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RELATED APPLICATIONS
[0001] This application is a continuation in part of applicant PCT application PCT/US97/17899 filed Oct. 1 st 1997.
BACKGROUND OF THE INVENTION
[0002] It is known that certain biologically active compounds are better absorbed through the oral mucosa than through other routes of administration, such as through the stomach or intestine. However, formulations suitable for such administration by these latter routes present their own problems. For example, the biologically active compound must be compatible with the other components of the composition such as propellants, solvents, etc. Many such formulations have been proposed. For example, U.S. Pat. No. 4,689,233, Dvorsky et al., describes a soft gelatin capsule for the administration of the anti-coronary drug nifedipine dissolved in a mixture of polyether alcohols. U.S. Pat. No. 4,755,389, Jones et al., describes a hard gelatin chewable capsule containing nifedipine. A chewable gelatin capsule containing a solution or dispersion of a drug is described in U.S. Pat. No. 4,935,243, Borkan et al. U.S. Pat. No. 4,919,919, Aouda et al, and U.S. Pat. No. 5,370,862, Klokkers-Bethke, describe a nitroglycerin spray for administration to the oral mucosa comprising nitroglycerin, ethanol, and other components. An orally administered pump spray is described by Cholcha in U.S. Pat. No. 5,186,925. Aerosol compositions containing a hydrocarbon propellant and a drug for administration to a mucosal surface are described in U.K. 2,082,457, Su, U.S. Pat. No. 3,155,574, Silson et al., U.S. Pat. No. 5,011,678, Wang et al., and by Parnell in U.S. Pat. No. 5,128,132. It should be noted that these references discuss bioavailability of solutions by inhalation rather than through the membranes to which they are administered.
SUMMARY OF THE INVENTION
[0003] A buccal aerosol spray or soft bite gelatin capsule using a polar or non-polar solvent has now been developed which provides biologically active compounds for rapid absorption through the oral mucosa, resulting in fast onset of effect.
[0004] The buccal aerosol spray compositions of the present invention, for transmucosal administration of a pharmacologically active compound soluble in a pharmacologically acceptable non-polar solvent comprise in weight % of total composition: pharmaceutically acceptable propellant 5-80%, non-polar solvent 20-85%, active compound 0.05-50%, suitably additionally comprising, by weight of total composition a flavoring agent 0.01-10%. Preferably the composition comprises: propellant 10-85%, non-polar solvent 25-89.9%, active compound 0.01-40%, flavoring agent 1-8%; most suitably propellant 20-70%, non-polar solvent 30-74.75%, active compound 0.25-35%, flavoring agent 2-7.5%.
[0005] The buccal polar aerosol spray compositions of the present invention, for transmucosal administration of a pharmacologically active compound soluble in a pharmacologically acceptable polar solvent are also administrable in aerosol form driven by a propellant. In this case the composition comprise in weight% of total composition: aqueous polar solvent 10-99%, active compound 0.1-25%, suitably additionally comprising, by weight of total composition a flavoring agent 0.05-10% and propellant: 2-10%. Preferably the composition comprises: polar solvent 20-97%, active compound 0.1-15%, flavoring agent 0.1-5% and propellant: 3-5%; most suitably polar solvent 25-97%, active compound 0.2-25%, flavoring agent 0.1-2.5% and propellant: 3-4%.
[0006] The buccal pump spray composition of the present invention for transmucosal administration of a pharmacologically active compound where said active compound is soluble in a pharmacologically acceptable non-polar solvent said composition comprise in weight % of total composition: non-polar solvent 30-99.69%, active compound 0.005-55%, and suitably additionally, flavoring agent 0.1-10%.
[0007] The buccal polar pump spray compositions of the present invention, for transmucosal administration of a pharmacologically active compound soluble in a pharmacologically acceptable polar solvent comprising in weight % of total composition: aqueous polar solvent 30-99.69%, active compound 0.001-60%, suitably additionally comprising, by weight of total composition a flavoring agent 0.1-10%. Preferably the composition comprises: polar solvent 37-98.58%, active compound 0.005-55%, flavoring agent 0.5-8%; most suitably polar solvent 60.9-97.06%, active compound 0.01-40%, flavoring agent 0.75-7.5%.
[0008] The soft bite gelatin capsules of the present invention for transmucosal administration of a pharmacologically active compound, at least partially soluble in a pharmacologically acceptable non-polar solvent, having charged thereto a fill composition comprise in weight % of total composition: non-polar solvent 4-99.99%, emulsifier 0-20%, active compound 0.01-80%, provided that said fill composition contains less than 10% of water, suitably additionally comprising, by weight of the composition: flavoring agent 0.01-10%. Preferably, the soft bite gelatin capsule comprises: non-polar solvent 21.5-99.975%, emulsifier 0-15%, active compound 0.025-70%, flavoring agent 1-8%; most suitably: non-polar solvent 28.5-97.9%, emulsifier 0-10%, active compound 0.1-65.0%, flavoring agent 2-6%.
[0009] The soft bite polar gelatin capsules of the present invention for transmucosal administration of a pharmacologically active compound, at least partially soluble in a pharmacologically acceptable polar solvent, having charged thereto a composition comprising in weight % of total composition: polar solvent 25-99.89%, emulsifier 0-20%, active compound 0.01-65%, provided that said composition contains less than 10% of water, suitably additionally comprising, by weight of the composition: flavoring agent 01-10%. Preferably, the soft bite gelatin capsule comprises: polar solvent 37-99.95%, emulsifier 0-15%, active compound 0.025-55%, flavoring agent 1-8%; most suitably: polar solvent 44-96.925%, emulsifier 0-10%, active compound 0.075-50%, flavoring agent 2-6%.
[0010] It is an object of the invention to coat the mucosal membranes either with extremely fine droplets of spray containing the active compounds or a solution or paste thereof from bite capsules.
[0011] It is also an object of the invention to administer to the oral mucosa of a mammalian in need of same, preferably man, by spray or bite capsule. a predetermined amount of a biologically active compound by this method or from a soft gelatin bite capsule.
[0012] A further object is a sealed aerosol spray container containing a composition of the non polar or polar aerosol spray formulation, and a metered valve suitable for releasing from said container a predetermined amount of said composition.
[0013] As the propellant evaporates after activation of the aerosol valve, a mist of fine droplets is formed which contains solvent and active compound.
[0014] The propellant is a non-Freon material, preferably a C 3-8 hydrocarbon of a linear or branched configuration. The propellant should be substantially non-aqueous. The propellant produces a pressure in the aerosol container such that under expected normal usage it will produce sufficient pressure to expel the solvent from the container when the valve is activated but not excessive pressure such as to damage the container or valve seals.
[0015] The non-polar solvent is a non-polar hydrocarbon, preferably a C 7-18 hydrocarbon of a linear or branched configuration, fatty acid esters, and triglycerides, such as miglyol. The solvent must dissolve the active compound and be miscible with the propellant, i.e., solvent and propellant must form a single phase at 0-40ยฐ C. at a pressure range of 1-3 atm.
[0016] The polar and non-polar aerosol spray compositions of the invention are intended to be administered from a sealed, pressurized container. Unlike a pump spray, which allows the entry of air into the container after every activation, the aerosol container of the invention is sealed at the time of manufacture. The contents of the container are released by activation of a metered valve, will does not allow entry of atmospheric gasses with each activation. Such containers are commercially available.
[0017] A further object is a pump spray container containing a composition of the pump spray formulation, and a metered valve suitable for releasing from said container a predetermined amount of said composition.
[0018] A further object is a soft gelatin bite capsule containing a composition of as set forth above. The formulation may be in the form of a viscous solution or paste containing the active compounds. Although solutions are preferred, paste fills may also be used where the active compound is not soluble or only partially soluble in the solvent of choice. Where water is used to form part of the paste composition, it should not exceed 10% thereof. (All percentages herein are by weight unless otherwise indicated.) The polar or non-polar solvent is chosen such that it is compatible with the gelatin shell and the active compound. The solvent preferably dissolves the active compound. However, other components wherein the active compound is not soluble or only slightly soluble may be used and will form a paste fill.
[0019] Soft gelatin capsules are well known in the art. See, for example, U.S. Pat. No. 4,935,243, Borkan et al., for its teaching of such capsules. The capsules of the present invention are intended to be bitten into to release the low viscosity solution or paste therein, which will then coat the buccal mucosa with the active compounds. Typical capsules, which are swallowed whole or bitten and then swallowed, deliver the active compounds the stomach, which results in significant lag time before maximum blood levels can be achieved or subject the compound to a large first pass effect. Because of the enhanced absorption of the compounds through the oral mucosa and no chance of a first pass effect, use of the bite capsules of the invention will eliminate much of the lag time, resulting in hastened onset of biological effect. The shell of a soft gelatin capsule of the invention may comprise, for example:
[0020] Gelatin: 50-75%, glycerin 20-30%, colorants 0.5-1.5%, water 5-10%, and sorbitol 2-10%.
[0021] The active compound may include. biologically active peptides, central nervous system active amines, sulfonyl ureas, antibiotics, antifungals, anti-virals, sleep inducers, antiasthmatics, bronchial dilators, antiemetics, histamine H-2 receptor antagonists, barbiturates, prostaglandins and neutraceuticals.
[0022] The active compounds may also include antihistamines, alkaloids, hormones, benzodiazepines and narcotic analgesics. While not limited thereto, these active compounds are particularly suitable for non-polar pump spray formulation and application.
BRIEF DESCRIPTION OF THE DRAWING
[0023] The figure is a schematic diagram showing routes of absorption and processing of pharmacologically active substances in a mammalian system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The preferred active compounds of the present invention are in an ionized, salt form or as the free base of the pharmaceutically acceptable salts thereof (provided, for the aerosol or spray compositions, they are soluble in the spray solvent). These compounds are soluble in the non-polar solvents of the invention at useful concentrations or can be prepared as pastes at useful concentrations. These concentrations may be less than the standard accepted dose for these compounds since there is enhanced absorption of the compounds through the oral mucosa. This aspect of the invention is especially important when there is a large (40-99.99%) First pass effect.
[0025] As propellants for the non polar sprays, propane, N-butane, iso-butane, N-pentane, iso-pentane, and neo-pentane, and mixtures thereof may be used. N-butane and iso-butane, as single gases, are the preferred propellants. It is permissible for the propellant to have a water content of no more than 0.2%, typically 0.1-0.2%. (All percentages herein are by weight unless otherwise indicated.) It is also preferable that the propellant be synthetically produced to minimize the presence of contaminants which are harmful to the active compounds. These contaminants include oxidizing agents, reducing agents, Lewis acids or bases, and water. The concentration of each of these should be. less than 0.1%, except that water may be as high as 0.2%.
[0026] Suitable non-polar solvents for the capsules and the non-polar sprays include (C 2 -C 24 ) fatty acid C 2 -C 6 esters, C 7 -C 18 hydrocarbon, C 2 -C 6 alkanoyl esters, and the triglycerides of the corresponding acids. When the capsule fill is a paste, other liquid components may be used instead of the above low molecular weight solvents. These include soya oil, corn oil, other vegetable oils.
[0027] As solvents for the polar capsules or sprays there may be used low molecular weight polyethyleneglycols (PEG) of 400-1000 Mw (preferably 400-600), low molecular weight (C 2 -C 8 ) mono and polyols and alcohols of C 7 -C 18 linear or branch chain hydrocarbons, glycerin may also be present and water may also be used in the sprays, but only in limited amount in the capsules.
[0028] It is expected that some glycerin and water used to make the gelatin shell will migrate from the shell to the fill during the curing of the shell. Likewise, there may be some migration of components from the fill to the shell during curing and even throughout the shelf-life of the capsule. Therefore, the values given herein are for the compositions as prepared, it being within the scope of the invention that minor variations will occur.
[0029] The preferred flavoring agents are synthetic or natural oil of pepper-mint, oil of spearmint, citrus oil, fruit flavors, sweeteners (sugars, aspartame, saccharin, etc.), and combinations thereof.
[0030] The active substances include the active compounds selected from the group consisting of cyclosporine, sermorelin, Octreotide acetate, cal-citonin-salmon, insulin lispro, sumatriptan succinate, clozepine, cyclo-benzaprine, dexfenfluramine hydrochloride, glyburide, zidovudine, erythromycin, ciprofloxacin, ondansetron hydrochloride, dimenhydrinate, cimetidine hydrochloride, famotidine, phenytoin sodium, phenytoin, carboprost thromethamine, carboprost, diphenhydramine hydrochloride, isoproterenol hydrochloride, terbutaline sulfate, terbutaline, theophylline, albuterol sulfate and neutraceuticals, that is to say nutrients with pharmacological action such as but not limited to carnitine, valerian, echinacea, and the like.
[0031] The formulations of the present invention comprise an active compound or a pharmaceutically acceptable salt thereof. The term โpharmaceutically acceptable saltsโ refers to salts prepared from pharmaceutically acceptable non-toxic acids or bases including organic and inorganic acids or bases.
[0032] When an active compound of the present invention is acidic, salts may be prepared from pharmaceutically acceptable non-toxic bases. Salts derived from all stable forms of inorganic bases include aluminum, ammonium, calcium, copper, iron, lithium, magnesium, manganese, potassium, sodium, zinc, etc. Particularly preferred are the ammonium, calcium, magnesium, potassium, and sodium salts. Salts derived from pharmaceutically acceptable organic non-toxic bases include salts of primary, secondary, and tertiary amines, substituted amines including naturally occurring substituted amines, cyclic amines and basic ion-exchange resins such as arginine, betaine, caffeine, choline, N,Nโฒ-dibenzylethylenediamine, diethylamine, 2-diethylaminoethanol, 2-dimethyl-aminoethanol, ethanolamine, ethylenediamine, N-ethylmorpholine, N-ethyl-piperidine, glucamine, glucosamine, histidine, isopropylamine, lysine, methyl-glucosamine, morpholine, piperazine, piperidine, polyamine resins, procaine, purine, theobromine, triethylamine, trimethylamine, tripropylamine, etc.
[0033] When an active compound of the present invention is basic, salts may be prepared from pharmaceutically acceptable non-toxic acids. Such acids include acetic, benzenesulfonic, benzoic, camphorsulfonic, citric, ethane-sulfonic, fumaric, gluconic, glutamic, hydrobromic, hydrochloric, isethionic, lactic, maleic, mandelic, methanesulfonic, mucic, nitric, pamoic, pantothenic, phosphoric, succinic, sulfuric, tartaric, p-toluenesulfonic, etc. Particularly preferred are citric, hydrobromic, maleic, phosphoric, sulfuric, and tartaric acids.
[0034] In the discussion of methods of treatment herein, reference to the active compounds is meant to also include the pharmaceutically acceptable salts thereof. While certain formulations are set forth herein, the actual amounts to be administered to the mammal or man in need of same are to be determined by the treating physician.
[0035] The invention is further defined by reference to the following examples, which are intended to be illustrative and not limiting.
[0036] The following are examples of each class (all values unless otherwise specified are in weight percent):
EXAMPLE 1
Biologically Active Peptides Including Peptide Hormones
[0037] [0037] A. Cyclosporine lingual spray most preferred Amounts preferred amount amount Cyclosporine 5-50 10-35 15-25 water 5-20 7.5-50โ 9.5-12โ ethanol 5-60 7.5-50โ 10-20 polyethylene glycol 20-60โ 30-45 35-40 flavors 0.1-5โโ 1-4 2-3
[0038] [0038] B. Cyclosporine Non-Polar lingual spray most preferred Amounts preferred amount amount Cyclosporine 1-50 3-40 โ5-30 Migylolโยฎ* 30-40 Polyoxyethylated 30-40 castor oil Butane 25-80โ 30-70โ 33-50 flavors 0.1-5โโ 1-4โ 2-3
[0039] [0039] C. Cyclosporine non-polar bite capsule most preferred Amounts preferred amount amount Cyclosporine โ1-35 5-25 10-20 olive oil 25-60 35-55โ 30-45 polyoxyethyl- 25-60 35-55โ 30-45 ated oleic glycerides flavors 0.1-5โโ 1-4โ 2-3
[0040] [0040] D. Cyclosporine bite capsule most preferred Amounts preferred amount amount Cyclosporine 5-50 10-35 15-25 polyethylene glycol 20-60โ 30-45 35-40 glycerin 5-30 7.5-25โ 10-20 propylene glycol 5-30 7.5-25โ 10-20 flavors 0.1-10โโ 1-8 3-6
[0041] [0041] E. Sermorelin (as the acetate) lingual spray Amounts preferred amount most preferred sermorelin (as the .01-5 .1-3โ โ.2-1.0 acetate) mannitol, โโ1-25 โ5-20 10-15 monobasic sodium 0.1-5 1-3 1.5-2.5 phosphate, dibasic sodium 0.01-5โ .05-3โโ 0.1-0.5 phosphate water ethanol โโ5-30 7.5-25โ 9.5-15โ polyethylene glycol โโ20-60 30-45 35-40 propylene glycol โโ5-25 10-20 12-17 flavors 0.1-5 1-4 2-3
[0042] [0042] F. Octreotide acetate (Sandostatin*) lingual spray most preferred Amounts preferred amount amount octreotide acetate 0.001-0.5โโ 0.005-0.250 0.01-0.10 acetic acid 1-10 2-8 4-6 sodium acetate 1-10 2-8 4-6 sodium chloride 3-30 โ .5-25 โ 15-20 flavors 0.1-5โโ 0.5-.4โ 2-3 ethanol 5-30 7.5-20โ 9.5-15โ water 15-95โ 35-90 65-85 flavors 0.1-5โโ 1-4 2-3
[0043] [0043] G. Calcitonin-salmon lingual spray most preferred Amounts preferred amount amount Calcitonin-salmon 0.001-5โโโ 0.005-2โโโ 01-1.5 ethanol 2-15 3-10 โ7-9.5 water 30-95โ 50-90โ 60-80โ polyethylene glycol 2-15 3-10 โ7-9.5 sodium chloride 2.5-20โโ 5-15 โ10-12.5 flavors 0.1-5โโ 1-4โ 2-3โ
[0044] [0044] H. insulin lispro, lingual spray most preferred Amounts preferred amount amount insulin, 20-60โ โโ4-55 5-50 glycerin, 0.1-10โโ 0.25-5โ 0.1-1.5โ dibasic sodium 1-15 2.5-10 4-8โ phosphate, m-cresol, 1-25 โโ5-25 7.5-12.5 zinc oxide 0.01-0.25โ โโ.05-0.15 0.075-0.10โ m-cresol, 0.1-1โโ โ0.2-0.8 0.4-0.6โ phenol trace amounts trace amounts trace amounts ethanol 5-20 7.5-15 9-12 water 30-90โ โ40-80 50-75โ propylene glycol 5-20 7.5-15 9-12 flavors 0.1-5โโ 0.5-3โ 0.75-2โโโ adjust pH to 7.0-7.8 with HCl or NaOH
EXAMPLE 2
CNS Active Amines and Their Salts: Including but not Limited to Tricyclic Amines, GABA Analogues, Thiazides, Phenothiazine Derivatives, Serotonin Antagonists and Serotonin Reuptake Inhibitors
[0045] [0045] A. Sumatriptan succinate lingual spray most preferred Amounts preferred amount amount sumatriptan succinate 0.5-30โโ โโ1-20 10-15 ethanol 5-60 7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 โ30-45 35-40 water 5-30 7.5-20 10-15 flavors 0.1-5โโ โ1-4 2-3
[0046] [0046] B. Sumatriptan succinate bite capsule most preferred Amounts preferred amount amount sumatriptan succinate 0.01-5โโ 0.05-3.5โ 0.075-1.75โ polyethylene glycol 25-70 30-60 35-50 glycerin 25-70 30-60 35-50 flavors 0.1-10โ 1-8 3-6
[0047] [0047] C. Clozepine lingual spray most preferred Amounts preferred amount amount Clozepine 0.5-30โโ โโ1-20 10-15 ethanol 5-60 7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 โ30-45 35-40 water 5-30 7.5-20 10-15 flavors 0.1-5โโ โ1-4 2-3
[0048] [0048] D. Clozepine Non-Polar lingual spray with propellent most preferred Amounts preferred amount amount Clozepine 0.5-30 1-20 10-15 Migylol โ20-85 25-70โ 30-40 Butane โ15-80 30-75โ 60-70 flavors 0.1-5โ 1-4โ 2-3
