placed in the neck 6 at a distance from the free edge 7; a hole 12 for evacuating 12 the treatment fluid punched in the wall 11, specifically axially (first variation) or laterally (second variation); and a chamber of air 13 bordered by the wall 11 and the part of the neck 6 between the wall 11 and the free edge 7.
When functioning, the container 1, with the cork taken out and the neck 6 pointing towards the bottom, is placed vertically in the water tank 3. A hook 14, which is telescopic and can equally comprise a mechanism adjusting the position of the container in the water tank 3 to regulate the height in relation to the water in which the container 1 is placed, or more generally any other similar maintenance device allowing the container 1 to be fixed in the water tank 3 so that it can be removed, in this position in such a way that the neck 6 can respectively be immersed in or taken out of the mass of water 15 in the tank 3 when it is full or empty. Consequently, the neck 6 is alternatively immersed and taken out when the water tank operated. The water level 16 in the mass of water 15 of the full water tank 3 extends to the height of the evacuation hole 12 at a distance sufficient to create the excess air pressure necessary to the functioning of the dosing device 10. This distance is approximately a few centimetres. For example, the water level 16 in the full water tank 3 is a little above the neck 6.
The dosing device 10 functions as follows.
When the water tank 3 fills with water, after being operated, the water level 16 rises to reach the free edge 7. At this moment, a mass of air is trapped in the air chamber 13. The level 16 continues to rise to the maximum level relating to the full water tank. This rise in the level 16 causes excess air pressure in the chamber 13 in relation to the existing pressure within the container 1. When there is sufficient excess air pressure, the air in the chamber 13 is expelled into the container 1 via the evacuation hole 12 and across the treatment fluid 2 up to the mass of air 9 then under the base 5, until a new pressure equilibrium is established on each side of the evacuation hole 12. In this first phase, an excess in air pressure is thus created in the container 1.
In this equilibrium situation the full water tank 3, the treatment fluid 2 cannot flow through the evacuation hole 12, takes account of the pressures on each side of the hole 12 and the dimensions of the hole 12.
When the tank 3 is operated, the mass of water 15 which it contains is evacuated and the level 16 goes down. When the level 16 reaches the free edge 7, the chamber of air 13 connects up with the external atmosphere and the excess of pressure which previously existed in this chamber 13 disappears. The result of this is that the pressure above the evacuation hole 12, where the treatment fluid 2 is found is greater than that which exists below said hole 12, in the chamber 13, as a result of the excess pressure previously created. This difference in pressure on each side of wall 11 causes partial evacuation of the treatment fluid 2 via the evacuation hole 12 (second phase). This flow of treatment fluid 2 stops when the relevant pressures considering the superficial tension of the treatment fluid 2 and the hydrostatic pressure are at equilibrium.
The dosing device 10 according to the invention comprises, according to a first variation and a first aspect of the invention (FIGS. 1 to 4), an adjusting mechanism 17a, mechanical, mobile, essentially functioning by gravity, and having as functions, on one hand, reduction of the opening of the passage leading to a discharge hole 18 at the second phase of the lowering of the water level 16 and discharge of fluid in such a way as to vary the point of equilibrium between the atmospheric pressure once the water receded and the pressure within the container 1 relating to the same equilibrium which would be obtained without mechanical adjustment and through a hole of invariable dimensions and, on the other hand, reduction of the variation relating to the total weight of the adjusting mechanism 17a and the column of treatment fluid 2 which it supports, given the appropriate weight of the adjusting mechanism 17a, this adjusting mechanism 17a being to regulate the doses distributed as soon as the container 1 is emptied.
As shown in FIGS. 1 to 4, the dosing device 10 according to the invention comprises, according to this same first variation and a second aspect of the invention, an adjusting mechanism 17a comprising a mobile piece 19 mounted with a passage 23 in a skirt 20 attached to the transverse wall 11, placed in the chamber of air 13, terminated at the side of the free edge 7 of the neck 6, specifically lower, by a discharge hole 18 and on the opposite side, that is towards the container 1, specifically higher, by the evacuation hole 12.
The mobile piece 19 comprises a lateral wall 21 extending from the lateral wall 22 from the skirt 20 to create a calibrated passage between them for the treatment fluid 2.
There are projections 24 or the like close to the evacuation hole 12, in such a way that the evacuation hole 17 remains permanently open, whatever the position of the mobile piece 19, particularly in the extreme high position.
The skirt 20 comprises a lower return 25 in which is embodied the discharge hole 18 in which the mobile piece 19 flows freely without sealing the discharge hole 18.
The return 25 is preferably conical, truncated, pyramidal or in the shape of the body of a pyramid, the point of which points towards the bottom, that is towards the free edge 7 the large base of which is pointing towards the top, that is towards the transverse wall ll.
It is understood that in all descriptions, the qualifications "top", "bottom", "higher" or "upper", "lower" refer to the container in the functioning position, the neck 6 pointing towards the bottom.
The skirt 20 comprises an upper return 26 in which the evacuation hole 12 is embodied.
The passage 23 between the mobile piece 19 and the skirt 20 and the discharge hole 18 have the same dimensions, according to the superficial tension of the maintenance fluid 2 to determine the flow-rate of the maintenance liquid 2. The evacuation hole 12 has sufficient dimensions to supply the passage 23 between the mobile piece 19 and the skirt 20. The passage 23 therefore has dimensions which allow evacuation of a precise dose of treatment fluid 2 and finally halt of evacuation.
The course of axial displacement of the mobile piece 19 is approximately the same size as the discharge hole 18.
In particular, the dimensions of the open discharge hole 18 depends on the superficial tension of the fluid which should be distributed as the desired flow-rate.
The size of the passage between the discharge hole 18 and the lower extremity of the mobile piece 19 is approximately the same or slightly greater than the dimensions of passage 23 between the mobile piece 19 and the skirt 20.
The weight of the mobile piece 19 is clearly larger than the weight of the column of treatment fluid 2 on the evacuation hole 12. For example, the mobile piece has a weight of approximately three to five times that of the column of treatment fluid 2 on the evacuation hole 12. This arrangement is such that the total weight of the mobile piece 19 and the column of treatment fluid 2 varies, in a relative manner, clearly less than if there had not been a mobile piece 19 of this weight. The result of this is an adjustment of the dosage of treatment fluid 2 issued.
As a result of the above, the mobile piece 19 does not comprise, properly speaking, a valve for hermetically sealing the discharge hole 18. Apart from the above-mentioned function of "tare" or countering added to the weight of the column of treatment fluid 2 on the evacuation hole 12, the mobile piece 19 has the function of considerably limiting the passage 23 between the mobile piece 19 and the skirt 20 to a suitable minimum value to halt the flow of treatment fluid 2 thus setting the point of equilibrium of the container 1 pressure and that of the atmospheric air to a higher level than normal without the existence of this mobile piece 19 does not exist in order to adjust the doses of treatment fluid 2 issued.
As a result of these two different but complementary functions, the mobile piece 19 has an adjusting effect on the doses of fluid issued, these being relatively invariable from one end of the container 1 to the other. These doses are, for example, from 0.125 ml to 0.250 ml of product which, for a container such as the above-mentioned, corresponds in normal use to a functioning duration of between approximately two and four months.
The mobile piece 19 can take two extreme positions, an extreme upper position and an extreme lower position. In the extreme upper position the mobile piece 19 is closest to the evacuation hole 12 and the two holes 12 and 18 are open. This position exists when, during the first functioning phase, the air in chamber 13 is compressed. In the extreme lower position, the extreme low part of the mobile piece 19 is inside the discharge hole 18 without necessarily blocking it and its cone-shaped walls rest on the equivalent walls of the lower return 25, the passage 23, at the contact points being reduced to a value so weak that, taking account of pressures in play and the superficial tension of the treatment fluid 2, the flow could be halted before the interior pressure of the container 1 has recovered the initial value. The container 1 therefore always remains in a slight excess pressure. This extreme low position is at the end of the second functioning phase.
Preferably the evacuation hole 12 is situated at the same level or in the immediate vicinity, specifically slightly above, the wall 11. Morover, the skirt 20 and the return 25 are situated entirely or almost entirely in the chamber 13.
For example, on one hand, the axial height H of the skirt 20 can be approximately the distance E between the wall 11 and the free edge 7 and equally, on the other hand, the diameter d of the skirt 20 can be approximately half diameter D of the chamber 13. Finally, the extent E can be the same size as the diameter D or slightly larger. Excellent results have been obtained with the above-mentioned container with H, E, d, D respectively in the vicinity of 1.5cm, 3cm, 1.25 cm, 2.75cm.
Preferably, the wall 11 is a plane annular panel of a fixed support piece 27 mounted in the neck 6 and comprising an external cylindrical part 28 (of diameter D) accommodated, particularly at force, in the neck 6 and an internal cylindrical part 29 comprising the external wall of the skirt 20. The lower return 25 is preferably formed by the fixed support piece 27.
Another piece 30 mounted at force within the support piece 27 comprises the internal wall of the skirt 20 and the upper return 26. This piece 30 is mounted after insertion within the skirt 20 and between the returns 25, 26 and the mobile piece 19.
The piece 30 can comprise an external annular projection 31 supported on wall 11 to axially block and correctly put in position the piece 30 on the support piece 27.
According to a first embodiment, the upper return 26 is approximately plane (outside the projections 24) and pependicular to the axis of the container 1. According to a second embodiment, the upper return 26 generally has a conical or pyramidal shape the point of which is directed towards the base 5 and the large base towards the mobile piece 19.
According to another embodiment, the mobile piece 19 has in axial cross-section a form bordered by a lateral wall 21, a transverse wall of upper extremity 32 specifically perpendicular to the axis of the container 1 and a lower wall 33, specifically in the form of a cone with the point directed towards the bottom. In transverse cross-section, the piece 19 is circular. According to a second embodiment, the mobile piece 19 is spherical.
These two above-mentioned embodiments can be combined.
As has resulted from the above, the weight of the mobile piece 19 serves to control the excess pressure created within the container 1 after its immersion in such a way as to act on the volume of the dose evacuated after each functioning of the flush 3.
The mobile piece 19, each time the doser is taken out, permits only one dose of treatment fluid 2 to be evacuated corresponding to only one part of the quantity of air introduced into the container 1 when the doser is immersed.
The dosing device 10, according to the invention, is such, according to the second variation and a first aspect of the invention (FIGS. 5 and 6) that a valve-needle forming part 17b belonging to a device 34 situated essentially between the upper transverse wall 11 and the lower return 25; is mobile between an extreme low position (as shown) in which it operates with the lower return 25, forming a seat to close the discharge hole 18 and an upper position (not shown) in which it is extended from the lower 25 to open the discharge hole 18 at least partially; and on which a descending vertical force is exerted which is, on one hand, greater than the maximum force exerted by the treatment fluid 2 on the evacuation hole 12 and, on the other hand, less than the force exerted on the discharge hole 18 as a result of water being in the full flush via the air chamber 13. In such a way, in the first place, when the tank 3 is full, the valve needle forming part 17b can be in the extreme lower position as a result of the force which is exerted on it. In the second place, when the tank 3 is emptied, this valve-needle forming part 17b first passes from the extreme lower position to a higher position as a result of this force being inferior to the force exerted in the opposite direction by the excess of air pressure in the container 1 above the treatment fluid 2 and the treatment fluid 2 itself until the flow of a dose of treatment fluid 2 though the discharge hole 18 and that this valve-needle forming part 17b passes then from the upper position to the extreme lower position whenn the force exerted in the opposite direction to the force which is exerted on this valve needle forming part is less than the latter force. In the third place, when the tank 3 fills, this valve needle forming part 17b passes first from its extreme lower position to this upper position as a result of the force exerted by the water in the tank 3 being greater than that exerted in the opposite direction by the treatment fluid 2 via the discharge hole 18, the passage 23 and the evacuation hole 12 participating thus in creating the said excess air pressure. This valve needle forming part 17b can then be passed from this upper position to its extreme lower position, as a result of the force exerted on said valve needle forming part 17b when the excess air pressure within the container 1 above the treatment fluid 2 and inside the air chamber 13 are substantially the same.
The dosing device 10, according to the invention is such, according to this same second variation, a second aspect of the invention and a first possible embodiment, (FIG. 5) that the valve needle forming part 17b forms a monobloc assembly, with the device 34 which is rigid and nondeformable accommodated at the axial slide in a fixed casing 35 comprising a transverse partition at the upper extremity 36 and a lateral partition 37 terminated by a lower opening 38. In this first variation, said force exerted on the valve needle forming part 17b, in this case the mobile device 34, is its own weight.
In addition, these two aspects of the invention in this second variation combine together.
The structure of the dosing device as referred to it FIG. 5, is now described in greater detail.
The passage 23 of treatment fluid is created, on one hand, by the radial distance existing between the skirt 20 and the lateral partition 37 and, on the other hand, by the axial distance existing between the lower return 25 and the lateral partition 37 the radial distance being connected to the axial distance.
The casing 35 comprises projections 39 attached to the lateral partition 37 and pointed towards the exterior, the function of which is, on the one hand, to keep in place, driven in with force, casing 35 in the skirt 20 and, on the other hand, to accommodate between the lateral partition 37 and the skirt 20 the distance, both radial and axial, comprising the passage 23 of the treatment fluid. For example, the projections 39 are at least three in number, particularly four or more, regularly divided around the axis 12 of the dosing device and have an axially elongated form, particularly extending along the entire axial height of the lateral partition 37.
The transverse partition at the upper extremity 36 and the upper transverse wall 11 are at least approximately coplanar and plane, the evacuation hole 12 being accommodated between them. The evacuation hole 12 is therefore generally ring-shaped.
The lower opening 38 and the discharge hole 18 are situated opposite and in close proximity to each other, the diameter of the lower opening 38 being larger (clearly larger than that of the discharge hole 18).
Otherwise, the area of the discharge hole 18 is clearly larger than the area of the evacuation hole 12. For example, the area of the discharge hole 18 is between around 2 and 3 times the area of the evacuation hole 12.
The return 25 is truncated with its point directed towards the bottom, the angle of the opening of which is between 107 degrees and 146 degrees approximately, more particularly between 114 degrees and 140 degrees approximately, specifically equal or close to 127 degrees.
The mobile device 34 is bordered by an upper transverse face 40, a lateral face 41 and a lower transverse face 42, the lateral face 41 operating with the lateral partition 37 with radial play 43 in such a way as to allow at the same time axial control and the axial slide of the mobile device 34.
The mobile device 34 projects, by its lower transverse face 42, from the opening 38 of the casing 35.
The lower transverse face 25 has, at least approximately, a conical form, the point of which 44 projects below the discharge hole 18.
The opening angle of the lower transverse face 42 is between 81 degrees and 111 degrees approximately, specifically it is equal or approximately 96 degrees.
The lower transverse face 42 forms at its extremity a bulging point 44.
At the extreme lower position, the mobile device 34 rests on the lower return 25, specifically at the edge of the discharge hole 18. In this position the real and artificial points respectively of the mobile device 34 and the lower return 25, conical and truncated, are joined or close together, the angle of the opening of the lower return 25 being larger than that of the lower transverse face 42 in such as way as to ensure, on one hand good contact with the mobile device 34 on the edge of the discharge hole 18 and, on the other hand, the existence close to the lateral face 41 of a play 45 between the lower transverse face 42 and the lower return 25 connecting up to the passage 23 by the said axial distance, which allows the treatment fluid 2 to act on the mobile device in the direction it is raised.
Preferably, the extreme lower edge 46 of the lateral partition 37 around the opening 38 is bevelled in such a way as to be approximately parallel to the lower return 25.
In the extreme upper position, the device 34, particularly its lower transverse face 42 is distanced from the lower return 25, in particular at the edge of the discharge hole 18 at a distance equal to or on the order of the axial distance between the lower return 25 and the lateral partition 37, more precisely its edge 46.
The slide course of the mobile device 34 is weak but necessary and sufficient to ensure optimum functioning of the dosing device 10.
The mobile device 34 and/or the casing 35 is of a rigid material, specifically polyacetal or equivalent.
Preferably, the return 25, the upper transverse wall 11 and the skirt 20 are monobloc and form part of a piece 27 comprising equally an external cylindrical part 28.
The piece 27 is of a material with a certain suppleness to facilitate impermeability with the container neck and/or the mobile device 34. with a lower part 42 comprising the valve needle forming part 17b which is conical or pseudoconical. It is mounted in a sliding manner with weak play and weak course in the casing 35 which, in an axial section, generally takes the form of an inverted U in such a way that the lower conical or pseudoconical part 42 projects from the opening 38 of the U-shape. The casing 35 is itself fixedly mounted, as a result of the projections 39, in the skirt 20 to form a vent. The piece 27 has a general double U form, that is a large inverted U defined in relation to the core of the upper transverse wall 11 and in relation to wings through the external cylindrical part 28, is concerned, and a small U placed in the large U defined in relation to the core, punched, by the lower return 25 and the wings through the skirt 20 linked to the core of the large U.
The weight of the mobile device 34 is for example on one hand, slightly greater than the maximum force exerted by the treatment fluid 2 on the evacuation hole 12 and/or, on the other hand, clearly smaller than the maximum force exerted by the flush water on the discharge hole 18 via the air chamber 13.
The dosing device 10 according to the invention is such, according to another aspect of the invention of this same second variation and the second preferable embodiment (FIG. 6), that the valve needle forming part 17b comprises the extreme lower part of a monobloc device 47, the extreme upper part 48 of which is fixed and has a general shape closely ressembling that of the above-mentioned fixed casing 35, with the notable exception of the lower opening 38 absent in this embodiment.
In addition, a flexibly ductile device 49 acts on the valve needle forming part 17b to produce on this part 17b the necessary force, as described above. In contrast to the first embodiment where said force results from the weight of the heavy mobile device 34, said force is, in this second embodiment essentially or substantially the result of an externally applied force.
In one possible embodiment the device 47 comprises an intermediary connecting part 50 between the valve needle forming part 17b and the extreme upper part 48, this intermediary connecting part 50 being ductile, in such a way that a relative axial displacement is possible between the parts 17b and 48, if there is axial displacement of part 17b, part 48 being immobilised. This ductility of the intermdiary part 50 can take various suitable forms, in particular weakening of the density of device 47.
The device 47 is, in one possible embodiment, a recess which creating a hermetically sealed central cavity 51 which is hermeically sealed in which the device 49 is accommodated.
The device 49 is for example a helical spring acting in such a way as to exert a force in the direction of an expansion.
The device 47 is, in one possible embodiment, such that the transverse partition of the upper extremity 36 is movable but can be hermetically sealed on the extreme upper part 48 of the device 47, for example by means of projections and recesses 52.
In the said embodiment, only the intermediary connecting part 50 is ductile, the valve needle forming part 17b being dimensionally stable, in particular sufficiently thick to form within the cavity 51 a seat for the spring 49.
In this embodiment, the angle of the opening of the lower transverse face 42 is equal to or approximately 120 degrees.
The dosing device according to the invention allows distribution of invariable or almost invariable doses of treatment fluid. These doses can be varied, for example, by 0.10ml to 0.25ml each. The container 1 can distribute 500 doses or more. The physical parameters of a dosing device (in particular dimensions, weight, force etc) are determined by the specialist according to the desired dose.
Whatever the variation in embodiment, the surface area of the evacuation hole 12 is equal to or slightly greater than that of the discharge hole. In addition, the course of the device 17, 19 depends on the function of the surface area of the flow in the passage 23 so that the opening of the discharge hole is not larger than the surface area of the flow within the passage 23.
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A container for distributing doses of a treatment fluid to a mass of water in a toilet tank which has a level which falls and rises upon slushing of the toilet tank comprises a fluid chamber at the top, a neck at the bottom, and a dosing device mounted in the neck. The fluid chamber contains the treatment fluid and a first mass of air above the treatment fluid, and has a single opening therein. The neck points downwardly into the toilet tank for alternate immersion and removal from the mass of water as the level of the mass of water rises and falls, is in fluid communication with the fluid chamber through the single opening in the chamber, and has a free edge. The dosing device has a first stage of operation when the level of the mass of water in the tank is rising and a second stage of operation when the level of the mass of water in the tank is falling, and comprises a transverse wall at a distance from the free edge of the neck means defining an air chamber and having an aperture therethrough, the aperture defining an evacuation hole means in the air chamber, a passage having an upper end which opens into the evacuation hole and a lower end having an opening defining a discharge hole, and gravity-operated, movable, mechanical regulating device positioned in the passage for regulating the doses distributed as the fluid chamber is emptied, the regulating device supporting a column of the treatment fluid.
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BACKGROUND
[0001] The present invention relates to ball screw and nut mechanisms wherein helical grooves are formed in the nut and screw to form raceways for load bearing and recirculation balls, and crossovers are provided as ball return elements.
[0002] Ball screws are mechanical devices widely used to convert rotary motion of either the nut or the screw into linear motion of the other. Matching helical grooves in the screw and nut form raceways within which balls roll when either the nut or screw are rotating. As the balls roll in response to this rotational motion they reach one end of the assembly and must be recirculated in a continuous path towards, but not necessarily all the way to the opposite end of the assembly, forming a closed circuit. In order to achieve this recirculation of the balls in the system, there are generally two types of return systems; external and internal. External ball return systems generally involve external ball return tubes which protrude above and around the outside diameter of the ball nut. Internal ball return systems generally involve the ball returning through or along the nut wall, but below the outside diameter. This invention relates to an internal ball return system.
[0003] There are several variations of internal ball return systems. In one variation, sometimes termed a “flop-over” design, the ball is forced to climb over the crest of the thread by the return system. In this system, the balls make often less than a full revolution of the shaft and the circuit is closed by a ball deflector that allows the balls to cross over adjacent grooves or thread crests. These ball deflectors often comprise a separately manufactured component, or crossover block, that is inserted, either from the internal diameter or the external diameter of the ball nut, through an opening in the ball nut. This machined slot or bore may have additional retention features incorporated to aid in the retention of the crossover block or may be simply be a straight-walled machined bore or slot, relying on retention features in the deflector. The deflector, whether inserted through the internal surface or the external surface of the ball nut, contains a ball pathway or channel through the center portion of the deflector, often curved in such a way and with a large enough radius such that balls may move over the aforementioned thread crests and recirculate into an adjacent ball raceway.
[0004] In another variation of the internal ball return system, the balls are returned to the opposite end of the nut through the nut wall utilizing a hole, or along the nut wall utilizing a channel, still below the outside diameter of the ball nut.
[0005] The crossover block of an internal ball return system may be retained in the opening of the ball nut with a press fit or a number of other retention features, including adhesives. If inserted from the interior of the ball nut, this retention may include a step feature towards the outer surface of the ball nut, such that the block is prevented from exiting the ball screw assembly through the hole or slot in the ball nut during operation. In addition, where the crossover block is inserted from the interior of the ball nut it is often only with a slip fit so that the block is retained in place by the constant recirculation of balls in the ball screw assembly. This arrangement allows for some minor movement of the crossover block while the balls recirculate, in turn, possibly causing noise and vibration. In addition, with these movements of the crossover block, the ingress/egress of the balls through the crossover block ball channel changes, possibly impacting ball velocity and causing ball to ball noise and friction.
[0006] The principle requirement of retaining such a crossover block within the hole through the ball nut is that the block be aligned properly, such that the ball threads align with the ball channel in the crossover block in order to provide an unobstructed path for recirculation of the balls. For that reason, it is known to locate the crossover block in relation to the interior surface, rather than an exterior surface or step, of the ball nut even where the block is inserted from the exterior of the ball nut, as it allows for less variation and better alignment of the crossover block channel and the ball threads. An example of such an arrangement is disclosed in U.S. Pat. No. 5,937,700, wherein tabs are formed on compressible arms that are pushed inwards during assembly and extend outwards once the tabs align with the ball raceways of the ball screw assembly. This arrangement is necessarily a slip fit, retained mainly by the constant recirculation of balls within the ball screw and through the crossover block channel.
SUMMARY OF THE INVENTION
[0007] Certain terminology is used in the following description for convenience and descriptive purposes only, and is not intended to be limiting to the scope of the claims. The terms “recirculation insert” and “crossover block” are used interchangeably. The terminology includes the words specifically noted, derivatives thereof and words of similar import.
[0008] The present invention relates to an internal recirculation insert for recirculating balls between adjacent raceways of a ball screw assembly. The internal recirculation insert has a body portion, either formed in one piece or multiple pieces and later joined, including a top wall, bottom wall and four side walls and a ball passage in the bottom wall that extends through the body portion to recirculate balls within the ball screw assembly from one helical raceway to another.
[0009] The internal recirculation insert is prevented from exiting the ball screw assembly, and particularly, the radial bore of the ball nut, by arms extending outwardly from the body portion of the internal recirculation insert and seating in adjacent helical raceways of the ball screw assembly. Other retention elements are possible, however, this configuration requires minimal or no additional machining of the radial bore of the ball nut. In order to more securely hold the recirculation insert within the radial bore, a friction or increased fit feature is included or added to the internal recirculation insert. This feature may include any number of elements, such as; an angularly extending tab machined or molded into the sides of the internal recirculation insert in contact with the walls of the radial bore of the ball nut; a similar metal or other rigid band seated into a groove in the body portion of the insert, also with an angularly extending tab in contact with the walls of the radial bore of the ball nut; a rubber or other malleable material o-ring seated in a groove in the body portion of the insert and in contact with the walls of the radial bore of the ball nut; or other such devices.
[0010] Any of these friction means operate to tightly secure the recirculating insert within the radial bore of the ball nut. Among other outcomes, this increased fit maintains a constant position of the insert relative to the helical raceways of the ball screw assembly, allowing for smooth transport of the balls from one raceway to another without any oscillation or associated movement or vibration of the insert.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The above mentioned and other features and advantages of the embodiments described herein, and the manner of attaining them, will become apparent and be better understood by reference to the following description of at least one example embodiment in conjunction with the accompanying drawings. A brief description of those drawings now follows.
[0012] FIG. 1 is a cross sectional view of a ball screw assembly, with the ball screw removed, including the internal recirculation insert with integral angular tab according to one embodiment of the invention.
[0013] FIG. 2 . is an enlarged cross sectional view of the internal recirculation insert of FIG. 1 .
[0014] FIG. 3 is an enlarged isometric view of the internal recirculation insert of FIG. 1 , showing the integrally molded or machined tab and securing arms extending from the sides of the body of the internal recirculating insert.
[0015] FIG. 4 is an enlarged rear cross sectional view of the internal recirculating insert of FIG. 1 , showing integrally molded or machined tabs on opposing sides of the internal recirculating insert.
[0016] FIG. 5 is a further enlarged cross sectional view of the tab shown in FIG. 4 .
[0017] FIG. 6 is a cross sectional view of a ball screw assembly, with the ball screw removed, with another embodiment of the invention, showing a rigid band seated in place in a molded or machined groove in the circumferential surface of the internal recirculating insert.
[0018] FIG. 7 is a an enlarged cross sectional view of the internal recirculating insert of FIG. 6 .
[0019] FIG. 8 is a top view of the internal recirculating insert of FIG. 7 , showing extended securing arms and no rigid band around the circumference of the insert.
[0020] FIG. 9 is a cross sectional view of the insert of FIG. 8 along line C-C, showing a grooved circumferential slot without a rigid band seated in place.
[0021] FIG. 10 is a top view of the internal recirculating insert of FIG. 7 , showing extended securing arms and a rigid band around the circumference of the insert, with protruding tabs.
[0022] FIG. 11 is a cross sectional view of the insert of FIG. 10 along line A-A, showing a grooved circumferential slot with a rigid band and extending tabs seated in place.
[0023] FIG. 12 is an enlarged cross sectional view of the seated rigid band of FIG. 11 .
[0024] FIG. 13 is an isometric view of the rigid band shown in FIGS. 6 , 7 , 10 , 11 and 12 .
[0025] FIG. 14 is a cross sectional view of a ball screw assembly, with ball screw removed, with another embodiment of the invention, showing an o-ring seated in place in a molded or machined grove in the circumferential surface of the internal recirculating insert.
[0026] FIG. 15 is an enlarged cross-sectional view of FIG. 14 .
[0027] FIG. 16 is an isometric view of the o-ring of FIGS. 14 and 15 .
[0028] FIG. 17 is a top view of the internal recirculating insert of FIG. 14 , without an o-ring seated in the circumferential groove of the insert.
[0029] FIG. 18 is a cross sectional view of the internal recirculating insert of FIG. 17 along line C-C, showing the circumferential o-ring ring without an o-ring in place.
[0030] FIG. 19 is a top view of the internal recirculating insert of FIG. 14 , with an o-ring seated in the circumferential groove of the insert.
[0031] FIG. 20 is a cross sectional view of the internal recirculating insert of FIG. 19 along line A-A, showing the circumferential o-ring ring with an o-ring in place.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Identically labeled elements appearing in different ones of the figures refer to the same elements but may not be referenced in the description for all figures. The exemplification set out herein illustrates at least one embodiment, in at least one form, and such exemplification is not to be construed as limiting the scope of the claims in any manner.
[0033] FIG. 1 shows a cross sectional view of a ball screw assembly 1 . Ball screw assembly 1 comprises ball nut 2 , ball screw (not shown), internal recirculation insert 4 , balls 5 , helical raceways 6 , and ball nut radial bore 7 . Ball nut 2 encircles ball screw (not shown), and includes complimental ball nut helical grooves 12 and complimental ball nut helical groove thread land 14 on the interior surface of ball nut 2 . Helical raceways 6 are formed by aligning ball nut helical grooves 12 with ball screw helical grooves (not shown) and ball nut helical groove thread land 14 with ball screw helical thread land (not shown). Within raceways 6 , a plurality of load bearing balls 5 are placed in order to transfer rotational movement of one of the ball screw (not shown) or ball nut 2 , into axial movement of the other.
[0034] Within ball nut 2 is at least one radial bore 7 extending through ball nut 2 into the interior of ball screw assembly 1 . Internal recirculating insert 4 is inserted into radial bore 7 . Internal recirculating insert 4 , in turn, comprises securing arms 8 , tabs 9 , ball channel 10 , and body portion 11 . Internal recirculating insert 4 includes outwardly extending securing arms 8 which, in this embodiment, seat in adjacent helical raceways 6 , providing location for ball channel 10 to transfer balls 5 between adjacent raceways 6 and also radially securing internal recirculating insert 4 within ball nut 2 . For example, the embodiment shown in FIG. 1 includes several radial bores 7 , each including an internal recirculating insert 4 . The left most internal recirculating insert 4 ′, has securing arm 8 ′ seated in turn 16 and 8 ″ seated in turn 17 , thus ball channel 10 ′ recirculates balls 5 between turn 16 and 17 . Generally, ball channel 10 ′ must have a sufficiently deep central portion to permit balls 5 to travel from turn 16 over ball screw helical land (not shown) into turn 17 . In turn, ball channel 10 may be of a generally round curvature or may be of several other configurations, such as a gothic arch. The configuration, construction and operation of ball channel 10 is known in the art and may be determined by those skilled in the art for any particular application.
[0035] As may be seen in FIG. 1 , and perhaps more clearly in FIG. 2 , although securing arms 8 prevent internal recirculating insert 4 from exiting ball nut 2 through radial bore 7 and loosely keep internal recirculating insert 4 in a set radial and axial position, in general internal recirculating insert 4 will only be assembled into radial bore 7 with a slip fit, allowing some minor movement or oscillation as balls 5 recirculate through ball channel 10 . In this embodiment, angular tabs 9 are machined or molded into body potion 11 of internal recirculating insert 4 and are proximate with ball nut radial bore walls 19 , effecting a tighter fit between radial bore 7 and body portion 11 , keeping internal recirculating insert 4 in a more stable position throughout operation of ball screw assembly 1 .
[0036] FIG. 3 shows an enlarged isometric view of the internal recirculating insert 4 . Body portion 11 may he formed in a single piece or durable material or of several pieces and later joined together. In either case, at least one tab 9 , and possibly a plurality of tabs, is molded, machined or otherwise formed into side walls 23 of body portion 11 . Tab 9 , shown here, is of a generally rectangular configuration, although other configurations are possible.
[0037] FIG. 4 is a cross sectional view of internal recirculating insert 4 , showing the complex curvature of ball channel 10 within bottom wall 22 of body portion 11 , securing arm 8 extending outwardly from body portion 11 and tabs 9 , in this case diametrically opposed. Although body portion 11 is of a generally oblong shape, sidewall 23 lies flat and parallel relative to radial bore walls 19 . From this surface, tabs 9 protrude at a small angle in order to contact radial bore walls 19 . Although not required for this invention, in this embodiment side wall 23 is shown as having an approximately right angled relationship relative to top wall 21 .
[0038] FIG. 5 is an enlarged cross sectional view of tab 9 shown in FIG. 4 . The small angular protrusion of tab 9 relative to a planar surface taken from point 9 a to point 9 b is more clearly shown.
[0039] FIG. 6 shows a cross sectional view of a further embodiment of the present invention. Ball screw assembly 1 remains the same as that shown in FIG. 1 , comprising ball nut 2 , ball screw (not shown), internal recirculation insert 4 , balls 5 , helical raceways 6 , and ball nut radial bore 7 . However, in this embodiment rather than internal recirculation insert 4 having an integrally molded or machined tab, insert 4 has a circumferential band groove 26 within which rigid band 25 may be seated. Rigid band 25 may be formed of a metallic or other substance and is formed around the circumference of body portion 11 , seating in band groove 26 . Rigid band tabs 27 extend outwardly from the planar surface of rigid band 25 , also contacting radial bore balls 19 , much like tabs 9 of the previous embodiment.
[0040] FIG. 7 shows an enlarged cross sectional view of the internal recirculating insert of FIG. 6 . Here, rigid band tabs 27 are more clearly visible, extending outward from a generally planar surface parallel with radial bore walls 19 , and contacting radial bore walls 19 with sufficient force to secure internal recirculating insert 4 within radial bore 7 .
[0041] FIG. 8 is a top view of internal recirculating insert 4 of the embodiment shown in FIG. 6 , without rigid band 25 seated in place. Securing arms 8 extend outwardly from side walls 23 in body portion 11 . In this embodiment, internal recirculating insert 4 has a generally oblong configuration, with securing arms 8 extending from the two longer side walls 23 . Also, side walls 23 lie at an approximate right angle to top wall 21 .
[0042] FIG. 9 is a cross sectional view of FIG. 8 taken through line C-C. Once again are shown ball channel 10 , body portion 11 , top wall 21 , side wall 23 and bottom wall 22 . Band groove 26 is shown without rigid band 25 seated within and is of a generally rectangular configuration, however other cross sectional configurations are possible.
[0043] FIG. 10 is a top view of internal recirculating insert 4 of the embodiment shown in FIG. 6 and FIG. 8 , with rigid band 25 seated in place. As shown in FIG. 8 , securing arms 8 extend outwardly from side walls 23 in body portion 11 . In addition, rigid band tabs 27 are shown extending outward from the surface plane of side wall 23 .
[0044] FIG. 11 is a cross sectional view of FIG. 10 taken through line A-A. Once again are shown ball channel 10 , body portion 11 , top wall 21 , side wall 23 and bottom wall 22 . Rigid band 25 is shown seated within band groove 26 . In this embodiment, rigid band tabs 27 are shown diametrically opposed to each other.
[0045] FIG. 12 is an enlarged cross sectional view of band groove 26 and rigid band 25 of FIG. 11 . Here, it is more clearly visible the small angle of rigid band tabs 27 relative to a planar surface taken from point 27 a to point 27 b , generally running parallel to radial bore walls 19 ( FIG. 6 ). Tabs 27 may be formed integrally with rigid band 25 or made separately and joined to rigid band 25 .
[0046] FIG. 13 is an isometric view of rigid band 25 , showing the generally oblong shape matching the shape of body portion 11 ( FIG. 8 ). Although two rigid band tabs are shown, any number are contemplated by this invention.
[0047] FIG. 14 shows a cross sectional view of a further embodiment of the present invention. Ball screw assembly 1 remains the same as that shown in FIG. 1 , comprising ball nut 2 , ball screw (not shown), internal recirculation insert 4 , balls 5 , helical raceways 6 , and ball nut radial bore 7 . In this embodiment o-ring groove 29 is provided on the circumference of body portion 11 , within which o-ring 30 may seat. O-ring 30 must be of sufficient thickness to protrude from side wall 23 and contact radial bore wall 19 , tightly securing internal recirculating insert 4 in radial bore 7 .
[0048] FIG. 15 is an enlarged cross sectional view of internal recirculating insert 4 shown in FIG. 14 . Once again, o-ring 30 seats in o-ring groove 29 , protruding outwardly from the planar surface of side wall 23 and contacting radial bore wall 19 , at least partially fixing internal recirculating insert 4 in place.
[0049] FIG. 16 is an isometric view of o-ring 30 . O-ring 30 is composed of any malleable material, such as rubber.
[0050] FIG. 17 is a top view of internal recirculating insert 4 of the embodiment shown in FIG. 14 , without o-ring 30 . Securing arms 8 extend outwardly from side walls 23 in body portion 11 .
[0051] FIG. 18 is a cross sectional view of FIG. 17 taken through line C-C. Once again are shown ball channel 10 , body portion 11 , top wall 21 , side wall 23 and bottom wall 22 . O-ring groove 29 is more clearly visible.
[0052] FIG. 19 is a top view of internal recirculating insert 4 of the embodiment shown in FIG. 14 , with o-ring 30 . As in FIG. 17 , securing arms 8 extend outwardly from side walls 23 in body portion 11 .
[0053] FIG. 20 is a cross sectional view of FIG. 19 taken through line A-A. Once again are shown ball channel 10 , body portion 11 , top wall 21 , side wall 23 and bottom wall 22 . O-ring groove 29 is more clearly visible with o-ring 30 seated in place. 0 -ring 30 protrudes past the planar surface created by side wall 23 , entering into the gap between side wall 23 and radial bore wall 19 ( FIG. 15 ).
[0054] In the foregoing description, example embodiments are described. The specification and drawings are accordingly to be regarded in an illustrative rather than in a restrictive sense. It will, however, be evident that various modifications and changes may be made thereto, without departing from the broader spirit and scope of the present invention.
[0055] In addition, it should be understood that the figures illustrated in the attachments, which highlight the functionality and advantages of the example embodiments, are presented for example purposes only. The architecture or construction of example embodiments described herein is sufficiently flexible and configurable, such that it may be utilized (and navigated) in ways other than that shown in the accompanying figures.
[0056] Although example embodiments have been described herein, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present example embodiments should be considered in all respects as illustrative and not restrictive.
[0057] List of Reference Symbols
1 Ball Screw Assembly 2 Ball Nut 4 Internal Recirculation Insert 5 Balls 6 Helical Raceways 7 Radial Bore 8 Securing Arms 9 Tabs 10 Ball Channel 10 ′ Left most Ball Channel Connecting Turns 16 and 17 11 Body Portion 12 Ball Nut Helical Grooves 14 Ball Nut Helical Groove Thread Land 16 Turn 16 17 Turn 17 19 Radial Bore Walls 21 Top Wall 22 Bottom Wall 23 Side Wall 25 Rigid Band 26 Band Groove 27 Rigid Band Tabs 29 O-ring Groove 30 O-ring
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An internal ball recirculation insert for a ball screw assembly. The ball screw assembly having a ball nut with at least one radial bore though it, a ball screw and load bearing balls. The ball screw and ball nut having complimental helical grooves, forming helical ball raceways when the ball screw and ball nut are assembled. The internal ball recirculation insert sized to fit into the radial bore of the ball nut, having a body portion, securing arms, a ball channel for channeling balls from one ball raceway to another and a friction or retention device around the circumference of the body portion. The friction device extending outwardly from a side wall of the recirculation insert, and contacting a wall of the radial bore in the ball nut.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Benefit is claimed of U.S. Patent Application 60/663,912, entitled “CONDENSATE HEAT TRANSFER FOR TRANSCRITICAL CARBON DIOXIDE REFRIGERATION SYSTEM” and filed Mar. 18, 2005. Copending application docket 05-258, entitled HIGH SIDE PRESSURE REGULATION FOR TRANSCRITICAL VAPOR COMPRESSION SYSTEM and filed on even date herewith, discloses prior art and inventive cooler systems. The present application discloses possible modifications to such systems. The disclosures of said applications are incorporated by reference herein as if set forth at length.
BACKGROUND OF THE INVENTION
[0002] The invention relates to refrigeration. More particularly, the invention relates to beverage coolers.
[0003] As a natural and environmentally benign refrigerant, CO 2 (R-744) is attracting significant attention. In most air-conditioning operating ranges, CO 2 systems operate in transcritical mode. An example of a transcritical vapor compression system utilizing CO 2 as working fluid comprises a compressor, a gas cooler, an expansion device, an evaporator and the like (see FIG. 1 ). The major difference between transcritical and conventional operation is that heat rejection in the gas cooler is in the supercritical region because the critical temperature for CO 2 is 87.8 F. Consequently, pressure is not solely dependent on temperature and this opens additional control and optimization issues for system operation.
[0004] FIG. 1 schematically shows transcritical vapor compression system 20 utilizing CO 2 as working fluid. The system comprises a compressor 22 , a gas cooler 24 , an expansion device 26 , and an evaporator 28 . The exemplary gas cooler and evaporator may each take the form of a refrigerant-to-air heat exchanger. Airflows across one or both of these heat exchangers may be forced. For example, one or more fans 30 and 32 may drive respective airflows 34 and 36 across the two heat exchangers. A refrigerant flow path 40 includes a suction line extending from an outlet of the evaporator 28 to an inlet 42 of the compressor 22 . A discharge line extends from an outlet 44 of the compressor to an inlet of the gas cooler. Additional lines connect the gas cooler outlet to expansion device inlet and expansion device outlet to evaporator inlet.
[0005] An electronic expansion valve is usually used as the device 26 to control the high side pressure to optimize the COP of the CO 2 vapor compression system. An electronic expansion valve typically comprises a stepper motor attached to a needle valve to vary the effective valve opening or flow capacity to a large number of possible positions (typically over one hundred). This provides good control of the high side pressure over a large range of operating conditions. The opening of the valve is electronically controlled by a controller 50 to match the actual high side pressure to the desired set point. The controller 50 is coupled to a sensor 52 for measuring the high side pressure.
[0006] As the airflow 36 passes over the heat exchanger 28 , cooling of the airflow 36 causes the condensation of water out of that airflow. Disposal of that water may need to be addressed. One way involves using the heat rejection heat exchanger to heat the water to induce its evaporation. An example of such a system 60 is shown in FIG. 2 .
[0007] In the illustrated system 60 , components similar to those of the system 20 are shown with like numerals. For illustration, the control and sensor components are hidden. The gas cooler 62 is split into first and second sections 64 and 66 . Along the refrigerant flowpath 66 , the first section 64 is upstream of the second section 66 . The sections 64 and 66 may be along a common air flowpath to receive a common airflow 68 (e.g., driven by a fan 70 ) or may be on separate air flowpaths (e.g., driven by separate fans). If on a common air flowpath, the first section may be upstream/downstream of the second section.
[0008] Water condensed from the airflow 36 is collected by a collection system 80 . An exemplary system 80 includes a pan 82 to which the water is delivered. A portion of the first section 64 is positioned to be immersed in a water accumulation in the pan. Heating of the water by the first section 64 encourages evaporation of the water.
SUMMARY OF THE INVENTION
[0009] For advantageous performance, however, the condensate may preferably be exposed to a more downstream section of the heat rejection heat exchanger. A bottle cooler system includes means for using atmospheric water condensate from the evaporator to draw heat from the condenser.
[0010] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic view of a prior art refrigeration system.
[0012] FIG. 2 is a schematic view of another prior art refrigeration system.
[0013] FIG. 3 is a schematic view of an inventive refrigeration system.
[0014] FIG. 4 is a side schematic view of a display case bottle cooler including a refrigeration and air management cassette.
[0015] FIG. 5 is a view of a refrigeration and air management cassette.
[0016] FIG. 6 is a partial side schematic view of an alternative cassette.
[0017] FIG. 7 is a partial side schematic view of an alternative cassette.
[0018] FIG. 8 is a partial side schematic view of an alternative cassette.
[0019] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0020] FIG. 3 shows a system 100 having a compressor 22 , expansion device 26 , and heat absorption heat exchanger (evaporator) 28 . These may be similar to corresponding components of the systems of FIGS. 1 and 2 . For illustration, the control and sensor components are hidden. The gas cooler 102 is split into first and second sections 104 and 106 . Along the refrigerant flowpath 66 , the first section 104 is upstream of the second section 106 . The sections 104 and 106 may be along a common air flowpath to receive a common airflow 108 (e.g., driven by a fan 110 ) or may be on separate air flowpaths (e.g., driven by separate fans). In the exemplary system, the first section 104 is upstream of the second section 106 with the fan 110 intervening.
[0021] Water condensed from the airflow 36 is collected by a collection system 112 . An exemplary system 112 includes a pan 122 to which the water is delivered. A portion of the second section 106 is positioned to be immersed in a water accumulation in the pan 122 . Heating of the water by the second section 64 may encourage evaporation of the water. Contrasted with the system of FIG. 2 , the section of the gas cooler which gives up heat to the condensate is relatively downstream along the refrigerant flow path (e.g., in the cooler half or quarter of the temperature drop prior to the expansion device). This is intended to reduce the refrigerant temperature as much as possible by exposing the coldest refrigerant to the condensate. For a transcritical CO 2 refrigeration system, to maintain peak efficiencies it is critical to minimize the temperature at the exit of the high-side (gas cooler) heat exchanger.
[0022] It is even more critical to minimize this exit temperature for a CO 2 bottle cooler refrigeration system. Manufacture costs are of particular concern. The result is that low cost/relatively lower efficiency heat exchangers (including but not limiting to wire-on-tube heat exchanger, plate-on-tube heat exchanger, finless heat exchanger etc.) are particularly useful for to control bottle cooler manufacture costs.
[0023] Thus, a particular area for implementation of the condensate heat exchange is in bottle coolers, including those which may be positioned outdoors or must have the capability to be outdoors (presenting large variations in ambient temperature). FIG. 4 shows an exemplary cooler 200 having a removable cassette 202 containing the refrigerant and air handling systems. The exemplary cassette 202 is mounted in a compartment of a base 204 of a housing. The housing has an interior volume 206 between left and right side walls, a rear wall/duct 216 , a top wall/duct 218 , a front door 220 , and the base compartment. The interior contains a vertical array of shelves 222 holding beverage containers 224 .
[0024] The exemplary cassette 202 draws the air flow 108 through a front grille in the base 224 and discharges the air flow 108 from a rear of the base. The cassette may be extractable through the base front by removing or opening the grille. The exemplary cassette drives the air flow 36 on a recirculating flow path through the interior 206 via the rear duct 210 and top duct 218 .
[0025] FIG. 5 shows further details of an exemplary cassette 202 . The heat exchanger 28 is positioned in a well 240 defined by an insulated wall 242 . The heat exchanger 28 is shown positioned mostly in an upper rear quadrant of the cassette and oriented to pass the air flow 36 generally rearwardly, with an upturn after exiting the heat exchanger so as to discharge from a rear portion o the cassette upper end. A drain 250 may extend through a bottom of the wall 242 to pass water condensed from the flow 36 to the drain pan 122 . A water accumulation 254 is shown in the pan 122 . The pan 122 is along an air duct 256 passing the flow 108 downstream of the heat exchanger first section 104 . The heat exchanger second section 106 is positioned to be at least partially immersed in the accumulation 254 . Exposure of the accumulation 254 to the immersed second section 106 and to the heated air in the flow 108 may encourage evaporation.
[0026] In an exemplary, coil routing of the second section 106 , the second section is divided into a first portion normally above the accumulation and in the airflow 108 and a second portion normally immersed. The refrigerant flow path may pass generally downstream along the air flow 108 through the first portion and then pass into the second portion before proceeding to the expansion device.
[0027] The FIG. 5 arrangement is consistent with a basic reengineering of a baseline cassette having a single heat rejection heat exchanger located where the first section 104 is and nothing where the second section 106 is. It is also consistent with a reengineering of a split system where the hotter section is in that latter position. However, the illustrated configuration has the disadvantage that the cooler section is downstream of the hotter section along the air flow path. Accordingly, it may be desirable to reverse the air flow to become back-to-front. A portion of this back-to-front air flow could be directed to flow over the cooler door window to avoid window fogging.
[0028] An alternative implementation might eliminate the physical separateness of the first section 104 . One example would be to only have a single heat rejecting heat exchanger unit positioned as represented by the second section 106 in FIG. 5 . The immersed portion of that exchanger unit could serve the role of the second section 106 while the exposed portion could serve the role of the first section 104 (see FIG. 6 below). Another simple variation could involve heat exchanger positioning so that water dripping from the drain flows over a leading portion of the heat exchanger (i.e., at the upstream end of the warm air flow).