[0049] [0049] E. Clozepine Non-Polar lingual spray without propellant most preferred Amounts preferred amount amount Clozepine 0.5-30 1-20 10-15 Migylol โ โโ 70-99.5โ 80-99โ 85-90 flavors 0.1-5โ 1-4โ 2-3
[0050] [0050] F. Cyclobenzaprine Non polar lingual spray most preferred Amounts preferred amount amount Cyclobenzaprine 0.5-30 1-20 10-15 (base) Migylol โ20-85 25-70โ 30-40 Iso-butane โ15-80 30-75โ 60-70 flavors 0.1-5โ 1-4โ 2-3
[0051] [0051] G. dexfenfluramine hydrochloride lingual spray preferred most preferred Amounts amount amount dexfenfluramine Hcl 5-30 7.5-20 10-15 ethanol 5-60 7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 โ30-45 35-40 water 5-30 7.5-20 10-15 flavors 0.1-5โโ โ1-4 2-3
EXAMPLE 3
Sulfonylureas
[0052] [0052] A. Glyburide lingual spray most preferred Amounts preferred amount amount Glyburide 0.25-25โโ 0.5-20 0.75-15โโ ethanol 5-60 7.5-50 10-20 propylene glycol 5-30 7.5-20 10-15 polyethylene glycol 0-60 โ30-45 35-40 water 2.5-30โโ โโ5-20 โ6-15 flavors 0.1-5โโ โ1-4 2-3
[0053] [0053] B. Glyburide non-polar bite capsule most preferred Amounts preferred amount amount Glyburide 0.01-10โโ 0.025-7.5โ 0.1-4โ olive oil 30-60 35-55 โ30-50 polyoxyethyl- 30-60 35-55 โ30-50 ated oleic glycerides flavors 0.1-5โโ 1-4 โ2-3
EXAMPLE 4
Antibiotics Anti-fungals and Anti-virals
[0054] [0054] A. zidovudine [formerly called azidothymidine (AZT) (Retrovir) non-polar lingual spray most preferred Amounts preferred amount amount zidovudine 10-50 15-40 25-35 Soya oil 20-85 25-70 30-40 Butane 15-80 30-75 60-70 flavors 0.1-5โโ 1-4 2-3
[0055] [0055] B. Erythromycin bite capsule bite capsule most preferred Amounts preferred amount amount Erythromycin 25-65โ 30-50 35-45 polyoxyethylene glycol 5-70 30-60 45-55 glycerin 5-20 7.5-15โ โโ10-12.5 flavors 1-10 2-8 3-6
[0056] [0056] C. Ciprofloxacin hydrochloride bite capsule most preferred Amounts preferred amount amount Ciprofloxacin 25-65 35-55 40-50 hydrochloride glycerin โ5-20 7.5-15โ โโ10-12.5 polyethylene glycol 20-75 30-65 40-60 flavors โ1-10 2-8 3-6
[0057] [0057] D. zidovudine [formerly called azidothymidine (AZT) (Retrovir) lingual spray most preferred Amounts preferred amount amount zidovudine 10-50 15-40 25-35 water 30-80 40-75 45-70 ethanol โ5-20 7.5-15โ โ9.5-12.5 polyethylene glycol โ5-20 7.5-15โ โ9.5-12.5 flavors 0.1-5โโ 1-4 2-3
EXAMPLE 5
Anti-emetics
[0058] [0058] A. Ondansetron hydrochloride lingual spray most preferred Amounts preferred amount amount ondansetron hydro- 1-25 2-20 2.5-15 chloride citric acid mono- 1-10 2-8โ 2.5-5โ hydrate, sodium citrate di- 0.5-5โโ 1-4โ โ 1.25-2.5 โ hydrate water 1-90 5-85 โ10-75 ethanol 5-30 7.5-20โโ 9.5-15 propylene glycol 5-30 7.5-20โโ 9.5-15 polyethylene glycol 5-30 7.5-20โโ 9.5-15 flavors 1-10 3-8โ โ โโ 5-7.5โ
[0059] [0059] B. Dimenhydrinate bite capsule most preferred Amounts preferred amount amount Dimenhydrinate 0.5-30โโ 2-25 3-15 glycerin 5-20 7.5-15โโ โ10-12.5 polyethylene glycol 45-95โ 50-90โ 55-85โ flavors 1-10 2-8โ 3-6โ
[0060] [0060] C. Dimenhydrinate polar lingual spray most preferred Amounts preferred amount amount Dimenhydrinate 3-50 4-40 5-35 water 5-90 10-80โ 15-75โ ethanol 1-80 3-50 5-10 polyethylene 1-80 3-50 5-15 glycol Sorbitol 0.1-5โโ 0.2-4โโ 0.4-1.0โ aspartame 0.01-0.5โ 0.02-0.4โ 0.04-0.1โ flavors 0.1-5โโ 1-4โ 2-3โ
EXAMPLE 6
Histamine H-2 Receptor Antagonists
[0061] [0061] A. Cimetidine hydrochloride bite capsule most preferred Amounts preferred amount amount Cimetidine Hcl 10-60 15-55 25-50 glycerin โ5-20 7.5-15โ โโ10-12.5 polyethylene 20-90 25-85 30-75 glycol flavors โ1-10 2-8 3-6
[0062] [0062] B. Famotidine lingual spray most preferred Amounts preferred amount amount Famotidine โโ1-35 5-30 7-20 water 2.5-25 3-20 5-10 L-aspartic acid 0.1-20 1-15 5-10 polyethylene glycol โ20-97 30-95โ 50-85โ flavors 0.1-10 โ1-7.5 2-5โ
[0063] [0063] C. Famotidine non-polar lingual spray most preferred Amounts preferred amount amount Famotidine โ1-35 โ5-30 โ7-20 Soya oil 10-50 15-40 15-20 Butane 15-80 30-75 45-70 polyoxyethyl- 10-50 15-40 15-20 ated oleic glycerides flavors 0.1-5โโ 1-4 2-3
EXAMPLE 7
Barbiturates
[0064] [0064] A. Phenytoin sodium lingual spray most preferred Amounts preferred amount amount Phenytoin sodium 10-60โ โ15-55 โ20-40 water 2.5-25โโ โโ3-20 โโ5-10 ethanol 5-30 7.5-20 9.5-15 propylene glycol 5-30 7.5-20 9.5-15 polyethylene glycol 5-30 7.5-20 9.5-15 flavors 1-10 โ3-8 โ โโ 5-7.5โ
[0065] [0065] B. Phenytoin non-polar lingual spray most preferred Amounts preferred amount amount Phenytoin โ5-45 10-40 15-35 migylol 10-50 15-40 15-20 Butane 15-80 30-75 60-70 polyoxyethyl- 10-50 15-40 15-20 ated oleic glycerides flavors 0.1-10โ 1-8 โโ5-7.5
EXAMPLE 8
Prostaglandins
[0066] [0066] A. Carboprost thromethamine lingual spray most preferred Amounts preferred amount amount Carboprost thrometha- 0.05-5โโโ 0.1-3โ 0.25-2.5โ mine water 50-95โ โ60-80 65-75โ ethanol 5-20 7.5-15 9.5-12.5 polyethylene glycol 5-20 7.5-15 9.5-12.5 sodium chloride 1-20 โโ3-15 4-8โ flavors 0.1-5โโ โ1-4 2-3โ
[0067] [0067] B. Carboprost non-polar lingual spray most preferred Amounts preferred amount amount Carboprost 0.05-5โโ 0.1-3โโ 0.25-2.5โ migylol 25-50 30-45 35-40 Butane โ5-60 10-50 20-35 polyoxyethyl- 25-50 30-45 35-40 ated oleic glycerides flavors 0.1-10โ 1-8 โโ5-7.5
EXAMPLE 9
Neutraceuticals
[0068] [0068] A. Carnitine as bite capsule (contents are a paste) most preferred Amounts preferred amount amount Carnitine fumarate 6-80 30-70 โโ45-65 soya oil 7.5-50โโ 10-40 12.5-35 soya lecithin 0.001-1.0โโ 0.005-0.5โ โโ.01-0.1 Soya fats 7.5-50โโ 10-40 12.5-35 flavors 1-10 2-8 โโ3-6
[0069] [0069] B. Valerian as lingual spray most preferred Amounts preferred amount amount Valerian extract 0.1-10โโ 0.2-7โ 0.25-5โ water 50-95โ โ60-80 โโ65-75 ethanol 5-20 7.5-15 โโ9.5-12.5 polyethylene glycol 5-20 7.5-15 โโ9.5-12.5 flavors 1-10 โ2-8 โโ3-6
[0070] [0070] B. Echinacea as bite capsule most preferred Amounts preferred amount amount Echinacea extract โ30-85 40-75 โโ45-55 soya oil 7.5-50 10-40 12.5-35 soya lecithin 0.001-1.0 โโโ 0.005-0.5โ โโ.01-0.1 Soya fats 7.5-50 10-40 12.5-35 flavors โโ1-10 2-8 โโ3-6
[0071] [0071] B. Mixtures of ingredients most preferred Amounts preferred amount amount Magnesium oxide 15-40 โโ20-35 โโ25-30 Chromium picolinate 0.01-1.0โ โ0.02-0.5 โโ.025-0.75 folic acid .025-3.0โ โ0.05-2.0 โ0.25-0.5 vitamin B-12 0.01-1.0โ โ0.02-0.5 โโ.025-0.75 vitamin E 15-40 โโ20-35 โโ25-30 Soya oil 10-40 12.5-35 โโ15-20 soya lecithin 0.1-5โโ 0.2-4 โโ0.5-1.5 soya fat 10-40 โโ15-35 17.5-20
EXAMPLE 10
Sleep Inducers (Also CNS Active Amine)
[0072] [0072] A. Diphenhydramine hydrochloride lingual spray most preferred Amounts preferred amount amount Diphenhydramine 3-50 4-40 5-35 Hcl water 5-90 10-80โ 50-75โ ethanol 1-80 3-50 5-10 polyethylene 1-80 3-50 5-15 glycol Sorbitol 0.1-5โโ 0.2-4โโ 0.4-1.0โ aspartame 0.01-0.5โ 0.02-0.4โ 0.04-0.1โ flavors 0.1-5โโ 1-4โ 2-3โ
EXAMPLE 11
Anti-Asthmatics-Bronchodilators
[0073] [0073] A. Isoproterenol Hydrochloride as polar lingual spray most preferred Amounts preferred amount amount Isoproterenol 0.1-10 0.2-7.5โ 0.5-6โโ Hydrochloride water โโ5-90 10-80โ 50-75โ ethanol โโ1-80 3-50 5-10 polyethylene โโ1-80 3-50 5-15 glycol Sorbitol 0.1-5โ 0.2-4โโ 0.4-1.0โ aspartame โ 0.01-0.5 โ 0.02-0.4โ 0.04-0.1โ flavors 0.1-5โ 1-4โ 2-3โ
[0074] [0074] B. Terbutaline sulfate as polar lingual spray most preferred Amounts preferred amount amount Terbutaline 0.1-10 โโ0.2-7.5 0.5-6 sulfate water โโ5-90 โโ10-80 โโ50-75 ethanol โโ1-10 โโ2-8 2.5-5 Sorbitol 0.1-5โ 0.2-4 โโ0.4-1.0 aspartame โ 0.01-0.5 โ โ0.02-0.4 โ0.04-0.1 flavors 0.1-5โ โโ1-4 โโ2-3
[0075] [0075] C. Terbutaline as non-polar lingual spray most preferred Amounts preferred amount amount Terbutaline 0.1-10 0.2-7.5 0.5-6โโ migylol โ25-50 30-45 35-40 isobutane โโ5-60 10-50 20-35 polyoxyethylated โ25-50 30-45 35-40 oleic glycerides flavors 0.1-10 1-8 โโ5-7.5
[0076] [0076] D. Theophylline polar bite capsule most preferred Amounts preferred amount amount Theophylline โ5-50 10-40 15-30 polyethylene 20-60 25-50 30-40 glycol glycerin 25-50 35-45 30-40 propylene glycol 25-50 35-45 30-40 flavors 0.1-5โโ 1-4 2-3
[0077] [0077] E. Albuterol sulfate as polar lingual spray most preferred Amounts preferred amount amount Albuterol sulfate 0.1-10 โโ0.2-7.5 0.5-6 water โโ5-90 โโ10-80 โโ50-75 ethanol โโ1-10 โโ2-8 2.5-5 Sorbitol 0.1-5โ 0.2-4 โโ0.4-1.0 aspartame โ 0.01-0.5 โ โ0.02-0.4 โ0.04-0.1 flavors 0.1-5โ โโ1-4 โโ2-3
EXAMPLE 12
Polar Solvent Formulations Using a Propellant
[0078] [0078] A. Sulfonylurea Most-Preferred Amount Preferred Amount Amount Glyburide โ0.1-25% โ0.5-15% 0.6-10% Ethanol โโ40-99% โโ60-97% โ70-97% Water 0.01-5%โ 0.1-4% 0.2-2%โ Flavors 0.05-10% 0.1-5% โ0.1-2.5% Propellant โโ2-10% โโ3-5% โ3-4%
[0079] [0079] B. Prostaglandin E 1 (vasodilator) Most-Preferred Amount Preferred Amount Amount Prostaglandin E 1 0.01-10% 0.1-5% 0.2-3% Ethanol โโ10-90% โโ20-75% โโ25-50% Propylene glycol โโ1-90% โโ5-80% โโ10-75% Water 0.01-5%โ 0.1-4% 0.2-2% Flavors 0.05-10% 0.1-5% โโ0.1-2.5% Propellant โโ2-10% โโ3-5% โโ3-4%
[0080] [0080] C. Promethazine (antiemetic, sleep inducer, and CNS active amine) Most-Preferred Amount Preferred Amount Amount Promethazine 1-25% 3-15% 5-12% Ethanol 10-90%โ 20-75%โ 25-50%โ Propylene glycol 1-90% 5-80% 10-75%โ Water 0.01-5%โโโ 0.1-4%โโ 0.2-2%โโ Flavors 0.05-10%โโ 0.1-5%โโ 0.1-2.5%โ Propellant 2-10% 3-5%โ 3-4%โ
[0081] [0081] D. Meclizine Most-Preferred Amount Preferred Amount Amount Meclizine 1-25% 3-15% 5-12% Ethanol 1-15% 2-10% 3-6โ โโ Propylene glycol 20-98%โ 5-90% 10-85%โ Water 0.01-5%โโโ 0.1-4%โโ 0.2-2%โโ Flavors 0.05-10%โโ 0.1-5%โโ 0.1-2.5%โ Propellant 2-10% 3-5%โ 3-4%
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Buccal aerosol sprays or capsule using polar and non-polar solvent have now been developed which provide biologically active compounds for rapid absorption through the oral mucosa, resulting in fast onset of effect. The buccal polar compositions of the invention comprises formulation I: aqueous polar solvent 30-99.89%, active compound 0.001-60%, optionally containing flavoring agent 0.1-10%. Propellant 2-10%. The non polar composition of the invention comprises formulation II: non-polar solvent 20-85%, active compound 0.005-50%, and optionally flavoring agent 0.1-10% and propellant 50-80%.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national phase entry under 35 U.S.C. ยง371 of International Patent Application PCT/AU2014/000711, filed Jul. 11, 2014, designating the United States of America and published in English as International Patent Publication WO 2015/003217 A1 on Jan. 15, 2015, which claims the benefit under Article 8 of the Patent Cooperation Treaty to Australian Patent Application Serial Nos. 2013903986 filed Oct. 6, 2013, 2013902805 filed Jul. 29, 2013, and 2013902571 filed Jul. 12, 2013.
TECHNICAL FIELD
This disclosure concerns flow control valves for immersion in channels of the type built for irrigation.
BACKGROUND
Irrigators rely on channels for delivery of water to areas where crops are grown. Such areas may have a laser-levelled surface so that an inbuilt incline ensures the water runs to the end of the channel whenever water is available.
When a head develops in the water supply network, the end of the channel overflows. If this continues, the ground surrounding the overflow site becomes muddy and the roots of the growing crop lack air and die. The grower loses a percentage of the crop and the muddy area is an obstacle to the free movement of the wheels of irrigation equipment.
The flow in the channels is ensured by bulk water delivered to the channels through pipes. In related Australian Patent Serial No. 2013902571, float-operated valves are described that include a rise and fall stop gate capable of stopping flow in the pipe supplying an installation such as a LINDSAYยฎ overhead irrigation device.
U.S. Pat. No. 1,343,871 describes a system for supplying water to different parts of a field by a pipe that fills a group of containers, each with its own float valve to allow water to flow to subsidiary boxes. A ball float on the end of an arm that progressively closes a valve to a valve seat stopping the flow is out of sight inside the container.
U.S. Pat. No. 2,362,747 describes a chain of tanks, each with an outlet for discharge into a soil channel. A control tank in the chain contains a float valve that opens and closes a valve in a pipe that supplies the whole chain.
U.S. Pat. No. 6,953,156 describes a system for irrigating sloping land. This too relies on a ball-type float valve that controls water entry into a distributor tank from which branch pipes flow to different areas depending on their slope.
The ball valves used for these systems cannot be inspected and maintained easily.
BRIEF SUMMARY
The apparatus aspect of the disclosure provides a stop valve for a duct pipe feeding an irrigation channel comprising a duct with an inlet and an outlet, a rise and fall gate between the inlet and outlet, a pair of float arms supported on pivots lying on an axis transverse to the duct direction and a float for determining the inclination of each float arm.
The duct may be linear with the gate at 90 degrees to the duct axis. The gate may have static guides that are wider than the inlet portion of the valve body and a flat gate that slides in the guides between an open position clear of the inlet portion and a closed position in which the gate lies in register with the inlet portion, thereby preventing flow.
The float arms may be rods that are free to rotate about the pivots, attached at one end to the rise and fall gate plate and at the opposite end to the float. The float may be spaced from the end of an aim by a rigid link.
Thus, when the floats ascend, the arms rotate to an inclined position in which the gate is drawn downward to its closed position. The duct may have a semi-circumferential slot in its upper half through which the leading edge of the gate plate projects. The leading edge may be semi-circular in order to conform to the circumferential wall of the duct.
The gate plate may be substantially M-shaped with the upright outer members sliding in the gap between the parallel edges of the gate guides.
The inlet may have a ring flange for joining it to the ring flange of a pipe, which supplies the channel.
Utilizing such an apparatus, channel overflow may be prevented with consequent crop saving.
Utilizing such an apparatus, although the valve may not be watertight, leakage level is acceptable.
Utilizing such an apparatus, the valve requires minimal maintenance and has reduced vulnerability to blockage.
A second apparatus aspect of the disclosure provides a stop valve for a tank comprising a duct with an inlet and an outlet, a rise and fall gate between the inlet and outlet, a float arm supported by the duct operable to open and close the gate in response to rise and fall movement of the float.
The duct may be T-shaped with the two outlets lying at 90 degrees to the inlet providing an axis parallel to the gate, whereby the float arm is pivotable about the axis, the gate being at one end of the arm and a float at the opposite end.
The T-shaped body has a cylindrical outlet portion with pairs of circumferential slots lying mutually opposite, and a coaxial sleeve inside the outlet portion, which is rotatable, in order to support a pair of parallel float arms that extend through the sleeve and the circumferential slots in order to connect the gate to a pair of floats attached to the float arms.
The circumferential gap between the valve sleeve and the valve body may be bridged by self-lubricating strip bearings.
The gate may have static guides that are wider than the inlet portion of the valve body and a flat gate that slides in the guides between an open position clear of the inlet portion and a closed position in which the gate lies in register with the inlet portion, thereby preventing flow.
The float arms may be rods fixed to the sleeve but free to rotate in the circumferential slots in order to cause the gate to execute linear motion moving from rise to fall and back. Each float arm may be connected to the gate by a link that accommodates the difference in linear and arcuate motion.
Thus, when the floats ascend, the arms rotate to an inclined diametrical position in which the gate is drawn downward to its closed position. As the floats descend, the arms rotate in the counter direction to a second inclined position in which the gate is elevated to its open position.
When the float arms lie horizontally, the gate lies in an intermediate position in which some flow restriction is imposed.
The leading edge of the sliding gate may be arrowhead shaped or convex.
The inlet portion of the valve body may have a ring flange for bolting the end of a branch pipe forming part of the distribution network.
A further apparatus aspect of the disclosure provides a combined flow regulator and stop valve comprising a T-shaped valve body with an inlet axis and an outlet axis lying transversely to the inlet axis, a gate disposed across the inlet parallel to the outlet axis, a cylindrical portion of the valve body disposed about the outlet axis, a cylindrical valve member retained in the cylindrical portion, having a flow aperture connecting the inlet to the outlet or outlets, pairs of circumferential slots in the cylindrical portion of the valve body and a pair of arms that pass diametrically through both the pairs of slots and the valve body, one end of each arm being attached to the gate, the opposite end being attached to a float, whereby ascent of the floats both rotates the valve member to reduce flow and causes the gate to move from an open position toward a closed position and descent of the floats also rotates the valve member to increase flow and causes the gate to move toward the open position.
Preferably, the inlet axis is disposed at 90 degrees to the outlet axis.
One apparatus aspect of the disclosure provides a flow-regulating valve for a liquid container comprising a valve body with an inlet and at least one outlet, a rotary valve member in the body, wherein the valve body has means to rotate the valve member in response to the water level outside the valve body in the container, thereby regulating flow rate.
The valve body may be cylindrical. The valve member may likewise be cylindrical.
The valve member rotates in response to the rise and fall of one or more floats.
The valve body is cylindrical having two ends, an inlet between the ends and the valve body may have a passage connecting the inlet with one or both ends, the rotation of the valve member being dependent on the rise and fall of the water level in the container.
The valve member may have a float arm projecting through the valve body and a float connectable to the float arm.
Preferably, the valve member is rotated by a pair of arms.
The body may have a slot for each arm extending 22-45 degrees around the circumference of the body. The valve member may rotate coaxially in the body and have a cutout shaped to change the flow as rotation occurs.
The valve may have bearings attached to the body or the member, which facilitate rotation. The bearings may be spaced at 120 degrees. The bearings may be circumferential strips of material with a low coefficient of friction.
The float arms may extend through the wall of the valve member being removably fixed to the member at one end. The opposite end may carry a counterweight biasing the member to the fully open position. The float arms retain the valve member inside the valve body, allowing its rotation but preventing axial movement.
The free ends of the float arms each have a chain shackle that allows the floats to be attached by chains.
The valve body may be made of plastic but will more usually be made of stainless steel. The diameter of the valve body may be 200 mm to 1800 mm. The wall thickness of the valve member may be 2 mm to 20 mm.
Another apparatus aspect provides a water distribution system comprising a bulk water container with a water inlet and one or more outlets for distributing water to land, a water inlet for receiving water from a pipe network, and a flow regulator admitting water to the container, wherein the regulator has a rotating flow restrictor that is float activated.
Utilizing such an apparatus, fluctuating network pressures are coped with while maintaining the required flow rate.
Utilizing such an apparatus, it is relatively easily inspectable for maintenance with few wearing parts requiring replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the disclosure is now described with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic section of farmland supplied by a network pipe through a distribution tank.
FIG. 2 is a perspective view of the regulator valve and floats.
FIG. 3 is a perspective view of the valve body.
FIG. 4 is a perspective view of the valve member.
FIG. 5 is a perspective view of a second embodiment with an added stop valve in the open position.
FIG. 5A is the same as FIG. 5 with the added stop valve in the closed position.
FIG. 6 is the same as FIG. 5 with the stop valve in an intermediate position.
FIG. 7 is a perspective view.