[0029] Various implementations may further maximize heat transfer via a counterflow exchange of condensate water and the refrigerant. This counterflow may be the exclusive method of heat exchange between the condensate and the refrigerant, or may supplement pan immersion or another mechanism. FIG. 6 shows such a system, wherein the drain 250 having an outlet 260 . A length 262 of the refrigerant line extends upward to the outlet. The length 262 is positioned to guide/wick droplets of water from the outlet 260 downwardly along the length 262 to the drain pan. With refrigerant flowing upward through the length 324 , the refrigerant and water are in counterflow heat exchange. A more upstream (along the refrigerant flow path) length 264 (or portion of the heat rejection heat exchanger) may be immersed in the water 254 in the pan. a yet more upstream portion 270 may be in the air flow
[0030] In another example of a supplementary situation, a relatively small downstream section of the gas cooler may run through/in the drain pan 122 . A smaller yet more downstream portion may run up into the to evaporator drain in a counterflow heat exchange (both along its length and/or merely a two step counterflow in combination with the portion in the pan). In the FIG. 7 example, the drain 250 is replaced by a more convoluted drain 300 . The drain 300 has an upwardly directed U-portion 302 defining a water trap containing a water slug 304 . The drain 300 and slug 304 may prevent air leakage between the hot and cold air flows and might be used independently in place of the simpler drain 250 . The slug is continuously replenished by condensate flowing into the drain 300 and continuously discharges condensate down toward the pan 122 . A portion 306 of the refrigerant line extends from a remainder of the second section 106 and through the drain 300 . The expansion device (not shown) may be positioned between the downstream end of the line portion 306 and the evaporator 28 . Thus refrigerant flowing through the line portion 306 is in counterflow heat exchange with the condensate flowing through the drain 300 . Although shown piercing the drain 300 , the line portion 306 may enter the drain outlet 308 and/or exit the drain inlet 310 and more closely follow the path of the drain.
[0031] FIG. 8 shows an alternate drain 320 having an outlet 322 . A length 324 of the refrigerant line extends upward to the outlet. The length 324 is positioned to guide/wick droplets of water from the outlet 322 downwardly along the length 324 to the drain pan. With refrigerant flowing upward through the length 324 , the refrigerant and water are in counterflow heat exchange. A more upstream (along the refrigerant flow path) portion of the heat rejection heat exchanger may be immersed in the water in the pan.
[0032] In other implementations, the condensate could be delivered to air flow (e.g., 108 ) just prior to its passing over the last portion of the heat rejecting heat exchanger (i.e., the gas cooler which would be a condenser if conditions were appropriate) so that the heat transfer is enhanced and hence the refrigerant temperature is reduced. This may be particularly effective in dry climates where evaporative cooling of the air flow is particularly relevant.
[0033] This condensate to air delivery could be done in several ways. A wick could be placed upstream of the relevant section of the heat exchanger along the air flow. A spray device could be similarly positioned to introduce the spray of condensate to the air flow. Such a spray could also or alternatively directly contact the relevant heat exchanger portion to cool via evaporative or conventional cooling. Similarly, a wick could contact the heat exchanger to transport the water and provide conventional and/or evaporative cooling.
[0034] Thus, it is seen that for transcritical bottle cooler applications, the water being condensed on evaporator surfaces is useful for refrigerant cooling to maintain efficiency. This approach especially provides additional efficiency for low cost, fouling resistant, heat exchangers like wire-on-tube, plate-on-tube, finless heat exchangers, and the like. This may enable performance comparable to high efficiency finned-tube conventional heat exchangers currently being used for bottle cooler applications. The protective coating typically present on low cost heat exchangers (wire-on-tube, plate-on-tube, etc.) may provide effective resistance to corrosion from the condensate to which the heat exchanger is exposed.
[0035] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, when implemented as a remanufacturing of an existing system or reengineering of an existing system configuration, details of the existing configuration may influence details of the implementation. Exemplary baseline systems could be transcritical CO2 systems or could have other operational domains and/or other refrigerants. Accordingly, other embodiments are within the scope of the following claims.
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A bottle cooler system includes means for using atmospheric water condensate from the evaporator to draw heat from the condenser.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of application Ser. No. 08/715,105 filed Sep. 18, 1996 now U.S. Pat. No. 5,916,947 which is a continuation-in-part of application Ser. No. 08/551,231 filed Nov. 1, 1995, now abandoned, which is a continuation-in-part of application Ser. No. 08/348,467 filed on Dec. 2, 1994, now abandoned.
FIELD OF THE INVENTION
The invention relates to particles for incorporation into substrates for imparting antifouling effects. The particles are particularly useful as coating compositions comprising at least 20% by weight photoactive zinc oxide and less than about 5% by weight photosensitizer(s). These compositions are useful for coating equipment submerged in natural waters, for example, fish nets, water conduits and boat hulls, but also find use in protecting and preserving surfaces in the air subjected to fouling, for example, shower curtains, hospital walls, toilet bowls, roofs, and masonry.
BACKGROUND OF THE INVENTION
Heretofore, the most successful antifouling coatings have comprised a relatively inert organic binder with a biocidal pigment which is leached from the paint. Zinc oxide has been used in the past in antifouling coating compositions as a white pigment, to impart flexibility and hardness to the coating and/or as an insolubilizing agent. Zinc oxide is not recognized as useful as a primary toxicant, probably because it is only sparingly soluble in neutral water. Thus, while heretofore zinc oxide has been widely used in antifouling coatings, its role is as a supporting compound to recognized biocidal agents.
Previously it was thought that coating compositions containing zinc oxide levels higher than 20 wt % greatly reduced the antifouling properties and life of the coating unless small levels of a very toxic material were also included. This is because higher levels imply replacing the primary toxicant with zinc oxide and the effectiveness of the coating was believed to be directly related to the level of the primary toxicant in the coating. Levels higher than 20 wt % have in the past been limited to coating compositions containing extremely toxic triorganotin moieties where only relatively small amounts of primary toxicant are necessary. (See, for example, U.S. Pat. No. 4,139,515 (Dennington) issued Feb. 13, 1959.)
Heretofore, ultraviolet light has been used to sterilize surfaces. However, the solution to the problem of using visible light to render surfaces toxic to pestiferous organisms has not been known in the art. A solution to the problem would be highly desired since visible light is more commonly available than is ultraviolet light and is a nontoxic, renewable resource.
Use of visible light to produce phototoxic surfaces would be especially useful for coatings on fish nets and boat bottoms. Equipment submerged in natural waters at depths of more than one meter only receives significant amounts of light energy in the blue-green region of the electromagnetic spectrum at around 500 nm. Thus a phototoxic surface which utilizes blue and green light would be highly desired by boat owners and aquaculturists to name a few.
This invention relates to utilizing visible light to photochemically synthesize an effective concentration of hydrogen peroxide by in situ reduction of oxygen on zinc oxide. It is known that photolysis of aqueous, aerated solutions containing zinc oxide pigment leads to the formation of hydrogen peroxide only when exposed to ultraviolet light of wavelengths greater than 400 nm and thus has been thought to be ineffective for producing phototoxic surfaces.
Hydrogen peroxide is a known toxicant but prior methods for generating hydrogen peroxide on surfaces are inefficient and expensive. Such techniques have included applying cathodic voltage and current to a conducting or semiconducting surface to produce at or near the surface an effective concentration of hydrogen peroxide.
The very success of toxic antifouling coatings based on biocidal pigment leaching has led to their over use. This has so polluted the environment that lead, mercury, and triorganotin based coatings are now banned in most parts of the world. Copper-based paints are still permitted, but they are classified as pesticides needing strict government controls for testing and use.
The leaching of soluble copper salts into navigable waters from pleasure craft, nuclear power plants, and the like is of great concern to State and Federal Authorities especially in areas of high concentrations of polluting sources. Present antifouling paints are a major cause of such concern. Copper-based paints now must exhibit limited release rates of copper to a point where for many applications they are ineffective.
Heretofore, toxic antifouling coatings relied entirely on the leaching into the environment of poisons contained within the coating. Over time, even the best heretofore available antifouling coating loses its toxicant and becomes ineffective.
SUMMARY OF THE INVENTION
Accordingly, the present invention comprises a new type of antifouling coating composition which provides excellent antifouling effects without the aforesaid problem of environmental pollution and is capable of protecting surfaces from biofouling for a length of time approximating the useful life of the surfacing. Consequently, the antifouling coating compositions are quite free from any antifouling agent causing environmental pollution and exhibit an excellent antifouling effect against a broad range of fouling organisms for long periods of time.
Specifically, the invention is a particle mixture in powder or slurry form which exhibits antifouling properties when incorporated into a carrier comprising: zinc oxide, said zinc oxide containing less than about 0.001% by weight of lead, cadmium and sulfur oxides and being obtained from colloidal ZnO and having a mean particle size of from about 0.10 to about 0.50 microns and a surface area from about 1 to about 10 square meters/gram and being in photoelectric proximity to a photosensitizer, said photosensitizer having a solubility below 5 ppm by weight in water and being able to absorb visible light and catalyze the production of peroxides when in contact with ZnO, water, O 2 and visible light.
By design and purpose, antifouling coatings are toxic to life. Paint authorities world-wide are unanimous that for any antifouling paint to work, it must contain a leachable toxic component. The investigations of the present inventors have led to the surprising discovery that a paint composition comprising a binder and about 20 to about 60 wt % of said composition of suspended zinc oxide pigment and less than about 5 wt % of photosensitizer(s) shows an excellent and unsuggested antifouling effect against fouling organisms for long periods of time despite the omission of the leachable toxic component generally recognized as a primary antifouling agent.
No exact mechanism by which this unexpected and surprising result is obtained has been elucidated, but as experimentally shown in the Examples given hereinbelow, the compositions of this invention are new types of antifouling compositions which do not cause environmental pollution.
It is possible that the coated surface, which results after application, drying and aging of the compositions of the invention, is very hostile to the attachment of juvenile plants and animals due to more than one mechanism. The present inventors have found that, especially in the presence of humid air or on immersion in aerated water, surfaces coated by the compositions of the invention and subjected to terrestrial sunlight become rich in peroxides. Peroxides are known biocides and powerful oxidants. Oxidation of the coated surface may result in organic acids which dissolve zinc oxide and complex with the resulting zinc ions to produce a toxic surface. Furthermore, especially when exposed to direct natural sunlight, the compositions of the invention utilizing organic binders slowly chalk with time. This exposes fresh zinc oxide which may help maintain the antifouling properties of the coating for years.
Zinc oxide pigments of high purity reflect visible light and absorb no photoenergy at wavelengths above about 350 nm. Surprisingly the energy from visible light can be absorbed according to this invention by contacting the surface of the zinc oxide with one or more peroxide-generating photosensitizer(s). According to this invention, these are limited to material(s) which absorb visible light with wavelengths between about 400 nm and about 700 nm, and, when contacted by said light, water, zinc oxide and oxygen, cause the photosynthesis of effective concentrations of hydrogen peroxide.
The suitability of all and any material to provide the phototoxic surface of this invention is determined by contacting said material with zinc oxide, water, oxygen and visible light and measuring the concentration of peroxide ions in said water with respect to time. Preferred materials are those wherein the peroxide concentration of the lighted test solution continues to increase with time to levels in excess of about 1.0 ppm.
Apparatus for measuring the concentration of peroxide ions are well known as are methods for measuring the ability of material to absorb visible light. Those skilled in the art will appreciate that photochemical efficiency for absorbing visible light and photosynthesizing peroxide ions on zinc oxide is maximized by selecting materials which (a) are chemically stable in the presence of oxygen, visible light and water, (b) have highly absorbing chromophores within the visible solar spectrum, and (c) have moderately high electrical conductivity so that efficient electron transfer from the light-absorbing material to the conduction band of zinc oxide is possible.
Preferred photosensitizers are substantially insoluble in water (solubility below 0.5 part per million by weight), absorb visible light, and catalyze the production of peroxides when contacted with zinc oxide, water, oxygen and visible light.
All materials at some concentration are harmful to life. However, according to this invention, preferred photosensitizers are those whose levels of use in the invention are generally regarded as safe and which are specifically permitted for use in antifouling coatings by the U. S. Environmental Protection Agency.
For long coating life, photosensitizers which are chemically stable under oxidizing conditions are especially preferred.
Certain photosensitizers will produce antifouling coatings without any zinc oxide present. By way of example, but not by way of limitation, limited antifouling results are achieved using compositions containing about 5 wt % of the yellow photosensitizer zinc pyrithione without any zinc oxide present. However, the investigations of the present inventors have surprisingly found that the mixture does much more than the sum of the components and that very much lower levels of photosensitizers are needed to produce very much more useful antifouling effects. The photosensitizers of this invention may cost about ten to many thousand times more per pound than zinc oxide. Thus, when coating cost is an object, the preferred antifouling compositions of this invention comprise zinc oxide pigment in the amount of about 20 to about 60 wt % and levels of photosensitizer(s) below about 5 wt % of said antifouling paint composition.
By way of example, but not by way of limitation, photosensitizers according to this invention include inorganic pigments such as anatase or strontium titanate and organic pigments such as hypericin, azulene, zinc pyrithione, tetrakis-4-N-methylpyridyl, and porphyrinatozinc. Said photosensitizers in the dark exhibit low toxicity to life, are insoluble in water, and cause zinc oxide to become more photoactive in visible terrestrial light.
The wavelength of visible light absorbed depends primarily on the choice of photosensitizer. Thus, for example, azulene absorbs red light strongly with a maximum around 694 nm while anatase absorbs only in the blue. By admixing more than one photosensitizer into a composition of the invention, a larger fraction of the incident white light energy can be used to photoactivate zinc oxide. This is often desirable for indoor applications, for example, hospital walls and toilet bowls, where either the intensity of incident white light is low and/or where a very toxic surface coating is desired.
Zinc oxide pigments of high purity are photoactive. While zinc oxide and the various polymer-based binders that are used for example, in paints and coatings are, by themselves, relatively stable to sunlight, their mixtures often photodegrade, or "chalk". This photodegradation is commonly initiated by the absorption of ultraviolet light, but less damaging absorption of blue, green, yellow, orange and even red light can be achieved according to this invention by containing the surfaces of the zinc oxide with suitable photoactive pigments. Absorption of light is known to produce electron-hole pairs in semiconductors. In the presence of water, electrons can reduce oxygen to peroxide radicals:
H.sub.2 O+O.sub.2 +e.sup.- OH.sup.- +OOH
and then to peroxide ions:
OOH+e-.sup.- OOH
Holes can directly oxidize many organic adsorbates including living cells. The surface exposed to light is thus oxidized in two ways: through direct oxidation by holes, and through oxidation by peroxides.
Various embodiments of the present invention provide a vehicle and zinc oxide as the principal pigment. The upper limit for the amount of zinc oxide is set by known choices of vehicle and method of application. Zinc oxide pigment levels of up to about 60 wt % represent compositions which are to be applied by brush and roller and which contain appreciable amounts of solvents or diluents as the means by which the composition may be applied. Compositions which are to be sprayed contain more vehicle and hence less zinc oxide pigment.
While useful antifouling effects are observed with commercial zinc oxide pigment in particle shapes from nodular, lamellar to coarse acicular and containing impurities in small amounts of metallic oxides and sulphur, superior antifouling particles are obtained from colloidal zinc oxide made from high-purity zinc metal under carefully controlled conditions so as to produce a mean particle size of about 0.10 to about 0.50 microns and surface area of about 1 to about 10 square meters/gram. Representative chemical properties are 99.6% zinc oxide containing less than about 0.001% of lead, cadmium and sulfur oxides. Said preferred zinc oxide pigment is commercially available as USP-1 or USP-2 grade zinc oxide from Zinc Corporation of America, Monaca, Pa.
Surprisingly, it has also been found that the antifouling effect may be greatly enhanced by including in the compositions according to this invention one or more photosensitizers. A photosensitizer is a substance that makes material reactive or sensitive to radiant energy, especially light. The photosensitizers of the present invention are narrowly chosen from this broad class specifically for their ability to make for example, dried surfaces that have been coated with the composition of the invention phototoxic when exposed to longwave ultraviolet and visible light. Said photosensitizers probably sensitize the wide-gap semiconductor zinc oxide, and, in doing so, permit the generation of holes and/or toxic oxides on said zinc oxide at conditions which are typical for many exposed surfaces. Surfaces exposed to indoor, outdoor and underwater conditions typically receive some solar radiation in the longwave ultraviolet and visible range of the spectrum and are typically also exposed to oxygen and water. This oxygen and water are believed to be the chemical source of the toxicant of this invention. Thus, unlike all known toxic surfaces, the invention produces toxicant from air and water and does not require an internal storehouse of toxicant to function for long periods of time.
In sum, photosensitizers according to this invention are pigments which can enhance the ability of the compositions of the invention to absorb energy from the terrestrial solar spectrum. Preferred photosensitizers are materials which, when contacted by zinc oxide and by visible light, cause zinc oxide to better absorb energy from visible light.
These and other aspects of the invention will become apparent upon reading the following detailed description of the invention.
DETAILED DESCRIPTION
Although the improved biocidal efficacy and environmental advantages associated with the present invention are expected to provide advantages when used in a wide variety of applications, e.g., paints, including indoor and outdoor household paints, industrial and commercial paints and, household cleaning products, particularly advantageous results are obtained when the compositions of the present invention are utilized in conjunction with marine paints, for example, on ship's hulls. In addition, the compositions of the present invention provide desirable results in the context of paints of all types including oil and water based types.
Typically, a paint composition will comprise a vehicle comprising a resin, one or more pigments, a suitable solvent for the resin, and various optional additives such as thickening agent(s), wetting agent(s), and the like, as is well-known in the art. The resin is preferably selected from the group consisting of vinyl, alkyl, epoxy, siloxane, polyurethane, acrylonitrile, acrylate, chlorinated elastomer type or polyester resins, and combinations thereof. For masonry exposed to the weather, a preferred vehicle comprises water and alkali silicates selected from the group consisting of sodium silicate, potassium silicate, quaternary ammonium silicate and ammonium silicate and their mixtures.
For environmental as well as safety reasons, it is very desirable to utilize water-based vehicles. While some desirable photosensitizers are commercially available as pigments dispersed in water, some are not. For those that are available as water-based dispersions, useful compositions according to this invention can be formulated by admixing said water-based dispersions directly with a water-based vehicle.
However, for photosensitizers that are available only as water-insoluble organic materials, a preformulation step is required which involves either subliming or solvent depositing the photosensitizer over the surfaces of the colloidal zinc oxide prior to suspending the zinc oxide pigment in the vehicle. Said step helps ensure that the photosensitizer contacts the zinc oxide and is used in economic amounts.
In addition, the paint compositions of the present invention optionally additionally contain additives which have a favorable influence on the viscosity, the wetting power and the dispersibility, as well as on the stability to freezing and electrolytes and on the foaming properties.
The compositions of the invention may be applied to the substrate to be protected by any of the conventional methods including dipping, spraying or brushing. The substrate should be clean and oil free. Bare metal surfaces should be primed prior to application.
The surprising technical advance achieved by the coating compositions according to the invention is apparent from the following examples which further explain but do not limit the invention.
EXAMPLE 1
A first coating composition according to the invention is formulated by mixing the ingredients:
______________________________________Ingredients: Parts by Weight______________________________________Zinc Oxide, USP-1 39.0 Solvent - Xylene 18.1 Solvent - Methyl Isobutyl Ketone 19.6 Gum Rosin, ww Grade 10.0 Vinyl Resin, VYHH 6.2 Plasticizer - Flexol LOE 1.5 Antisettling Agent - MPA 2000X 0.6 Thickening Agent - Fumed Silica 0.4 Photosensitizer 3.0 Pigment 1.6 TOTAL 100.0______________________________________
The vinyl resin (VYHH) and the plasticizer (Flexol LOE) are commercially available from Union Carbide Chemicals and Plastics Co., Danbury, Conn. 06817. The settling agent (MPA 2000X) is a product of N. L. Chemicals Inc., Hightstown, N.J. 08520. Said photosensitizers are chosen according to the invention for their insolubility in water, for their lack of broad toxicity, and especially for their ability to increase the absorption by zinc oxide of visible light energy. All are capable in the presence of oxygen, water and zinc oxide of producing oxidizing species including singlet oxygen, superoxide, hydroxyl radicals and peroxides. All of these short-lived species can oxidize cellular substrates and are thus capable of killing life. Photosensitizers tested were fumed anatase (Titanium Dioxide P-25, Degussa Corporation, Dublin Ohio 43017), bianthrone (Aldrich Chemical Co., Milwaukee, Wis. 53233), azulene (Aldrich Chemical Co., Milwaukee, Wis. 53233), zinc pyrithione (Olin Corp., Cheshire, Conn. 06410), terthiophene (99%, Aldrich Chemical Co., Milwaukee, Wis. 53233) and hypericin (95%, Sigma Chemical Co., St. Louis, Mo. 63178) separately and in mixtures.
The photosensitizers illustrated in the first coating do not posses broad spectrum toxicity to animal life. Anatase and bianthrone are considered biologically inert. Azulene is an irritant. Zinc pyrithione has limited toxicity for bacteria and fungus and is so safe An for humans that it is the principal ingredient in antidandruff shampoo. Terthiophene is the biocidal constituent of various species of marigolds. Hypericin derives its name from Hypericum, a genus of plants which probably biosynthesize the pigment to protect themselves from grazing animals. Both terthiophene and hypericin require sunlight, water and oxygen to exhibit toxicity. The pigments tested were phthalocyanine blue, phthalocyanine green, titanium dioxide (rutile) and carbon black which produce blue, green, white and gray coatings respectively.
A second coating composition according to the invention is formulated by mixing the ingredients:
______________________________________Ingredients: Parts by Weight______________________________________Zinc Oxide, USP-1 25.4 Wetting Resin, 24.0 polyester-urethane dispersion Water 40.0 Hydroxyethyl cellulose .5 Crosslinker, hexamethoxy methyl melamine 6.4 Wetting Agent, silicone surfactant 1.5 Dimethylethanolamine .9 Blocking Catalyst, p-TSA .3 Photosensitizer, P-25 anatase 1.0 TOTAL 100.0______________________________________
The photosensitizer (Titanium Dioxide P-25, Degussa Corporation, Dublin Ohio 43017), is nanocrystalline and developed for use in photochemical degradation of organic contaminants in water. This second coating composition illustrates a water-based formulation in the simplest form.
Said coating compositions were according to the invention painted over the primed surfaces of fiber-glass reinforced plastic sheets and these surfaces placed alongside uncoated control surfaces in the Atlantic Ocean, on the shady side of a roof of a building in New England and in a shower stall whose walls and curtain regularly foul with mildew. In all cases, after one year of exposure, the surfaces coated with said coating compositions were free of biological growth or staining while the control panels were covered with biological growth and very unsightly.
These results were totally unexpected since known zinc-containing compositions have very limited activity for preventing algal growth and no known activity underwater for preventing the attachment of barnacles, tube worms or sea squirts. None of the ingredients of the invention are recognized in prior art as having broad spectrum biological activity in the dark. Thus, EXAMPLE 1 shows unexpected and hitherto unrecognized effectiveness of the compositions of this invention comprising more than about 20 wt % zinc oxide and less than about 5 wt % photosensitizer.
EXAMPLE 2
In order to attempt to elucidate the exact mechanism(s) for the remarkable and long-lived antifouling behavior of surfaces coated with this invention, a number of control experiments were performed.
Compositions containing less than 20 wt % zinc oxide pigment and about 35 wt % metallic zinc dust were suspended in a solvent-based vehicle containing a vinyl resin binder, painted onto fiberglass surfaces, allowed to air dry, and then immersed in the Atlantic Ocean during the summer months. After 30 days of immersion, these compositions were badly fouled. These tests confirm the popular view of experts that zinc oxide is insufficiently toxic by itself to inhibit marine fouling despite high levels of zinc ions produced by the corrosion of metallic zinc in the presence of saltwater. This suggests that the mechanism is not directly related to the known algicidal properties of zinc-containing compositions (e.g., U.S. Pat. No. 3,507,676 (McMahon) issued Apr. 21, 1970.). Since the compositions of EXAMPLE 1 contain neither small amounts of heavy metals (e.g., copper, tin or lead) nor broad spectrum organic toxicants, the toxicity of the coatings of the invention must come from other source(s).
One possible mechanism for the surprising behavior illustrated in EXAMPLE 1 is the formation on the coating surface of oxidizing species due to the presence of oxygen, photocatalysts and light. To explore this possibility, the following laboratory control experiments were performed.
Into a 50 mL beaker was charged 5 grams of wood rosin, 12 grams of xylene, 14 grams of methyl isobutyl ketone and 4 grams of vinyl resin (VROH grade, Union Carbide, Houston, Tex.). The mixture was stirred at ambient temperature until a coating vehicle was obtained. According to this invention, 10 grams of zinc oxide pigment (USP-1 grade, representing about 22 wt % of the composition) as well as 1 gram of zinc pyrithione powder (representing about 2 wt % of the photosensitizer) was then admixed into the coating vehicle and the mixture was thoroughly stirred until homogeneous. Said coating composition was then applied to two identical Plexiglas cylinders which were 2.5 inches in diameter by 6 inches long. In both cases, the coatings were applied to the cylinders in a band that covered 200 sq. cm. of surface. The coated cylinders were allowed to air dry for 48 hours before testing. Each cylinder was placed in a separate polycarbonate tank containing 1.5 L of synthetic seawater (ASTM D1141) at room temperature. One tank was continuously aerated by means of an electric air pump connected to a bubbler placed in the synthetic seawater, while the second tank was covered to seal it from the air atmosphere. In this way, one cylinder served as a nonaerated control.