FIG. 8 is a plan view of FIG. 7 .
FIG. 9 is a perspective view when in the gate closed position.
FIG. 10 is a front view of the gate plate.
FIG. 11 is a cross-sectional diagram of a channel in which the device is deployed.
FIG. 12 is a perspective of the valve in FIG. 5 with a gate collar.
DETAILED DESCRIPTION
Referring now to FIG. 1 , network pipe 2 is 900 mm in diameter and branch pipe 4 brings water to the 1200-mm diameter tank 6 through a butterfly valve 8 past a flow meter 10 .
Referring now to FIGS. 2 and 3 , the regulator valve 12 is bolted to the end of the branch pipe 4 and discharges into the tank. The valve body stem 14 is a T-shaped pipe of 320 mm diameter, the body being 510 mm long and the valve body stem 14 terminating in a connector ring 16 with bolt holes 18 for connection to the end of the branch pipe 4 . Both the body 20 and the valve member 22 ( FIG. 4 ) are made of stainless steel. Water enters the regulator valve 12 via the valve body stem 14 and discharges through the open ends of the body 20 . The flow through the valve is controlled by the valve member 22 , which is a sleeve of the same length as the valve body, namely 510 mm.
Referring now to FIG. 2 , the circumferential gap 24 is bridged by a trio of bearing strips 26 made of a slippery polymer and attached to the edge of the valve member by stainless steel fasteners (not shown). The strips are spaced at 120 degrees, enabling the member to rotate in the body with minimum friction.
Referring now to FIG. 4 , the crown of the valve member 22 has a cutout 28 with a straight edge 30 and tapered edges 32 extending over about 90 degrees of the circumference of the member. The cutout 28 lies in register with the connector ring 16 .
The ends of the valve body 20 have pairs of slots 34 , 36 , 11 mm wide (see FIGS. 2, 3 and 5 ) extending 90 degrees around the quadrants facing the water below the valve body 20 . The slots 34 , 36 define the path of a pair of 10-mm diameter stainless steel rods 38 that are a slide fit in the slots. The rods pass through bores 39 near the edge of the valve member and are bent at one end into a foot 40 ( FIG. 2 ) that is secured to the valve member by a split pin 42 ( FIG. 2 ). The foot 40 is housed in the thickness of the valve member 22 and the end of the pin 42 rides in the slot in the valve body.
Referring to FIG. 2 , the opposite end of each rod has a bore that receives a shackle 44 for connecting the arm to float chain 46 . The chain is about 600 mm long and runs through the shackle and is attached to itself. The chains each capture a spherical molded plastic float 48 . The floats are balanced by pivoted counterweights 50 . The chain 46 adjusts to suit the water level required. This allows for almost any water level required to be accommodated without affecting the functionality of the valve.
In use, the pipework is installed and the valve is suspended above or within the operational range of water levels in the tank. The floats lie on the surface of the water and the counterweights rotate the valve body to the open position. As the land dries and the tank empties the floats lie on the tank floor.
When the operator opens the butterfly valve 8 , the meter begins to measure flow. The operator selects a suitable flow rate and the container allows inflow to feed the outflow pipes.
The tank level rises and equilibrium is established. If the incoming flow fluctuates, the valve restores the equilibrium by rotating.
It is not the purpose of the valve to halt flow. That is the task of the butterfly valve 8 . The valve ensures a constant head of water in the tank, whereby the irrigation proceeds in an orderly manner despite the fluctuations in the network. A head of 3 m to 5 m is usual in such networks, but this may spike to 10 m.
In a second embodiment, FIGS. 5, 5A and 6 show valve body stem 14 is divided by a pair of square frame plates 52 , 54 . Plate 52 is attached to the valve body 20 . Plate 54 is attached to the part of the stem with the connector ring 16 . The gap 62 between the parallel plates 52 , 54 is bridged by pairs of gate guides 56 , 58 attached to the upright side edges of frame plates 52 , 54 . For both guides 56 , 58 , the gate gap 62 extends the full length of the guide.
The gate itself is a modified M-shape made of steel sheet that is wider than the gate guides spacing and has two legs 64 , 66 joined by an upper part 68 with a convex leading edge 70 . The legs have slots 72 , 74 for reception of the pivoting connections 76 , 78 ( FIG. 7 ) of float arms 38 .
In the open position shown in FIG. 5 , the gate rises clear of the frame plates 52 , 54 . In the closed position shown in FIG. 9 , the leading edge 70 meets the circular perimeter of valve body stem portion 14 and the part 68 registers with the frame plates 52 , 54 .
The float arms 38 are fixed to the sleeve 22 to ensure that the floats exert the same uplift force as in the previous embodiment. The pivoting connections each have a central self-lubricating bush through which the float arm is free to slide in order to accommodate the linear rise and fall of the gate. The projection of the rods through the legs 64 , 66 is seen in FIGS. 6, 7 and 9 . The counterweights' mass is increased to adjust for the weight of the gate.
The float arms lie in an intermediate position when the tank is both filling with network inflow and emptying into the irrigation pipes. The cutout 28 of sleeve 22 registers with the valve body stem 14 and, from this position, the floats quickly react to any increase in head. If the head persists, the floats press the gate into the closed position. As the tank drains, the floats descend. If the head has diminished, the gate may not reopen. If the tank drains further, the gate may reopen.
In a third embodiment, FIG. 11 shows an irrigation channel 3 m to 4 m wide and 2 m deep that is fed by a steel pipe that brings pumped water from a bulk source such as a dam. The shape of the channel is as shown in FIG. 11 and the pipe is submerged so that the floats can exert flow control on the incoming water.
Referring now to FIGS. 8 and 9 , the float-activated stop valve is connected to the external delivery conduit by ring flange 16 . Stem 14 is 300 mm in diameter and 700 mm long. The rise and fall gate straddles an incision (not shown) in the upper half of valve body stem 14 . The steel gate guides 56 , 58 are separated by gap 62 and welded to the outer surface of the valve body stem 14 . Gate gap 62 extends the full length of the guides.
The gate itself (see FIG. 10 ) is a modified M-shape, made of stainless steel that is wider than the width of the gate guides and has two legs 64 , 66 joined by an upper part 68 with a convex leading edge 70 . The legs have slots 72 , 74 for the reception of the pivoting connections 76 , 78 of float arms or rods 38 . The guides 56 , 58 have pairs of slots 77 adjacent gate gap 62 in order to support the screws of pairs of vertical self-lubricating polymer strips 79 . The slots 77 allow accurate adjustment of gap 62 size leading to smooth motion of the gate. Upper part 68 supports a semi-circular collar 80 , 25 mm wide, which overlies the incision when the gate is closed. In the closed position, the convex leading edge 70 contacts the circular wall of the stem.
The 22.5 degree rotary motion of the float arms 38 is made possible by the horizontal transverse pivots 82 welded to the outside wall of the valve body stem 14 . The counterweights and floats work in the same way as described in related Australian Patent Application Serial No. 2013902805. The water flow passes between the parallel float arms.
Referring now to FIG. 12 , the leading edge 70 closes the duct by descending to contact the lower cylindrical wall of the valve body stem 14 . The semi-circular collar 80 then rests on the upper part of the same wall.
It is to be understood that the word โcomprisingโ as used throughout the specification is to be interpreted in its inclusive form, i.e., use of the word โcomprisingโ does not exclude the addition of other elements.
It is to be understood that various modifications of and/or additions to the disclosure can be made without departing from the basic nature hereof. These modifications and/or additions are, therefore, considered to fall within the scope of the invention.
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Irrigation valves for channels and for irrigation tanks are of three types. All are activated by a pair of tilting float arms to which a pair of floats are attached. One type is a T-shaped duct with a cylindrical valve disposed at 90 degrees to the part that is connected to the incoming flow. The floats rotate the valve. The second type has the same construction as the first type, thereby giving flow control but additionally has a rise and fall gate in the duct part that is connected to the incoming flow. The gate acts as a stop valve. The third type has a cylindrical duct connectable to the incoming flow but no valve and provides both flow control and stop valve facilities through a rise and fall gate actuated by the tilting of the float arms.
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This application is a continuation, of application Ser. No. 763,722 filed Aug. 8, 1985, now abandoned.
BACKGROUND OF THE INVENTION
Known nuclear reactors, such as pressurized water reactors, include control rods that contain neutron absorbers with varying absorption capability for shutdown or power level control and sometimes also non-neutron absorbing materials to first breed plutonium and to later burn it as a fuel component.
Generally, these rods are mounted, via their upper end, to an assembly, or spider, which supports a plurality of such rods from simultaneous movement into and out of the reactor active core region. While in the core region, the control rods enter fuel assembly thimbles.
The assembly of a spider and a plurality of control rods may be designated a rod cluster control or a water displacer rod assembly, depending on the function to be performed by the control rods.
During reactor operation, the control rods are withdrawn from the active core region by lifting the assembly into the upper internals of the reactor pressure vessel. Movements of the assembly are guided by a guide tube presenting a plurality of guide sections, or cards, which contact the rods in respective regions. The number of guide sections provided for each control rod is selected as a compromise between the desire to reduce drag forces, which entails a minimum number guide sections, and the need to reduce the distance between guide sections in order to limit the amplitude of flow-induced vibration forces.
Drag forces can be controlled by design approaches which limit the drag forces, and thus reduce drag friction, by a hydraulic pressure balance.
The drag which does exist is a source of wear along each rod surface which slides along a guide section. In addition, when the rods are being maintained in their raised position in the guide tube, they experience movement relative to the guide sections due to flow induced vibration, which movement is a further cause for wear.
Such wear can influence the useful life of the control rods.
The rate of such wear is partly determined by the materials of the control rods and guide sections. The latter are usually made of stainless steel, while neutron absorber control rods are generally sheathed in stainless steel and water displacer rods are sheathed in a non-neutron absorbing material such as zircalloy.
Thus, wear improsed on neutron absorbing rods occurs primarily during insertion and withdrawal movements. In the case of water displacer rods, movements are limited, but since the material is softer, these rods are more susceptible to wear due to flow induced vibration while the rods are in their raised, or parked, position.
Once the outer wall of a control rod has been worn to a certain depth at one location, the rod must be replaced. Therefore, if such wear can be retarded, the useful life of the spider-rod assembly can be increased.
SUMMARY OF THE INVENTION
It is an object of the invention to increase the useful life of such rods.
Another object of the invention is to distribute the wear occurring at the outer surface of the rods so that the rate at which a defined surface layer of each rod is worn away is reduced.
These and other objects are achieved, according to the invention, in a nuclear reactor including a core, a plurality of control rods, support means supporting the control rods for movement in the longitudinal direction of the control rods between a first end position in which the control rods are fully inserted into the core and a second end position in which the control rods are retracted from the core, and guide means contacting discrete regions of the outer surface of each control rod at least when the control rods are in the vicinity of the second end position, the control rods being longitudinally movable relative to the guide means to thereby cause the outer surface of the control rods to experience wear as a result of sliding contact with the guide means, by the improvement constituded by displacement means operatively coupled to the control rods for periodically rotating the control rods in order to change the locations on the outer surfaces of the control rods at which the control rods are contacted by the guide means.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational view, partly in cross-section, of a rod and spider assembly incorporating one preferred embodiment of a rod displacement arrangement according to the invention.
FIG. 2 is a cross-sectional detail view of a portion of the embodiment of FIG. 1.
FIG. 3 is a developed, detail view of a camming structure employed in the embodiment of FIG. 2.
FIG. 4 is a view similar to that of FIG. 2 illustrating a second embodiment of the invention.
FIG. 5 is a cross-sectional detail view illustrating a third embodiment of the invention.
FIG. 6 is a detail plan view illustrating one type of guide structure with which an arrangement according to the invention can be employed.
FIG. 7 is a view similar to that of FIG. 6 illustrating a second type of guide structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an elevational view of a typical rod and spider assembly which can be constructed according to the present invention.
This assembly includes a spider 2 which supports a plurality of rods 4 for vertical movement as needed to achieve the required reactor control. Each rod is supported on spider 2 via a respective support unit 6, one embodiment of which is shown in FIG. 2.
The support unit 6 is composed of a housing 8 and a housing cap 10 which together delimit a cylindrical chamber 12. Each control rod 4 is connected to an extension piece 16 into which is threaded a support rod 20 that extends vertically through unit 6 and its chamber 12 and is movable axially relative to unit 6.
A ring 22 is fixed to rod 20 and a compression spring 24 is interposed between ring 22 and the bottom wall of chamber 12. Thus, rod 20 is supported by unit 6 via spring 24.
Reverting to FIG. 1, when the assembly composed of spider 2 and rods 4 is raised into the upper internals of the reactor vessel in order to withdraw rods 4 from the active core region of the reactor, each rod 4 is guided by guide sections or cards 30 (note: this reference numeral must be added to FIG. 1), which are spaced apart around the associated rod 4. Contact between each rod 4 and its associated guide sections or cards 30 produces drag forces whenever rods 4 are raised or lowered. These drag forces, of course, produce a certain amount of wear on the outer surface of the rod 4.
As the assembly 2, 4 arrives at its uppermost position, the upper end of each support rod 20 comes to abut against a stop 34 installed in the guide tube and positioned so that when assembly 2, 4 is in its uppermost position, each ring 22 will have been pushed downwardly in chamber 12 from the position illustrated in FIG. 2 and spring 24 will be essentially fully compressed.
According to the present invention, this downward movement of ring 22, together with support rod 20, extension piece 16 and the associated rod 4 will be accompanied by a rotation relative to housing 8. This rotation will change the locations of each rod 4 which are in contact with its associated guide sections or cards.
One suitable mechanism for effecting the desired rotation is illustrated in developed form in FIG. 3. This mechanism includes a boss 36 on the outer surface of support rod 20, as well as a group of upper bosses 38, 40, 42 . . . and a group of lower bosses 44, 46 . . . provided on the wall of chamber 12 and extending around the periphery thereof. Boss 36 is provided with a lower camming surface 50 arranged to cooperate with guide surfaces 52, 54 on lower bosses 44, 46, respectively. In addition, boss 36 is provided with an upper camming surface 58 arranged to cooperate with guide surfaces such as 60, 62 on upper bosses 40, 42, respectively.
Rotation of support rod 20, together with extension piece 16 and the associated control rod is effected each time the assembly 2, 4 is raised into the parked position and then lowered again into the reactor core. When the assembly reaches its uppermost position, the upperend of each support rod 20 is halted by its associated stop member 34. Spider 2 and housings 8 then continue to move upwardly over a short distance relative to support rods 20 so that camming surface 50 of cam 36 slides along guide surface 52, thereby effecting an incremental rotation of support rod 20. Thus, cam 36 comes into alignment with the gap between lower bosses 44 and 46.
Then, when spider 2 is again lowered, each support rod 20 initially remains in contact with its associated stop 34 so that each housing 8 moves downwardly relative to its associated rod 20 as spring 24 expands. During this time, camming surface 58 will slide upwardly along guide surface 60 of upper boss 40, thereby effecting a further incremental rotation of support rod 20 and bringing boss 36 into alignment with the gap between upper bosses 40 and 42.
According to one embodiment of the invention, the total rotation imparted to rod 20 by the sliding movement along surfaces 52 and 60 will be of the order of 45 degrees. Then, when the assembly is lowered into the reactor core, each control rod 4 will have an angular position which is offset by 45 degrees from the previous position. As a result, each guide section, or card will contact a new surface area of its associated rod 4, at a location which is angularly offset from the surface area which it previously contacted.
FIG. 4 illustrates an alternative rod support unit 64 which includes a top end plug 66 fastened to spider 2 and having an axial passage for support rod 20. A housing 68 is screwed onto the bottom of plug 66 and is then secured thereto by a locking pin. This embodiment allows for a larger space within housing 68 to accommodate a larger spring 24 and facilitate formation of bosses, such as 38, 40, etc of FIG. 3, on the inner wall of housing 68.
FIG. 5 illustrates a second embodiment of a mechanism for rotating each rod in accordance with the present invention. This embodiment includes a housing 68 having the same form as that shown in FIG. 4. However, one advantage of the structure illustrated in FIG. 5 is that the interior of housing 68 need not be provided with bosses, such as 38, . . . In this embodiment, the control or water displacer rod is supported by means of a support rod 70 which, in turn, is supported in housing 68 by means of compression spring 24. Extending downwardly into housing 68 is a drive rod 72 which extends upwardly through the top end plug connected to rod 68, the top end plug being as shown in FIG. 4 and not being illustrated in FIG. 5. The upper end of drive rod 72 is disposed to engage the stop 34 shown in FIG. 1. The lower end of drive rod 72 carries a rotation producing member 74 provided with two individual, angularly offset external threads 75 which engage in helical recesses 76 in the inner wall of housing 68. The lower end of member 74 has an annular sawtooth structure composed of vertical surfaces alternating with gradually sloping surfaces.
Fixed to the upper end of support 70 is a disk 78 having, at its top, a sawtooth structure constructed to mate with the sawtooth structure at the lower end of member 74. The lower end of disc 78 is equally provided with an annular sawtooth structure composed of vertical surfaces alternating with inclined surfaces, with these inclined surfaces being inclined in the opposite direction to the gradually sloping surfaces at the upper end of disk 78.
In the normal operating state, when spider 2 is spaced from the retracted position, spring 24 is in its elongated state and presses disk 78 against member 74, so that member 74 and drive rod 72 are equally supported by spring 24. The spider is lifted into its retracted position, and the upper end of drive rod 72 comes to abut against stoop 34, continued upward movement of housing 68 together with spider 2 causes the external threads 75 to be guided in helical recesses 76, thereby imposing a rotational movement on member 74, so that member 74 is thereby driven downwardly relative to housing 68.
As a result of cooperation of the sawtooth structure at the lower end of member 74 and the upper end of disk 78, this equally causes disk 78, rod 70 and the control rod supported thereby to rotate and to move downwardly relative to housing 68. This rotational movement is not impeded by spring 24 since, as is apparent from FIG. 5, the upper end of spring 24 will slide along the inclined surfaces at the lower end of disk 78. The lower end of spring 24 is seated in a bore formed at the bottom of the chamber defined by housing 68, so that spring 24 is itself prevented from rotating. However, spring 24 will be axially depressed by the downward movement of disk 78 relative to housing 68.
According to one exemplary embodiment of the invention, drive rod 72, threads 75 and receses 76 are dimensioned to cause the rod rotation system to undergo a rotation of between 90 and 180 degrees as the spider moves to its fully retracted position.
Then, as the spider is subsequently moved downwardly away from the retracted position, spring 24 becomes active to urge disk 78 upwardly relative to housing 68. This produces an upward force on member 74 which causes member 74 to move upwardly relative to housing 68 while threads 75 travel along recesses 76 in order to also rotate member 74. However, during this movement, the upper end of spring 24 will come to abut against one of the vertical surfaces of the sawtooth structure at the lower end of disk 78, whereupon further rotation of disk 78 and support rod 70 will be prevented and the sloping surfaces of the sawtooth structure at the lower end of member 74 will be forced to slide along the sloping surfaces at the upper end of disk 78. At the end of this return movement, member 74 and disk 78 will again be in the positions shown in FIG. 5, but disk 78, support rod 70 and the control rod supported thereby will have undergone a net rotation of 90ยฐ. While FIG. 5 illustrates sawtooth structures, each composed of 4 teeth, it will be appreciated that a different number of teeth can be provided, if desired, and the inclination of threads 75 and helical recesses 76 can be varied in order to produce a different amount of rotation during each retraction movement of the spider.
It will be noted that in the normal operating position shown in FIG. 5, when the spider assembly is spaced from its retracted position, each vertical surface of the sawtooth at the bottom of member 74 is spaced circumferentially from the associated vertical surface of the sawtooth structure at the top of disk 78. This spacing is provided to assure that, when member 74 is being urged upwardly relative to housing 68 by the action of spring 24, member 74 will come to rest at a position where the vertical surfaces of its associated sawtooth structure will be properly positioned relative to the vertical surfaces of the sawtooth structure at the top of disk 78 to produce the next 90ยฐ rotation of disk 78 and the components secured thereto.
A significant advantage of this structure is that very little machining must be carried at the interior of housing 68. In effect, the only machining required is the formation of a small diameter bore at the bottom of the chamber enclosed by housing 68 and the machining of helical grooves 76 near the open top of housing 68. The machining of such grooves at that location is a relatively simple matter.
FIGS. 6 and 7 are detail plan views illustrating portions of two types of guide arrangements which can be employed for guiding rods 4 primarily during movement in the upper internals of the reactor pressure vessel. Such guide arrangements are fixed in the pressure vessel so that the rods move vertically therepast.
FIG. 6 illustrates a portion of one guide card which can be employed for guiding the rods of a rod cluster control. A complete card can be in the form of a cruciform structure, one arm of which is illustrated. This card is compared simply of a plate 82 having a central slot 84 for passage of an arm of spider 2, and accurate openings 86. Each opening 86 guides a respective rod, so that the total number of openings 86 is a card 82 will equal the number of rods carried by spider 2 of FIG. 1. Plate 82 is of a suitable metal and of a suitable thickness, for example 3.7 cm.
The openings 86 are slightly larger in diameter than the rods 4 which they guide so that, as a general rule, each rod 4 bears against a particular part of the periphery of its associated opening 86, at which location the rod 4 will be subject to wear. When rod 4 is rotated, the portion of its surface which bears against the particular part of opening 86 changes.
Typically, a number of, e.g. five, cards or plates, 82 is provided, the cards being spaced apart vertically along the upper portion of the pressure vessel interior.
FIG. 7 illustrates a similar portion of a guide arrangement suitable for guiding the rods of a water displacer rod assembly. Here, the guide region is delineated by upper and lower end plates 88 having slots 90 and between which extend, vertically, a plurality of C-tubes, such as 92, and a plurality of half-tube assemblies, such as 94. Each tube 92 and assembly 94 guides a respective water displacer rod. As shown, each assembly 94 is composed of two tube sections each coextensive with less than half the diameter of an associated rod.
Here, again, the internal diameter of tubes 92 and assemblies 94 are slightly less than the diameters of rods 4 so that each rod will tend to bear against a particular part of its associated tube or half-tube assembly.
In the case of water displacement rods, the above-described rotation will have the effect of renewing the locations at which the guide sections or cards bear against the rod surfaces, so that the locations where wear occurs will be varied. The new contact surfaces on each rod 20 will previously have become oxidized to form a hard zirconium layer which serves to retard wear.
The magnitude of each rotation step, for example 45 degrees, can be selected to take advantage of the longitudinal growth of zircalloy due to fast fluence effects while the rods are in the reactor core. As a result, even after the rods have undergone a rotation of 360 degrees, the new wear locations will not coincide with the locations which existed prior to the full 360 degrees of rotation. Moreover, the resulting helical wear paths will have a less significant effect on the longitudinal strength of the control rods.
In the case of rod cluster control, the magnitude of each rotation step can be selected to renew the contact surfaces, and also to keep the wear lines symetrically located. This will reduce any effect which the wear lines may have upon bowing of the control rods.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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In a nuclear reactor including a core, a plurality of control rods, a support supporting the control rods and movable for displacing the control rods in their longitudinal direction between a first end position in which the control rods are fully inserted into the core and a second end position in which the control rods are retracted from the core, and guide elements contacting discrete regions of the outer surface of each control rod at least when the control rods are in the vicinity of the second end position, the control rods being longitudinally movable relative to the guide elements to thereby cause the outer surface of the control rods to experience wear as a result of sliding contact with the guide elements, there is provided a displacement device operatively coupled to the control rods for periodically rotating the control rods in order to change the locations on the outer surfaces of the control rods at which the control rods are contacted by the guide elements.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Patent Application No. 61/727,028 filed Nov. 15, 2012 entitled Piling Boot.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to sealing members in general and in particular to a method and apparatus for sealing around a ground piling.
[0004] 2. Description of Related Art
[0005] In many industries, storage tanks are utilized to store or otherwise contain a variety of fluids. Some of such fluids may be hazardous or otherwise polluting to the environment, such as, by way of non-limiting example diesel fuel, glycol, or other chemicals utilized for industrial or commercial applications. Disadvantageously, such storage tanks may periodically have leaks, spills or other failures which may lead to contaminants entering the local soil and polluting the environment.
[0006] One common method of reducing possible impact of contaminant spills has been to place the storage tank on pilings inserted into the soil and to then also cover the surrounding soil with a ground sheet. As the ground sheet is required to contain any contaminants escaping from the storage tank, it has commonly been necessary to seal the ground sheet around piling. Previous solutions to the above difficulty have been to seal the ground sheet directly to the piling or to provide a collar extending from the sheet which may then be sealed to the
[0007] One disadvantage of such a system is the difficulty of maintaining the seal between the ground sheet and the pilings. In many locations, the ground surrounding such storage tanks may be prone to expansion, contraction, shifting or settling due to the influence of time, water infiltration or ground freezing and thawing. Such fluctuations in ground level may cause the ground sheet to move relative to the pilings making sealing such ground sheet around the pilings difficult. As the connection between the ground sheet and the piling may become stretched due to the movement of the ground sheet past the strength limits of the connection or the ground sheet.
SUMMARY OF THE INVENTION
[0008] An apparatus for sealing a piling to a planar member extending around the piling. The apparatus comprises a base collar sized to surround the piling at a first location and having a planar base flange extending therefrom and an upper collar sized to extend around the piling at a second location, the upper collar being sealable around the piling. The apparatus further comprises a longitudinally extendable sleeve extending between the base collar and the upper collar, the sleeve sealing the base collar to the upper collar.
[0009] The sleeve may comprise a cylindrical bellows. The sleeve may comprise tubular member having an s-shaped wall cross-section. The sleeve may be sealable to the base collar and upper collar. The sleeve may be integrally formed with the base collar and upper collar.
[0010] The base flange may extend substantially perpendicularly from the base collar. The base flange may have a substantially rectangular outer edge.
[0011] The upper collar may be sealed around the piling by a clamp. The clamp may comprise a hose clamp. The base flange may be sealed to the ground sheet.
[0012] Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,
[0014] FIG. 1 is a perspective view of a piling and ground sheet having an apparatus for sealing the piling to the ground sheet according to a first embodiment of the present invention applied thereto.
[0015] FIG. 2 is a cross sectional view of the apparatus of FIG. 1 as taken along the line 2 - 2 at a first or retracted position.
[0016] FIG. 3 is a cross sectional view of the apparatus of FIG. 1 as taken along the line 2 - 2 at a second or extended position.
[0017] FIG. 4 is a cross sectional view of the apparatus of FIG. 1 as taken along the line 2 - 2 according to a further embodiment of the present invention.
[0018] FIG. 5 is an exploded perspective view of the apparatus of FIG. 4 .
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 , an apparatus for sealing around a piling 8 to a ground sheet 6 according to a first embodiment of the invention is shown generally at 10 . The apparatus a top collar 12 , a base collar 20 , and a longitudinally extendable sleeve 40 extending therebetween. The base collar 20 surrounds the piling and includes a flange 28 extending substantially radially therefrom.
[0020] The top collar is sealably secured to the piling such that the apparatus seals the ground sheet around the piling so as to prevent contaminants from escaping the ground sheet past the penetration through ground sheet provided for the piling.
[0021] With reference to FIGS. 2 and 3 , the top collar 12 comprises a substantially tubular member defining a central passage 14 therethrough and may be secured to the piling with a hose clamp 16 or the like. The central passage 14 may be substantially circular, rectangular or any other shape so as to correspond to the outer surface of the piling. The clamp 16 may comprise any suitable clamping member, such as by way of non-limiting example, a hose clamp, band clamp or the like. Optionally, the top collar 12 may be secured to the piling by any other known method, such as, by way of non-limiting example, adhesives, welding or the like. The central passage 14 may be sized to be slightly larger than the outer surface of the piling so as to facilitate installation thereover or may also optionally have an interference fit with the piling. The top collar 12 may be formed of any suitable material, such as by way of non-limiting example, metal, plastic, natural or synthetic rubbers or composite materials. In particular, it has been found that forming the top collar 12 of high density polypropylene has been particularly useful. The top collar may have any length as is necessary to provide a secure fitting and seal around the piling, such as, by way of non-limiting example, between 2 and 16 inches (51 and 406 mm) although it will be appreciated that other lengths may be useful as well.
[0022] The base collar 20 comprises a substantially tubular member extending between top and bottom ends, 24 and 26 , respectively and having a central passage 22 extending therethrough. The base collar 20 includes a flange 28 extending substantially radially from the bottom end 26 of the base collar for securing to the ground sheet 6 as will be further described below. The central passage 22 may be substantially circular, rectangular or any other shape so as to correspond to the outer surface of the piling and is sized so as to surround the piling without engaging thereon. In such a manner it will be observed that the central passage 22 and also the base collar 20 are freely movable relative to the piling. The base collar 20 may be formed of any suitable material, such as by way of non-limiting example, metal, plastic, natural or synthetic rubbers or composite materials. In particular, it has been found that forming the base collar 20 of high density polypropylene has been particularly useful. The bottom collar may have any length as is desired by a user, such as, by way of non-limiting example, between 2 and 16 inches (51 and 406 mm) although it will be appreciated that other lengths may be useful as well.
[0023] The flange 28 comprises a sheet of material extending substantially radially from the bottom end 26 of the base collar 20 . The flange 28 may have any outline as desired by a user, such as, by way of non-limiting example, circular, square, octagonal, triangular or irregular. The flange may be formed of any suitable material, such as by way of non-limiting example, metal, plastic, natural or synthetic rubbers or composite materials. In particular, it has been found that forming the flange 28 of high density polypropylene has been particularly useful. The flange 28 may be formed separately from the base collar 20 and thereafter secured to by way of welding, adhesives or the like or may optionally be co-formed with the bottom collar. As illustrated in FIG. 1 , the flange 28 may include an outer edge portion 30 which may be utilized to be sealably secured to the ground sheet 6 by adhesives, plastic welding or the like as is commonly known in the art.
[0024] The sleeve 40 is formed of an outer, or first tubular portion 42 , and an inner, or second tubular portion 44 which are co-axial with each other about a central axis 15 of the apparatus. As illustrated in FIG. 2 , the base collar 20 , and first and second tubular portions 42 and 44 form an s-shaped cross-section which permits the apparatus to longitudinally extend along its axis 15 . The sleeve 40 may be formed of any suitable material, such as by way of non-limiting example, metal, plastic, natural or synthetic rubbers or composite materials. In particular, it has been found that forming the sleeve 40 of high density polypropylene has been particularly useful. The sleeve may be formed separately from the base collar 20 and the top collar 12 and thereafter secured to by way of welding, adhesives or the like or may optionally be co-formed with the bottom collar.
[0025] As illustrated in FIGS. 2 and 3 , the sleeve may further include additional one or more additional secondary tubular portion 43 offset from the second tubular portions 42 with a step 47 . Similarly the additional secondary tubular portion 43 and the top collar 12 may be offset by a step 45 . The additional secondary tubular portions 43 and the second tubular portions 44 provide additional diameters which may be utilized as the top collar. In particular the sleeve may be cut along the additional secondary tubular portion 43 proximate to the step 45 such that the additional secondary tubular portion 43 then forms the top of the apparatus. In such configuration, the additional secondary tubular portion 43 will then form the top collar for use with a larger diameter piling. It will be appreciated that a plurality of such additional secondary tubular portions 43 may be utilized so as to accommodate a plurality of potential piling diameters. Additionally, the second tubular portion 44 may also be cut proximate to the step 47 so as to cause the second tubular portion 44 to form the top collar.
[0026] As illustrated the first and second tubular portions 42 and 44 may be co-formed with the base collar 20 with a first radiused bend 46 located between the base collar 20 and the first tubular portion and a second radiused bend 48 located between the first and second tubular portions 42 and 44 . As the piling 8 is moved in an upward direction, generally indicated at 50 in FIG. 3 , relative to the ground sheet the second radiused bend 48 may be shifted along the sleeve so as to shorten the first tubular portion 42 and lengthen the second tubular portion 44 due to the deformation of the sleeve. While undergoing such movement, it will be appreciated that the piling 8 will move freely upward relative to the base collar 20 and the ground sheet 6 while moving through a bore 7 in the base sheet 6 . It will also be appreciated that other deformations within the sleeve 40 may be possible to permit such free movement of the top collar 12 relative to the base collar 20 .
[0027] In operation, a user may place the assembled or pre-formed apparatus 10 around the piling after piling has been driven into the ground and the ground sheet has been located around the base of the piling. In such a configuration, the piling 8 will extend through a bore 7 in the ground sheet 6 and be unconnected thereto. After locating the apparatus 10 around the piling 8 , the user may seal the top collar to the piling with a hose clamp 16 or the like and may then seal the outer edge 30 of the flange 28 to the ground sheet 6 through adhesives, welding or the like. Thereafter, the apparatus will maintain the seal of the ground sheet 6 around the piling 8 during movement of the underlying soil structures due to frosts, soil erosion or the like and thereby prevent spills of any contaminants. As illustrated the apparatus 10 has a substantially cylindrical profile so as to surround a tubular piling 8 however it will be appreciated that other cross-section profiles, such as, by way of non-limiting example, square, triangular, octagonal or irregular may also be utilized so as to conform to the cross-section of the piling.
[0028] With reference to FIGS. 4 and 5 , an alternative embodiment of the present invention is illustrated. As illustrated in FIGS. 4 and 5 , the apparatus may include top and base collars 12 and 20 as set out above with an longitudinally expandable sealing member 60 therebetween. The seal member 60 may be formed of first and second end sleeves, 62 and 64 , respectively and a corrugated or bellows section 66 therebetween. The corrugated section 66 is longitudinally extendable along the axis 15 of the apparatus 10 as set out above. The corrugated section 66 may be formed integrally with the top and base collars 12 and 20 or may optionally be formed separately therefrom and thereafter connected to the top and bottom sleeves by adhesives fasteners or the like.
[0029] The apparatus 10 may be formed of any suitable material, such as by way of non-limiting example, metal, plastic, natural or synthetic rubbers or composite materials. In particular, it has been found that forming the apparatus of high density polypropylene has been particularly useful. The separate elements of the apparatus 10 may be formed separately and thereafter secured to each by way of welding, adhesives or the like or may optionally be co-formed with the bottom collar.
[0030] While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.
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An apparatus for sealing a piling to a planar member extending around the piling comprises a base collar sized to surround the piling at a first location and having a planar base flange extending therefrom and an upper collar sized to extend around the piling at a second location, the upper collar being sealable around the piling. A longitudinally extendable sleeve extends between the base collar and the upper collar sealing the base collar to the upper collar.
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This application claims the benefit of U.S. Provisional Application No. 60/557,852, filed Mar. 30, 2004.
TECHNICAL FIELD
This invention relates generally to cotton harvesting machines including a cotton receiver for receiving and holding harvested cotton, and more particularly, to an expandable accumulator for a cotton receiver, which can be deployed to increase the capacity of a precompacting area of the receiver, and which can be folded or stored when not in use.
BACKGROUND ART
Commonly, cotton harvesting machines can unload harvested cotton into a container such as a trailer known as a boll buggy in the field, while remaining in the rows for harvesting the cotton plants. Essentially, a boll buggy is a container open on the top that is pulled by a tractor or other vehicle up to the cotton harvesting machine while in the field. The harvesting machine can be stopped and the boll buggy pulled alongside the cotton receiver, and the cotton in the receiver unloaded into the boll buggy. The cotton harvesting machine can then resume harvesting and the boll buggy is typically transported to a standard module builder located in an accessible location such as the end of the rows, and unloaded. As a result, the harvesting machine does not have to come out of the rows to unload when full. Newer cotton harvesting machines which compact and form or package the cotton into a unitary body or module as the cotton is conveyed into a cotton receiver on the machine, are typically required to unload the cotton module or compacted body of cotton at the end of the rows, or a location where the module or compacted body of cotton can be picked up by a module truck or the like for transport to the gin for processing. The end of the rows provides a suitable location, as the terrain is typically relatively level. It is undesirable to unload a module or compacted body of cotton in the field, as the field contains stalks and the ground is uneven as a result of being formed into raised beds for the plants.
A typical modern cotton harvesting machine with an on-board module building and/or packaging capability can produce a compacted module or body of cotton that can weigh between about 8,000 and about 11,000 pounds, depending upon crop conditions. Conventional cotton harvesting machines typically can hold a maximum of about 10,500 pounds. This large capacity allows both machines to make one or more passes in the field depending on row length and yield (pounds of cotton per acre). Conventional cotton harvesting machines can unload at any time, either in the field into a boll buggy, or at the end of the rows by driving up to a module maker and unloading the cotton into it. In contrast, for maximum efficiency, a cotton harvesting machine which can package or compact cotton into a unitary module or body, is desirably unloaded when the module or body is completely formed. Partial modules or bodies should only be unloaded when finishing up a field, and these should still be unloaded at the end of the rows in what is known as the turn row where the cotton harvesting machine turns around to enter new rows for harvesting the cotton therefrom. Therefore, because of widely varying row lengths and yield conditions, there is a need for cotton harvesting machines to have the capability to hold cotton above the compactor apparatus to allow the operator to continue to harvest cotton until the end of a swath of rows or other suitable location for unloading, is reached.
Therefore, what is sought is apparatus and a method which overcomes the problems and provides the capability set forth above.
SUMMARY OF THE INVENTION
What is disclosed is a cotton accumulator for the cotton receiver of a harvesting machine, capable of receiving and holding harvested cotton at a location separate from that in which the cotton is compacted or otherwise formed into a unitary body or module, and then, after a compacted body or module of cotton is unloaded, will allow the collected cotton to fall or be conveyed into the lower compacting region for formation by compactor apparatus into the next compacted body or module.
The accumulator will preferably have a capability to be movable between a deployed position providing the sought after cotton holding capacity, and a stored position when not in use and for transport. The accumulator is preferably located in association with the upper region of the cotton receiver, in a precompacting area above the compactor apparatus, such that the compactor apparatus can serve to hold the cotton in the accumulator as compacted cotton in the receiver already is compacted or formed into a unitary body or module can be completed and unloaded. The accumulator can be moved between its deployed and stored positions using any suitable apparatus, such as one or more drivers, such as a fluid cylinder, winch, or mechanical actuator. The accumulator can also be moved between its positions by movement of the compactor apparatus, which can be of conventional, well known construction. The accumulator can be deployed manually, by operator action, or automatically, as desired or required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a cotton harvesting machine including a cotton accumulator in a deployed position according to the invention;
FIG. 2 is a simplified side view of a cotton receiver of the machine of FIG. 1 , showing the accumulator in its deployed position above a cotton receiver of the machine and the flow of cotton therein;
FIG. 3 is another simplified side view of the cotton receiver, showing the accumulator in its stored position;
FIG. 4 is another simplified side view of the receiver with the accumulator in its stored position, showing airborne conveyance of cotton into the interior of the receiver;
FIG. 5 is a fragmentary side view of the receiver, showing the accumulator in its stored position, and a representative mechanism for moving the accumulator between its stored position and deployed position; and
FIG. 6 is another fragmentary side view of the receiver showing the accumulator moved to its deployed position by the mechanism of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, in FIG. 1 a cotton harvesting machine 10 is shown, including a cotton accumulator 12 constructed and operable according to the teachings of the present invention on a cotton receiver 14 of the machine. Harvesting machine 10 includes a plurality of harvesting units 16 arranged in an array across a forward end 18 of machine 10 for harvesting cotton from plants as machine 10 is moved in the forward direction along rows of the plants (not shown). The harvested cotton is conveyed by air flows through an array of ducts 20 extending upwardly and rearwardly from units 16 to a precompacting area 22 of cotton receiver 14 , as denoted by arrows A, in the well known conventional manner.
Referring also to FIGS. 2 , 3 and 4 , cotton receiver 14 is shown. Cotton receiver 14 is a structure of rectangular shape, including an interior compacting chamber 24 defined by a floor 26 , forward and rearward end walls 28 and 30 , and opposing side walls including a side wall 32 shown. End walls 28 and 30 , and the side walls including side wall 32 , extend upwardly from floor 26 to precompacting area 22 which defines a generally upwardly facing opening, which is occupied and enclosed by cotton accumulator 12 . Cotton accumulator 12 , end walls 28 and 30 , and the side walls are preferably constructed of an air permeable material, such as a mesh or perforated sheeting having holes or openings therein adequate for dissipation of air flow therethrough, but which will retain the cotton conveyed into compacting chamber 24 as denoted by arrows A.
Compactor apparatus 34 is shown in the upper region of interior compacting chamber 24 . Compactor apparatus 34 includes side-to-side extending cross bars 36 adjacent end walls 28 and 30 which extend through vertical slots 38 through the side walls, including side wall 32 , and are supported by a support structure 40 , including a pair of fluid cylinders 42 located beside the side walls, for moving compactor apparatus 34 upwardly and downwardly within chamber 24 , as denoted by arrow B in each of the figures. A substantially complete compacted body of cotton or module 44 is shown in each of FIGS. 2 , 3 and 4 for illustration of usage of accumulator 12 . Essentially, in operation, as cotton denoted by arrows A is conveyed into interior chamber 24 , compactor apparatus 34 will be operated to move in the upward and downward direction denoted by arrow B, against the collected cotton to compact the cotton against floor 26 to gradually build a compacted body or module as represented by module 44 . As explained above, a completed compacted cotton module such as module 44 can have a weight of between about 8,000 and 11,000 pounds, and will be relatively large, having dimensions corresponding to those of compacting chamber 24 . It is an important objective of the use of compacting apparatus such as apparatus 34 and the making of compacted bodies and modules of cotton, such as module 44 , to reduce manpower and handling, and facilitate transport of the cotton from the field to the gin for processing. Currently, compacted bodies of cotton, such as module 44 , are preferably unloaded from machines, such as harvesting machines 10 , on a level surface, such as the ground at the end of the rows of a cotton field, to facilitate picking up and loading the cotton onto trucks used for transporting it. Cotton fields usually include rows of raised beds separated by spaces or channels for carrying irrigation water, and after picking typically include stubble and/or intact plants, which make an undesirable surface onto which to unload a compacted body or module of cotton, as it would greatly inhibit pickup and loading onto a transport truck. As a result, it is desirable to limit unloading to times when machine 10 has completed a swath of rows of cotton, at the turn row where the machine is turned around to proceed along a new swath of rows through the field. However, it has been often found that the interior compacting chamber such as chamber 24 of machine 10 will be filled, and/or a compacted body or module such as module 44 completed, before the end of the rows is reached. This is a problem as without extra cotton carrying capacity, the harvesting operation must be interrupted, the machine moved to a suitable unloading location, unloaded, and returned to the harvesting operation, or the completed module unloaded at an undesirable location in the field.
Cotton accumulator 12 overcomes the problems and shortcomings set forth above by providing added cotton receiving capacity to precompacting area 22 of cotton receiver 14 . In FIGS. 1 and 2 , cotton accumulator 12 is shown in a deployed position with a rearward end 46 thereof extended upwardly, denoted by arrow C in FIG. 2 , for increasing the interior volume of precompacting area 22 above compactor apparatus 34 for receiving cotton conveyed therein as denoted by arrows A, the cotton being held above module 44 by the compactor apparatus 34 . As a result, the harvesting operation can continue and the harvesting machine moved to a convenient and suitable unloading location such as the end of the rows being harvested, without interruption of the harvesting process. Then, after the body of cotton or module, such as module 44 is unloaded, the cotton collected in accumulator 12 above compactor apparatus 34 can be allowed to fall into, or be moved or conveyed into, the lower portion of chamber 24 for compaction into a compacted body or module in the above-described manner. Here, it should be noted that compactor apparatus such as apparatus 34 will typically include one or more rotatable augers capable of conveying cotton on top of apparatus 34 into the compacting chamber located therebelow, as is well known in the art. Such augers can be actuated to convey the cotton from accumulator 12 into the lower region of the chamber.