Both transparent tank lids were illuminated with the same 100 Watt incandescent light bulb. Both illuminated coatings were kept under the synthetic seawater. Aliquots of the test solutions were periodically taken and tested for the presence of peroxides by titration with a standard potassium permanganate solution. Control tests were used to correct for the presence of dissolved materials in the synthetic seawater that could give false positive peroxide readings. Peroxide concentration measurements were performed after 48, 72 and 200 hours of immersion as shown below:
______________________________________ Unaerated test Aerated test Time (hours) H.sub.2 O.sub.2 (ppm) H.sub.2 O.sub.2 (ppm)______________________________________0 0.0 0.0 48 0.0 0.4 72 0.0 0.4 200 0.0 1.4______________________________________
These results indicate that the peroxide content of the aerated test solution continues to increase with time, where as the control without additions of dissolved oxygen generates no measurable peroxide over the same time period. The aerated and the unaerated tanks were then covered with aluminum foil to block out all light. No peroxide generation was observed when the coating was kept in the dark irrespective of the presence or absence of oxygen.
These tests demonstrate that the invention generates peroxides and that both light and oxygen are required. Hydrogen peroxide alone or when combined with ferrous salts has been shown (Katayama, Yasunaga, and Wakao; Marine Biology, 99, 145-150, 1988 and U.S. Pat. No. 4,440,611 (Dhar) issued Apr. 3, 1984) to be a very effective means for preventing attachment of aquatic organisms to surfaces. Therefore, it may be that the surprising and unexpected antifouling behavior of the invention is to some extent due to visible-light-induced generation of peroxide species.
EXAMPLE 3
Photosensitizers are typically much more expensive per pound than zinc oxide. Since the role of the photosensitizers may be catalytic rather than chemical, the possibility of producing toxic surfaces with very low levels of photosensitizers in combination with more than 20 wt % levels of zinc oxide was explored. In the same manner as described in EXAMPLE 2, the solvent-based coating vehicle was prepared and it was used to prepare compositions according to the invention containing 22 wt % ZnO and only 0.01 wt % hypericin. In order to insure uniform coating of the zinc oxide pigment, the hypericin was first dissolved in acetone and the zinc oxide washed with this acetone solution. After the acetone had evaporated, the hypericin-coated zinc oxide powder was admixed in the coating vehicle. Said composition were then applied to two pairs of Plexiglas test cylinders to determine the relative peroxide generating capabilities of the dried coatings in the presence and absence of light and air. One cylinder was used as the test cylinder, the second as a control. Peroxide generation was observed only when both light and air were present. The peroxide levels in both light and air depended on the exposure time to artificial light as illustrated in the table below. As controls, pigments which are known to catalyze the decomposition of hydrogen peroxide (1 wt % cobalt phthalocyanine or zinc phthalocyanine) were substituted for the hypericin. As an additional control, zinc oxide was left out of the hypericin composition.
______________________________________ Incubation Peroxide, Photoactive Pigment Time (hrs.) (ppm)______________________________________CoPc 96 0.0 ZnPc 100 0.0 Hypericin & ZnO 120 1.7 Hypericin w/o ZnO 120 0.0______________________________________
These results illustrate that the combination of zinc oxide and photosensitizer(s) produces peroxide levels lethal to bacteria even though the components under these conditions do not. Furthermore, only very small levels of hypericin are needed to produce high levels of peroxides in the presence of zinc oxide, light, water and oxygen. These four compositions were painted over four 6" by 24" sections of a common fiberglass test panel separated by a one inch unpainted border. After air drying at room temperature for two days, this test panel was immersed in the ocean in Jupiter, Florida vertically at a depth of three feet. After eight months of exposure, this test panel was completely fouled except for the 6" by 24" panel painted according to the invention with zinc oxide and hypericin. This section was completely free of marine fouling.
EXAMPLE 4
For optimum antifouling results, the level of zinc oxide in the coating composition should be maintained above a minimum level. In order to experimentally determine this level, a series of coating compositions were prepared in which the zinc oxide content plus inert filler was maintained at 42 wt %. The rest of said compositions was 1 wt % zinc pyrithione (the photosensitizer), 11 wt % gum rosin (WW Grade), 7 wt % vinyl resin (VYHH, Union Carbide Corp., Houston, Tex.), 11.5 wt % MIBK, 26 wt % xylene, and 1.5 wt % dioctyl phthlate. Three separate coatings were then prepared from this basic vehicle in which the zinc oxide and rutile titanium oxide pigment (Ti-Pure, DuPont Corporation, Wilmington, Del.) content were varied as shown in the following table.
______________________________________ Zinc Oxide Content Coating (wt %) Ti-Pure Content (wt %)______________________________________1 30 12 2 24 18 3 12 30______________________________________
Unlike the anatase form of titanium dioxide illustrated in EXAMPLE 1, the rutile form used in this example shows little photoactivity for visible light. To reduce the photoactivity still further, Ti-Pure is coated by the manufacturer with oxides such as alumina, zirconia and silica which help destroy the photocatalytic effect. Thus Ti-Pure acts like an inert filler for the purposes of these tests.
The resulting formulations were applied to individual 6 in by 24 in sections of a common fiberglass panel separated by a one inch uncoated strip and allowed to air dry at ambient temperature for two days. The dry coating thickness was approximately 0.5 millimeters. All of the coatings appeared to have an even beige color upon drying. Said coated panel was immersed in the ocean at New Bedford, Mass. from a stationary platform during the summer. These coatings were periodically inspected to determine the type and degree of marine biofouling. After two months of immersion, Coatings 1 and 2 were completely clean while Coating 3 had a thin layer of algae with 3 or 4 medium size barnacles firmly attached.
These results show that at a minimum the zinc oxide content of an effective coating should be more than about 20 wt %.
In addition to being used in paints, zinc oxide particles coated in accordance with the present invention can be used as an additive in household and commercial cleaners such that a film is left on the surface being cleaned after the surface dries that prevents bacterial or other unwanted organic growth. Thus, for example, into any commercially known powdered cleaner of the type normally used to clean kitchen counters, bath tubs and the like up to as much as about 20% by weight zinc coated particles may be included in the cleaner. Since the zinc oxide does not readily dissolve in water, it can leave a thin film on the cleaned surface after drying that prevents bacterial growth.
The coated particles can also be used in spray cleaners where the particles are present in the cleaner as a colloid which is then dispersed on the surface to be cleaned upon spraying.
While the above is illustrative of what is now contemplated to be the best mode of carrying out the present invention, the compositions for preventing or retarding biological fouling are subject to modification without departing from the spirit and scope of the invention. For example, the photosensitizer may be produced from many materials, for those skilled in the art may easily measure water insolubility, toxicity, light fastness, light absorbance as a function of wavelength, and increased peroxide generation in the presence of light, water, oxygen and zinc oxide. Therefore, the invention is not restricted to the particular photosensitizers illustrated and described, but covers all modifications which may fall within the scope of the following claims. It is the applicants'intention in the following claims to cover such modifications and variations as fall within the true spirit and scope of the invention.
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A non-toxic, antifouling coating composition is provided which comprises zinc oxide contacted with photosensitizer(s) which increase the capability of zinc oxide to absorb visible light.
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BACKGROUND OF THE INVENTION
The present invention relates generally to an apparatus for forming components from a continuous stock of wire, strip or tube.
Modern wire forming and spring making machines combine a wire feeding mechanism, multiple cam actuated forming tools to bend the wire in required different directions and a cutoff tool to sever the finished part from the wire stock. However, when a change is required or a new part is to be manufactured, it is a costly and time-consuming process to either adjust the operation of the tools or replace the tools for the current part with a new set of tools for the new part.
Historically, wire forming and spring making companies have pursued speed as the answer for much needed productivity improvements. But in many cases, speed alone may compound existing quality and inventory related issues. Complicated parts requiring secondary or multiple operations will accumulate at high speed during the primary operation, only to wait in staging areas to be completed with slower operations such as coining, trimming, looping, broaching, bending, chamfering, etc.
Naturally, optimum speed will always be a basic issue, but for many production parts this should not be the main focus. Since no component can be completed faster than its slowest operation, starting there and working backwards makes sense when establishing the best production process. Next, utilizing automation to tie these operations together reduces labor, inventory and the cost of quality. Redundant inspections will be eliminated.
SUMMARY OF THE INVENTION
The present invention concerns a modular forming apparatus for forming components from continuous stock supplied by a stock feeder. A tool bed mounted on a base has a plurality of horizontally extending tooling rails mounted on a vertical front surface for selectively and releasably attaching one or more of a plurality of tool pallets. A source of pressured fluid (hydraulic and/or pneumatic) is connected to actuators for the tools for performing forming operations on stock received from the stock feeder. The tool actuators mounted on the pallet are connected to the fluid source through valves operated by a control panel. The tool pallets are easily replaced for maintenance or changeover to a new component. The control panel generates a plurality of screens for programming, testing and automatically running programs consisting of forming steps to be performed.
In response to a growing demand for equipment which can automatically produce completed wire, strip or tube components, the present invention is a unique production machine that enables the user to eliminate costly secondary operations by capturing and transferring components during the production process.
Unlike conventional cam driven mechanical systems such as fourslides or other geared forming machines, the modular machine according to the present invention is not limited by cam rotation, tool bed space or slide position. A vertical machine bed allows automated in-line production that can include operations originally performed as secondaries.
Whereas mechanical cam actuated forming machines have fixed tool paths that place limits on tool positioning, the modular machine according to the present invention utilizes hydraulic or pneumatic cylinders for tool actuation, allowing almost infinite tool positioning options. The use of keyed tooling rails on a bed allows the mounting of slides and form-tools above, below, behind or in front of the wire line, at any required angle. Multi-plane forming is never a problem.
Another advantage of the hydraulic forming system according to the present invention is the ability to increase or decrease the forming power for each individual slide simply by selecting the required, hydraulic cylinder tonnage. Whereas typical slide machines have identical tonnage on every slide, the modular machine enables the technician to have additional power when needed.
Since cams are limited to their dwell (normally fast in/out tool movement) and 360° rotation, slide time on the tool is severely limited. In the case of many spring steel parts, the hydraulically actuated cylinder slide of the present invention can actually dwell (using time delays) on a specific point, creating a “setting” action for the tool. This is particularly useful for critical dimensions or compensating for material spring-back.
Also, the speed of entry or retraction can be set for each slide of the present invention simply by adjusting the individual flow controls for each valve. This feature is particularly important when the technician wishes to prevent a long material segment from whipping during the forming process. By slowing the cylinder action, the material will move smoothly into position, assuring the success of the following operation.
Designers no longer need to worry about completing a specific part within the normally required 360° of cam rotation. This constant limitation is eliminated through the use of cylinder actuated slides and tooling in the modular machine according to the present invention. Timing becomes less a factor of tool design and more of a total process issue.
Through the use of a touch screen interface or MMI (Man-Machine-Interface) for programming, designers can “fire” tools independently, in any sequence or in any combination, during any step of the setup process. Any machine input may be actuated on demand, simplifying and shortening the setup and tryout process. Repeated “hits” can be made with individual tools without cycling the machine through any other phase of the program. Once a step or operation is satisfactorily completed, the tool designer or technician can move on to the next operation. After all of the individual operations are completed, they can be tried in partial or total sequence until the final part is correct.
Ultimately, after the tooling is proven station by station, the transfers are installed to move the component from operation to operation, across the face of the machine. Successful transfer to, and completion of each additional operation, is achieved by never losing control of the part.
The modular machine according to the present invention also includes the ability to run two parts at the same time. By placing feed systems on both sides of the machine, the machine can produce two identical or different parts as needed. This feature is often used to increase capacity without adding another machine. The dual feed system also provides the opportunity to assemble the two components by transferring one to the other.
DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
FIG. 1 is a perspective view of a component forming apparatus in accordance with the present invention;
FIG. 2 is a front elevation view of the tool bed portion of the component forming apparatus shown in FIG. 1;
FIG. 3 is a rear elevation view of the tool bed and base portions of the component forming apparatus shown in FIG. 1;
FIG. 4 is a schematic view of the control system for the component forming apparatus shown in FIG. 1; and
FIGS. 5-11 are various screens generated on the display of the component forming apparatus shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIG. 1 a component forming apparatus 10 according to the present invention. The apparatus 10 includes a box-like ground-engaging base 11 supporting a box-like tool bed 12 . The base 11 has a plurality of leveling feet 13 for leveling the apparatus 10 upon installation. To the right of the tool bed 12 is positioned a horizontally extending stock feeder 14 that is attached at one end to the tool bed and is supported adjacent an opposite end by a downwardly extending leg 15 having a leveling foot 13 at the lower end thereof. The stock feeder 14 typically unwinds coiled metal stock (not shown) and straightens it before feeding the stock to tools mounted on the tool bed 12 as required to make the desired component. Depending upon the component to be formed, the stock can be wire, strip or tube in configuration.
A control panel 16 is suspended from a movable arm 17 extending from a top face of the tool bed 12 . As explained below, the control panel 16 permits an operator to set up the program of operations to be performed to form a selected component, test the program and control production. The component forming apparatus 10 is a user-friendly system that includes quick change-over from job to job, the option to use palletized modular tooling, easy to understand programming format, and part program storage retrieval capability, utilizing a state-of-the-art touch screen 18 built into the control panel.
As shown in FIGS. 1 and 2, four generally horizontally extending tooling rails 19 are mounted on an open front face of the tool bed 12 with opposite ends of the rails attached to a frame 20 of the tool bed. The rails 19 are approximately equally spaced in a vertical direction and slotted for mounting modular tool pallets in any of a plurality of selected positions. As explained below reference to FIG. 3, the rear surfaces of the rails 19 are accessible through a rear face of the tool bed 12 to permit free access for mounting tool pallets on both the front and rear surfaces of the rails.
As best shown in FIG. 2, a first tool pallet 21 is mounted on the rails 19 adjacent a right side of the tool bed 12 to receive stock from the stock feeder (not shown) located to the right thereof and perform at least one forming operation. A second tool pallet 22 is mounted on the rails 19 to the left of the first tool pallet 21 to perform at least another forming operation on the stock. A component guide pallet 23 is mounted on the rails 19 below the tool pallets 21 and 22 to direct completed components to a collection box (not shown) or the like. Passing between the rails 19 are a number of hydraulic lines 24 and pneumatic lines 25 to supply pressured fluid to operate various tool actuators mounted on the pallets 21 and 22 .
FIG. 3 is a rear view of the component forming apparatus 10 with a pair of doors 26 open to expose the rear surfaces of the lower rails 19 and a plurality of solenoid controlled hydraulic valves 27 mounted in the base 11 . The valves 27 can be double valves to each control one double-acting hydraulic operation or two single-acting hydraulic operations. The valves 27 are connected between the hydraulic lines 24 and a source of hydraulic fluid (not shown). In addition, as shown in FIG. 2, a plurality of pneumatic valves 28 are mounted on the inside surface of a left side face of the tool bed 12 . The valves 28 can be double valves to each control one double-acting pneumatic operation or two single-acting pneumatic operations. The valves 28 are connected between the pneumatic lines 25 and a source of compressed air (not shown).
As an example of the hydraulic and pneumatic circuits for controlling the tools, a hydraulic actuator 29 is shown in FIG. 2 mounted on the first tool pallet 21 . The actuator 29 is connected to a pair of the hydraulic lines 24 and is mechanically coupled to a component forming tool 30 also mounted on the tool pallet 21 . Similarly, a pneumatic actuator 31 is mounted on the first tool pallet 21 . The actuator 31 is connected to a pair of the pneumatic lines 25 and is mechanically coupled to another component forming tool 32 also mounted on the tool pallet 21 .
A control system for the component forming apparatus 10 is shown in FIG. 4. A source of pressured hydraulic fluid 33 is connected to each of the hydraulic valves 27 . Each of the hydraulic valves 27 is connected to an associated one of the hydraulic actuators 29 through one or two of the hydraulic lines 24 . Each of the hydraulic actuators 29 is coupled to an associated component forming tool like the tool 30 . In a similar manner, a source of pressured pneumatic fluid 34 is connected to each of the pneumatic valves 28 . Each of the pneumatic valves 28 is connected to an associated one of the pneumatic actuators 31 through one or two of the pneumatic lines 25 . Each of the pneumatic actuators 31 is coupled to an associated component forming tool like the tool 32 .
The control panel 16 includes a CPU 35 that has outputs connected to the display 18 , the hydraulic valves 27 and the pneumatic valves 28 . The CPU 35 runs a stored program that controls the automatic operation of the valves 27 and 28 to form desired components. A human operator can use an input device 36 connected to an input of the CPU 35 to change a stored program, store a new program and manually operate each of the valves 27 and 28 during a setup or troubleshooting mode of operation. The input device 36 can be in the form of soft keys generated on the display 18 or a keyboard/key pad. The control panel 16 can be a Model SLC 5/03 control processor ( 35 ) and PowerView 1000 touch screen ( 18 ) both manufactured by Allen Bradley.
Component part programming screens generated on the display 18 present the operator with an easy to understand spreadsheet format with each line representing one step in the forming process. The operator can select which outputs will be turned on and which outputs will be turned off during each step. Time delays between these steps are also user selectable, from 0.01 seconds to 99.99 seconds. “Position Sensing” is a built in, selectable feature that can be toggled “On ” for any output. This feature allows the operator to set which outputs need sensor confirmation of position. The system will wait for the appropriate sensor input, before proceeding to the next step. If the system doesn't receive the input, it will flash an alarm screen, indicating which output sensor to check. Set-up of tooling is made easier with a “Force Mode”, allowing the user to “Force” on or off any output or group of outputs to check tooling position.
When the component forming apparatus 10 is powered on, an “Initial” screen 37 is generated on the display 18 as shown in FIG. 5 . The “Initial” screen provides to the operator navigation links to: a “Config” screen via a touch button 38 ; an “AutoCycle/Step” screen via a touch button 39 ; a “Navigate” screen via a touch button 40 ; and a “Fabrication” screen via a touch button 41 . The “Config.” screen is simply a setup screen for the control panel 16 . The “AutoCycle/Step” screen is the main operating screen for the apparatus 10 . The “Navigate” screen is the navigation hub for all program/operator screens. The “Fabrication” screen is the first of twenty-four part programming screens.
When the touch button 40 on the “Initial” screen 37 is touched by the operator, the display changes to a “Navigate” screen 42 as shown in FIG. 6 . The “Navigate” screen allows quick access to all screens by providing a menu of available screens 43 , an “Up” touch button 44 and a “Down” touch button 45 for moving in the menu and an “Enter” touch button 46 for selecting the highlighted screen identification. Also, included on this screen 42 are a “Pump Start” touch button 47 and a “Pump Stop” touch button 48 . The “Pump Start” button 47 reads “Pump Start”(not shown) when the pump is not running, and changes to “Running”(shown) after it is pushed, and the hydraulic pump motor begins running. The “Pump Stop” button 48 reads “Pump Stopped”(not shown) with flashing text when the pump motor is not running. By pressing the “Up” or “Down” buttons to highlight the screen that you wish to navigate to and pressing “Enter”, the screen display will change to the requested one.
When the touch button 40 on the “Initial” screen 37 (FIG. 5 ), or the “AutoCycle” designation on the menu 43 (FIG. 6 ), is touched by the operator, the display changes to an “AutoCycle” screen 49 as shown in FIG. 7 . This is an operations control screen including a “Pump Start” touch button 50 that will start the hydraulic power unit if there is not an existing fault. A “Pump Stop” touch button 51 will stop the hydraulic power unit. An “AutoCycle Start” touch button 52 will begin execution of the automatic component forming program. The first line of programmed outputs 1 - 4 on the menu 43 will become active and the system will examine for input signals for those outputs that have a “Position Sensing” feature toggled on. A programmed time delay between the steps will time-out, and if the correct inputs are seen, then the next line of programmed outputs will become active. Pressing an “AutoCycle Stop” touch button 53 will cause the “AutoCycle” operation to stop after the completion of the currently running component.
An “—Alarm Clear—Proceed” touch button 54 is also provided. During “AutoCycle” or “Step” operation, if there is “Position Sensing” toggled on for any output and the correct input signal is not received by the CPU 35 , the system will not resume operation until the button 54 is pressed. This allows the operator the opportunity to investigate the cause of the incorrect input signal so that it may be corrected.
Pressing an “Immediate Stop” touch button 55 will stop the program execution immediately. However, this is not an E-Stop (emergency stop); the program is still active, and the outputs are energized. This feature allows the operator to stop program execution, and resume the program execution from the point of interruption, without having to reset the component forming apparatus, and without losing control of the forming process. This control is a maintained switch in that the operator pushes the button to activate the stop, and pushes it again to de-activate the stop. The program execution can then be resumed by selecting “AutoCycle Start” button 52 , or can be stepped through by selecting a “Step Mode” touch button 56 and pushing a “Step Advance” touch button 57 to step through the programmed sequence.
A “Reset Program to Beginning” touch button 58 will reset the program sequence to the beginning step. During the initial loading of material, the component forming program can be used in the step mode to initially feed the material and cut-off to set the home, or zero position. Then the “Reset Program to Beginning” button 58 can be pressed to cause the program to return to the starting point. The program step executed after resetting will always be the first step in the program. A display window 59 directly below the button 58 indicates the current step in the program. After resetting, this field will show “Initial”, indicating the “initialization” of the programmed sequence.
Pressing a “Count Preset” touch button 60 will cause a numeric entry keypad to appear so that the operator can enter the number of parts that he wishes to run, in any number combination, up to “65,535”, and press an “Enter” symbol in the keypad. The numeric entry keypad will then disappear and the number entered will appear in the button area. This number of components can then be produced in the “AutoCycle” mode of operation, and when the total count of components produced equals the “Count Preset” number, the “AutoCycle” operation will stop. A “Total Count” display window 61 is provided to show the total of components produced since the counter was last reset. A “Press Here to Reset the Count” touch button 62 is provided to change the screen to a “Counter Clear” screen (not shown) where the operator is given the choice to “Clear” the counter, and/or return to the previous screen.
Pressing an “Interior Lights” touch button 63 will turn on a light located within the frame of the component forming apparatus. The button indicates the condition of the interior lamp with a white color when the lamp is on, and a black color when the lamp is off.
Pressing a “Navigate” touch button 64 will change the display to the “Navigate” screen 42 shown in FIG. 6 . All other screens can be quickly accessed from the “Navigate” screen.
The “Step Mode” touch button 56 will initiate the “Step Mode” of operation. Once pressed, the button 56 will begin to flash, indicating that the “Step Mode” is active. The program can then be “stepped” through one sequence step at a time by pressing the “Step Advance ” touch button 57 . Each pressing of the “Step Advance” button 57 will advance the program forward one step at a time if the system is in the “Step Mode”. If the system is not in the “Step Mode”, pressing this button will do nothing.
There is shown in the FIG. 8 a “Fabrication” screen 65 for the outputs 1 - 4 . The screen 65 can be accessed through the “Fabrication” button 41 on the “Initial” screen 37 (FIG. 5) or through the menu 43 on the “Navigate” screen 42 (FIG. 6 ). These screens are the heart of the ease and versatility of the control system according to the present invention. All of the “Fabrication” screens are similar with only the output labels and step labels changing as the operator “pages” through the programming blocks. Pressing a “Go Back” touch button 66 will change back to the last screen viewed. Pressing a “Set Delays” touch button 67 will take the operator to a “Time Delay” screen (not shown), where the delay time between sequence steps can be set.
Pressing a “Load/Save” touch button 68 will take the operator to a “Program Load/Save” screen (not shown), where the current program can be saved, and/or another previously saved program can be loaded into the operations screens. Pressing an “Enter Number of Steps” touch button 69 will open a numeric entry keypad. The operator can enter the total number of steps in the component forming program (up to twenty steps) he wants to run and press an “Enter” key. The program will execute the number of steps entered here, even if the number entered is greater than the number of steps with programmed outputs. Pressing a “Navigate” touch button 70 will change screens to the “Navigate” screen 42 of FIG. 6 . All other screens can be quickly accessed from the “Navigate” screen. Pressing an “Enter All” touch button 71 will enter the programmed switch “states” into a sequencer to be available for the forming operation. A new or edited program can be entered by pressing this button 71 . Any edits to an operating program must be “Entered” to be effective.
A “Continued” touch button 72 on each “Fabrication” programming screen allows the programming of four double-acting outputs. This control allows the operator to page through these blocks of outputs, so that outputs “1” through “24” can be programmed to extend or retract. A “Step Navigation Multi-Screen Selector” area 73 is provided in the center of each “Fabrication” programming screen for programming five sequence steps. Thus, the control allows the operator to select any set of five program steps, from “1-5” through “16-20”. When a screen change is made to another set, the edits made in the previous screen are automatically “Entered” in the sequencer to be available for the forming operation. This feature enables the operator to continue through the screens without having to worry about forgetting to press enter on every screen. On the last screen edited the “Enter All” button 71 control should be pressed.