The embodiment of cotton accumulator 12 can have a variety of interior capacities, as required or desired for a particular application. The capacity of accumulator 12 shown is illustrated by dotted crosshatching and is shown having a triangular or wedge sectional shape, but could likewise have other shapes including a more rectangular shape, or a more curved or rounded shape. Accumulator 12 is shown in FIGS. 3 and moved downwardly to a stored position contained at least substantially within precompacting area 22 of receiver 14 when its use is not required. As shown in FIG. 4 , in this position, cotton can be conveyed into receiver 14 in the conventional manner as denoted by arrows A for compaction by compactor apparatus 34 . The illustrated embodiment of accumulator 12 has an upper wall 48 which is generally flat and covers the forward-to-rearward and side-to-side extent of accumulator 12 . Accumulator 12 includes a pair of side walls extending downwardly from upper wall 48 , as illustrated by side wall 50 , the side walls having a wedge shape which tapers divergently in the rearward direction. A rearward end wall 52 extends between upper wall 48 and the side walls including side wall 50 for enclosing the rearward end of accumulator 12 . Side walls 50 and end wall 52 can be of suitable construction, for holding cotton, including of a suitable mesh material or sheet material including holes therethrough for the passage of air but not the cotton, or of an alternative material including a solid sheet metal, or the like. Accumulator 12 has a forward end 54 which in this embodiment is pivotally connected to a forward end of receiver 14 in a suitable manner, for instance, by one or more hinges 56 to allow movement of accumulator 12 between its deployed and stored positions. Suitable seals can be provided as required between the lower periphery of accumulator 12 and walls 28 , 30 and 32 .
Accumulator 12 can be manually moved between its deployed and stored positions, or automatically moved using a suitable actuator or mechanism such as one or more fluid cylinders, a winch, or the like. FIGS. 5 and 6 illustrate one exemplary embodiment of a mechanism 58 for moving accumulator 12 between its stored position ( FIG. 5 ) and its deployed position ( FIG. 6 ). Mechanism 58 includes an arm 60 mounted by pivot 62 to the side of receiver 14 . Arm 60 includes a first end portion 64 pivotally connected to a rod 66 of a fluid cylinder 68 , and an opposite end portion 70 including a roller which contacts a downwardly facing surface of a plate 72 mounted along the side edge of accumulator 12 . Fluid cylinder 68 is pivotally connected to the side of cotton receiver 14 and when extended will pivot arm 60 about pivot 62 to pivotally move accumulator 12 about hinge 56 to the deployed position as shown in FIG. 6 . Similarly, when fluid cylinder 68 is retracted, arm 60 will be pivoted in the opposite direction to move accumulator 12 to its stored position as shown in FIG. 5 . Here, it should be noted that mechanism 58 is but one of any number of mechanisms that could be utilized for moving accumulator 12 between its deployed and stored positions, and therefore is in no way to be considered as limiting.
It will be understood that changes in the details, materials, steps, and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown.
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A cotton receiver for a cotton harvesting machine and a method of operation of the same. The receiver includes a cotton compacting chamber, a precompacting area above the chamber, and an accumulator deployable upwardly from the precompacting area to increase the cotton holding capacity thereof. Compactor apparatus is located in the compacting chamber and is configured for holding cotton thereabove separate from cotton therebelow. The compactor apparatus is movable downwardly against cotton therebelow for compacting it into a unitary body or module, including while holding cotton thereabove, and is controllably operable for conveying cotton held thereabove downwardly therethrough, subsequent to unloading a completed compacted body of cotton.
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The present invention was made with the support of the Government under NIH Grant No. AI20943. The U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
Cell growth is controlled, to a large degree, by extracellular ligands which bind to specific receptors on the surface of cells. Cross et al., Cell , 64, 2172 (1991). A number of these receptors, including the epidermal growth factor (EGF) receptor, have intrinsic protein tyrosine kinase (PTK) activity. Yarden et al., Ann. Rev. Biochem., 57, 443 (1988). Ligand-dependent activation of receptor associated tyrosine kinases or unregulated synthesis of tyrosine kinase oncoproteins results in tyrosine phosphorylation of cellular substrates which have a critical role in the control of mitogenesis, cell cycle regulation, cell survival and cellular transformation. Ullrich et al., Cell, 61, 203 (1990).
Among the cellular enzymes that are involved in signal transduction, the protein tyrosine kinases (PTKs) appear to play key roles in the initiation of various signaling cascades. PTKs can be divided into two major groups on the basis of their predicted structures. The first PTK group, which contains those that possess extracellular domains which generally function to bind peptide hormones, are the receptor PTKs. Examples of PTKs included in this group are the receptors for epidermal growth factor, the nerve growth factor and platelet-derived growth factor.
The second PTK group comprises those that lack the extracellular domains and are referred to as nonreceptor PTKs, even though many members of this group appear to be associated, albeit noncovalently, with some type of cell surface ligand-binding protein. Members of this group include the Src family of PTKs as well as the members of the fes/fps and abl gene families. The nonreceptor class of PTKs is growing with regard to the number of enzymes it includes, which are also demonstrating surprising diversity in predicted structure.
The Src family of nonreceptor PTK enzymes currently contains nine members: Src, Yes, Fyn, Lyn, Lck, Hck, Fgr, Blk, and Yrk. The Src, Yes, Fyn, and Lyn proteins are expressed in a variety of cell types, whereas the Lck, Hck, Fgr and Blk proteins are expressed primarily in different types of hematopoietic cells. Also, Src is expressed by the cells associated with colon cancer, breast cancer and ovarian cancer as well as virtually all other forms of human cancer. Likewise, Fyn and Lyn are expressed in virtually all forms of human cancer.
Tyrosine-specific protein kinase activity is also known to be associated with oncogene products of the retroviral Src gene family. Hunter et al., Annu. Rev. Biochem., 54, 897 (1985). This kinase activity is strongly correlated with the ability of retroviruses to transform cells, since mutants with reduced kinase activity have lower transforming efficiency, and mutants which lack tyrosine kinase activity are transformation defective. Bishop, Annu. Rev. Biochem., 52, 301 (1983). Similar kinase activity is also associated with the cellular receptors for several growth factors such as EGF, platelet derived growth factor, insulin, and insulin-like growth factor I. Ushiro et al., J. Biol. Chem., 255, 8363 (1980); Ek et al., Nature, 295, 419 (1982); Kasuga et al., Nature, 298, 667 (1982); Jacobs et al., J. Biol. Chem., 258, 9581 (1983). Therefore, it is likely that tyrosine phosphorylation plays an important role for cell proliferation and malignant cell transformation, and a drug capable of PTK inhibition would be likely to exhibit desirable antiproliferative, pro-differentiating effects. Therefore, PTKs represent potential targets for the development of anti-cancer drugs or drugs intended to control pathologies associated with abnormal cellular proliferation.
A number of PTK inhibitors have been investigated as potential anticancer reagents. They include isoflavones (genistein), tyrphostins (erbstatin), lavendustin analogues, staurosporine analogues (dianilinophthalmides), polyhydroxylated stilbene analogues of piceatannol, dithiobis (indole-alkanoic acid), dihydroxyisoquinolines and others. For example, see T.R. Burke, Jr., "Protein-tyrosine kinase inhibitors," Drugs of the Future, 17, 119 (1992); P. Workman et al., Seminars in Cancer Biology, 3, 369 (1992); and D.W. Fry, Exp. Opin. Invest. Drug, 3, 577 (1994).
For the purpose of obtaining highly specific inhibitors, bicyclic compounds as ring-constrained inhibitors of PTK have recently been introduced. They are expected to interact with the flat, cleft-like catalytic cavity of the kinase domain with high specificity. Iminochromenes belong to this type of compound. For example, several 3-carbamoyl-2-iminochromenes with weak PTK inhibitory activity toward p56 lck have been reported by T.R. Burke et at., J. Med. Chem., 36, 425 (1993). These compounds are of general formula (1): ##STR3## wherein X is 6-, 7- or 8-hydroxy or 6,7 or 7,8-dihydroxy. Earlier, C. N. O'Callaghan et al., Proc. R.I.A., 79, 87 (1979) reported that compounds of formula (1) wherein X is 6- or 8-methoxy, 6-chloro, 6-nitro or 8-ethoxy exhibited anti-tumor activity against P388 murine lymphocytic leukemia. G. Keri et al. (published PCT application WO 93/16084) disclose compounds of formula (1) wherein X represents up to four benzo-substituents, including trihydroxy or trialkoxy. These compounds are generally disclosed to be anti-tumor agents due to their ability to inhibit TK enzymes. However, no biological data was reported for these compounds.
Therefore, a need exists for selective TK inhibitors which broadly inhibit the pathological division of cells, such as tumor cells, without exhibiting undesirable cytotoxicity to normal cells.
SUMMARY OF THE INVENTION
The present invention provides compounds of formula (I) ##STR4## wherein R 2 is H, OH, halo or O(C 1 -C 4 )alkyl; R 3 is OH, halo or O(C 1-C 4 )alkyl; and R 1 is ##STR5## wherein n is 0-12, preferably 0-4; R 4 is H, OH, halo, O(C 1-C 4 )alky)CH 2 OH, C(O)CH 3 , C(O)N(R) 2 , wherein each R is H, (C 1 -C 4 )alkyl or phenyl or C(O)R 6 , wherein R 6 is OH or O(C 1 -C 4 )alkyl; and R 5 is OH, halo, O(C 1 C 4 )alkyl CH 2 OH, C(O)CH 3 , C(O)N(R) 2 , or C(O)R 6 , and the pharmaceutically acceptable salts thereof. As drawn, --R 2 , --R 3 , --R 4 , and --R 5 can occupy any available position on their respective rings. Preferably, when one of R 2 and R 3 is O(C 1 -C 4 )alkyl and the other is H; and R 4 is H and R 5 is OH or halo, R 4 is 3'-OH, 4'-OH, or 5'-OH or 3'-halo , 4'-halo, or 5'-halo. Halo is Cl, Br, F or I.
These compounds are inhibitors of the activity of the 60-kDa src gene product, p60 c-src kinase. D. K. Luttrell et al., PNAS USA, 91, 83 (1994) have reported that p60 c-src kinase may be involved with two major signaling pathways in human breast cancer cells. It binds to activated epidermal growth factor receptor and to p185HER2/neu. It also interacts with raf-1 in a non-phosphotyrosine-dependent manner. (V. Cleghem et al., J. Biol. Chem., 269, 17749 (1994). Its activity is elevated in many tumors. See, for example, J.B Bolen et al., PNAS USA, 84, 2251 (1987) (colon carcinoma); S.A. Lynch et al., Leukemia, 7, 1416 (1993) (hairy cell leukemia, B-cell lymphoma); A.E. Ohenhoff-Kalff et al., Cancer Res., 52, 4773 (1992) (breast cancer); and P. Fanning et al., Cancer Res., 52, 1457 (1992) (bladder carcinoma).
Therefore, the present invention also provides a method to inhibit TK activity in populations of mammalian cells having cell surface receptors associated with TK activity. The preselected cell population is contacted either in in vivo or in vitro with a compound of the invention, in an amount effective to inhibit the TK activity, and thus, the cellular events associated with TK activity, in said population. It is expected that the compounds of the present invention will be effective in the treatment of diseases or pathologies associated with the pathological proliferation of mammalian cells such as B-cells, NK cells and T-cells, either used alone or in combination with immunotoxins or with conventional therapies for such afflictions. Such pathologies include other cancers, such as acute lymphoblastic leukemia, B-cell lymphoma, Burkitt's lymphoma; carcinomas such as lung, breast, bladder, colon, or ovarian cancer; epidermoid cancers, such as malignant melanoma and cancers of the CNS, and other leukemias.
The compounds of the present invention may also be useful as immunosuppressive agents to suppress or inhibit cellular proliferation such as T-cell proliferation associated with organ rejection or the proliferation of NK cells involved in rejection of bone marrow transplants. The compounds of formula (I) may be used to treat autoimmune diseases including, but not limited to, systemic lupus erythematosus, rheumatoid arthritis, non-glomerular nephrosis, psoriasis, chronic active hepatitis, ulcerative colitis, Chrohn's disease, Sjogren's syndrome, Behcet's disease, chronic glomerulonephritis (membranous), chronic thrombocytopenic purpura, allograft rejection and autoimmune hemolytic anemia.
Certain of the compounds of formula I are also useful as intermediates in the preparation of other compounds of formula I. For example, arylhalides can be converted to hydroxymethyl- or hydroxy-aryl compounds by the reaction of the Grignard reagent with ethyl formate or oxygen, respectively, as disclosed in Org. Synth. Coll. Vol. 2, 179 (1943) or J. Amer. Chem. Soc., 77, 6032 (1955). Likewise, alkoxy groups can be converted to OH by methods known to the art.
DETAILED DESCRIPTION OF THE INVENTION
Compounds of formula (I) can be prepared by the reaction of methyl cyanoacetate and arylamines or aralkyamines in a suitable solvent such as a lower alkanol at about 50ยฐ-100ยฐ C. for about 30 min-18 hr. The resultant N-phenyl -or N-phenylalkyl cyanoacetamides, of general formula (R 4 )(R 5 )Ph(CH 2 ) 2 NHC(O)CH 2 CN, wherein n, R 4 and R 5 are defined above, are isolated by cooling and filtering the reaction mixture, in accord with the general procedure of A. Gazit et al., J. Med. Chem., 34, 1896 (1991). The desired 3-(N-phenyl) carbamoyl-2-iminochromenes are prepared by the condensation of variously R 2 , R 3 substituted 2-hydroxybenzaldehydes with the (N-phenyl, or N-phenylalkyl) acetamides in a suitable solvent, e.g., an organic base at 30ยฐ-75ยฐ C. for about 5 min-5 hr. The reaction mixture is cooled to 20ยฐ-25ยฐ C. or below, and the compounds of formula (I) are isolated by filtration of the reaction mixture. Synthesis of compounds of formula (I) can also be accomplished as disclosed by T. R. Burke et al., J. Meal Chem., 36, 425 (1993), or by G. Keri et al. (PCT WO/93/16064), by replacing H 2 NC(O)CH 2 CN with (R 4 )(R 5 )Ph(CH 2 ) n NHC(O)CH 2 CN in Scheme III of Burke et al., or as disclosed at pages 5-12 of Keri et al.
Preferably, in the compounds of formula (I), R 2 and/or R 3 are OH or OCH 3 ; n is 0-2, most preferably O, and R 4 and R 5 are not both H; most preferably R 4 is H and R 5 is 2'-, 3'-, or 4'-OH. As used herein, "alkyl" or --(CH 2 ) n -- includes branched and straight chain alkyl groups, as well as cycloalkyl and cycloalkylalkyl. Lower alkyl is preferably (C 1 -C 4 )alkyl.
Although the free-base form of formula I compounds can be used in the methods of the present invention, it is preferred to prepare and use a pharmaceutically acceptable salt form. Thus, the compounds used in the methods of this invention form pharmaceutically acceptable acid and base addition salts with a wide variety of inorganic and, preferably, organic acids and include the physiologically acceptable salts which are often used in pharmaceutical chemistry. Such salts are also part of this invention. Typical inorganic acids used to form such salts include hydrochloric, hydrobromic, hydroiodic, nitric, sulfuric, phosphoric, hypophosphoric, and the like. Salts derived from organic acids, such as aliphatic mono and dicarboxylic acids, phenyl substituted alkanoic acids, hydroxyalkanoic and hydroxyalkandioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, may also be used. Such pharmaceutically acceptable salts thus include acetate, phenylacetate, trifluoroacetate, acrylate, ascorbate, benzoate, chlorobenzoate, dinitrobenzoate, hydroxybenzoate, methoxybenzoate, methylbenzoate, o-acetoxybenzoate, naphthalene-2-benzoate, bromide, isobutyrate, phenylbutyrate, ฮฒ-hydroxybutyrate, butyne-1,4-dioate, hexyne-1,4-dioate, caprate, caprylate, chloride, cinnamate, citrate, formate, fumarate, glycollate, heptanoate, hippurate, lactate, malate, maleate, hydroxymaleate, malonate, mandelate, mesylate, nicotinate, isonicotinate, nitrate, oxalate, phthalate, terephthalate, phosphate, monohydrogenphosphate, propriolate, propionate, phenyl-propionate, salicylate, sebacate, succinate, suberate, sulfate, bisulfate, pyrosulfate, sulfite, bisulfite, sulfonate, benzenesulfonate, p-bromophenylsulfonate, chlorobenzenesulfonate, ethanesulfonate, 2-hydroxyethanesulfonate, methanesulfonate, ethanesulfonate, 2-hydroxyethanesulfonate, methanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, p-toluenesulfonate, xylenesulfonate, tartarate, and the like.
The pharmaceutically acceptable acid addition salts are typically formed by reacting a compound of formula I with an equimolar or excess amount of acid. The reactants are generally combined in a mutual solvent such as diethyl ether or benzene. The salt normally precipitates out of solution within about one hour to 10 days and can be isolated by filtration or the solvent can be stripped off by conventional means.
The pharmaceutically acceptable salts of formula I compounds generally have enhanced solubility characteristics compared to the compound from which they are derived, and thus are often more amenable to formulation as liquids or emulsions.
As used herein, the term "effective amount" means an amount of compound of the methods of the present invention which is capable of inhibiting the symptoms of the pathological conditions herein described. The specific dose of a compound administered according to this invention will, of course, be determined by the particular circumstances surrounding the case including, for example, the compound administered, the route of administration, the condition of the patient, and the severity of the pathological condition being treated. A typical daily dose will contain a nontoxic dosage level of from about 0.25 mg to about 400 mg/day of a compound of the present invention. Preferred daily doses generally will be from about 1 mg to about 20 mg/day. Dosages can be extrapolated to some extent from the dosages of coumarin shown to be effective against melanoma (50 mg/day). See R. D. Thornes et al., J. Cancer Res. Clin. Oncol., 120 (Suppl.): S 32-34 (1994). Doses found to inhibit rumor growth in murine models, i.e., as disclosed by C. N. O'Callaghan et al., Proc. R.I.A., 79, Sect. B, 87 (1979) can be extrapolated to arrive at dosages for human patients as taught by Borch et al. (U.S. Pat. No. 4,938,949).
The compounds of this invention can be administered by a variety of routes including oral, rectal, transdermal, subcutaneous, intravenous, intramuscular, and intranasal. These compounds preferably are formulated prior to administration, the selection of which will be decided by the attending physician. Typically, a formula I compound, or a pharmaceutically acceptable salt thereof, is combined with a pharmaceutically acceptable carrier, dilueut or excipient to form a pharmaceutical formulation, or unit dosage form.
The total active ingredients in such formulations comprises from 0.1% to 99.9% by weight of the formulation. By "pharmaceutically acceptable" it is meant that the carrier, diluent, excipients, and/or salt must be compatible with the other ingredients of the formulation, and not deleterious to the recipient thereof.
Pharmaceutical formulations containing a compound of formula I can be prepared by procedures known in the art using well known and readily available ingredients. For example, the compounds of formula I can be formulated with common excipients, diluents, or carriers, and formed into tablets, capsules, suspensions, powders, and the like. Examples of excipients, diluents, and carriers that are suitable for such formulations include the following fillers and extenders such as starch, sugars, mannitol, and silicic derivatives binding agents such as carboxymethyl cellulose and other cellulose derivatives, alginate, gelatin, and polyvinyl-pyrrolidone; moisturizing agents such as glycerol; disintegrating agents such as calcium carbonate and sodium bicarbonate; agents for retarding dissolution such as paraffin; resorption accelerators such as quaternary ammonium compounds; surface active agents such as cetyl alcohol, glycerol monostearate; adsorptive carriers such as kaolin and bentonite; and lubricants such as talc, calcium and magnesium stearate, and solid polyethylene glycols.
The compounds also can be formulated as tablets or in capsules or as elixirs or solutions for convenient oral administration or as solutions appropriate for parenteral administration, for example, by intramuscular, subcutaneous or intravenous routes.
Additionally, the compounds are well suited to formulation as sustained or controlled release dosage forms. The formulations can be so constituted that they release the active ingredient only or preferably in a particular physiological location, optionally over a period of time. The coatings, envelopes, and protective matrices may be made, for example, from polymeric substances or waxes. The compounds can also be delivered via patches for transdermal delivery, s.c. implants, infusion pumps or via release from implanted depot sustained release dosage forms.
The invention will be further described by reference to the following detailed examples, wherein preferred compounds of formula (I) were prepared as shown on Table 1, below:
TABLE 1______________________________________Synthesis of 3-(N-phenyl)carbamoyl-2-iminochromenes______________________________________ ##STR6## ##STR7## ##STR8##7: X = 6-OH T: Y = 4'-OH8: X = 7-OH TA: Y = 3'-OH9: X = 8-OH TO: Y = 2'-OH15: X = 7-OCH.sub.3 TABA: Y = 3'-CH.sub.2 OH16: X = 6-OCH.sub.3 TOBA: Y = 2'-CH.sub.2 OH18: X = 7,8-di OH ACTA: Y = 3'-COCH.sub.319: X = 5,7-di OH AN: Y = H25: X = H32: X = 8-OCH.sub.3______________________________________
As shown in Table 1, cyanoacetamides were prepared by the reaction of methyl cyanoacetate with arylamines in ethanol at 70ยฐ C. for 0.5-1 hr. N-phenyl-cyanoacetamides were isolated by cooling and filtration of the reaction mixture. The listed 3-(N-phenyl)carbamoyl-2-iminochromenes were prepared by condensation of various derivatives of 2-hydroxybenzaldehyde with (N-phenyl) cyanoacetamides in ethanol containing piperidine at 40ยฐ C. to 60ยฐ C. for 5 min to 10 min. After cooling, the products were isolated by filtration of the reaction mixture. The melting points and H 1 NMR spectra of the compounds listed on Table 1 are summarized on Table 2, below.