The operation of the component forming apparatus 10 will now be described. To create a new program for forming a component, the operator must determine the sequence of events that must take place. Every action needed to create the new component must be programmed—every extend action, every retract action, every time delay. All tools will remain at the last position in which they were placed until they are command to move. The program sequence is entered in the “Fabrication” screens beginning with the “Fabrication” screen 65 that has Steps 1-5, Outputs 1-4. The operator presses the “Enter Number of Steps” button 69 control and enters the number of the last step on the numeric keypad which pops up. Pressing the “Enter” symbol enters the number and returns to the main screen 65 . The operator then presses the cell that corresponds to the output action wanted, in the step in which it is to occur, and the cell will toggle from “OFF” to “ON”. Obviously the output cannot be turned “ON” and “OFF” at the same time (during the same step), therefore pressing the “extend” of an output will turn off the “retract” of the output if it is already “On” in the same step, and conversely, pressing the “retract” will turn off the “extend”. At any point in the program, the operator can select an action to be monitored by the system, by pressing the position sensing cell directly beneath the programmed output to be monitored. Each “page” or screen of outputs is completed and the “Enter All” button 71 is pressed when all the sequence steps have been entered.
Position sensing is available for any or all actuators (outputs). When selected or “On”, the system will look for an “Input Signal” to confirm that the output function has been completed, (i.e. cylinder extended). This signal could come from a proximity sensor, a photoelectric eye, or a limit switch depending upon the application. A sensor 74 is shown in the FIG. 4 for determining a position (retracted or extended) of the hydraulic actuator 29 . An output of the sensor 74 is connected to an input of the CPU 35 to generate the associated “Input Signal”.
When the program sequence is completely transferred to the touch screen, the “Set Delays” button 67 is pressed and the system will automatically default to two seconds. The delay times are the time that the system has to complete a programmed step before the next step is activated. The display transfers to a “Delay” screen 75 shown in FIG. 9 . The default delay times can be changed in small increments and tested to minimize delays. The delays between the steps are selectable, from 0.01 seconds to 99.99 seconds utilizing “Delay” touch buttons 76 associated with each Step 1 - 20 . Pressing one of the buttons 76 brings up a numeric entry keypad. The delay times can be changed during operation in “AutoCycle” mode, but caution should be used, or excessively short delays could cause tooling crashes.
A “Force” screen 77 is shown in FIG. 10 and can be accessed from the “Navigate” screen 42 by selecting “Force Control” on the menu 43 shown in FIG. 6 . From the “Force” screen 77 the operator can select and force any or all outputs on or off. This is useful in setup and adjustment of tooling, checking tool-path clearance, and verifying correct operation. To force an output, the operator simply locates the associated valve and selects the action desired to occur by pressing the screen on an “Extend” touch button 78 or a “Retract” touch button 79 . The pressed button will “toggle” or change state. To de-select an output, the operator presses and holds the opposite action just until they are both on. For example, if “Extend” is selected (“On”) the operator presses the “Retract” button until both buttons indicate “On”, and releases. Since the same valve cannot “Extend” and “Retract” at the same time, both actions will go to the “Off” state. Now the operator must press an “Activate Force Mode” touch button 80 to enable the force mode operation. To cause the selected output action to occur, the operator presses an “Initiate Force/Step” touch button 81 and the selected output action will immediately occur.
A “Load/Save” screen 82 is shown in FIG. 11 and can be reached by touching the “Load Save” button 68 on any of the “Fabrication” screens 65 (FIG. 8 ), or by using the menu 43 on the “Navigate” screen 42 (FIG. 6 ). Here the operator can save the finished program into any one of ten available file folders listed in a menu 83 . To delete a program stored in a folder, the operator must save an empty program over the data in the folder. A new operating program is saved by selecting an empty folder indicated in the menu 83 utilizing an “Up” touch button 84 or a “Down” touch button 85 to highlight a folder, pressing an “Enter” symbol touch button 86 to select the folder, and pressing a “Save Program” touch button 87 .
The operator also can reload any of the already saved programs into the operating system. The operator selects the desired saved program on the menu in the manner described above. Instead of pressing the “Save Program” button 87 , the operator presses a “Load Program touch button 88 .
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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An apparatus for forming components from continuous stock includes a stock feeder, a tool bed, a source of pressured fluid and a control panel. The tool bed has a plurality of horizontally extending tooling rails mounted on a vertical front surface for selectively and releasably attaching one or more of a plurality of tool pallets. Each tool pallet has one or more tools for performing forming operations on stock received from the stock feeder. Tool actuators mounted on the pallet are connected to the fluid source through valves operated by the control panel. The tool pallets are easily replaced for maintenance or changeover to a new component. The control panel generates a plurality of screens for programming, testing and automatically running programs consisting of forming steps to be performed.
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FIELD OF THE INVENTION
This invention relates to new gels in the form of highly hydrated self-supporting film, the process for their preparation and their use in the therapy of cutaneous lesions and/or pathologies.
PRIOR ART
Hydrogels consisting of synthetic or semisynthetic polymers or synthetic polymers with small additions of natural polymers and having the characteristic of being only slightly or not reabsorbable are already known for the treatment of cutaneous lesions.
Xerogels, i.e. anhydrous gels consisting of fibres of calcium alginate presented in the form of bioreabsorbable unwoven tissue, are also known.
Protective film of various types used for treating cutaneous lesions are also known.
For example, DE patent 30 17 221 describes an ointment containing a soluble alkaline metal alginate salt which when applied to the lesion and treated in situ with a soluble calcium salt forms a protective film of Ca alginate; to obtain this film the ointment must be reconstituted at the moment of use.
WO patent 80/02300 describes the process for preparing an unwoven tissue based on calcium alginate fibres.
U.S. Pat. No. 4,393,048 describes a gel containing an alkaline metal alginate and glycerol for wound medication which on drying forms a protective adhering film, and U.S. Pat. No. 4,391,799 describes the same gel in association with silver salts for treating white phosphorus burns.
European patent application EPA 83301149.7 describes wound medications in the form of hydrogel membranes composed of hydrophilic biopolymers derived from keratin, glycosaminoglycan or collagen.
U.S. Pat. No. 4,664,105 describes a wound medication composed of granulated cellulose material or a polysaccharide.
Gels in the form of highly hydrated self-supporting alginate-based film have never been described.
An object of the present invention is to provide a wound medication in the form of a thin self-supporting film which maintains a high degree of hydration for a prolonged time, this being of known and considerable importance for the repair to take place in a short time and within the dictates of the process physiology, to result in cicatrices with optimum characteristics both from the physiological and from the aesthetic aspect.
A further object of the present invention is to provide a wound medication in the form of a bioreabsorbable film, this characteristic allowing the medication to be replaced at a much lesser rate, thus avoiding further irritation to the lesion and facilitating the reparative process.
A further object of the invention is to provide a wound medication in the form of a film with good mechanical characteristics which is soft, pliable, easily handled and properly adaptable to the lesion, but which is only slightly adhesive and can therefore be easily removed without damaging the newly formed tissues, and further which is non-toxic, sterilizable in an autoclave and by gamma rays, compatible with a large number of drugs, therefore allowing their incorporation, does not need to be reconstituted at the moment of use, can absorb exudates, is permeable to gases but not to liquids or bacteria, and which is transparent to enable the development of the reparative process to be followed.
A further object of the invention is to provide a medication which is economically valid in that it reduces the number of medications required.
SUMMARY OF THE INVENTION
These and further objects are attained by the composition according to the present invention, which relates to new gels characterised by being in the form of highly hydrated self-supporting film comprising one or more alkaline alginates, an alkaline earth alginate, a polyalcohol and a natural, synthetic or semisynthetic polymer of hydrophilic character. In one embodiment of the invention a medicament is dispersed within the gel. These gels in highly hydrated self-supporting film form are prepared by a new process which together with the use of the new film in the therapy of human lesions and/or pathologies also form part of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates preparation of the alginate film by extrusion and coagulation.
DETAILED DESCRIPTION
The gel in highly hydrated self-supporting film form according to the present invention contains a quantity of between 1% and 7.5%, and preferably 3.5%, (all percentages being by weight) of one or more alkaline alginates, preferably sodium alginate; a quantity of between 0.1% and 5%, and preferably 1%, of an alkaline earth alginate, preferably calcium alginate; a quantity of between 0.1% and 10%, and preferably 5%, of a polyalcohol, preferably glycerol; and a quantity of between 0.05% and 10%, and preferably 0.5%, of a natural, synthetic or semisynthetic polymer of hydrophilic character, preferably sodium hyaluronate, plus optionally between about 0.01% and 10% of one or more medicaments, the remainder being water. Other alkaline alginates which can be advantageously used are for example potassium and ammonium alginates.
The described film is obtained with the required characteristics according to the invention by starting from an initial fluid gel containing a quantity of between 3.5% and 7.5%, and preferably 3.5%, of one or more alkaline alginates, preferably sodium alginate, a quantity of between 0.5% and 7.5%, and preferably 5%, of a polyalcohol, preferably glycerol, a quantity of between 0.1% and 10%, and preferably 0.2%, of a natural, synthetic or semisynthetic polymer of hydrophilic character, preferably sodium hyaluronate, plus optionally a medicament.
The initial fluid gel is extruded by pumping through a slit of adjustable width and thickness, and coagulated by passage through between 2 and 4 successive baths, preferably 2, at controlled temperature, the baths containing one or more soluble calcium salts.
The concentration of Ca 2+ ions in the various coagulation baths is between 0.1 and 10% and preferably 1% in the first coagulation bath, and 2% in the subsequent baths.
The coagulation bath temperature is between 15° C. and 40° C. and preferably 20° C. for the first, and 30° C. for the subsequent baths.
After passage through the last coagulation bath a highly hydrated gel is obtained in the form of a self-supporting thin film having a thickness variable between 0.1 and 5 mm, preferably 0.4 mm, with a pH of between 5.5 and 7.5, preferably between 6.5 and 7.2. The final film characteristics, such as its mechanical and hydration characteristics, can be varied according to requirements by varying the initial gel composition and the coagulation bath conditions.
In a preferred embodiment of the process according to the invention, the alginate film is prepared by extrusion and coagulation using the device shown in FIG. 1.
The initial fluid gel is placed in a container vessel 1 from which it is drawn by a pump 2 operating at a suitable r.p.m., then passed through a filter 3 and fed to the filming extruder 4 comprising a slit of suitable variable size immersed in the first coagulation bath.
Coagulation occurs immediately on leaving the filming extruder, the recovered film being passed below a guide drum 5 immersed in the first coagulation bath. The film then leaves the bath, passes through a dragging roller 6 driven by a motor 7, enters a second coagulation bath through which it is guided by a second drum 8, leaves the bath guided by a third drum 9 and is wound onto a winding reel 12 by a calender 10 driven by a motor 11.
The size-setting of the extruder, the pump r.p.m., the dragging roller speed and the winding roller speed can be varied to define the final characteristics of the film.
For example a film according to the present invention with a thickness of 300μ is obtained by using the device of FIG. 1 under the following operating conditions:
pump r.p.m.: 15 r.p.m. equivalent to a throughput of 18 cc/min
size setting of filming extruder: 200μ
dragging roller r.p.m.: 2.15 r.p.m.
temperature 1st bath (CaCl 2 1% w/v): 20° C.
temperature 2nd bath (CaCl 2 2% w/v): 27° C.
extruded film length produced per minute: 0.4 m.
Any active principle compatible with the gel composition, such as substances of antiseptic, antibiotic, anti-inflammatory, antihistaminic or other activity, can be incorporated into the gel either alone or in association. The concentration of the active principle incorporated into the gel depends on its pharmacological characteristics, and would represent a quantity such as to make it effective for the purpose of the specific application. The medicament quantity in the compositions of the invention can vary from about 0.01% to 10% of the weight of the final product.
The film obtained in this manner can be easily stored, handled and used advantageously as covering or medication material for cutaneous lesions and/or pathologies such as the treatment of wounds of surgical or traumatic origin, burns or lesions of pathological origin such as stasis ulcers, bedsores and the like.
Some non-limiting examples of the preparation of self-supporting film according to the invention are described below.
EXAMPLE 1
24.5 g of sodium alginate are dispersed at ambient temperature in 50 ml of water under continuous stirring. A viscous gel forms, to which are added 1.4 g of sodium hyaluronate Hyalastine fraction (European patent EP 0138572 granted on 25 Jul. 1990), 35 g of glycerol and 7 g of NaCl dissolved in 250 ml of water under stirring, the final solution volume then being adjusted to 700 ml. Slow stirring, to avoid incorporating air, is then continued for about 20 hours, after which the viscous solution is filtered through a 20μ mesh filter and degassed under vacuum.
The solution is extruded by pumping through a slit of width 12 cm and of set thickness, and is coagulated by passing through two successive baths containing calcium chloride, the first at 20° C. with a concentration of 1% and the next at 30° C. with a concentration of 2%. The film obtained, having a thickness of about 0.250 mm, is wound on a suitable spool, washed by immersion in a water bath for 1 hour and finally stored in an aqueous solution containing 5% glycerol, 0.2% methylparaben, 0.02% propylparaben and 0.2% sodium dehydroacetate.
EXAMPLE 2
Following the procedure described in Example 1, 1.4 g of sodium hyaluronate Hyalectine fraction (European patent EP 0138572 granted on 25 Jul. 1990) are added in place of the Hyalastine fraction, to obtain a film having analogous characteristics to those of the film obtained in Example 1.
EXAMPLE 3
50 ml of an aqueous solution containing 0.4 g of hyaluronic acid ethyl ester of 75% esterification (HYAFF 7 p75 European patent application EPA 216453 of 7 Jul. 1986) are added to 150 ml of an aqueous solution containing 7 g of sodium alginate, 10 g of glycerol and 2 g of NaCl. After filtration and degassing, the final solution is extruded and coagulated by the procedure described in Example 1 to obtain 150 g of film with a thickness of 0.250 mm. The film is stored in the solution of glycerol and preservatives described in Example 1.
EXAMPLE 4
50 ml of an aqueous solution containing 5 g of polyethyleneglycol 1500 are added to 150 ml of an aqueous solution containing 7 g of sodium alginate, 10 g of glycerol and 2 g of NaCl. After filtration and degassing, the final solution is extruded and coagulated by the procedure described in Example 1 to obtain 150 g of film with a thickness of 0.250 mm. The film is stored in the solution of glycerol and preservatives described in Example 1.
EXAMPLE 5
50 ml of an aqueous solution containing 2.5 g of p-(aminomethyl) benzenesulphonamide acetate are added to 150 ml of an aqueous solution containing 7 g of sodium alginate, 10 g of glycerol and 2 g of NaCl. After filtration and degassing, the final solution is extruded and coagulated by the procedure described in Example 1 to obtain 150 g of film with a thickness of 0.250 mm. The film is stored in the solution of glycerol and preservatives described in Example 1.
EXAMPLE 6
50 ml of an aqueous solution containing 0.1 g of the neomycin salt of hyaluronic acid partly esterified with ethanol (75% of the carboxyl groups esterified with ethanol, 25% of the carboxyl groups esterified with neomycin in accordance with Example 29 of European patent application EPA 216453 filed on 7 Jul. 1986) and 0.3 g of the 75% esterified partial ethyl ester of hyaluronic acid ape added to 150 ml of an aqueous solution containing 7 g of sodium alginate, 10 g of glycerol and 2 g of NaCl. After filtration and degassing, the final solution is extruded and coagulated by the procedure described in Example 1 to obtain 150 g of film with a thickness of 0.250 mm. The film is stored in the solution of glycerol and preservatives described in Example 1. The final neomycin content of the film is 0.00305 g/100 g.
EXAMPLE 7
50 ml of an aqueous dispersion of 10 g of microbeads obtained from mixed ethyl and hydrocortisone ester of hyaluronic acid (Example 15 of European patent application EPA 216453 of 7 Jul. 1986) are added to 150 ml of an aqueous solution containing 7 g of sodium alginate, 10 g of glycerol and 2 g of NaCl. The final dispersion is extruded and coagulated by the procedure described in Example 1 to obtain 150 g of film with a thickness of 0.250 mm. The film is stored in the solution of glycerol and preservatives described in Example 1.
To demonstrate the advantages and activity of the highly hydrated self-supporting film according to the present invention a trial was conducted using 45 male Sprague-Dawley rats of weight 225-250 g. The Pats were divided into three groups and were given a heat lesion by a suitable instrument containing a metal prod of known area able to maintain a constant temperature. By applying this instrument to the back of the animal in a region close to the caudal reproducible heat lesions were obtained classifiable as third degree burns.
The treatment scheme involved a group of untreated animals, a group of animals treated conventionally with VASELINE® gauze and a third group treated with a film of hydrated gel as described in Example 1 of the present patent. The medications were changed every 3 days, 5 animals of each group being sacrificed 9, 15 and 25 days after the lesion. After a planimetric evaluation of the lesion area and eschar area, biopsies were taken for histological examination. The results of these tests are given in Table 1.
TABLE 1__________________________________________________________________________ day 9 day 15 day 25 NT GG G NT GG G NT GG G__________________________________________________________________________Persistence of eschar + + + + + ± + ± -Reduction in lesion area - - ± - - + - ± ++Neoangiogenesis - - + - - ++ - - +++__________________________________________________________________________ NT = not treated; GG = VASELINE ® gauze; G = gel film - = not apparent; ± = hardly apparent; + = apparent; ++ = very apparent; +++ = extremely apparent
The results summarized in the table show that burns treated with the composition described in Example 1 of the present patent have a positive effect on early eschar fall, reduction in lesion area and neovascularization.
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This invention provides new gels in the form of highly hydrated self-supporting film, comprising one or more alkaline alginates, an alkaline earth alginate, a polyalcohol and a natural, synthetic or semisynthetic polymer of hydrophilic nature, and their preparation process. These polysaccharide-matrix gels in highly hydrated self-supporting film form are suitable for use as covering and protection materials for cutaneous lesions and/or pathologies in that they are obtainable in self-supporting form in the desired thickness, are transparent, flexible, have good mechanical characteristics, are adaptable to the lesion surface without strongly adhering to it, and are permeable to gas but are impermeable to liquids and bacteria; one or more pharmacologically active substances can also be incorporated in the gel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. § 119 of Korean Patent Application No. 10-2008-0122415, filed on Dec. 4, 2008, the contents of which in their entirety are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This disclosure relates to a receptacle (container, vessel, jar, cup, and the like, hereinafter, referred to as “airtight container”) to which a lid is fastened in a lockable type and a mold for press-forming the airtight container.
[0004] 2. Description of the Related Art
[0005] FIG. 1 is a sectional view illustrating an existing airtight container 14 having a container body 10 and a screw lid 12 which is fastened to the body 10 .
[0006] As illustrated in FIG. 1 , in general, on the container body 10 to which the screw lid 12 is fastened, a spiral line 18 is formed along the outer circumference of an opening portion 16 of the container body 10 . In addition, a spiral line 20 which is engaged with the spiral line 18 is formed along the inner peripheral surface of the lid 12 . The lid 12 and the container body 10 employ an opening and closing structure in which the lid 12 and the container body 10 are fastened to or released from each other as the spiral lines 18 and 20 are engaged or disengaged.
[0007] However, in the screw opening and closing structure, in order for the lid 12 to be fastened to or removed from the container body 10 , the lid 12 has to be rotated continuously. To do so, a lot of finger movement and manual effort are needed for a user. Therefore, it is annoying and takes time to open and close.
[0008] In addition, when the lid 12 is screwed tight on the container body 12 to prevent leakage, it is not easy to rotate the lid 12 to open it, and there is a problem in that it is difficult to open the container body 10 .
[0009] When the user exerts too much force in order to open the screw lid 12 that is screwed tight, pain and damage may be may be applied to the wrist of the user, and the pain makes the user feel inconvenient. Thus, for the users with weak muscle or grasping power, for example, women, the weak and the aged, it is very difficult to open the screw lid 12 .
BRIEF SUMMARY OF THE INVENTION
[0010] The disclosure provides an airtight container having a container body of which an opening portion can be easily opened and closed with a small force while maintaining convenience and promptness of the airtight container having a type in which a lid is screwed on the container body, in order to solve problems of the screw-type opening and closing structure.
[0011] The disclosure also provides a mold for press-forming the airtight container.
[0012] In one aspect, there is provided an airtight container including: a container body having an opening portion and a flange formed along an outer circumference of the opening portion; and a lockable lid that is disposed to cover the opening portion of the container body and that has a locking wing at an edge, wherein the locking wing further comprises upper and lower supporting protrusions disposed on an inner surface of the locking wing at an interval that permits engagement of the flange is engaged between the upper and lower supporting protrusions.
[0013] A convex protrusion may be formed at an end portion of the upper supporting protrusion to engage an upper surface of the upper supporting protrusion, and the convex protrusion may comprise a surface that is curved toward the lower supporting protrusion.
[0014] In addition, an outer surface of the convex protrusion may be formed as a curved surface, and a concave groove having an arc-shape may be formed at an upper surface of the flange to be in contact with and to be engaged with the curved outer surface of the convex protrusion.
[0015] In another aspect, there is provided a mold for press-forming an airtight container including: a first mold that is formed vertically to press-form a flange having upper area and an opening portion; a second mold that is disposed outside the first mold to press-form a lower area of the flange; and a third mold that is disposed under the second mold to press-form a container body lower area below the flange, wherein the first mold further comprises a convex protrusion protruding downward at a press-formed portion of the first mold corresponding to a spot where the flange opening portion and a root of the flange meet each other and wherein the flange upper area further comprises a groove press-formed by the convex protrusion during the press-forming.
[0016] Accordingly, in the airtight container, closing the container body tight by fastening the lid or opening the container body becomes easy while maintaining convenience and promptness of the airtight container of which the lid is screwed on the container body to open and close. In addition, there is an advantage in that a smaller force is required to open and close the lid.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0017] 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:
[0018] FIG. 1 is a sectional view illustrating an existing airtight container having a container body and a screw lid which is fastened to the body;
[0019] FIG. 2 is a perspective view illustrating an airtight container according to an embodiment;
[0020] FIG. 3 is a partial sectional view taken along line I-I of FIG. 2 , which illustrates a lockable lid in a locking procedure;
[0021] FIG. 4 is a sectional view illustrating a mold according to an embodiment for press-forming the container body; and
[0022] FIG. 5 is an enlarged view illustrating a portion of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0023] Hereinafter, an airtight container and a mold for press-forming the airtight container according to embodiments now will be described more fully with reference to the attached drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth therein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of this disclosure to those skilled in the art. In the description, details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the presented embodiments.
[0024] FIG. 2 is a perspective view illustrating the airtight container 30 according to the embodiment. FIG. 3 is a partial sectional view taken along line I-I of FIG. 2 , which illustrates a lockable lid 32 in a locking procedure.
[0025] As illustrated in FIGS. 2 and 3 , the airtight container 30 of the embodiment includes a container body 34 and the lockable lid 32 which covers the upper surface of an opening portion 16 of the container body 34 .
[0026] A flange 36 is formed along the outer circumference of the opening portion 16 so that the container body 34 is locked with the lockable lid 32 . The lockable lid 32 includes locking wings 38 rotatably extending from the edge, and upper and lower supporting protrusions 40 and 42 which are fixed to the inner surface of the end portion of each locking wing 38 to be disposed at an interval D in the width direction.
[0027] According to the embodiment, on the upper surface of the flange 36 , an arc-shaped concave groove 44 is formed. In addition, an arc-shaped convex protrusion 46 is formed at the end of the upper supporting protrusion 40 which is to be engaged with the concave groove 44 . The convex protrusion 46 is curved and inclined with respect to a direction toward the lower supporting protrusion 42 .
[0028] In FIG. 3 , a reference numeral 48 denotes a sealing packing.
[0029] According to the embodiment, as described above, the inner surface of the concave groove 44 and the outer surface of the convex protrusion 46 are “arc-shaped” curved surfaces, but not limited thereto. The inner and outer surfaces of the concave groove 44 and the convex protrusion 46 , respectively, may be formed to have any shape to be smooth curved surfaces such that the concave groove 44 accommodates the convex protrusion 46 and the convex protrusion 46 can be smoothly released from the concave groove 44 .
[0030] In addition, as described above, the convex protrusion 46 is curved in the direction toward the lower supporting protrusion 42 , but not limited thereto. As long as the convex protrusion 46 presses the upper surface of the flange 36 , the convex protrusion 46 may be formed to be horizontal with the upper supporting protrusion 40 without being curved.
[0031] In the locking structure of the airtight container according to the embodiment, the lockable lid 32 is disposed to cover the opening portion 16 of the container body 34 , and the locking wing 38 is rotated in a locking direction so that the flange 36 of the container body 34 is engaged between the upper and lower supporting protrusions 40 and 42 of the locking wing 38 , thereby enabling locking of the airtight container.
[0032] More specifically, in the locking procedure, while the convex protrusion 46 meets the upper surface of the flange 36 and moves toward the concave groove 44 , the upper supporting protrusion 40 is lifted and the interval D is slightly increased as compared with the initial state.
[0033] In addition, while the convex protrusion 46 moves toward the concave groove 44 , the flange 36 is naturally engaged between the upper and lower supporting protrusions 40 and 42 , so that the convex protrusion 46 meets the concave groove 44 .
[0034] As described above, when the convex protrusion 46 meets the concave groove 44 , due to the restoring force of the upper supporting protrusion 40 which is lifted, the convex protrusion 46 comes in contact with the concave groove 44 to be accommodated, and the arc-shaped surfaces are in contact to be engaged with each other. Specifically, in the engaged state where the upper and lower supporting protrusions 40 and 42 grasp the upper and lower surfaces of the flange 36 , respectively, due to complicated effects such as the grasping force exerted to press the flange 36 by the convex protrusion 46 and engagement between the convex protrusion 46 and the concave groove 44 , the lockable lid 32 and the container body 34 can be maintained in a tightly locked state or tightly engaged state.
[0035] Both of the convex protrusion 46 and the concave groove 44 have arc-shaped curved surfaces. Accordingly, when the locking wing 38 is rotated outward in the engaged state, the convex protrusion 46 can be smoothly separated from the convex groove 44 .
[0036] In addition, after the convex protrusion 46 is slightly misaligned from the concave groove 44 , the sliding action proceeds more smoothly. Accordingly, the locking wing 38 can be easily released from the flange 36 of the container body 34 with less force.
[0037] As described above, since locking and releasing can be easily performed with a small force, force is not exerted excessively on the convex protrusion 46 and the flange 36 during the locking and releasing. Therefore, problems such as deformation or breakage of the convex protrusion 46 and the flange 36 do not occur.
[0038] FIG. 4 is a sectional view illustrating a mold according to an embodiment for press-forming the container body 34 , particularly, the container body 34 made of a glass material. FIG. 5 is an enlarged view illustrating a portion denoted by a reference numeral 48 of FIG. 4 . A description of the container body 34 is provided with reference to FIGS. 2 and 3 .
[0039] Here, press-forming the container body 34 that is to be shaped in the embodiment is performed in the state where the concave groove 44 is not formed at the flange 36 yet and the shape of container body 34 is not exactly formed as a semi-finished product. In addition, the container body 34 is sectioned to be press-formed.
[0040] Specifically, the mold includes a first mold 50 which is formed vertically to press-form a flange upper area a in addition to the opening portion 16 , a second mold 52 which is disposed outside the first mold 50 to press-form a flange lower area b, and a third mold 54 which is disposed under the second mold 52 to press-form a container body lower area c below the flange 36 .
[0041] As described above, when the container body 34 as the semi-finished product is transferred to a molding apparatus, the first mold 50 which reciprocates vertically comes in contact with the upper portion 16 and the flange upper area a, and the second and third molds 52 and 54 which move horizontally then come in contact with the flange lower area b and the container body lower area c, respectively, to exert pressure together, thereby performing press-forming.
[0042] Here, a convex protrusion 58 protruding downward is formed at a press-formed portion 56 of the first mold 50 corresponding to a spot S where the opening portion 16 and the root of the flange 36 meet each other, so that the concave groove 44 formed by the convex protrusion 58 during the press-forming can be formed at the upper surface of the flange 36 .
[0043] 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 this disclosure as defined by the appended claims.
[0044] In addition, many modifications can be made to adapt a particular situation or material to the teachings of this disclosure without departing from the essential scope thereof. Therefore, it is intended that this disclosure not be limited to the particular exemplary embodiments disclosed as the best mode contemplated for carrying out this disclosure such as the aforementioned containers, vessels, jars, cups, and the like, but that this disclosure will include all embodiments falling within the scope of the appended claims.
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Disclosed is an airtight container comprising: a container body having an opening portion and a flange formed along an outer circumference of the opening portion; and a lockable lid that is disposed to cover the opening portion of the container body and that has a locking wing at an edge, wherein the locking wing further comprises upper and lower supporting protrusions disposed on an inner surface of the locking wing at an interval that permits engagement of the flange between the upper and lower supporting protrusions.
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FIELD OF INVENTION
[0001] The present invention relates generally to the art of semiconductor devices, and more particularly to a dual guardring arrangement that is useful during both electrostatic discharge (ESD) events as well as during normal operating conditions.
BACKGROUND OF THE INVENTION
[0002] Electrostatic discharge (ESD) is a continuing problem in the design, manufacture and utilization of semiconductor devices. Integrated circuits (ICs) can be damaged by ESD events stemming from a variety of sources, in which large currents flow through the device in an uncontrolled fashion. In one such ESD event, a packaged IC acquires a charge when it is held by a human whose body is electrostatically charged. An ESD event occurs when the IC is inserted into a socket, and one or more of the pins of the IC package touch the grounded contacts of the socket. This type of event is known as a human body model (HBM) ESD stress. For example, a charge of about 0.6 μC can be induced on a body capacitance of 150 pF, leading to electrostatic potentials of 4 kV or greater. HBM ESD events can result in a discharge for about 100 nS with peak currents of several amperes to the IC. Another source of ESD is from metallic objects, known as the machine model (MM) ESD source, which is characterized by a greater capacitance and lower internal resistance than the HBM ESD source. The MM ESD model can result in ESD transients with significantly higher rise times than the HBM ESD source. A third ESD model is the charged device model (CDM), which involves situations where an IC becomes charged and discharges to ground. In this model, the ESD discharge current flows in the opposite direction in the IC than that of the HBM ESD source and the MM ESD source. CDM pulses also typically have very fast rise times compared to the HBM ESD source.
[0003] ESD events typically involve discharge of current between one or more pins or pads exposed to the outside of an integrated circuit chip. Such ESD current flows from the pad to ground through vulnerable circuitry in the IC, which may not be designed to carry such currents. Many ESD protection techniques have been thusfar employed to reduce or mitigate the adverse effects of ESD events in integrated circuit devices. Many conventional ESD protection schemes for ICs employ peripheral dedicated circuits to carry the ESD currents from the pin or pad of the device to ground by providing a low impedance path thereto. In this way, the ESD currents flow through the protection circuitry, rather than through the more susceptible circuits in the chip.
[0004] Such protection circuitry is typically connected to I/O and other pins or pads on the IC, wherein the pads further provide the normal circuit connections for which the IC was designed. Some ESD protection circuits carry ESD currents directly to ground, and others provide the ESD current to the supply rail of the IC for subsequent routing to ground. Rail-based clamping devices can be employed to provide a bypass path from the IC pad to the supply rail (e.g., VDD) of the device. Thereafter, circuitry associated with powering the chip is used to provide such ESD currents to the ground. Local clamps are more common, wherein the ESD currents are provided directly to ground from the pad or pin associated with the ESD event. Individual local clamps are typically provided at each pin on an IC, with the exception of the ground pin or pins.
SUMMARY OF THE INVENTION
[0005] The following presents a simplified summary in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor to delineate the scope of the invention. Rather, the primary purpose of this summary is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
[0006] A semiconductor dual guardring arrangement is provided which is useful during electrostatic discharge (ESD) events as well as during normal operating conditions. In particular, an inner guardring that is located closer to an active area provides desirable performance during normal operating conditions, while an outer guardring located further from the active area provides desirable performance during an ESD event.
[0007] To the accomplishment of the foregoing and related ends, the following description and annexed drawings set forth in detail certain illustrative aspects and implementations of the invention. These are indicative of but a few of the various ways in which one or more aspects of the present invention may be employed. Other aspects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic diagram illustrating an exemplary dual guardring arrangement suitable for use with one or more NMOS transistors.
[0009] FIG. 2 is a schematic diagram illustrating an exemplary dual guardring arrangement suitable for use with one or more PMOS transistors.
DETAILED DESCRIPTION OF THE INVENTION
[0010] One or more examples are described with reference to the drawings, wherein like reference numerals are generally utilized to refer to like elements throughout, and wherein the various structures are not necessarily drawn to scale. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more examples. It may be evident, however, to one skilled in the art that one or more examples may be practiced with a lesser degree of these specific details. In other instances, known structures and devices are illustrated to facilitate describing one or more examples.
[0011] Turning to FIG. 1 , an exemplary dual guardring arrangement 100 is illustrated that is suitable for use with one or more NMOS transistors. The illustration is a top view of the arrangement 100 , which is formed on a semiconductor substrate 102 , where the substrate 102 may comprise any type of semiconductor body (e.g., silicon, SiGe, SOI) such as a semiconductor wafer or one or more die on a wafer, as well as any other type of semiconductor and/or epitaxial layers grown thereon and/or otherwise associated therewith. Since the illustrated arrangement 100 has application to one or more NMOS transistors, the illustrated portion of the substrate 102 may be doped to have a p type electrical conductivity, such that the arrangement 100 can be said to be formed in a p type well in the substrate 102 .
[0012] An active area 104 is centrally located in the arrangement 100 . The active area 104 comprises a region of the substrate 102 wherein one or more semiconductor devices can be formed. As such, since this arrangement has application to NMOS devices, the active area 104 is doped to have an n type electrical conductivity, and can thus be said to comprise an n type well. Additionally, one or more regions of electrically conductive material 106 , such as patterned polysilicon, for example, are formed over the active area 104 to serve as, at least part of, one or more NMOS transistor gates, for example.
[0013] A first guardring 108 is formed in the substrate 102 around the active area 104 and the conductive regions 106 . The first guardring 108 is doped to have p type electrical conductivity. The guardring 108 generally extends down to a subsurface or underlying substrate layer, such as a backgate region of the one or more NMOS transistors, for example. The first guardring 108 is situated relatively close to the active area 104 to satisfy normal operating requirements. Although the distance 110 between the first guardring 108 and the active area 104 may be technology dependent, the first guardring 108 and the active area 104 are generally separated by a distance 110 of between about 0.25 and about 1.5 microns, for example.
[0014] A second guardring 112 is formed in the substrate 102 around the first guardring 108 . Like the first guardring 108 , the second guardring 112 comprises an area of the substrate 102 that is doped to have a p type electrical conductivity. The second guardring 112 also generally extends down to a subsurface or underlying substrate layer, such as a backgate region of the one or more NMOS transistors, for example. The second guardring 112 is distanced away from the active area 104 to satisfy requirements during an ESD event. The second guardring 112 and the active area 104 are generally separated by a distance 114 of between about 2.5 and about 25 microns, for example.
[0015] A schematically illustrated inverter 120 is operatively coupled to the first guardring 108 . The inverter 120 comprises first and second transistors 122 , 124 , where the gates (G) of the transistors are coupled to a first voltage Vdd, which generally comprises a supply voltage. The source (S) of the first transistor 122 is also coupled to the supply voltage Vdd, while the source (S) of the second transistor 124 is coupled to second voltage Vss, which generally corresponds to ground. The respective drains (D) of the first 122 and second 124 transistors are operatively coupled to the first guardring 108 . The second guardring 112 is operatively coupled to the second voltage Vss.
[0016] As previously mentioned, the first or inner guardring 108 operates during normal operating conditions, while the second or outer guardring 112 becomes operational during an ESD event. The first guardring 108 serves as a tap or input/output buffer for the n well active area 104 by inhibiting hot carriers and/or other undesirable particles or contaminants from entering into and exiting out of the active area 104 . The distance 110 between the first guardring 108 and the active area 104 is accordingly kept small to minimize any such adverse effects. For example, keeping the first guardring 108 close to the one or more NMOS transistors that are touching pads mitigates well/ground bounce effects wherein well or ground voltages can be inadvertently changed. This orientation also mitigates noise injection where noise can be undesirably introduced into the circuitry. This orientation further facilitates appropriate latch up robustness whereby desired current flow is generated within and/or between devices.
[0017] The distance 114 between the first guardring 108 and the active area 104 is kept large, on the other hand, to facilitate desired operation during ESD events. For example, during ESD conditions it is desirable to have tap guardrings placed far from the one or more NMOS transistors touching the pads. During human body model (HBM) ESD events, for example, locating the guardring far from the devices facilitates increased resistance from the substrate 102 which is beneficial for the uniform conduction of the one or more NMOS transistors being protected. Similarly, during charged device model (CDM) ESD events the separation between the guardring 108 and the devices facilitates enhanced gate to bulk oxide breakdown.
[0018] By way of further example, during normal operation Vdd is applied to the respective gates of the first 122 and second 124 transistors of the inverter 120 . As such, the first guardring 108 is pulled down to Vss through the connection to the respective drains of the devices 122 , 124 . As a result, both guardrings 108 and 112 are at Vss which is desirable for normal operating conditions. During an ESD event, however, Vdd is floating such that the respective drains of the first 122 and second 124 transistors of the inverter 120 are floating as well. As such, the first guardring 108 floats accordingly due to the coupling to the respective drains of the devices 122 and 124 . Thus, merely the second or outer guardring 112 is connected during an ESD event, which is desirable for the reasons described above.
[0019] Turning to FIG. 2 , an exemplary dual guardring arrangement 200 is illustrated that is suitable for use with one or more PMOS transistors. The illustration is similar to that depicted in FIG. 1 , except that electrical conductivities are reversed/opposite. Accordingly, the substrate 202 may be doped to have an n type electrical conductivity, such that the arrangement 200 can be said to be formed in an n type well in the substrate 202 .
[0020] An active area 204 is centrally located in the arrangement 200 . The active area 204 comprises a region of the substrate 202 wherein one or more semiconductor devices can be formed. As such, since this arrangement has application to PMOS devices, the active area 204 is doped to have a p type electrical conductivity, and can thus be said to comprise a p type well. Additionally, one or more regions of electrically conductive material 206 , such as patterned polysilicon, for example, are formed over the active area 204 to serve as, at least part of, one or more PMOS transistor gates, for example.
[0021] A first guardring 208 is formed in the substrate 202 around the active area 204 and the conductive regions 206 . The first guardring 208 is doped to have and n type electrical conductivity. The guardring 208 generally extends down to a subsurface or underlying substrate layer, such as a backgate region of the one or more PMOS transistors, for example. As with the arrangement illustrated in FIG. 1 , the first guardring 208 is situated relatively close to the active area 204 to satisfy normal operating requirements. In particular, the first guardring 208 and the active area 204 are generally separated by a distance 210 of between about 0.25 and about 2.5 microns, for example.
[0022] A second guardring 212 is formed in the substrate 202 around the first guardring 208 . Like the first guardring 208 , the second guardring 212 comprises an area of the substrate 202 that is doped to have an n type electrical conductivity. The second guardring 212 also generally extends down to a subsurface or underlying substrate layer, such as a backgate region of the one or more PMOS transistors, for example. The second guardring 212 and the active area 204 are generally separated by a distance 214 of between about 2.5 and about 25 microns, for example.
[0023] A schematically illustrated inverter 220 is operatively coupled to the first guardring 208 . The inverter 220 comprises first and second transistors 222 , 224 , where the source (S) of the first transistor 222 is coupled to a first voltage Vdd, which generally comprises a supply voltage. The source (S) of the second transistor 224 is coupled to a second voltage Vss, which generally corresponds to ground. The respective gates (G) of the transistors 222 , 224 are also coupled to Vss. The respective drains (D) of the first 222 and second 224 transistors are operatively coupled to the first guardring 208 . The second guardring 212 is operatively coupled to the source voltage Vdd.
[0024] As with the NMOS related arrangement 100 illustrated in FIG. 1 , the first or inner guardring 208 operates during normal operating conditions, while the second or outer guardring 212 becomes operational during an ESD event. During normal operation, the application of Vss to the gates of the first 222 and second 224 transistors causes Vdd to be at the respective drains of the transistors 222 , 224 such that the first guardring 208 is pulled up to the Vdd through the connection to the drains of the devices 222 , 224 . As a result, both guardrings 208 and 212 are at Vdd which is desirable for normal operating conditions. During an ESD event, however, Vdd is floating such that the respective drains of the first 222 and second 224 transistors of the inverter 220 are floating as well. As such, the first guardring 208 floats accordingly due to the coupling to the respective drains of the devices 222 and 224 . Thus, merely the second or outer guardring 212 is connected during an ESD event, which is desirable for the reasons set forth above.
[0025] Although the invention has been shown and described with respect to one or more examples, equivalent alterations, modifications and/or implementations may occur to others skilled in the art based upon a reading and understanding of this specification and the annexed drawings. The invention includes all such modifications and alterations and is limited only by the scope of the following claims. In addition, while a particular feature or aspect of the invention may have been disclosed with respect to only one of several implementations, such feature or aspect may be combined with one or more other features or aspects of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” Also, the term “exemplary” is merely meant to mean an example, rather than the best. Further, while the guardrings and other features have been illustrated as being substantially square or rectangular, they are not intended to be limited to these exact shapes.
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A semiconductor dual guardring arrangement is provided which is useful during electrostatic discharge (ESD) events as well as during normal operating conditions. In particular, an inner guard that is located closer to an active area provides desirable performance during normal operating conditions, while an outer guardring located further from the active area provides desirable performance during an ESD event.
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FIELD OF ART
The field of art to which the invention relates comprises the merchandising and selection of pre-fabricated furniture, such as cabinets and component cabinet parts for custom design of a living space.
BACKGROUND OF INVENTION
Individual cabinets and associated cabinet accessories are typically either of a pre-fabricated construction or custom built on-site by skilled cabinet makers. However, custom built on-site cabinetry is considerably more expensive than prefabricated construction due to the higher labor charges associated with the services of skilled trandesmen. The overall installation is therefore considerably more costly than might otherwise occur if it were possible to eliminate much of this labor expense. The ideal situation, from a cost standpoint, would therefore be to provide prefabricated cabinets for quick and easy selection by the do-it-yourselfer.
DESCRIPTION OF THE PRIOR ART
While various merchandising techniques have been developed for the do-it-yourself market, a quick, convenient and effective method for custom cabinet planning and selection by the less skilled, more novice, do-it-yourself handyman has not been available prior to this invention. As a consequence, this area of the do-it-yourself market has not been effectively tapped.
OBJECTS OF THE INVENTION
It is therefore an object of the present invention to provide a novel system for the planned selection and installation of custom quality pre-fabricated cabinets for selected living spaces.
It is a further object of the invention to effect the previous object with a highly simplified approach enabling relative unskilled workmen to select and install cabinetry in a preplanned arrangement at lower costs than heretofore achieved.
It is a still further object of the invention to effect the previous objects with reduced labor costs, economic efficiency, and simplicity of selection of desired cabinet combinations.
SUMMARY OF THE INVENTION
This invention relates to an improved method and system for the planning, merchandising, and selection of custom quality cabinet structures for a living space such as a kitchen, den, living room, bedroom, etc. More specifically, the invention relates to a coordinated system that readily lends to the layout, planning, selection, and merchandising of high quality cabinet combinations in clustered arrangements.
The foregoing is achieved in accordance with the invention by prepackaging unassembled furniture components, such as wall and base cabinet units, in color coded cartons corresponding to the particular category of such components. The individual cabinet units within a particular category grouping, but of different dimensions, are then furthermore designated by alphanumeric coding representative of such dimensional differences. The color and alpha-numeric coded merchandise are then depicted and listed in customer brochures and graphic materials from which the desired merchandise can readily be identified and then selected from the correspondingly coded merchandise display of cartons containing the unassembled furniture components.
Being merchandised in this manner enables rapid and convenient selection of the desired cabinet units by the consumer by choosing the selected cartons from the shelf in accordance with their respective identifying coded indicia. Once purchased and removed to the site of installation, the cabinets can then be readily assembled pursuant to instructions and a previously prepared layout. Thus, the resulting ease of selection is of value to any class of purchaser, and particularly the do-it-yourself handyman.
Additional features and advantages of the present invention will become readily apparent and appreciated by those skilled in the art upon reading the following detailed description of a preferred embodiment of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a graphic depiction of various cabinet types and accessories as would appear in a consumer brochure or the like, in which the various furniture components are grouped together by category, with color coding being indicative of the particular category, and alpha-numeric coding being indicative of different dimensional units within each category grouping;
FIG. 2 is a typical selection chart for listing the cabinets and accessories of FIG. 1 and their corresponding numbered merchandise carton;
FIG. 3 is a plan layout of an exemplary kitchen area in which the cabinets and components of FIG. 1 are to be installed;
FIG. 4 is a perspective view of the kitchen area after the cabinets and components have been installed in accordance with the layout of FIG. 3;
FIG. 5 is a merchandise display of the inventory of cabinets and accessories in their cartons, each carton having coding corresponding to the coding set out in FIGS. 1 and 2; and
FIG. 6 is a typical label from the face of the cartons depicted in FIG. 5 reflecting the merchandise coding technique of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the description which follows, like parts are respectively designated throughout the specification and the drawings with the same reference numerals. The drawings are not necessarily to scale, and in some instances portions have been exaggerated for purposes of clarity.
Referring now to the drawings, and initially to FIG. 1, various cabinet or furniture items are depicted as they would be in a customer brochure or other similar printed display, the items grouped in accordance with the color coding and the alpha numeric coding format of the present invention. For example, wall cabinets 10 of varying categories 10', 10" and 10''' are respectively grouped adjacent color code designators "R", "B", and "Y" respectively representing, for example, color squares of red, blue, and yellow backgrounds. Similarly, base cabinets 12 are arranged into category groups 12', 12", 12''', 12'''', and 12''''', with color code designators "G", "L", "P", "K", and "O" respectively representing, for example, color squares of light green, lavender, purple, dark green and orange, being respectively disposed adjacent each such category. A third grouping of accessories 30, such as dishwasher returns, fillers, valances, etc., may have a color code designator "C" of a dark gray background, for example, adjacent and identifying such grouping.
Each of the cabinets and accessories of each grouping are of the same type, but of different dimensions. Consequently, each item of a category grouping also has associated therewith an alpha-numeric code designation comprised of initial letters, such as "C-W" (Cabinet-Wall), followed by numerical digits representing its particular dimension. For example, the first wall cabinet in the "red" grouping 10' is designated by the alpha-numeric C-W 1230, the first two numbers "12" representing the width of that cabinet in inches, and the second two numbers "30" representing its height. For the base cabinets 12', 12", 12''', etc., the models are of a standard height, typically 341/2 inches, with the alpha-numeric coding being C-B (Cabinet-Base) followed by the numeric representing the cabinet width. Thus C-B15 is the base cabinet, category code 12', having a 15 inch width. With respect to the accessories 30, the number in the model code, for example the "3" in WF3 likewise represents its width in inches.
FIG. 2 represents a customer selection chart on which the various cabinet models depicted in FIG. 1 are listed (Column 18), along with the box number (Column 14) in which that unassembled cabinet is packaged with the color coding associated with that particular box being summarized in Column 16. Furthermore, adjacent each cabinet model is the model number of the cabinet door to be associated with that cabinet, indicating the model number of a white door (Column 20) or an almond door (Column 22). The white background accessories are listed in column 24 and the almond in column 26, along with the identification of the boxes (21-27) in which they are packaged bearing the color coded gray background designator "C".
As best illustrated in FIGS. 5 and 6, the packaged merchandise is presented and displayed to the consumer in accordance with the same color coding as previously described with reference to FIG. 1. It is to be understood that this display is only by way of example, as the method of this invention is equally applicable, for example, to warehouse racks or other fixture displays, with the merchandise being any type of fixture.
Specifically, the wall cabinets 10, base cabinets 12, and accessories 30 are pre-boxed unassembled in cartons 43 stacked on a lower shelf 52 of a merchandise gondola type display case 44 having end walls 46 and 48. In accordance with a unique feature of the invention, each of the cartons 43 has at its front face a label 54 (FIG. 6) bearing color background segments (for example at portions 29) respectively corresponding to the background color of the color code designator representing the furniture item within the package and as depicted in FIG. 1. In the example shown in FIG. 6, the color is purple. Furthermore, each box bears a number designator 40 (in the illustrated example, the number 17) corresponding to the box number listed in column 14 of the sheet depicted in FIG. 2 containing the particular furniture item.
As specifically illustrated in FIG. 5, all the cartons 54 are stacked in numerically ascending order from left to right and grouped according to the color code which designates the particular group. The wall cabinets 10 are thus in boxes 1-10 (and in color groupings red, blue and yellow), while the boxes 11-20 contain the base cabinets 12 (in color groupings green, lavender, purple, dark green and orange, respectively). The accessories 30 are in boxes 21-27 with dark gray color coding.
At the top of the gondola on shelves 56, 58, 60, and 62 are disposed additional cartons 72 containing the various doors and other components. These cartons can also be color coded and numbered to correspond to the various furniture item color coding.