TABLE 2______________________________________Com- mppounds ยฐC. .sup.1 H NMR, ppm______________________________________7T 182 8.77(1H, s, vinyl)7.26(2H d, J=8.8Hz) 6.72(2H, d, J=8.8Hz)6.95(1H, d, J=2.7Hz) 6.82(2H, d, J=13Hz)6.78(1H. dd, J=2Hz, 11Hz) 9.06(1H, br, s, NH). 7.3(1H, br, s, โNH) 12.5(1H, br, s, OH)7TA 170 8.77(1H, s, vinyl). 7.19(1H, t, J=7.9Hz) 7.02(1H, d, J=2.7Hz)6.83(1H, dd, J=2.7Hz, 8.84z) 6.69(1H, dd, J=2Hz, 8.1Hz)6.78(1Hdd. J=2.7Hz, 8.4Hz)8T 240 8.71(1H, s, vinyl), 7.33(1H, d, J=7.3Hz) 7.19(2H, J=8, 7Hz)6.77(2H, J=8.7Hz) 6.33(1H, dd, J=2.1Hz, 8.3Hz)6.24(1H, d. J=2.2Hz). 9.54(br, s,. 1H. NH). 7.4(br, s, 1HโNH) 10.12(1H, s, OH)13.78(1H, s, OH)8TA 164ยฐ C. 8.73(1H, s vinyl), 7.4(1H, d, J=8Hz) 6.35(1H, dd, J=2.2Hz, 8Hz)6.26(1H, d, J=2.2Hz) 6.65-7.2(4H, m). 9.7(1H, br, s, NH)8TO 270ยฐ C.9T 140ยฐ C. 8.84(1H, s, vinyl), 7.0(1H, dd, J=2.2Hz. 7Hz) 6.74(1H, t, J=7.5Hz)6.86(1H, dd, J=2.1Hz, 7.8Hz) 7.28(2H, d, J=8.8Hz). 6.81(2H, d, J=8.8Hz)9TA 296ยฐ C. 8.78(1H, s, vinyl). 7.0(1H, d) 6.8-7.4(6H, m)9TO 127ยฐ C. 8.94(1h, s, vinyl), 6.69-7.4(7H, m)9TABA 223ยฐ C.9TOBA 118ยฐ C.15T 8.78(1H, s, vinyl), 7.44(1H, d, J=8.6Hz) 7.23(2H, d, J=8.7Hz)6.79(2H, d, J=8.7Hz) 6.49(1H, dd, J=2.3Hz, 8.5Hz)6.44(1H, d, J=2.2Hz) 3.78(3H, s, CH3O)9.61(1H. br, s,. NH) 7.50(1H, br, s,. โNH). 13.95(1H, s, OH)16T 8.85(1H, s, vinyl), 7.17(1H, d, J=3Hz) 7.3(2H, d, J=8.8Hz)6.8(2H, d, J=8.8Hz) 6.95(1H, dd, J=3Hz. 9Hz). 6.83(1H, d, J=9Hz) 3.72(3H, s, CH3), 9.65(1H, br, s,. NH)12.75(1H, s, OH)18T 234ยฐ C. 8.69(1H, s, vinyl). 7.20(2H, d, J=8.7Hz) 6.78(2H, d, J=8.7Hz). 6.86((1H, d, J=8.4Hz) 6.36(1H, d, J=84Hz). 9.51(1H, br, s,. --NH) 7.35(1H, br, s, --NH). 13.95(1H, br s, OH)18TA 199.6ยฐ C. 8.70(1H, s, vinyl), 6.90(1H, d. J=8.6Hz). 6.37(1H, d, J=8.6Hz), 6.71(1H, t, J=2Hz) 6.64(1H, dd, J=2Hz, 8.1Hz), 7.20(1H, t, J=8Hz) 7.75(1H, d, J=8.2Hz). 8.1(br, s,. 1H, --NH)18TO 199.9ยฐ C. 8.76(1H, s, vinyl). 7.38(1H, dd, J=1.5Hz, 7.9Hz), 7.03(1H, t, J=7.3Hz) 6.93(1H, dd, J=1.4Hz, 8.0Hz), 6.87(1H, t, J=7.6Hz) 6.83(1H, d, Jโฆ8.7Hz), 6.26(1H, d, J=8.6Hz) 9.49(1H, br, s, NH)18TABA 149.6 8.92(H, s, vinyl)7.27-7.40(3H, m, aromatic) 6.92(1H, dd, J=1.6Hz, J=7.6Hz). 7.09(1H, d, J=7.8Hz) 6.78(1H, d, J=7.8Hz) 9.25(1H, br, s, NH) 4.6(2H, s, CH2)4.35(s. 1H, OH)18TOBA 8.70(1H, s, vinyl). 8.12(1H, br, s,. --NH) 7.49(1H, dd. J=7Hz)7.25-7.32(3H, m) 6.94(1H, d, J=8.4Hz). 6.42(1H. d, J=8.5Hz) 9.8(1H, br, s,. --NH)18ACTA 199.4ยฐ C. 8.85(1H, s, vinyl), 8.12(1H, brs, โNH). 7.87(1H, d, J=1.8Hz), 7.82(1H, d. J=7Hz) 7.6(1H, t, J=7.4Hz,. 8.5Hz). 7.2(1H, d, J=8.9Hz) 7.0(1H, d, J=8.6Hz). 6.45(1H, d, J=8.5Hz) 9.8(1H, br, s, NH)3.78(3H, s, CH.sub.3)18AN 163.3ยฐ C. 10.29(1H, br, s,. --NH)9.8(1H, s, vinyl) 7.05(1H, d, J=7.4Hz), 7.32(1H, d, J=7.4Hz) 7.1-7.6(5H, m, aromatic)19T 179.3ยฐ C. 8.34(1H, s, vinyl), 6.38-6.48(6H, m)19TA >300 8.85(1H, s, vinyl), 9.7(1H, brs, NH), 7.18(1H, t), 5.79-6.78(5H, m)19TO 286.5ยฐ C. 8.85(1H, s, vinyl), 7.8(1H, brs, โNH) 9.7(1H, brs, NH), 6.34-6.72(4H, m), 6.36(1H, s)5.75(1H, s)25T 138.8 8.95(1H, s, vinyl). 7.56(1H, d. J=7.5Hz) 7.35(1H, d. J=7.51Hz), 6.90(2H, m) 7.29(2H, d, J=8.7Hz)6.81(2H, d, J=8.7Hz) 9.7(1H, br, s, NH), 7.6(1H, br, s, โNH) 13.43(1H, s, OH)25TA 98.5ยฐ C.25TO 187.2ยฐ C. 8.95(1H, s, vinyl), 9.7(1H, brs, NH) 7.5(1H, d), 7.3(2H, m), 7.1(1H, t) 6.8-7.0(4H, m)______________________________________
Table 3 shows the inhibitory activities (IC 50 ) of several 3-(N-phenyl) carbamoyl-2-iminochromene derivatives on purified tyrosine kinase p60 c-src and against five tumor cell lines and human fibroblasts. Purified p60 c-scr and Src-family kinases p56 lck , p56 lyn , and p55 fyn were obtained from Upstate Biotechnology Inc. Kinase assays were performed as described by A. Gezit, J. Med. Chem., 34, 1896 (1991), using poly [Glu,Tyr](4:1) as a substrate.
The source of the cancer cell lines were: HL-60, HT-29, and BT-20, from American Type Culture Collection, Rockville, Maryland; A-1 from Dr. M. H. Freedman, MG-63, from Dr. M. Hurley, and human fibroblast from Dr. R. Zeff. Cells were grown in the culture treated with or without various compounds for 3 days. Cells (except BT-20) were then recovered and treated with Trypan Blue and the number of viable cells counted. For BT-20 cells, a new rapid and simple method using Alamar Blue Assay was used, as described by S. A. Ahmed et al., J. Immunol. Meth., 170, 211 (1994). The symbol i on the Table indicates "not
TABLE 3__________________________________________________________________________Structure-Activity Relationship of the 3-(N-phenyl-carbamoyl)-2-iminochromenes (IC.sub.50, ฮผg/ml) IC50 (ฮผg/ml) Human fibro-Compound p60.sup.c-src. p56.sup.lck. p56.sup.lyn. p55.sup.fyn. HL-60 cells A-1 cells HT-29 cells blasts cells MG-63 BT-20__________________________________________________________________________7T 3.2 >10 i i 4.2 3 i i i 4.57TA 1.3 i >10 i 6.5 4.5 i i i i8T 1.2 >10 i i 5 5 i i i 148TA 9 i >10 i 3.3 i i i i i8TO 0.6 i i i 8 i i i i i9T 1.9 0.62 20 >20 2.5 1.9 4 i 1.25 79TA 0.035 0.62 <10 20 10 6 20 i i i9TO >10 1.2 >20 >20 1.5 1.9 4 i i i18AN >20 >20 >20 >20 >20 17 i i i i18T 3.6 5 >20 >20 3.5 8 20 i i 7.218TA 0.225 20 18 >20 9 20 >20 i i i18TO 12 20 >20 >20 2 2 15 i i i19T 0.2 2 5 i 1 1 2.5 >20 2.5 419TA 1.25 3.75 5 i 2.5 15 10 >20 5 >2019TO 2.1 i >>5 i 5 2.5 0.625 >20 2.5 >2025T >20 >10 10 i >10 i i i i 1025TA 10 i i i i i i i i i25TO >20 i i i i i i i i i9TABA 2.5 i 20 i 3 i 11 i i >20 i9TOBA 1.8 i i i 6 i i i 5 i18TABA 5 >20 20 >20 2.5 2.5 i i i i18TOBA 0.9 5 >20 >20 6 >20 i i i i18ACTA 3 >20 10 20 i 15 i i i i15T >10 >10 i i 7.5 i i i i >2016T 12.5 7.5 i i 5 i i i i >2032TA 1.3 i i i i 12 i i i i__________________________________________________________________________
As shown by the data on Table 3, the parent compound, 3-(N-4-hydroxyphenyl) carbamoyl-2-iminochromene (25T) poorly inhibits p60 c-src kinase with an IC 50 >20 ฮผg/ml. Mono- or dihydroxylation of the iminochromene ring of the parent compound at positions 5,6,7 or 8 leads to an enhancement of the activity [7T (IC 50 3.2 ฮผg/ml), 8T (IC 50 1.2 ฮผg/ml), 9T (IC 50 1.9 ฮผg/ml), 18T (IC 50 3.6ฮผg/ml), and 19T (IC 50 0.2ฮผg/ml)]. Compound 19T which contains 5,7-dihydroxylation of the iminochromene ring is 200 fold more potent than the parent compound 25T. Substitution of the hydroxyl groups with methoxy groups resulted in a reduction of activity (15T is 8-fold less active than 8T and 16T is 4-fold less active than 7T).
The effects of varying the positions of hydroxyl substitution on the N-phenyl ring of the 3-carbamoyl group were studied. Three compounds containing 8-hydroxylation of the iminochromene ring (9T, 9TA, 9TO) were tested. The compound 9TA, which contains hydroxylation of the N-phenyl ring at 3' position, is 285-fold more potent than the compound 9TO, which contains hydroxylation of the N-phenyl ring at 2'-position. 9TA is 54-fold more potent than the compound 9T, which contains hydroxylation of the N-phenyl ring at the 4-position. Similar results were observed with the compounds 18T, 18TA, and 18TO, which contain 7,8-dihydroxylation of the iminochromene ring but differs in the positions of hyroxyl substitution on the N-phenyl ring: 18T (IC 50 3.6 ฮผg/ml), 18TA (IC 50 0.225 ฮผg/ml), and 18TO (IC 50 12 ฮผg/ml).
In contrast, compounds containing hydroxymethylation of the N-phenyl ring at 2-position (9TOBA, 18TOBA) are much more potent than their hydroxylated parent (9TOBA and 18TOBA) are much more potent than 9TO and 18TO, respectively).
However, hydroxymethylation of the N-phenyl ring at 3'-position does not produce compounds more potent than their parent hydroxylated compounds (9TABA and 18TABA are not more potent than 9TA and 18TA, respectively). Compounds containing hydroxylation of the iminochromene ring at 6-position (7T, 7TA), 7-position (8T, 8TA, 8TO), 5 and 7 positions (19T, 19TA and 19TO) or no hydroxylation (25T, 25TA and 25TO) are less sensitive to the effect of varying the positions of hydroxyl substitution on the N-phenyl ring of the carbamoyl group. Compound 18AN which does not contain an hydroxylation group on the N-phenyl ring is inactive (IC 50 >20 ฮผg/ml).
Hydroxylation of the N-phenyl ring at 3'-position produces the compound 18TA which is 88-fold more potent than 18AN. Acetoxylation of the 3'-position of compound 18TA produced 18ACTA which is 13-fold less potent than 18TA. The most active compound 9TA (IC 50 0.035 ฮผg/ml) which is hydroxylated at 3ยฐ-and 8-positions.
Several compounds were also examined for their selectivity against other tyrosine kinases of the Src family including lck, lyn and fyn. The compounds were relatively weak inhibitors for these kinases. The pattern of structure-activity relationship observed with p60 c-src was not reproduced with these kinases.
As shown on Table 3, several compounds of formula (I) were tested for their ability to inhibit the growth of human cancer cells including promyelocytic leukemia HL-60 cells (S. J. Collins et al., Blood, 70, 1233 (1987)); acute lymphocytic leukemia A-1 cells, (S. Kamel-Reid et al., Leukemia, 6, 8 (1992)); human osteosarcoma MG-63, (A. Pirskanen et al., J. Bone and Mineral Res., 1635 (1994)); human breast carcinoma BT-20 (G. G. Castles et al., Cancer Res., 58, 5934 (1992)); and human colon adenocarcinoma HT-29 cells (R. Garcia et al., Oncogene, 6, 1983 (1991)).
Surprisingly, compounds which show a strong inhibitory effect against p60 c-src (e.g., 9TA and 18TA) are not as potent against these cell lines as some of the compounds with relatively weak activity against p60 c-src (e.g., 9TO and 18TO). Also, the pattern of structure-activity relationship observed with HL-60 cells was not reproduced in other cell lines. For the HT-29 cells, 19TO appeared to be most effective (IC 50 0.625 ฮผg/ml). For the HL-60, MG-63, BT-20, and A-1 cells, 19T appeared to be the most potent compound (IC 50 1 ฮผg/ml). Compounds which are inactive (IC 50 > 20 ฮผg/ml) against p60 c-src (e.g., 18AN, 25T) are also less active in inhibiting cell growth. The most effective compounds for inhibiting cancer cell growth, 19T, 19TA and 19TO are not effective in inhibiting the growth of human fibroblast cells (IC 50 >20 ฮผg/ml), thus demonstrating their ability to discriminate between cancerous and normal cells.
All publications, patents and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
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Protein tyrosine kinase inhibitors are provided of formula (I): ##STR1## wherein R 2 is H, OH, halo or O(C 1 -C 4 )alkyl; R 2 is OH, halo or O(C 1 -C 4 )alkyl; R 1 is ##STR2## wherein R 4 is H, OH, halo, CH 2 OH, C(O)CH 3 , C(O)N(R) 2 wherein each R is H or (C 1 -C 4 )alkyl; or C(O)R wherein R 6 is OH or O(C 1 -C 4 )alkyl; and R 5 is OH, CH 2 OH, C(O)CH 3 , C(O)N(R) 2 or C(O)R 6 ; or a pharmaceutically acceptable salt thereof, which inhibit the pathological proliferation or growth of mammalian cells, such as cancer cells.
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BACKGROUND OF THE INVENTION
The present invention relates to an image-forming apparatus which forms an image in such a manner that the recording head transfers a color agent from a transfer member onto a sheet.
Among conventional transfer apparatuses of this type is a thermal transfer printer which prints an image by heating a ribbon impregnated with a color agent. It is small, low-priced, noise-free, and can print an image on ordinary paper. Therefore, it has recently been used in computers, recorders, word processors, and copying apparatuses.
In the thermal transfer printer of this type, to form an image, a ribbon (or transfer material) containing a color agent is brought into contact with a recording head, and the color agent is melted by heat and transferred to a sheet. In this process, the color agent or foreign material such as dust can undesirably attach to the recording head.
Conventionally, to clean the recording head, the ribbon must be removed so as to expose the recording head. However, it is difficult to remove the ribbon, and the space around the recording head is too small to allow manual cleaning. For this reason, manual cleaning of the head is difficult and time-consuming.
SUMMARY OF THE INVENTION
Accordingly, the object of the present invention is to provide an image-forming apparatus having a cleaning device whose recording head can be easily and quickly cleaned.
According to the present invention, there is provided an image-forming apparatus in which a recording head transfers a color agent from a transfer member to a sheet to develop a latent image, a cleaning device is provided to clean the recording head, a cassette containing the transfer member can be removed at a position where it opposes the head, and a cleaning member, which is provided in the cassette, is brought to oppose the head so as to clean the head.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a heat transfer apparatus used for one embodiment of the present invention;
FIG. 2 is a broken away, perspective view schematically showing the transfer apparatus of FIG. 1;
FIG. 3 is a vertical sectional view schematically showing the transfer apparatus of FIG. 1;
FIG. 4 is a perspective view for illustrating the transferring operation of the transfer apparatus of FIG. 1;
FIG. 5 is a plan view showing the way ink is applied to a ribbon used in the transfer apparatus of FIG. 1;
FIGS. 6 to 9 are sectional views for illustrating the operation of the transfer apparatus of FIG. 1;
FIG. 10 is a block diagram showing the arrangement of the main part of the thermal transfer printer shown in FIG. 1;
FIG. 11 is a sectional view of a ribbon cassette used in the transfer apparatus of FIG. 1;
FIG. 12 is a perspective view of the ribbon cassette shown in FIG. 10;
FIG. 13 is another perspective view of the ribbon cassette of FIG. 11 taken from another direction;
FIGS. 14 and 15 are perspective views for illustrating how the ribbon cassette of FIG. 12 is set in place;
FIG. 16 is a view for explaining an operation for replacing a ribbon cassette loaded in a heat transfer apparatus with a cleaning cassette;
FIG. 17 is an illustration showing a state where foreign material is attached to a thermal head in a thermal transfer mode;
FIG. 18 is an illustration showing a cleaning state of the thermal head;
FIG. 19 is a plan view showing a cleaning member stored in the cleaning cassette;
FIG. 20 is a sectional view of the cleaning member shown in FIG. 19;
FIG. 21 is a sectional view showing a cleaning member according to another embodiment of the present invention; and
FIG. 22 is a plan view showing a cleaning member according to still another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings of FIGS. 1 to 22. Referring first to FIGS. 1 to 20, one embodiment of the invention will be described in detail.
In FIG. 1 a thermal transfer copying apparatus is indicated generally by the number (transfer apparatus) 10. As shown in FIGS. 1 and 2, a housing 12 has an original table 14, on which an original may be placed. The original table 14 is formed of a transparent material such as glass. Under the original table 14 lies a scanning unit 16 for scanning the original paper on the original table 14. The scanning unit 16 is provided with an optical exposure system 18 which can move in the direction of arrow N to expose the original. The scanning unit 16 also has a function to convert optical information obtained through the exposure system 18 into an electric signal. Disposed in the central portion of the housing 12 is an image forming unit 20 for forming an image on a sheet in accordance with the electric signal from the scanning unit 16.
A tray 22 is secured to the top of the housing 12 for receiving the copied sheet from the image forming unit 20. A sheet cassette 24 for supplying the image forming unit 20 with sheets is removably attached to the front of the housing 12. Provided at the upper front portion of the housing 12 is an operator control panel 32 with a start button 26, a keyboard including ten keys 28 bearing numerals 0 to 9, a display 30 for indicating operator guidance, such as "clogging", and a button 31 for ejecting the ribbon cassette.
A door 36 is attached to the flank of the housing 12 which can be opened and closed when setting a ribbon cassette 34 (mentioned later) as a transfer member in the housing 12. The door 36 is provided with a lock mechanism 40 (see FIGS. 16 and 17) which can be locked by operating the numeral keys 28.
The image forming unit 20 comprises a holder 42 which regulates the position of the ribbon cassette 34 and holds it in place when the ribbon cassette 34 is set in the housing 12, and a thermal head 46 for heating that portion of the ribbon 44 which is exposed from the ribbon cassette 34 for ink transfer. The heating elements of the thermal head 46 are selectively energized in accordance with the electric signals from the exposure system 18, and melt a color agent applied to the ribbon 44 and transfer it to the sheet. A platen 48 for pressing the ribbon 44 and the sheet P against the thermal head 46 faces the thermal head 46 with the ribbon 44 between them. A radiating board 50 for radiating heat generated from the thermal head 46 is disposed at the back (on the sheet cassette side) of the thermal heat 46.
Referring now to FIG. 3, the image forming unit 20 will be described in detail. A takeout roller 52 is provided in front of the sheet cassette 24 to take sheets P from the cassette 24 one by one. Arranged close to the roller 52 are a pair of guide plates 54 for guiding each sheet P taken out by the takeout roller 52. Also arranged near the roller 52 are a pair of aligning rollers 56 for aligning the front edge of the guided sheet P. Two backup rollers 58 are arranged above and below the platen 48 to press the sheet P fed from the rollers 56 against the platen 48.
The tray 22, which adjoins the image forming unit 20, is integrally formed of a bearing plate 60 to receive the copied sheets. First and second guide plates 62 and 64 are provided to guide the sheets during the image forming process, such that the sheets are temporarily held on them. A pair of exit rollers 66 for discharging the sheets from the image forming unit 20 onto the bearing plate 60 are arranged at the inner end portion of the bearing plate 60. The tray 22 and the exit rollers 66 form one unit and are removably attached to the housing 12.
A first distribution guide 68 for changing the course of the sheets during the image forming process is swingably set between the aligning rollers 56 and the platen 48. The first distribution guide 68 selectively guides those sheets from the aligning rollers 56 toward the platen 48 and the sheets from the platen 48 to the first guide plate 62. Likewise, a second distribution guide 70 is swingably set between the exit rollers 66 and the platen 48 to guide the sheets to the bearing plate 60 and to the second guide plate 64. As shown in FIG. 3, numeral 72 designates a sheet-bypass guide 72. Through this bypass an operator may manually feeds sheets one by one into the apparatus.