In accordance with the utilization of the system of the invention, the consumer first procures a brochure depicting the various furniture components shown in FIG. 1. Next, and with reference to FIG. 3, the dimensions "A" and "B" of the particular living space 34 to be "cabineted" is determined, the dimensions of the cabinets and/or other fixtures to fill the space calculated, and a scaled plan like that shown in FIG. 3 prepared. For example, the particular living space 34 shown in FIG. 3 is a kitchen in which cabinets are to be installed in clusters about a refrigerator space 36, a stove or range space 38, and a window 40 (FIG. 4) behind a sink or wash basin 42. Based upon one's desired category and the height and width dimensional availability, wall cabinets 10" [color coding B] are selected for the spaces shown, with the different dimensions chosen [as indicated by C-W 3615, CW 3030, and CW 3018]. In similar manner, wall cabinets 10' (coding R), wall cabinet 10''' (coding Y), base cabinets 12' (coding G), 12''' (coding P), 12'''' (coding K), and 12''''' (coding 0), valance 70 (coding C), and fillers 80 and 90 (coding C) are selected for the plan.
Once the plan scaled layout shown in FIGS. 3 and 4 is completed to satisfaction, it remains only to purchase and install the various cabinet and accessory items in conformity with the plan. From that point the customer proceeds to a suitable commercial outlet where the various components for the selected cabinets can be readily purchased. From the chart of FIG. 2, the correlated color code and box number indicia can be readily obtained, and the customer can readily identify and easily select the desired items from the display on the gondola 44 (FIG. 5) by the color and alpha-numeric coded label 54 (FIG. 6) on the front of each carton.
With the approach of this invention, not only is the selection of the various cabinets and furniture components significantly simplified, but the reordering and restocking by the merchant is facilitated.
Although the invention has been specifically described in association with a clustered installation of cabinets in a kitchen area, it will be appreciated that the method and system hereof can be readily adapted for application to the furnishing of essentially any living space. Moreover, while the invention has been described in a specific combination of color and/or alpha-numerical code indicia, the coding method and display may alternatively utilize, for example, print patterns, rather than colors, for the category group coding.
Other changes and modifications of the above described embodiment, as well as other embodiments, will become apparent without departing from the scope of the invention as solely defined by the appended claims.
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A system for merchandising and selecting pre-fabricated cabinets for installation in a living space. Comprising the system are informational display and selection charts on which a unique code indicia, particularly color coded, is assigned to each cabinet unit. Following a scaled plan layout of the cabinet area in an intended living space for which installation is contemplated, the selected units can be readily retrieved from a merchandising display on which the various units are clearly identified by their codes.
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This application claims benefit of provisional application 60/185,343 filed Feb. 26, 2000.
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of manufacture of electronic devices. In particular, the present invention relates to compositions and methods for the reduction of defects during the manufacture of electronic devices.
Photoresists are photosensitive films used for transfer of images to a substrate. A coating layer of a photoresist is formed on a substrate and the photoresist layer is then exposed through a photomask to a source of activating radiation. The photomask has areas that are opaque to activating radiation and other areas that are transparent to activating radiation. Exposure to activating radiation provides a photoinduced chemical transformation of the photoresist coating to thereby transfer the pattern of the photomask to the photoresist-coated substrate. Following exposure, the photoresist is developed to provide a relief image that permits selective processing of a substrate.
A photoresist can be either positive-acting or negative-acting. For most negative-acting photoresists, those coating layer portions that are exposed to activating radiation polymerize or crosslink in a reaction between a photoactive compound and polymerizable agents of the photoresist composition. Consequently, the exposed coating portions are rendered less soluble in a developer solution than unexposed portions. For positive-acting photoresists, exposed portions are rendered more soluble in a developer solution while areas not exposed remain comparatively less developer soluble. In general, photoresist compositions include at least a resin binder component and a photoactive agent.
Following exposure, the film layer of the photoresist composition is preferably baked at temperatures ranging from about 70° C. to 160° C. Thereafter, the film is developed. The exposed resist film is rendered positive working by employing a polar developer, typically an aqueous based developer, such as quaternary ammonium hydroxide solutions, such as tetra-alkyl ammonium hydroxide, preferably a 0.26 N tetramethylammonium hydroxide; various amine solutions, such as ethylamine, n-propylamine, diethylamine, triethylamine or methyl diethylamine; alcohol amines, such as diethanolamine, triethanolamine; cyclic amines, such as pyrrole, pyridine, and the like.
After development of the photoresist coating, the developed substrate may be selectively processed on those areas bared of resist, for example, by chemically etching or plating substrate areas bared of resist in accordance with procedures known in the art. For the manufacture of microelectronic substrates, e.g. the manufacture of silicon dioxide wafers, suitable etchants are a gas etchant, such as a chlorine- or fluorine-based etchant, such as Cl 2 or CF 4 /CHF 3 etchant applied as a plasma stream. After such processing, the resist may be removed from the processed substrate using any stripping procedures known in the art.
Following contact of the photoresist with developer or stripper, the electronic device, e.g. a wafer, is then rinsed, typically first with iso-propanol and then with deionized water. Such rinses are used to remove any remaining developer or stripper solution and to help remove any remaining photoresist particles or residue. Even after such development, stripping and rinsing, the electronic device may contain on its surface residual photoresist, either in the form of polymer, particulates or residue. Such residual photoresist can cause defects, such as shorts, in the resulting electronic device.
There is thus a need for an effective method for reducing the number of defects in electronic devices, particularly those due to residual photoresist or photoresist residue remaining after development or stripping of the photoresist.
SUMMARY OF THE INVENTION
It has been surprisingly found that the number of defects in electronic devices can be significantly reduced according to the present invention. Yield losses due to defects are also improved by the compositions and methods of the present invention.
In one aspect, the present invention provides a method for reducing the number of defects in an electronic device including the step of contacting the electronic device with a composition including one or more surfactants and water, wherein the amount of surfactant in the composition is less than the critical micelle concentration.
In a second aspect, the present invention provides a method of manufacturing an electronic device including the steps of at least partially removing a photoresist layer from a substrate; and contacting the substrate having the partially removed photoresist with a composition including one or more surfactants and water, wherein the amount of surfactant in the composition is less than the critical micelle concentration.
In a third aspect, the present invention provides an electronic device prepared according to the method described above.
In a fourth aspect, the present invention provides a method of removing photoresist including the steps of contacting a photoresist layer on a substrate with a composition including one or more surfactants and water wherein the amount of surfactant in the composition is less than the critical micelle concentration; and at least partially removing the photoresist layer.
DETAILED DESCRIPTION OF THE INVENTION
As used throughout this specification, the following abbreviations shall have the following meanings unless the context clearly indicates otherwise: DI=deionized; ppm=parts per million; % wt=percent by weight; and RPM=revolutions per minute. All percents are by weight and all numerical ranges are inclusive.
The compositions of the present invention are suitable for reducing defects in an electronic device by removing polymeric residue from the surface of such device. In particular, the compositions of the present invention are particularly suitable for reducing defects in an electronic device by removing photoresist residue from the surface of such device. While not intending to be bound by theory, it is believed that the compositions of the present invention function to help solubilize, disperse, chelate, entrain, encapsulate or otherwise remove polymer residue, particularly polymer particulates, from the surface of the substrates so treated. The present invention may be used in the manufacture of any electronic devices, such as, but not limited to, wafers, circuit boards, and the like.
The compositions of the present invention include one or more surfactants and water, wherein the amount of the surfactant in the composition is less than the critical micelle concentration. While any grade of water is suitable for use in the present invention, deionized water is preferred.
The particular surfactant used in the present invention is not critical. Thus, any surfactant is suitable for use in the present invention. Thus, anionic, cationic, nonionic and amphoteric surfactants may be advantageously used in the present invention. It is preferred that the surfactant is cationic or nonionic, and more preferably nonionic. Particularly suitable nonionic surfactants are ethylene oxide/propylene oxide (“EO/PO”) copolymers. It will be appreciated by those skilled in the art that mixtures of surfactants may be suitably used in the present invention. Thus, mixtures of cationic and nonionic surfactants and mixtures of anionic and nonionic surfactants may be used in the present invention. Such surfactants are generally commercially available from a variety of sources and may be used without further purification. Such surfactants may be available as an aqueous composition, which may be used in the present invention.
Any amount of surfactant is suitable for use in the present invention as long as it is less than the critical micelle concentration (“CMC”). “Critical micelle concentration” refers to the concentration of surfactant in water above which the surface tension remains substantially invariant with increasing surfactant concentration. Such critical micelle concentration is well known to those skilled in the art. Typically, the amount of surfactants used in the present invention is less than about 5000 ppm, preferably less than about 1000 ppm, more preferably less than 500 ppm and most preferably less than about 250 ppm.
The compositions of the present invention may optionally include one or more additional components, such as, but not limited to, corrosion inhibitors, cosolvents, chelating agents and the like. It is preferred that the compositions of the present invention are free of corrosion inhibitors. It is also preferred that the compositions of the present invention are free of cosolvents.
Any corrosion inhibitor which reduces corrosion metal film layers, is water soluble and is compatible with the one or more surfactants is suitable for use in the present invention. Suitable corrosion inhibitors include, but are not limited to, catechol, (C 1 -C 6 )alkylcatechol such as methylcatechol, ethylcatechol and tert-butylcatechol, benzotriazole, (C 1 -C 10 )alkylbenzotriazoles; (C 1 -C 10 )hydroxyalkylbenzotriazoles; 2-mercaptobenimidazole, gallic acid; gallic acid esters such as methyl gallate and propyl gallate; and the like. Such corrosion inhibitors are generally commercially available from a variety of sources, such as Aldrich (Milwaukee, Wis.) and may be used without further purification.
The corrosion inhibitors are typically present in the compositions of the present invention in an amount in the range of from about 0.01 to about 5% wt, based on the total weight of the composition. It is preferred that the amount of corrosion inhibitor is from about 0.1 to about 3% wt.
Any solvent which is water miscible and is compatible with the one or more surfactants is suitable for use in the present invention. Suitable cosolvents useful in the present invention include, but are not limited to, (C 1 -C 20 )alkanediols such as ethylene glycol, diethylene glycol, propylene glycol, 2-methylpropanediol and dipropylene glycol; (C 1 -C 20 )alkanediol (C 1 -C 6 )alkyl ethers such as propylene glycol monomethyl ether, propylene glycol dimethyl ether, propylene glycol n-butyl ether, dipropylene glycol monomethyl ether, dipropylene glycol dimethyl ether, dipropyleneglycol monobutyl ether, tripropyleneglycol monomethyl ether and propylene glycol methyl ether acetate; aminoalcohols such as aminoethylaminoethanol; N-(C 1 -C 10 )alkylpyrrolidones such as N-methylpyrrolidone, N-ethylpyrrolidone, N-hydroxyethylpyrrolidone and N-cyclohexylpyrrolidone; (C 1 -C 10 )alcohols such as ethanol and iso-propanol; and the like. It is preferred that the cosolvent is one or more of (C 1 -C 20 )alkanediols, (C 1 -C 20 )alkanediol (C 1 -C 6 )alkyl ethers and (C 1 -C 10 )alcohols and more preferably one or more of propylene glycol monomethyl ether, propylene glycol dimethyl ether, propylene glycol n-butyl ether, dipropylene glycol monomethyl ether, dipropylene glycol dimethyl ether, dipropyleneglycol n-butyl ether, tripropylene glycol monomethyl ether, propylene glycol methyl ether acetate ethanol and iso-propanol. Such cosolvents are generally commercially available from a variety of sources, such as Aldrich (Milwaukee, Wis.) and may be used without further purification.
When such cosolvents are used they are typically present in an amount in the range of about 0.5 to about 80% wt, based on the total weight of the composition, and preferably about 1 to about 45% wt.
The compositions of the present invention may be prepared by combining the one or more surfactants and water in any order. It is preferred that the one or more surfactants are added to water. When mixtures of surfactants are used, they may be first combined and then added to the water, and preferably added to the water separately.
The compositions of the present invention are suitable for a variety of applications in the manufacture of electronic devices, such as, but not limited to, as a pre-wetting agent prior to development or stripping of a photoresist, as a rinse after development or stripping of a photoresist, and as a final polish after rinsing.
When the compositions of the present invention are used as a pre-wetting agent, the photoresist layer is contacted with the treatment solution of the present invention prior to being at least partially removed. By “at least partially removing” the photoresist is meant that a portion of the photoresist layer is removed. Such at least partial removal includes development of the photoresist where only exposed or unexposed portions of the photoresist are removed as well as stripping where substantially all of the photoresist layer is removed.
In such pre-wetting process, the photoresist layer on the substrate is contacted with the compositions of the present invention for a period of time sufficient to wet the surface of the photoresist layer. Such “wetting” enhances the ability of developers or strippers to remove the desired portions of the photoresist layer. After wetting, the photoresist layer is optionally rinsed, such as with iso-propanol or water, before being contacted with either developer or stripper. Following development or stripping of the photoresist, the substrate is subjected to conventionally processing conditions such as, but not limited to, rinsing and drying.
The compositions of the present invention are effective in reducing the amount of polymeric residue, and in particular photoresist residue, after development or stripping of a photoresist layer on a substrate, such as an electronic device. Thus, the present invention is useful in reducing the number of defects in an electronic device including the steps of contacting the electronic device with a composition including one or more surfactants and water, wherein the amount of surfactant in the composition is less than the critical micelle concentration.
Typically, the photoresist layer on a substrate is at least partially removed by development or stripping. After such development or stripping, the substrate is optionally rinsed such as with water or iso-propanol, and then contacted with the compositions of the present invention. The substrate is contacted with a composition of the present invention for a period of time sufficient to remove any photoresist, either in the form of polymer, particulates or residue. Typically, the substrate is contacted with the compositions of the present invention for about 120 seconds or less, preferably for about 60 seconds or less, and more preferably for about 30 seconds or less. After such contact with the treatment solutions of the present invention, the substrate may be rinsed a second time such as with DI water or iso-propanol prior to drying. In an alternative embodiment, such second rinse may be eliminated and the substrate may be dried after contact with the treatment solution.
The compositions of the present invention may be used as a final polish. Thus, a substrate may be contacted with the composition, rinsed with DI water, and then contacted with a fresh bath of the composition prior to drying.
The substrates may be contacted with the compositions of the present invention by any known means, such as immersing the substrates in a bath containing the compositions or by dispensing such compositions on the substrate, such as by spraying. It is preferred that the compositions of the present invention are sprayed onto a substrate and more preferably onto a spinning substrate.
The substrate may be dried by any known means, such as spin drying or under an atmosphere stream, such as a nitrogen stream. It is preferred that the substrate is spin dried. When the substrate is spin dried, it may be dried at any speed, such as from 100 to 5000 RPM. It is preferred that the substrate is spin dried at a slower speed. Thus, it is preferred that the substrate is spin dried at a speed of from about 100 to about 1500 RPM.
The present invention is particularly useful in the manufacture of electronic devices, such as but not limited to, wafers, semiconductors, printed wiring boards and the like. Thus, the present invention provides a method of manufacturing electronic devices including the steps of at least partially removing a photoresist layer from a substrate; and contacting the substrate having the partially removed photoresist with a composition including one or more surfactants and water, wherein the amount of surfactant in the composition is less than the critical micelle concentration. Electronic devices produced by the methods of the present invention have significantly reduced numbers of defects as compared to electronic devices manufactured by conventional methods.
An advantage of the present invention is that the treatment solutions may be used as a replacement for iso-propanol rinses in the manufacture of electronic device, particularly iso-propanol rinses following development or stripping of photoresist layers.
The following examples are intended to illustrate further various aspects of the present invention, but are not intended to limit the scope of the invention in any aspect.
EXAMPLE 1
Two surfactant solutions were prepared. Sample A contained 25 ppm of a commercially available EO/PO copolymer nonionic surfactant in DI water. Sample B contained 50 ppm of the same surfactant as Sample A in DI water. A series of test wafers containing a photoresist layer that had been exposed were developed using standard methods. Following development, a portion of the wafers were rinsed using Sample A and a portion of the wafers were rinsed using Sample B. Following rinsing with Samples A or B, the wafers were dried by spin drying at two speeds. The slow spin dry speed was 500 RPM and the fast spin dry speed was 5000 RPM. After drying, defect maps of the test wafers were prepared using a Tencor defect scan and standard techniques. The sum of all defects are reported in Table 1 as an average of duplicate experiments. The control sample was a wafer coated with a photoresist layer that was not exposed, but was developed in the same manner as the test wafers and was then rinsed with DI water and spin dried at only 4000 RPM. The defect scan of the control sample stopped counting defects when approximately 75% of the wafer had been scanned as the number of defects surpassed a preset maximum.
TABLE 1
Average Number of Defects
Sample
Slow Spin Dry
Fast Spin Dry
A
1475
20270
B
2000
24350
Control
>31000
>31000
The above data clearly show that the treatment solutions of the present invention significantly reduce the number of defects, particularly at slow spin drying speeds.
EXAMPLE 2
The procedure of Example 1 was repeated except that after development, the test wafers were rinsed with DI water prior to rinsing with Samples A or B. The results are reported in Table 2.
TABLE 2
Average Number of Defects
Sample
Slow Spin Dry
Fast Spin Dry
A
240
30700
B
420
30700
Control
>31000
>31000
The above data clearly show that the treatment solutions of the present invention significantly reduce the number of defects, particularly at slow spin drying speeds.
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Disclosed are methods for the reduction of defects during the manufacture of electronic devices. Also disclosed are electronic devices having reduced numbers of defects.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to PCT Application No. PCT/EP2015/055755, having a filing date of Mar. 19, 2015, based off of German application No. DE 102014206053.2 having a filing date of Mar. 31, 2014, the entire contents of which are hereby incorporated by reference.
FIELD OF TECHNOLOGY
[0002] The following relates to methods and apparatuses for increasing quality of service in a network.
BACKGROUND
[0003] In addition to transmitting voice and image data, networks are nowadays often used for safety-critical applications. For example, an automation system consists of a plurality of control computers, sensors and actuators which constitute nodes in a network. In this case, data communication between the nodes must not be disrupted by a malfunction of an individual node in such a manner that the functional safety of the entire automation system is jeopardized. Such a fault is known under the name “babbling idiot”, for example. This can be understood as meaning a node which, contrary to planned resource agreements and possibly even contrary to a data communication specification, transmits a large quantity of data and therefore occupies the network and hinders or even corrupts communication between other nodes.
[0004] A German patent application DE 10 2012 000 185 proposes ensuring improved failure safety and fault analysis in a network in the event of transmission and hardware faults, in particular in the event of “babbling idiot” faults, by assigning fuse devices at receiving ports of switch devices for the purpose of monitoring a respective data transmission rate. The fuse devices block reception of data at the respective receiving port if a previously predefined maximum data transmission rate is exceeded. This procedure is advantageous since it can be easily implemented and achieved. However, the disadvantage is that, in the event of severe fluctuations in the data transmission rate, a false alarm could be triggered on the basis of the predefined maximum data transmission rate, which false alarm incorrectly blocks the reception of data. This results in undesired loss of data, as a result of which quality of service of the network falls. In addition, it is necessary to know and set an expected data rate in advance.
SUMMARY
[0005] An aspect relates to specifying methods and apparatuses which are used to increase quality of service in a network if there is a faulty node which can result in data traffic being overloaded in at least one part of the network.
[0006] Embodiments of the invention relate to a method for increasing quality of service in a network having a plurality of nodes if there is a faulty node, in which the nodes are connected to one another via respective connections for the purpose of interchanging data packets, the faulty node is coupled to at least one device, and the at least one device operates as a data sink and/or a data source, having the following steps of:
a) selecting at least one of the nodes as a monitored node; b) producing at least two observer nodes by selecting from the plurality of nodes, the monitored node being excluded from the selection, in such a manner that
both incoming data traffic of a respective data packet class to the monitored node from at least one of the at least two observer nodes and outgoing data traffic of the respective data packet class from the monitored node to at least one of the at least two observer nodes are completely determined;
c) recording the incoming data traffic and the outgoing data traffic of the respective observer nodes; d) generating expected total outgoing data traffic of the monitored node on the basis of (i) the outgoing data traffic produced by the respective incoming data traffic of the respective data packet class and (ii) expected data traffic of the data source of the at least one device; e) generating a difference value from a difference between the outgoing data traffic and the expected total outgoing data traffic; f) detecting the monitored node as a faulty node if the difference value exceeds a predefinable threshold value.
[0015] The method exhibits the advantage that the monitored node can be identified as a faulty node on the basis of the incoming data traffic. In other words, the threshold at which the monitored node is identified as a faulty node is dynamically adapted to the incoming data traffic. This makes it possible to use embodiments of the invention in a singular Ethernet ring structure, in which the necessary redundancy is achieved by using both directions in the ring, for fail-operational communication.
[0016] Completely means that the entire data traffic from one node to the monitored node and from the monitored node to one of the nodes in the network is analyzed by the observer nodes. The nodes K 1 and K 3 are selected as observer nodes KB 1 , KB 2 since they can completely record the entire incoming data traffic and the entire outgoing data traffic of the node K 2 . In particular, the incoming and outgoing data traffic runs completely via these observer nodes. Completely does not mean that all data packet classes have to be included in the monitoring. In particular, it may be advantageous to monitor only safety-critical or high-priority data packet classes.
[0017] In an extension of embodiments of the invention, the expected total outgoing data traffic of the monitored node is formed by summing
(i) one or more expected outgoing data traffic items and (ii) the expected data traffic of the data source of the at least one device, a respective expected outgoing data traffic item being formed by multiplying (a) a number of outgoing data packets for each incoming data packet of the respective data packet class and (b) the respectively associated incoming data traffic.
[0022] This specifies a calculation rule for determining the expected total outgoing data traffic, which rule can be implemented and carried out in a simple and therefore cost-effective manner.
[0023] The data packet class is advantageously determined by at least one of the following properties of the respective data packet of the incoming data traffic and of the outgoing data traffic:
a) “unicast” forwarding type b) “multicast” forwarding type c) “broadcast” forwarding type d) priority class.
[0028] As a result, the expected total outgoing data traffic can be determined in a very accurate manner since the determination takes into account the specific characteristics of different data packet classes. The accurate determination makes it possible to improve incorrect identification of the monitored node as a faulty node or as a node which is not faulty, thus further increasing the quality of service in the network.
[0029] The expected outgoing data traffic is thus set to be equal to the incoming data traffic for the data packet class of the “unicast” forwarding type. The expected outgoing data traffic for the data packet class of the “multicast” forwarding type is thus determined by a result of multiplying an available number of connection outputs of the monitored node to directly adjacent nodes of the monitored node by the incoming data traffic, the available number being determined between zero and a number of connection outputs to directly adjacent nodes of the monitored node which has been reduced by one. The expected outgoing data traffic for the data packet class of the “broadcast” forwarding type can thus be determined by a result of multiplying a number of connection outputs to directly adjacent nodes of the monitored node which has been reduced by one by the incoming data traffic. Using these specific calculation rules advantageously makes it possible to ensure that different implementations of embodiments of the invention identify the monitored node as a faulty node in the same manner. This further increases the reliability of the network.
[0030] The steps of the method are advantageously carried out only if the outgoing data traffic exceeds a predefinable volume of data per unit of time. This ensures that the method loads system resources of a network only if critical volumes of data are received.
[0031] In one advantageous development of embodiments of the invention, at least one of the connections of the monitored node, in particular at least one of the connections going out from the monitored node, is interrupted if the monitored node is detected as a faulty node. This avoids a malfunction of the network since the network is not flooded with a large volume of data. This increases the quality of service of the network if the faulty node is present.
[0032] Embodiments of the invention also relates to an apparatus for increasing quality of service in a network having a plurality of nodes if there is a faulty node, in which the nodes are connected to one another via respective connections for the purpose of interchanging data packets, the faulty node is coupled to at least one device and the at least one device operates as a data sink and/or a data source, having the following units:
a) a first unit for selecting at least one of the nodes as a monitored node; b) a second unit for producing at least two observer nodes by selecting from the plurality of nodes, the monitored node being excluded from the selection, in such a manner that
both incoming data traffic of a respective data packet class to the monitored node from at least one of the at least two observer nodes and outgoing data traffic of the respective data packet class from the monitored node to at least one of the at least two observer nodes are completely determined,
c) a third unit for recording the incoming data traffic and the outgoing data traffic of the respective observer nodes; d) a fourth unit for generating expected total outgoing data traffic of the monitored node on the basis of (i) the outgoing data traffic produced by the respective incoming data traffic of the respective data packet class and (ii) expected data traffic of the data source of the at least one device; e) a fifth unit for generating a difference value from a difference between the outgoing data traffic and the expected total outgoing data traffic; f) a sixth unit for detecting the monitored node as a faulty node if the difference value exceeds a predefinable threshold value.
[0041] This makes it possible to advantageously implement and carry out embodiments of the invention. Advantages of the apparatus are similar to those of the corresponding method steps.
[0042] In one advantageous development of the apparatus, the apparatus has a seventh unit which is configured in such a manner that one or more of the method steps described above can be implemented and carried out using the seventh unit. Advantages of the apparatus are similar to those of the corresponding method steps.