In the thermal transfer printing using the thermal head 46, as shown in FIG. 4, ink (color agent) 74 applied to the ribbon 44 is heated and melted by the thermal head 46, and is transferred to a sheet P. During the thermal transfer, the ribbon 44 and the sheet P simultaneously move in the directions of arrows S and T, respectively.
As shown in FIG. 5, the ribbon 44 has a continuous range A covering, for example, a yellow-ink region 76, a magenta-ink region 78, and a cyan-ink region 80. It may have a range B covering all these regions 76, 78 and 80 plus a black-ink region 82. In the transfer, one of those ink colors is first transferred to the sheet P. The sheet P is returned to its original position to be subjected to ink transfer for another color. Thus, by repeating this transfer process, some ink colors are superposed to provide a color print. In general, a black color can be obtained by superposing the three colors in the range A. A deeper black color may be obtained by using a ribbon having the range B which covers the four color-ink regions including the black-ink region 82.
Referring now to FIGS. 6 to 9, the operation of the image forming unit 20 will be described.
When the takeout roller 52 rotates in the direction of arrow C, as shown in FIG. 6, a sheet P is taken out from the sheet cassette 24. Then, the sheet P is guided to the aligning rollers 56 by the guide plate 54. The front edge of the sheet P is aligned by the aligning rollers 56. The sheet P is further conveyed to reach the platen 48. Since the platen 48 is rotated in the direction of arrow D, the sheet P moves along the platen 48 to face the thermal head 46 across the ribbon 44. As mentioned before, the thermal head 46 heats the ribbon 44 in accordance with the signals from the exposure system 18, thereby printing the first-color ink of the ribbon 44 on the sheet P.
As shown in FIG. 7, the second distribution guide 70 is located substantially parallel to the second guide plate 64, and guides the sheet P having undergone the first printing cycle for the first color so that it is temporarily located on the second guide plate 64. The first distribution guide 68 is lifted up when the sheet P is about to finish passing by the guide 68.
The sheet P having undergone the first printing cycle for the first color is moved from the upper surface of the second guide plate 64 to the upper surface of the first guide plate 62, as shown in FIG. 8. Namely, the sheet P is temporarily returned to the first guide plate 62 for the second printing cycle for the second color. The platen 48 is rotated counterclockwise or in the direction of arrow E, so that the sheet P is moved along the first guide plate 62. Since the first distribution guide 68 is lifted upward, the sheet P smoothly moves along the upper surface of the first guide plate 62.
When the sheet P has been transferred to the upper surface of the first guide plate 62, the platen 48 rotates again in the direction of arrow D, as shown in FIG. 9, for the second printing cycle for the second color. After the printing process is thus repeated for the second, third and fourth color, the second distribution guide 70 is held in its upward position so that the sheet P can be discharged onto the bearing plate 60. After the printing (image formation) has been completed, the sheet P is discharged onto the bearing plate 60 of the tray 22.
The control system for controlling the thermal transfer printer 10 will be described with reference to FIG. 10. A color changing unit 79 and a memory unit 81 are arranged between the scanning unit 18 and the heat transfer unit (image forming unit) 20. The color changing unit 79 is connected to the scanning unit 18. Color component signals (i.e., green, yellow, cyan and black color signals) detected by the scanning unit 18 are converted so as to correspond to the color agents (inks) (i.e., magenta, yellow, cyan and black) coated on the ribbons. The color changing unit 79 is connected to the memory unit 81. The memory unit 81 stores position data on the document in association with the respective colors. The memory unit 81 is connected to the heat transfer unit 20. The heat transfer unit 20 transfer the respective inks in accordance with the color data and position data which are read out from the memory unit 81, thereby forming an image on the sheet P. An AND gate 85 is inserted between the heat transfer unit (image forming unit) 20 and the memory unit 81 so as to generate a black signal by gating the magenta, yellow and cyan signals.
The scanning unit 18, the color changing unit 79, the memory unit 81 and the heat transfer unit 20 are commonly connected to a CPU (central processing unit) 83 which then controls the signal generation timings of the respective units and the operations thereof.
Referring now to FIGS. 11 to 15, the ribbon cassette 34 will be described in detail. In the case 84 of the ribbon cassette 34 two substantially parallel roll shafts 86 and 88, around which the two end portions of the ribbon 44 are wound, are arranged, as shown in FIG. 10. The ribbon 44 is enclosed by the case 84 so as to be partially exposed.
As shown in FIGS. 11 to 13, a slit 94 to receive the holder 42 is defined between case portions 90 and 92 which contain the roll shafts 86 and 88, respectively, and the ribbon 44 wound on the roll shafts 86 and 88. As shown in FIG. 13, the slit 94 extends along the extending direction of the roll shafts 86 and 88 and terminates in the middle of the case 84. A pair of notches 98 for the connection with a drive mechanism 96 (mentioned later) are formed in the slit-side end portion of each of the roll shafts 86 and 88.
In the ribbon cassette 34, moreover, a space 100 capable of receiving the thermal head 46 is defined between the exposed portion of the ribbon 44 and the case portions 90 and 92. As shown in FIG. 12, the space 100 extends along the extending direction of the roll shafts 86 and 88. With this arrangement, as shown in FIGS. 14 and 15, the ribbon cassette 34 is pushed in the direction of arrow F against the holder 42 and the thermal head 46 when it is inserted into the housing 12. When the ribbon cassette 34 is removed from the housing 12, it is drawn out in the direction of arrow G.
The dimensions of the ribbon cassette 34 are as follows. In FIGS. 11 to 15, the width of the ribbon 44 is indicated by L R (FIG. 12); the maximum ribbon roll diameter is indicated by L S (FIG. 11); the slit width is indicated by L B (FIG. 13); the slit height is indicated by L H (FIG. 12); the overall ribbon cassette length is indicated by L C (FIG. 13); the width of slitless portion of ribbon cassette is indicated by L A (FIG. 13); the holder thickness is indicated by H L (FIG. 14); and the holder width is indicated by H B (FIG. 15). Hereupon, there is given a relation L B >1/2L C . In this embodiment, L C and L B are set to be 250 mm and approximately 160 mm, respectively. Thus, the width L B of the slit 94 to receive the holder 42 is greater than one-half of the overall length L C of the ribbon cassette 34, so that the holder 42 can securely hold the ribbon cassette 34 over a long range when the ribbon cassette 34 is set in the housing 12.
Since the transverse supporting strength of the thermal head 46 depends on the width H B (approximately 160 mm in this embodiment) of the holder 42, the slit 94 is formed in a manner such that L B (approximately 160 mm) is greater than L A (approximately 90 mm).
The slit height L H is a little greater than the holder thickness H L (approximately 10 mm in this embodiment), while the slit width L B is substantially equal to the holder width H B (approximately 160 mm). Thus, in loading the housing 12 with the ribbon cassette 34, no play or backlash will occur between the holder 42 and the case 84.
After the thermal head printer 10 prints for a long period of time, foreign material such as dust or ink of the ribbon 44 can attach to the thermal head 46. In this case, the function of the thermal head 46 is degraded, and a clear image cannot be formed on a sheet. For this reason, the thermal head 46 must be cleaned.
When the thermal head 46 is cleaned, a cleaning cassette 102 is loaded in the printer 10 in place of the ribbon cassette 34, as shown in FIG. 16. The cleaning cassette 102 has substantially the same arrangement as that of the ribbon cassette 34 except for storing a cleaning member 104 instead of the ribbon 44. Therefore, a detailed description of the cleaning cassette 102 is omitted and reference is made to the ribbon cassette 34 shown in FIGS. 11 to 15. The cleaning member 104 stored in the cleaning cassette 102 will be described in detail with reference to FIGS. 16 to 22.
The cleaning member 104 is formed in the same sheet form as the ribbon 44, and two end portions thereof are wound around the roll shafts 86 and 88, respectively (FIG. 11), in the cleaning cassette 102. As shown in FIGS. 19 and 20, the cleaning member 104 comprises a knitted fiber member 106, e.g., cotton or felt. In this manner, since the cleaning member 104 comprises the knitted fiber member 106, it has a sufficient elasticity. For this reason, the cleaning member 104 can be brought into sufficient contact, that is wide contact, with the thermal head 46. A thickness (t2) of the cleaning member 104 is preferably larger than a thickness (t1, e.g., about 0.1 to 0.5 mm) of the ribbon 44. In other words, the relation t2>t1 is established, and the thickness t2 is about 0.5 mm. In the case of ink transfer operation as shown in FIG. 17, because the ribbon 44 is brought into tight contact with the thermal head 46 to have contact in region n1, foreign material 43 mainly attaches to an area corresponding to a peripheral portion of the contact region n1. Therefore, when the thermal head 46 is cleaned, the cleaning member 104 is preferably brought into tight contact with the thermal head 46 at a contact region n2 which is larger than the region n1 around which foreign material attaches. If the thickness t2 of the cleaning member 104 is sufficiently greater than the thickness t1 of the ribbon 44, the contact region n2 between the head 46 and the cleaning member 104 can be made sufficiently large. Therefore, the thermal head 46 can be effectively cleaned.
In the case of cleaning, after loading the cleaning cassette 102 in a portion used for loading the ribbon cassette 34, the roll shafts in the cleaning cassette 102 are driven, thereby moving the cleaning member 104 and removing the foreign material attached to the thermal head 46. In other words, the cleaning member 104 moves in substantially the same manner as the ribbon in the ribbon cassette 34 moves in the case of thermal transfer.
In the above embodiment, the cleaning cassette 102 is provided separately from the ribbon cassette 34. However, the present invention is not limited to this arrangement. For example, the ribbon 44 stored in the case 84 of the ribbon cassette 34 can be removed therefrom together with the roll shafts 86 and 88, and the cleaning member 104 with the roll shafts 86 and 88 can then be stored therein. In this case, the case 84 of the cassette 34 is formed as to be openable.
As described above, according to the present invention, the cleaning device of the image-forming apparatus comprises a cassette, and the recording head can be easily and quickly cleaned.
The present invention is not limited to the above embodiment, and various changes and modifications may be made within the spirit and scope of the present invention.
For example, in the above embodiment, only the fiber material is used as the cleaning member. However, the fiber material can also be dipped into a liquid, e.g., a thinner for cleaning the thermal head (recording head). The cleaning member is not limited to a fiber material, but can be synthetic resin. In this case, foreign material attached to the thermal head can be electrostatically attracted by the cleaning member.
As shown in FIG. 21, the cleaning member can be a cleaning member 112 consisting of a base 108 having a thickness of t3 and a carpet-like fiber material 110 arranged thereon. In this case, since a thickness of the cleaning member can be increased (t2+t3) and it has sufficient elasticity, the thermal head can be more effectively cleaned.
Alternatively, as shown in FIG. 22, the cleaning member can be coupled to a rear end portion of the ribbon 44 stored in the cassette case. In this case, since the ink ribbon 44 and the cleaning member are stored in a single ribbon cassette, the thermal head can be cleaned without using a separate cassette for cleaning use, i.e., while loading the ribbon cassette. Note that the position of the cleaning member is not limited to the rear end portion of the ribbon 44. For example, the cleaning member can be formed in a portion of the ribbon 44 at a predetermined distance from a distal end thereof, thus cleaning the thermal head at an appropriate time.
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An image-forming apparatus in which a recording head transfers a color agent from a transfer material in accordance with a latent image so as to form an image on a sheet, and which has a cleaning device for cleaning the recording head. The cleaning device includes a cassette case which is detachable at a position opposing the recording head, and a cleaning member which is stored in the cassete case and, at a time of cleaning the recording head, is opposed thereto to clean the head to clean it.
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FIELD OF THE INVENTION
[0001] The subject matter of the present disclosure relates generally to the placement of a ring into a tire cavity against an interior surface of the tire.
BACKGROUND OF THE INVENTION
[0002] Noise emitted by a tire rolling across a road surface is attributable mainly to the vibrations of the contacting surface of the tire with road surface irregularities that generate various acoustic waves. At least a portion of these acoustic waves can be perceived by the human ear as noise both inside and outside of the vehicle. The amplitude of the noise is dependent on e.g., vibration modes of the tire and also the nature of the road surface on which the vehicle moves. The frequency range corresponding to the noise generated by the tire typically ranges from about 20 Hz to 4000 Hz.
[0003] Noise outside the vehicle can be attributed to various interactions between e.g., the tire and the road surface and the tire and the air, each of which can cause discomfort to persons along the moving vehicle. The sources of such noise include the impact of the roughness of the road with the contact area of the tire as well as noise generated due to the arrangement of the elements of the tread and its resonance along different paths. The frequency range for such noise can range from about 300 Hz to about 3000 Hz.
[0004] Regarding the noise heard inside the vehicle, the modes of sound propagation include vibrations transmitted through the wheel center and the suspension system (up to about 400 Hz) as well as vibrations from aerial transmission of acoustic waves, which can include the high frequency spectrum (about 600 Hz and over).
[0005] One important contribution to the noise heard inside the vehicle is provided by cavity noise, which refers to the discomfort caused by the resonance of the air within the tire cavity. This cavity noise is predominant in a specific frequency spectrum between 200 Hz and 250 Hz depending on the geometry of the tire.
[0006] To reduce the rolling noise of a tire, particularly cavity noise, it is known to provide the inner wall of the tire with a layer of foam such as e.g., a foam as described in patents or patent applications WO 2006/117944 or U.S. Pat. No. 7,975,740, WO 2007/058311 and U.S. 2009/0053492, U.S. 2007/0175559, WO 2008/062673 and U.S. 2010/0038005, U.S. 2009/0053492, WO 2010/000789 and U.S. 2011/0308677, EP 1529665 or U.S. Pat. No. 7,182,114.
[0007] Challenges exist with development of processes and equipment for repeatedly locating the foam in the tire cavity and along the interior surface or wall. For example, tires are currently produced in a wide range of sizes and shapes requiring either different placement machines or adjustability of such machines. Also, if the foam is to be placed by insertion in the tire cavity against the inner surface of the tire in the crown portion, navigation past the tire seat must be considered. The tire seat has a smaller diameter relative to the diameter of the inner surface of the tire. Other challenges also exist.
[0008] Accordingly, a system for positioning noise attenuating foam inside a tire against the interior surface would be useful. Such a system that can consistently position the foam over a range of different tires sizes and shapes would be beneficial. Such a system that can be automated would also be particularly useful.
SUMMARY OF THE INVENTION
[0009] The present invention provides a system for placement of noise attenuating foam along an inside surface of a tire to attenuate cavity noise. The system can be used with tires of various sizes and shapes such that different foam sizes may be utilized. The system provides for automating the process of foam placement in a manner that allows for consistent placement of the foam during e.g., tire manufacture. Additional objects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
[0010] In one exemplary embodiment of the present invention, a device for placement of a ring onto an interior surface of a tire is provided. The device defines a central axis. The device includes a plurality of holders arranged around the central axis and configured for selectively holding and releasing the ring. A plurality of telescoping arm assemblies are arranged around the central axis, each arm assembly supporting at least one of the holders. Each arm assembly is configured for selectively extending and retracting the holder along a radial direction that is orthogonal to the central axis. A positioning plate is rotatable about the central axis and includes a plurality of guides extending from the central axis along the radial direction. Each guide is in receipt of at least one telescoping arm assembly and is configured so that rotation of the positioning plate about the central axis causes the telescoping arm assemblies to move along the guides and outwardly or inwardly along the radial direction depending upon the direction of rotation of the positioning plate.
[0011] In another exemplary aspect, the present invention provides a method for placement of a ring onto an interior surface of a cavity of a tire. The ring has an outside diameter and defines radial and circumferential directions. The method includes the steps of contracting the ring along the radial direction from a first shape to a smaller, second shape, wherein second shape comprises a plurality of folds of the ring along the circumferential direction; placing the ring while in the second shape into the tire cavity; expanding the ring to the first shape and within the tire cavity so as to remove the plurality of folds of the ring along the circumferential direction; and positioning a radially-outermost surface of the ring against the interior surface of the tire.
[0012] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0014] FIG. 1 is a schematic representation of certain steps in an exemplary method of the present invention. In FIG. 1 , the sidewall of an exemplary tire is not shown for purposes of additional clarity in explaining this exemplary method.
[0015] FIG. 2 is an elevation view of an exemplary embodiment of the present invention.
[0016] FIG. 3 is a top view of the exemplary embodiment of FIG. 2 supporting an exemplary foam ring.
[0017] FIG. 4 is a bottom view of the exemplary embodiment of FIG. 2 .
[0018] FIG. 5 provides a perspective view of a partial cross-section of the exemplary embodiment of FIG. 2 .
[0019] FIG. 6 is a partial side view of an exemplary telescoping arm assembly in a retracted position.
[0020] FIG. 7 is another partial side view of the exemplary telescoping arm assembly of FIG. 6 in an extended position so as to place the exemplary foam ring against the inside surface of a tire.
[0021] FIG. 8 is a perspective view of an exemplary holder of the present invention.
[0022] FIG. 9 is an end view of the exemplary holder of FIG. 8 before gripping an exemplary foam ring.
[0023] FIG. 10 is another end view as in FIG. 9 of the exemplary holder while gripping the foam ring.
[0024] FIG. 11 is another elevation view of the exemplary embodiment of FIG. 2 with the foam ring elevated into position for insertion into a tire cavity.
[0025] FIG. 12 is another top view of the exemplary embodiment of FIG. 2 supporting the exemplary foam ring in an exemplary first shape.
[0026] FIG. 13 is another top view of the exemplary embodiment of FIG. 2 supporting the foam ring in an exemplary second shape.
[0027] FIG. 14 is another elevation view of the exemplary embodiment of FIG. 2 with the foam ring supported by exemplary holders and a ring support plate in a lowered position.
[0028] FIG. 15 is another elevation view of the exemplary embodiment of FIG. 2 with an exemplary tire before insertion of the foam ring.
[0029] FIG. 16 is another elevation view of the exemplary embodiment of FIG. 2 illustrating positioning of the foam ring into the tire cavity against the interior surface with telescoping arm assemblies shown in an extended position.
[0030] FIG. 17 repeats the elevation view of FIG. 11 with telescoping arm assemblies shown in a retracted position.
DETAILED DESCRIPTION
[0031] For purposes of describing the invention, reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents
[0032] FIG. 1 provides a schematic representation of an exemplary method of the present invention as illustrated in steps 1 A through 1 D. In step 1 A, an exemplary foam ring 50 is provided for insertion in the cavity 46 of a tire 40 for purposes of noise attenuation. Foam ring 50 is shown in a first shape, which corresponds to its original, uncontracted state before insertion into tire 40 . Foam ring 50 defines a radial direction R and a circumferential direction C.
[0033] In this first shape, ring 50 has an outside diameter D 1 that exceeds the inner seat diameter D 3 of the seat 44 of tire 40 . By way of example, foam ring 50 may comprise a polyurethane foam as described in WO/2013/182477, but other materials may also be used. Similarly, the shape and dimensions of ring 50 shown in FIG. 1 and other figures herein are provided by way of example only as other constructions may be used as well. In step 1 A, an adhesive may be applied to the radially-outermost surface 60 of foam ring 50 for purposes of adhering foam ring 50 to interior surface 42 (e.g., the inner liner) of tire 40 . Alternatively, the adhesive may have previously been applied to the interior surface 42 of the tire 40 for the same purposes.
[0034] In step 1 B, foam ring 50 is contracted along radial direction R from the first shape shown in step 1 A to a smaller, second shape. In this second shape, foam ring 50 forms a plurality of outward opening folds 52 and inward opening folds 54 in an alternating manner along circumferential direction C (also shown e.g., in FIG. 13 ). For this exemplary embodiment, the folds are U-shaped and provide a โdaisyโ configuration with a contracted diameter D 2 as depicted in step 1 B. Contracted diameter D 2 is less than the original outside diameter D 1 and is also less than seat diameter D 3 . In one exemplary aspect of the present invention, the contracted, second shape shown in step 1 B is created by pulling foam ring 50 radially inward at multiple points 56 along circumferential direction C so as to form folds 52 and 54 .
[0035] As shown in step 1 C, foam ring 50 is next inserted through the seat 44 of tire 40 and into tire cavity 46 . Because contracted diameter D 2 is less than seat diameter D 3 , foam ring 50 may be readily placed into tire cavity 46 . The folded or contracted configuration used for the second shape of foam ring 50 allows the present invention to be used with a variety of different tire shapes and sizes.
[0036] In step 1 D of FIG. 1 , foam ring 50 is expanded back to the first shape. This step may performed by moving the foam ring 50 radially outward at multiple points 56 along circumferential direction C so as to remove the plurality of folds 52 and 54 . The inherent resiliency of the foam ring 50 may be sufficient to restore foam ring 50 back to its first shape during the expanding step 1 D. Notably, it should be understood that foam ring 50 may not be returned completely to original diameter D 1 upon expansion and placement against interior surface 42 and such is not necessarily required.
[0037] As foam ring 50 is expanded, its radially-outermost surface 60 is eventually placed into contact with the interior surface 42 of tire 40 along its crown portion. If an adhesive has been applied to radially-outermost surface 60 , such contact will allow foam ring 50 to be adhered to the interior surface 42 of tire 40 . Once foam ring 50 is secured to interior surface 42 , tire 40 can be e.g., mounted onto a wheel of a vehicle to provide noise attenuation during operation of the vehicle.
[0038] A side view of an exemplary foam ring placement device 100 is shown in FIG. 2 while a top view is shown in FIG. 3 . Device 100 defines a central axis CA ( FIG. 2 ) along its centerline and a radial direction R ( FIG. 3 ) that is orthogonal to central axis CA. For this exemplary embodiment, central axis CA is shown parallel to vertical direction V. A plurality of holders 102 are positioned adjacent to each other along circumferential direction C around central axis CA. Holders 102 are configured for selectively holding and releasing foam ring 50 as will be further described. While eight holders 102 are shown for this embodiment, it should be understood that in other embodiments a different number of holders 102 may be employed.