BRIEF DESCRIPTION
[0043] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members wherein:
[0044] FIG. 1 a network having a faulty node according to a first exemplary embodiment;
[0045] FIG. 2 a network according to a second exemplary embodiment in which a plurality of possibly faulty nodes are monitored together;
[0046] FIG. 3 an apparatus for carrying out the invention; and
[0047] FIG. 4 a monitored node having incoming data traffic and outgoing data traffic.
[0048] Elements having the same function and method of operation are provided with the same reference symbols in the Figures.
DETAILED DESCRIPTION
[0049] A first exemplary embodiment according to FIG. 1 shows six nodes K 1 , . . . , K 6 which are connected to one another via connections V 1 , . . . , V 7 . A respective arrow indicates a transmission direction for each connection. A unidirectional transmission direction therefore exists from the node K 2 to the node K 1 via a partial connection V 21 and a further unidirectional partial connection V 22 exists from node K 1 to node K 2 . An arrow direction therefore indicates a unidirectional transmission direction.
[0050] Some of the nodes have coupled devices G, G 1 , G 2 , these devices, in contrast to the nodes, not forwarding data packets to further nodes, but rather themselves being in the form of a data sink, that is to say a receiver of data packets, and/or a data source, that is to say a producer of data packets.
[0051] In the present example, the network NET is part of an automation network in a production plant, the devices G 1 , G 2 each being position sensors which provide the respectively coupled nodes with measured values for a geographical position of components on a conveyor belt in the form of a respective data packet at regular intervals for forwarding. In addition, these devices can be parameterized with parameters received by the devices by means of data packets, for example in terms of the times at which measured values are intended to be recorded.
[0052] The intention is then to check whether the node K 2 is a faulty node KF which, like a “babbling idiot”, hinders data communication from the node K 3 to the node K 1 on account of excessive packet generation. The node K 2 is therefore a monitored node (WK).
[0053] For this purpose, two observer nodes KB 1 , KB 2 are first of all selected in the network, which observer nodes completely record both incoming data traffic DZU of a respective data packet class CLA to the monitored node and outgoing data traffic DAB of the respective data packet class CLA from the monitored node to the nodes. Completely means that the entire data traffic from one node to the monitored node and from the monitored node to one of the nodes in the network is analyzed by the observer nodes. The nodes K 1 and K 3 are selected as observer nodes KB 1 , KB 2 since they can completely record the entire incoming data traffic and the entire outgoing data traffic of the node K 2 . In particular, the incoming and outgoing data traffic runs completely via these observer nodes.
[0054] According to FIG. 1 , the incoming data traffic DZU is obtained by the partial connections V 22 and V 32 . For this purpose, the observer nodes observe their respective outputs which belong to the partial connections V 22 and V 32 , that is to say the associated ports, and determine the volumes of data occurring there for each data packet class over a predefinable period of 100 ms (ms milliseconds), for example. In the example, it is assumed that there is only a single data packet class. In the present example, the incoming data traffic DZU is 20 kB. In a similar manner, the observer nodes observe the partial connections V 21 and V 31 at their respective inputs, that is to say ports, which partial connections correspond in total to the outgoing data traffic DAB. In the present example, DAB=30,000 bytes.
[0055] It is also known that the device G 1 can produce expected data traffic DVG of 200 bytes in the period of 100 ms.
[0056] In an intermediate step, expected outgoing data traffic DVW 1 is calculated by
[0000] DVW1=A(CLA)×DZU.
[0057] In this case, a number A determines how many outgoing data packets are produced for each incoming data packet for a predefinable data packet class. In the current example, a length of an incoming data packet is assumed to be identical to the corresponding outgoing data packet.
[0058] In the present example, it is assumed that the data packets of the respective data traffic are exclusively of a data packet class of a unicast forwarding type. The forwarding type is predefined, for example, by a special mark in the data packet or by the configuration of the network. In this context, unicast means that a data packet which is received by a node is forwarded only to one of the adjacent nodes or to the device. Therefore, A(CLA)=1. In the present example, the first expected outgoing data traffic DVW 1 is determined as
[0000] DVW1=1×20 kB=20,000 bytes.
[0059] Since only data packets in the data packet class of the unicast forwarding type are sent, the expected total outgoing data traffic GDV resulting from the expected outgoing data traffic and the expected data traffic of the data source of the device G 2 is determined as:
[0000] GDV=DVW1+DVG=20 kB+200 bytes=20,200 bytes.
[0060] This means that the node K 2 should produce total outgoing data traffic of 20.2 kB.
[0061] It is then checked whether the monitored node WK is a faulty node KF. For this purpose, a difference value is formed from the difference between the outgoing data traffic DAB and the expected total outgoing data traffic GDV as
[0000] DIFF=DAB−GDV=30,000 bytes−20,200 bytes=9800 bytes.
[0062] This difference value is then compared with a predefinable threshold value SWLL. If the difference value exceeds the predefinable threshold value, that is to say DIFF>SWLL, the monitored node WK is detected as a faulty node KF. In the present case, the threshold value is set to 1500 bytes in order to be able to take into account delays when processing data packets received at the monitored node WK and data packets sent at the monitored node WK. Since (DIFF=9800 bytes)>(SWLL=1500 bytes), the node K 2 is identified as a node operating in a faulty manner.
[0063] In an alternative embodiment, the threshold SWLL is set to a predefinable percentage of the incoming data traffic DZU, for example SWLL=10%×DZU, in order to be able to adapt the threshold to different volumes of data of the incoming data traffic.
[0064] Since the node K 2 is identified as a faulty node KF, it is removed from the network, with the result that it can then no longer disrupt the entire network. For this purpose, the nodes K 1 and K 3 can interrupt their connections V 2 , V 3 , for example by neither transmitting data to the faulty node nor accepting data from the faulty node. This prevents the faulty node KF, which acts as a “babbling idiot”, from disrupting the entire network or data communication in the network coming to a standstill on account of the multiplicity of data packets.
[0065] In the preceding exemplary embodiment, the forwarding type of the data packets was selected as “unicast”. In addition, yet further forwarding types such as “broadcast” and “multicast” are common. The broadcast forwarding type means that a plurality of data packets are produced for each data packet arriving at one of the nodes and are output at the respective outputs of the node. Second expected outgoing data traffic DVW 2 is therefore determined by multiplying a number of connection outputs to directly adjacent nodes of the monitored node which has been reduced by one by the incoming data traffic. Specifically, FIG. 1 shows that the monitored node has two outputs which are connected to directly adjacent nodes K 1 and K 3 . The second expected outgoing data traffic is therefore determined as DVW 2 =(2−1)×DZU. A data packet is therefore forwarded in the case of the “broadcast” forwarding type. In another scenario, a node has five outputs to directly adjacent nodes. In this case, the second expected outgoing data traffic DVW 2 is determined as DVW 2 =(5−1)×DZU. In this case, four data packets are produced by said node for an incoming data packet.
[0066] In one development or alternative embodiment of the invention, “multicast” is selected as the forwarding type. This forwarding type is distinguished by the fact that a data packet is transmitted to 0, 1 to n outputs which lead directly from the node to adjacent nodes. The specific number of data packets to be transmitted for each incoming data packet depends on the specific parameterization of the node; for example, three of five outputs of the node are parameterized in such a manner that a “multicast” data packet is forwarded only to the three of the five outputs.
[0067] Instead of or in addition to the forwarding types as data packet classes, such as “unicast” or “multicast”, embodiments of the invention can distinguish priority classes. For example, there are three priority classes: basic, extension 1 and extension 2. In this case, the faulty node can be located specifically for one of the three priority classes. Alternatively, however, it is also possible to consider two or more classes together in order to determine the expected total outgoing data traffic GDV therefrom. For example, the observer nodes consider the data packets which correspond to the basic priority class and, at the same time, correspond to unicast or broadcast as forwarding types. According to this specification, the observer nodes determine the incoming data traffic and outgoing data traffic matching this specification for each data packet class.
[0068] In the subsequent determination of the expected total outgoing data traffic, the respective expected outgoing data traffic is determined separately for each data packet class.
[0069] The following table shows an overview of the respective incoming data traffic, the respective outgoing data traffic and the respective expected outgoing data traffic for each data packet class for an observation period of 2 s, the respective traffic values resulting from a sum of the respective values determined at the respective observer nodes:
[0000]
Incoming data
Outgoing data
traffic DZU of
traffic DAB of
the respective
the respective
Expected
Data packet
data packet
data packet
outgoing data
class
class
class
traffic
1.
unicast
5000 bytes
4500 bytes
DVW1 = 5000
bytes
2.
broadcast
7500 bytes
20,000 bytes
DVW2 = 2 × 7500
bytes = 15,000
bytes
[0070] In the present exemplary embodiment, the expected total outgoing data traffic can be determined by summing the respective expected outgoing data traffic values of the respective data packet class and the expected data traffic of the data source of the at least one device. This results in:
[0000] GDV=DVW1+DVW2+DVG=5000 bytes+15,000 bytes+250 bytes
[0000] GDV=20,250 bytes
[0071] On account of the time delays between receiving and transmitting data packets, the threshold value SWLL=1000 bytes is selected. The difference value
[0000] DIFF=(4500 bytes+20,000 bytes)−20,250 bytes=4250 bytes
[0072] Since SWLL>DIFF, the monitored node is a faulty node KF.
[0073] In one alternative of the method, not only is a single node having a device monitored, but rather two or more nodes, which are each at least coupled to a device, can also be monitored.
[0074] In FIG. 2 , the nodes K 1 and K 2 having the devices G 1 , G 2 are intended to be monitored. For this purpose, a collective node KS is first of all formed from the nodes G 1 , G 2 , which collective node has all connections which leave from K 1 and K 2 but not the connections to the respective devices and not to K 1 and K 2 themselves. The collective node comprises the connections V 1 , V 5 and V 3 . The observer nodes are then selected as K 6 , K 5 and K 3 which can determine the entire incoming data traffic to the collective node and the entire outgoing data traffic from the collective node. The collective node is the monitored node WK.
[0075] A procedure for determining the expected total outgoing data traffic, the difference value and the statement regarding whether or not the monitored node is a faulty node is similar to that in the preceding examples. The evaluation in order to determine whether the monitored node is a faulty node then indicates, however, that at least one of the two nodes K 1 , K 2 is a faulty node. If the monitored node is identified as a faulty node, both nodes K 1 , K 2 can be removed, that is to say isolated, from the network, with the result that no data packets are sent to them or accepted from them.
[0076] In order to locate which of the two nodes K 1 , K 2 contained in the collective node is a faulty node, it is then possible to proceed in such a manner that the node K 1 and the node K 2 are checked separately in order to determine whether the respective node is a faulty node. In the present example according to FIG. 2 , only the node K 2 is then examined for faulty behavior. If it emerges that node K 2 is faulty, it can be blocked. If it emerges that node K 2 is operating in a fault-free manner, the faulty node must be K 1 . In this case, node K 1 can be blocked in such a manner that it cannot send any data into the network.
[0077] In order to avoid excessive loading of the respective nodes by using the individual steps of embodiments of the invention, the method can be used to increase the quality of service only when a connection or the outgoing data traffic of a specific node exceeds an adjustable volume of data per unit of time. For example, the network allows a bandwidth of 100 Mbit/s on the respective connections. The data threshold is thus set to 70%×100 Mbit/s=70 Mbit/s, for example. This means that, if a connection and/or outgoing data traffic of a specific node exceed(s) this predefinable volume of data DS per time, the method is started and a check is carried out in order to determine whether or not the considered node is a faulty node.
[0078] Embodiments of the invention can be implemented and carried out by means of an apparatus VOR having a plurality of units. FIG. 3 shows an exemplary apparatus having the following units:
a) a first unit M 1 for selecting at least one of the nodes K 1 , . . . , K 6 as a monitored node WK; b) a second unit M 2 for producing at least two observer nodes KB 1 , KB 2 by selecting from the plurality of nodes K 1 , K 3 , the monitored node WK being excluded from the selection, in such a manner that
both incoming data traffic DZU, DZU 1 of a respective data packet class CLA to the monitored node WK from at least one of the at least two observer nodes KB 1 , KB 2 and outgoing data traffic DAB of the respective data packet class CLA from the monitored node WK to at least one of the at least two observer nodes K 1 , K 3 are completely determined,
c) a third unit M 3 for recording the incoming data traffic DZU and the outgoing data traffic DAB of the respective observer nodes KB 1 , KB 2 ; d) a fourth unit M 4 for generating expected total outgoing data traffic GDV of the monitored node WK on the basis of (i) the outgoing data traffic produced by the respective incoming data traffic DZU of the respective data packet class CLA and (ii) expected data traffic DVG of the data source DQ of the at least one device G; e) a fifth unit M 5 for generating a difference value DIFF from a difference between the outgoing data traffic DAB and the expected total outgoing data traffic GDV; f) a sixth unit M 6 for detecting the monitored node WK as a faulty node KF if the difference value DIFF exceeds a predefinable threshold value SWLL.
[0086] The apparatus VOR may also have a seventh unit M 7 which can be used to implement and carry out extensions and/or alternatives of embodiments of the invention.
[0087] The units M 1 , . . . , M 7 can be implemented in one or more of the nodes in the network, for example in the observer nodes KB 1 , KB 2 , the nodes communicating with one another via the network in order to communicate and also interchange values such as the incoming data traffic. In order to ensure secure communication between said nodes, the latter may possibly communicate via connections, these connections not leading via the monitored node. Therefore, some of the units may be implemented and realized on a plurality of nodes and some other units may be implemented and realized only on one of the nodes. The units and their functions can be distributed among the observer nodes as follows:
Observer node KB 1 :
First unit M 1 Second unit M 2 Third unit M 3 Fourth unit M 4 Fifth unit M 5 Sixth unit M 6 Seventh unit M 7
Observer node KB 2 :
Third unit M 3
[0098] It is noted that not all units or method steps need to be distributed among the observer nodes. Rather, the units or method steps can be implemented and realized in a manner distributed among a plurality of nodes in the network, the monitored node itself not realizing any of the units or method steps.
[0099] The units M 1 , . . . , M 7 may be in software, hardware or in a combination of software and hardware. In this case, individual method steps may be stored in a machine-readable code in a memory. The memory can be connected to a processor in such a manner that this processor can read the machine-readable code from the memory and can execute the respective coded instructions of the machine-readable code. The processor can also be connected to an input and/or output unit which can be used to interchange information with other units and nodes.
[0100] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
[0101] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.
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Methods and apparatuses for increasing quality of service in a network having nodes if there is a faulty node which can result in data traffic being overloaded in at least one part of the network are provided. The disclosed embodiments of the invention can be used in the field of safety-critical applications, such as medial applications, monitoring devices, and in-vehicle communication systems.
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BACKGROUND AND OBJECTS OF THE INVENTION
This invention is directed to a bird feeder construction and more particularly with a bird feeder which may selectively increase or decrease the flow of seed therethrough to a feed position for birds.
Desirable features of bird feeders include the ability to effectively distribute different sized feed material, that is, the feeder should be able to be utilized on one hand for the distribution of fine seeds such as thistle seed and be similarly capable for efficient distribution of large, i.e., sunflower, seeds with a minimum of adjustment or modification. Another desirable bird feeder feature is that they may additionally present the feed in a position which is readily accessible for the feeding of birds in a natural position and thus enables the effective use of the device for intended bird species. In addition, this position in which the seed is presented should desirably be one in which a mass or body of seed is held together such that the birds can peck at to dislodge individual seeds such that a more natural way of feeding is simulated, that is, the feeder should be capable of preventing the free flow or scattering of the seed.
Many types of bird feeder constructions are available which provide for one or more of the above such indicated desirable features but none provide such an effective or unique operational manner as the present invention.
Accordingly, the above and other objects of the present invention are accomplished by a feed device for birds including an upper vertically disposed container for the receipt and storage of seed and a seed distribution assembly mounted at said container bottom such that seed from said container may pass therethrough, said assembly including a downwardly outwardly slanted lower wall on which said seed may collect in a pile therein and further including an upstanding circular, peripherally extending combination perch and seed collection tray disposed at the bottom thereof and an intermediate wall extending upright from the outer periphery of said lower wall, said intermediate wall having a plurality of separate circumferentially-spaced feed openings therethrough such that seed from said pile is visible through said intermediate wall, said assembly further including an upright circular band frictionally mounted on the outside of said intermediate wall for limited rotational positioning with respect thereto, said band including a plurality of separate circumferentially-spaced openings such that rotation of said band selectively at least partially blocks some of said feed openings in said intermediate wall and wherein said lower wall openings and said band openings each have laterally-spaced first and second side edges defining the lateral extent of said openings and wherein at least some of said opening side edges are angularly slanted such that superposing a slanted first side edge of said band with a second side edge of said lower wall forms a somewhat triangular limited feed access opening through which birds may pluck seed from said pile.
Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings.
DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
FIG. 1 is a perspective view of a bird feeder construction including the present invention;
FIGS. 2 through 4 are partial views of the bird feeder bottom shown in FIG. 1 wherein a portion of the distribution assembly thereof, namely, the rotatable band, is positioned in various positions with respect to the remaining bird feeder portions;
FIG. 5 is a view similar to FIGS. 2 through 4 but partially in section showing the manner in which the seed distribution assembly of the present invention is particularly supported from the remaining portions of the bird feeder device;
FIG. 6 is an enlarged sectional portion of FIG. 5 and shows particularly the manner in which the various seed distribution assembly parts relate to each other.
FIGS. 7 and 8 are enlarged views showing the manner in which the seed opening can be varied from large to small respectively; and
FIG. 9 is a view similar to FIG. 7 showing an alternate form of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings and particularly FIG. 1 thereof, the present bird feeder construction 10 is shown. Such feeder device 10 includes a container portion 12 generally of cylindrical configuration and formed from a transparent or semi-transparent material such as butyrate, polycarbonate or the like. The upper container 12 portion is provided with a combination closure and hanging assembly 14 including a cover 16 and a bail 18. The generally open bottom end of the container 12 is provided with a distribution assembly 20. The assembly 20 is supported in the displayed position by mounting means 22 including a laterally extending connecting bar 24 having terminal fingers 26 which extend into slots or openings provided in the container 12 wall. A central portion of the bar 24 includes a threaded opening 28 for receipt of a threaded rod 29 upwardly extending from a base portion of the distribution assembly and in a manner which will hereinafter be more clearly apparent. It should also be pointed out that although the mounting of the assembly 20 is depicted at the bottom of the container portion 12 that such assembly could be mounted at a position intermediate the container portion 12 and that the phrase bottom does not preclude such placement.
The distribution assembly 20 includes a lower wall 30 on which seed stored in the container portion 12 is adapted to rest. Because of the downward outward radial slope of the wall 30, seed collects thereon in a generally conical pile and further forces the seed to the outer peripheral portions of the distribution assembly. The assembly further includes an upright intermediate wall 32 which is essence surrounds the lower peripheral surface of the lower wall 30. The intermediate wall 32 upper terminal portion includes a radially inward offset portion 34 which is adapted to slidingly receive the container 12 lower terminal portions which in turn rest upon a ledge 36 formed thereby. Also as best seen in the FIG. 5 drawing, the bolt or other threaded member 29 extends through a central opening 38 in the lower wall 30 and may be firmly positioned in the depicted manner by tightening the bolt head 40 positioned beneath the lower wall 30.
Generally the lower wall 30 is part of an overall stamping 39 which includes at the lower peripheral portions thereof a combination perch and seed receiving tray 41. Certainly, however, this part or element 39 may alternatively be made by casting or stamping and is preferably formed of aluminum, stainless steel or some other lightweight metal alloy but certainly includes the use of plastic resins as well. The tray 41 includes an upright peripheral perch portion 42 and a shallow generally U-shaped tray portion 43 for receiving seed which may fall there as birds feed from the device.
The intermediate wall portion 34 is provided with a plurality of circumferentially-spaced openings 44. These openings 44 include a generally straight or flat bottom edge 45 which preferably coincides with or in essence forms a continuation of the lower wall 30 such that seed diverted from the container 12 by reason of the lower wall is presented to such openings. This configuration is particularly desirable since it reduces or eliminates the build up of dust or sediment which can clog openings which are otherwise spaced above the lower feed wall and facilitates the cleaning of the device as well. Additionally, the openings 44 upwardly extend to a top wall 46 and are preferably in a generally inverted U shape configuration although certainly other configurations are contemplated. These wall openings 44 also include laterally spaced first and second side edges 47 and 48 respectively.
The distribution assembly 20 further includes a band 50 preferably formed from an integral metal strip which terminates in tabs 52 adapted to abut each other and through which a screw of other fastening means 54 is adapted to extend through openings such that the circular band may be frictionally positioned about the device 10 lower end and particularly surrounding the intermediate wall portion 34. The band 50 is further provided with openings 56. The openings 56 generally correspond to the shape of the openings 44 and include first and second side edges 57 and 58 respectively.
As the drawings illustrate, it may be apparent the band as particularly shown in FIGS. 2, 3 and 4 and in FIGS. 7, 8, and 9 can be variously positioned vis-a-vis the intermediate wall portion 34.
For instance, the openings 56 and 44 may be somewhat fully aligned as shown in FIGS. 2 and 9 such that full or nearly full seed accessibility is achieved. Alternatively, the openings 56 and 44 may be aligned so that only a minor portion of opening 44 remains accessible through opening 56 such that partial seed accessibility is achieved. Such minor effective opening is achieved. Such minor effective opening is shown in FIGS. 4 and 8. An increased amount of partial seed accessibility can be achieved by moving band 50 to the slightly larger effective openings shown by FIGS. 3 and 7. The openings 56 can, of course, be completed misaligned with the openings 44 such that feed access is totally blocked. It should also be pointed out the lower wall 30 extends a short distance to in effect form a ledge 62 on which both the band 50 and the intermediate wall 34 are adapted to rest. In addition, the entire seed distribution assembly 20 is simply held to the bottom of container 12 by the action of the rod 29. Thus tightening of the rod via head 40 forces the container 12 down against the ledge 36 via the bar 28. This in turn forces the intermediate wall 34, assuming it is a separate part, against the ledge 62 of the lower wall 30. In addition, the band 50 also is adapted to rest on the ledge 62 and extends preferably above the bottom of the lower edge of the container 12. When tightened, the band thus further serves to hold the container in round since these plastic tube-type structures often tend to be out of round. The positioning of the band 50 on the ledge 62 also enables the bottom of the openings 56 with the openings 44 to be aligned so as to eliminate seed dust, etc. from building up.
As previously stated, one of the key features of this structure is its ability to hold back the seed from freely flowing through the openings 44 and while the size of the openings 44 are such that large seed (sunflower, etc.) would bridge across the opening 44 behind the intermediate wall 34 and be presented to birds for the desired pecking removal. Smaller seed, however, requires a correspondigly smaller effective opening (that is, the visible opening 60 when a band opening 56 is partially superposed over an intermediate wall opening 44) to achieve this bridging effect so that the seed is presented to the perching bird in the aforementioned desired feeding manner. To achieve this ability to vary the effective or visible feed opening, at least one of the side edges of the openings 44 or 56 are downwardly laterally slanted such that full or partial superposing this slanted edge with an opening achieves a visible or effective feed opening 60 of somewhat triangular configuration. This triangular configuration has been found to be particularly effective in achieving the desired seed bridging effect in a wide variety of seed types and seed sizes. Of course, the slanted side edge could be placed on both sides of the opening 56 such as shown by 57a and 58a in FIG. 9. Similarly, the slanted side edge could be located in the intermediate wall, that is, forming a part of openings 44, and could also be inwardly slanted (that is, to the left) rather than outwardly (that is, to the right as shown in the drawings). Similarly, the slanted side edge could be partially curved such that visible openings of ovate or crescent shapes are formed, the term "slanted" being intended to cover such above-mentioned alternatives to these configurations specifically illustrated.
Operation of the above assembly is simply achieved by loosening the band 50 through the screw means, then rotationally adjusting the band vis-a-vis the container 12 such that the desired alignment of openings 56, 44 is achieved such as the sample illustrations shown in FIGS. 7-9, and then the screw means tightened such that the desired alignment is retained.
Turning now to FIGS. 7 and 9 particularly, the manner in which the seed is available through the respective openings provided in the intermediate wall 32 and the band 50 is illustrated. Therein a bird B perched upon the flange wall or perch 42 can extends its beak through the effective openings 60 should the openings 56 be aligned or superposed with the openings 44. Similarly if it is desired to attract very small birds such as those that feed on fine seed such as thistle seed, the container is appropriately loaded with such seed and band 50 positioned such that the effective feed openings 60 are very small thus restricting seed flow as is appropriate for finer seed.
While there is shown and described herein certain specific structure embodying this invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.
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A feed device for birds in which a feed distribution assembly is mounted at the bottom of a feed container. The distribution assembly includes a downwardly outwardly slanted lower wall which forces seed to the inner outside peripheral surfaces of the assembly against an intermediate wall which includes openings therethrough. Such openings are normally partially aligned with similar openings formed in an encircling band about the intermediate wall which band is adjustably rotatable thereon such that the desire rate of feed distribution is dependent on the species to be attracted and the seed size utilized.
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