[0039] A plurality of telescoping arm assemblies 104 are also arranged around central axis CA. Each telescoping arm assembly 104 supports at least one holder 102 and is configured for selectively extending and retracting holder 102 along radial direction R. Stated differently, telescoping arm assemblies can move holders inwardly and outwardly relative to central axis CA along radial direction R. In FIG. 2 , holders 102 are shown in an extended position while in FIG. 3 holders 102 are shown in a retracted position. Additional details of telescoping arm assemblies 104 will be further described.
[0040] FIG. 3 also depicts an exemplary foam ring 50 that has been placed onto a ring support plate 112 . Various mechanisms (not shown) can be used to raise or lower (arrows U and D in FIG. 2 ) ring support plate 112 along central axis CA. Ring support plate 112 includes a plurality of slots 114 positioned about the circumferential direction C for providing clearance of other elements of ring placement device 100 . The size of ring support plate 112 allows for foam rings 50 of various diameters D 1 to be supported during operation of device 100 .
[0041] Each telescoping arm assembly 104 includes a post 106 that extends vertically upward from a positioning plate 110 and a fixed plate 116 . Positioning plate 110 is rotatable about central axis CA relative to fixed plate 116 and is used to move each post 106 outwardly or inwardly along radial direction R depending upon the direction of rotation of plate 110 . One or more mechanisms (not shown) can be used for rotating position plate 110 during operation of device 100 .
[0042] FIG. 4 provides a bottom view (along the direction of arrows 4 - 4 in FIG. 2 ) of positioning plate 110 . FIG. 5 provides a perspective view of cross-section of plates 110 , 112 , and 116 along with a single telescoping arm assembly 104 for purposes of additional clarity in describing this exemplary device 100 of the invention. Each post 106 of a telescoping arm assembly 104 is attached with a support base 128 , which is connected with a boss 122 . Boss 122 is received into a linear slot 120 (defined by fixed plate 116 ) that extends along radial direction R. Boss 122 is freely movable within linear slot 120 such that telescoping arm assembly 104 can move inwardly or outwardly along radial direction R.
[0043] An axle 126 extends through support base 128 and supports a roller 124 that is freely rotatable about axle 126 . Roller 124 is received into a guide 118 that, for this exemplary embodiment, is configured as a spiral slot 118 that spirals outwardly along radial direction R from central axis CA. As best seen in FIG. 4 , a plurality of such spiral slots 118 are defined by positioning plate 110 and are positioned adjacent to one another with each slot 118 receiving a roller 124 of one of the telescoping arm assemblies 104 .
[0044] The rotation of positioning plate about central axis CA and the reaction forces of rollers 124 in spiral slots 118 and bosses 122 in linear slots 120 causes movement of each telescoping arm assembly 104 outwardly or inwardly along radial direction R depending upon the direction of rotation. For example, rotation in the direction of arrow O ( FIG. 4 ) causes the telescoping arm assemblies 104 to move away from central axis CA (and each other) or outwardly along radial direction R. Conversely, rotation in the direction of arrow I ( FIG. 4 ) causes the telescoping arm assemblies 104 to move towards central axis CA (and each other) or inwardly along radial direction R. As such, positioning plate 110 can be used to selectively position telescoping arm assemblies relative to foam ring 50 on ring support plate 112 .
[0045] FIG. 6 provides a close-up and partial side view of telescoping arm assembly 104 in a retracted view. FIG. 7 provides the same view with telescoping arm assembly 104 in an extended position with a holder 102 placing foam ring 50 against the interior surface 42 along the crown portion 48 of tire 40 . Holder 102 is connected with post 106 by a plurality of links 146 , 148 , 150 , and 152 that pivot relative to post 106 as holder 102 is extended or retracted along radial direction R.
[0046] More particularly, a pair of slidable links 146 , 148 are pivotally connected at one end by pivot points P 1 to holder 102 , and at another end by pivot points P 3 to post 106 . Pivot points P 3 are able to move or slide up or down post 106 along vertical direction V. A motor 108 ( FIG. 2 ), such as e.g., a solenoid or pneumatic cylinder, is used to selectively control the position of pivots points P 3 by extension or retraction of shaft 130 .
[0047] Slidable links 146 and 148 are pivotally connected at pivot points P 2 to fixed links 150 and 152 , which are in turn pivotally connected along an opposite end at pivot points P 4 to post 106 . The position of pivot points P 4 is fixed relative to post 106 . For this embodiment, pivot points P 2 are located at about a midpoint along the length of slidable links 146 and 148 .
[0048] As shaft 130 is extended downwardly (arrow D in FIG. 6 ), pivot points P 3 slide downwardly. However, a reaction force provided by fixed links 150 and 152 causes slidable links 146 and 148 to pivot outwardly along radial direction R thereby extending holder 102 along radial direction R away from central axis CA. Conversely, as shaft 130 is withdrawn upwardly (arrow U in FIG. 7 ), pivot points P 3 slide upwardly and slidable links 146 and 148 pivot inwardly along radial direction Rโthereby withdrawing holder 102 along radial direction R and retracting holder 102 towards central axis CA.
[0049] FIG. 8 provides a perspective view of an exemplary holder 102 while FIGS. 9 and 10 provide end views of such holder 102 . As shown, holder 102 includes a receptacle 134 with a cover 132 providing a foam ring contact surface 136 . A plurality of slots 140 are defined by contact surface 136 . Slots 140 extend laterally over contact surface 136 and are arranged parallel to each other along the longitudinal direction L of holder 102 . A plurality of pins 142 , 144 are extendable through slots 140 . More particularly, pins 142 are provided in a row along one side of contact surface 136 while pins 144 are provided in a row along the other side of contact surface 136 . Pins 142 and 144 are disposed in an alternating manner along slots 140 .
[0050] Holders 102 are employed to grasp or hold foam ring 50 during its contracting, expanding, and positioning in tire 40 . In one exemplary method, as depicted in FIG. 9 , contact surface 136 is positioned against the radially-innermost surface 58 of foam ring 50 . Pins 142 and 144 can be extended (arrows I) through slots 140 to project into foam ring 50 and thereby secure its position onto contact surface 136 of holder 102 . Once foam ring 50 is positioned against the interior surface 42 of tire 40 , pins 142 and 144 can be retracted so as to release foam ring 50 from holder 102 .
[0051] An exemplary method of using foam ring placement device 100 to position foam ring 50 will now be described with reference to the various figures. It should be understood that the steps set forth herein, including their sequence, is provided by way of example and other steps and/or sequences may be employed as well. Beginning with FIGS. 3 and 11 , foam ring 50 is placed onto ring support plate 112 . For this starting operation, holders 102 are fully retracted along radial direction R against posts 106 ( FIG. 2 ). Posts 106 are also at their radially-innermost position nearest central axis CA ( FIG. 2 ) with rollers 125 at their radially-innermost position along guides 118 ( FIG. 4 ).
[0052] Next, ring support plate 112 is moved (arrows U in FIG. 11 ) relative to central axis CA so as to position foam ring 50 at the same height along the vertical direction as holders 102 . In FIG. 11 , foam ring 50 is shown in its original, first shape with diameter D 1 as previously described in step 1 A of FIG. 1 .
[0053] Referring primarily to FIG. 12 , positioning plate 110 is rotated (direction O in FIG. 4 ) so as to cause rollers 124 of the telescoping arm assemblies 104 to track along guides 118 and move the assemblies 104 radially outward (arrow O). Rotation of positioning plate 110 is continued until each holder's contact surface 136 is placed in contact with (or in close proximity) to the radially innermost surface 58 of foam ring 50 . In the event foam ring 50 has been placed on ring support plate 112 in a non-concentric manner relative to central axis CA, the radially-outward movement of telescoping arm assemblies 104 within slots 114 of ring support plate 112 will advantageously center foam ring 50 . Additionally, because of the range of movement available for telescoping arm assemblies 104 relative to positioning plate 110 , foam rings 50 of various diameters D 1 ( FIG. 1 ) can be positioned using device 100 . Once holders 102 have been positioned as just described, pins 142 and 144 are deployed into foam ring 50 as previously described with reference to FIGS. 9 and 10 .
[0054] Next, in order to provide foam ring 50 with an overall diameter D 2 less than the seat diameter D 3 of tire 40 , positioning plate 110 is rotated (arrow I in FIG. 4 ) in a manner that causes telescoping arm assemblies to move radially inward towards central axis CA. As illustrated in FIG. 13 , this movement pulls foam ring 50 at multiple points 56 along circumferential direction C to provide a contracted or second shape having a plurality of folds 52 and 54 in a manner as previously described with reference to step 1 B in FIG. 1 .
[0055] As shown in FIG. 14 , ring support plate 112 is lowered (arrows D) in preparation for placement of tire 40 . Foam ring 50 remains fixed in position by holders 102 , and also remains in its second shape.
[0056] Referring now to FIG. 15 , tire 40 is now positioned with its center TC along central axis CA and above device 100 . Tire 40 is lowered (arrow D) until along vertical direction V until its center TC coincides with the center RC of foam ring 50 as depicted in FIG. 16 . Because the overall diameter D 2 of foam ring 50 is less than the seat diameter D 3 of tire 40 , foam ring 50 can be readily placed within tire cavity 46 as previously described with reference to step 1 C in FIG. 1 .
[0057] Referring now to FIG. 16 , motors 108 on telescoping arm assemblies 104 are deployed to move shafts 130 downward (arrows D) and thereby cause holders 102 to extend outwardly along radial direction R. Additionally, positioning plate 110 is again rotated (arrow O in FIG. 4 ) in a manner that causes telescoping arm assemblies 104 to move outward along the radial direction R so as to move foam ring 50 toward tire 40 until the radially-outermost surface of foam ring 50 is positioned against the interior surface 42 of tire 40 along crown portion 48 . As previously stated, the use of adhesive allows foam ring 50 to be adhered to tire 40 . Ability to positioning holders 102 over a wide range along radial direction R allows tire of different shapes and sizes to be equipped with a foam ring.
[0058] Once ring 50 is installed, positioning plate 110 is rotated (arrow I in FIG. 4 ) so as to move telescoping arm assemblies 104 towards each other and central axis CA. Motor 108 is now activated to cause shafts 130 to return as shown by arrows U in FIG. 17 , which also retracts holders 102 along radial direction R away from tire 40 and towards central axis CA. Tire 40 with installed support ring 50 can now be lifted from the machine 100 along central axis CA and the process repeated for another tire and ring.
[0059] While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.
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A system is provided for placement of noise attenuating foam along an inside surface of a tire to attenuate cavity noise. The system can be used with tires of various sizes and shapes such that different foam sizes may be utilized. The system provides for automating the process of foam placement in a manner that allows for consistent placement of the foam during e.g., tire manufacture.
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FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION
[0001] The present invention relates to knitted therapeutic medical compression garments. More particularly, the present invention relates to knit therapeutic graduated compression stockings having courses of crimped bi-component yarns having an elastomeric core with a thermoplastic sheath and inlay courses containing spandex yarn.
[0002] Therapeutic medical compression stockings have been used on a relatively wide scale to assist in the prevention of venous diseases and/or embolism in a patient. The purpose of such stockings is to overcome the elevated internal pressures within a human extremity caused by gravity or disease processes.
[0003] The pressure gradient stocking and its use are well documented in the literature. The custom pressure gradient stocking was developed by Conrad Jobst a sufferer of venous disease. Mr. Jobst found relief from his problem while standing in a swimming pool. Mr. Jobst reasoned that the water pressure in the pool, which increases with depth, cancelled out the internal pressure in the veins of his leg. Jobst and others have identified a need to apply a relatively large compressive force in proximity to the ankle. See, page 535 of the article entitled โConrad Jobst and the Development of Pressure Gradient Therapy for Venous Disease.โ Also see, the article entitled โTreatment of venous diseaseโThe innovatorsโ at page 681 thereof quoting from an article by J. Horner, et al. entitled โValue of graduated compression stockings in deep venous insufficiency,โ Br Med J. 1980; zz: 820-1 wherein it is stated โthe greater the compression gradient between the ankle and calf produced by the stocking, the lower the ambulatory pressures.โ Cited in U.S. Pat. No. 5,823,195.
[0004] Therapeutic medical graduated compression stockings are designed to provide sufficient external circumferential counter pressure to maintain the normal venous and lymphatic pressures at a given level in the extremity, thus assisting the movement of venous blood and lymph from the extremity. Another important effect of compression is the reduction of the venous volume. Reduction of venous volume leads to an increase of the venous flow velocity. Gerwen H J L van. Pressure gradient tolerance in compression hosiery . Katholike Universiteit Nijmegen. 1994, pp. 103-105.
[0005] Furthermore, while the exact mechanism(s) of action of gradient compression therapy remain unknown improvements in skin and subcutaneous tissue microcirculatory hemodynamics may contribute to the benefits of compression therapy. The direct effect of compression on subcutaneous pressure is a plausible mechanism. Edema reduction and edema prevention is the goal in patients with chronic venous insufficiency, lymphedema, and other edema causing conditions. Subcutaneous pressures increase with elastic compression. Nehler M R, Moneta G L, Woodard D M, et al. Perimalleolar subcutaneous pressure effects of elastic compression stockings. J Vasc Surg 1993;18(5):783-88. This rise in subcutaneous tissue pressure should act to counter transcapillary Starling forces, which favor leakage of fluid out of the capillary.
[0006] For instance, gradient compression stockings 20 mmHg and above have demonstrated the following effects in persons with venous insufficiency:
[0007] Improved venous hemodynamics
[0008] Prolonged (more normalized) venous refill time (VRT). Samson R H, Scher L A, Veith F J, et al. Compression stocking therapy for patients with chronic venous insufficiency. J Cardiovasc Surg 1985;26:10.
[0009] Reduced venous volume and increased venous flow velocity Reduction and control of edema. Dale W A. The Swollen Limb in Current Problems In Surgery , edited by Mark M Ravitch, et al. 1973 Year Book Medical Pub, Chicago. p. 29-31.
[0010] Most of the patients suffering from minor to moderate varicosities, moderate edema, superficial thronbophlebitis, and post sclerotherapy need to use stockings with the compression at ankle in the range from 15-20 to 20-30 mm Hg. More complicated and severe cases require pressure of 40 mm Hg and higher.
[0011] A variety of therapeutic medical graduated compression stockings are on the market today. The stockings of various descriptions have been proposed. Unfortunately, therapeutic stockings, in order to provide the necessary compression, are often thick and rather unsightly or have other drawbacks. An example of a therapeutic stocking is described in U.S. Pat. No. 3,975,929 which describes a thigh length anti-embolism stocking made with alternating courses of covered spandex yarn on a circular hosiery knitting machine. Another example of a therapeutic stocking is described in U.S. Pat. No. 4,069,515 to Swallow, et al., which discloses a non-slip therapeutic stocking having a covered elastomeric yarn (spandex core-nylon covering) inlaid into every other course of the jersey knit stitches made of stretch nylon. In particular, the Swallow patent describes the foot portion as having alternating courses of jersey knit stitches of non-elastomeric yarn. One of these yarns is a Z-twist stretch nylon and the other is an S-twist nylon. A covered elastomeric yarn such as a single covered elastomeric yarn having a 280 denier spandex core and covered with nylon 6 yarn is preferably inlaid into every other course of the jersey stitches.
[0012] The use of bi-component crimped yarns is known in the manufacture of pantyhose. Such garment construction is described in U.S. Pat. No. 5,352,518 to Muramoto, et al., who teach a stocking having a bi-component core and sheath type yarn wherein the sheath is composed of a fiber forming a thermoplastic polymer and the core is composed of a fiber forming elastomer. It is stated that the filament has excellent elastic properties, a small surface friction coefficient and a matting effect due to diffusion reflection of light caused by rough surfaces, and is agreeable when worn in the form of a knitted textile structure, particularly as a lady's stocking.
SUMMARY OF THE INVENTION
[0013] A principle feature of the present invention is the provision of a therapeutic medical compression stocking made with bi-component fibers. It has been found that the use of bi-component yarns, in particular, those crimped yarns having an elastomeric core and a thermoplastic sheath when knit with inlaid courses of spandex or spandex covered with a bi-component yarn form therapeutic stockings that provide excellent compression control. In addition, these therapeutic stockings are more transparent than conventional therapeutic stockings. The therapeutic stockings of the present invention may be knit on a conventional circular knitting machine.
[0014] In a first preferred embodiment every course of the therapeutic stocking is knit with a crimped bi-component yarn having an elastomeric core and a thermoplastic sheath. Courses of an inlay yarn of spandex are provided at least every third course. In a second embodiment, the therapeutic stocking is knit with every other course being the crimped bi-component yarn and the inlay yarn is spandex present in every course. The alternate courses are covered spandex yarn. It was found that the use of spandex yarns in combination with the bi-component yarn enables the reduction in size of the spandex used in the inlay courses and maintains the desired compression.
[0015] In yet another embodiment of the present invention, there is provided a knitted therapeutic stocking comprising a crimped bi-component yarn in every course and an inlay yarn of spandex covered with a bi-component yarn. In a fourth embodiment there is provided a knitted therapeutic stocking comprising a crimped bi-component yarn in every other course and inlay course of spandex covered with a bi-component yarn.
[0016] It has been found that the therapeutic medical compression stockings of this invention provide a smooth, silky, cool and supple hand of fabric; easier donning, lighter weight, good durability and very good compliance with patient needs.
[0017] It is an object of the present invention to provide a therapeutic stocking having excellent compression by using an improved bi-component crimped yarn of the present invention.
[0018] Another object of the present invention is to provide an improved air-permeable therapeutic stocking because the spandex inlay yarns do not need to be covered.
[0019] Yet another object of the present invention is to provide a therapeutic stocking having improved transparency.
[0020] Other features and advantages of the present invention will become apparent in the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0022] [0022]FIG. 1 is an isometric view of a therapeutic stocking of the present invention;
[0023] [0023]FIG. 2 shows a bi-component, uncrimped yarn used to knit the therapeutic stockings of the present invention illustrating;
[0024] [0024]FIG. 3 shows the bi-component yarn of FIG. 2 used to make the therapeutic stockings of this invention in its crimped condition;
[0025] [0025]FIG. 4 is a photomicrograph of a fragmentary portion of a fabric made of bi-component yarns showing a first embodiment of a knit fabric used to make the therapeutic stocking of the present invention taken in the area of rectangle A in FIG. 1;
[0026] [0026]FIG. 5 is a photomicrograph of a fragmentary portion of a fabric made of bi-component yarns showing a second embodiment of a knit fabric used to make the therapeutic stocking of the present invention taken in the area of rectangle A in FIG. 1;
[0027] [0027]FIG. 6 is an enlarged view of a fragmentary portion of a fabric made of bi-component yarns showing a third embodiment of a knit fabric used to make the therapeutic stocking of the present invention taken in the area of rectangle A in FIG. 1;
[0028] [0028]FIG. 7 is an enlarged view of a fragmentary portion of a knit fabric made of bi-component yarns showing a fourth embodiment of the fabric used to make the therapeutic stocking of the present invention taken in the area of rectangle A in FIG. 1;
[0029] [0029]FIG. 8A shows a spandex yarn covered with a double bi-component yarn used in the inlay courses of the therapeutic stockings of the fourth embodiment of the present invention; and
[0030] [0030]FIG. 8B shows a spandex yarn covered with a single covering of bi-component yarn used in the inlay courses of the therapeutic stockings of the fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] 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. 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 so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0032] There is shown in FIG. 1 the therapeutic medical compression stocking 10 of the present invention. The stocking 10 includes a leg portion having an enlarged upper section 11 and a foot portion 12 . The foot portion 12 including a heel pocket 13 and a toe pocket 14 . The upper section 11 of the medical stocking can be provided with an upstanding and integrally knit band 15 for knee length or thigh length stockings, or a sewn in anti-slip band. Alternatively, the stockings can be an integral part of a panty hose garment.
[0033] An example of a bi-component yarn used to make the therapeutic medical compression stockings is shown in FIG. 2. The yarn 20 is composed of an elastomeric core 21 , that is preferably a polyurethane, more preferably a cross-linked polyurethane. Any of such known polyurethane as polycarbonate-urethanes, polyactone-urethanes and polyether-urethanes may be used as the polymer that forms the polyurethane core in the form of a homopolymer or copolymer of polyurethane or a mixture thereof. As a yarn forming thermoplastic polymer forming the sheath 22 of the yarn a polyamide such as nylon 6, nylon 66, or nylon 12 is preferred. Additionally, polyolefins also can be suitably employed. The core/sheath bi-component weight ratio is in the range between 20:80 and 80 : 20 , with 50:50 by weight especially preferred. The core/sheath bi-component ratio is preferably within the range between 5/1 and 90/1, more preferably between 10/1 and 50/1, by cross-sectional area. Especially preferred are those polyurethane yarns disclosed in U.S. Pat. No. 5,164,262, incorporated herein by reference.
[0034] Additionally, the bi-component yarn may have an eccentric configuration such as those yarns disclosed in U.S. Pat. No. 5,352,518. The use of eccentric yarns allows the attainment of latent crimping properties that allow coil-like crimps to be produced by the crimp development treatment. An illustration of a bi-component yarn in crimped configuration is shown in FIG. 3 wherein the crimped yarn 30 has an elastomeric core 31 and a polyamide sheath 32 . The bi-component yarns used to make the therapeutic stocking of this invention may be self-crimping yarns that form crimps, including helical coil-like crimps spontaneously. The yarns may also be externally treated such as by using an elevated temperature, or a swelling agent. Such bi-component yarns are commercially available under the name Sideriaยฎ available from Kanebo of Japan.
[0035] The elastomeric yarn used in the alternating or inlay courses is preferably spandex, such as Globe's Clearspanยฎ manufactured by Globe Manufacturing Inc., Fall River, Mass. Other spandex yarns that may be used includes Lycraยฎ spandex manufactured by DuPont, or Dorlastanยฎ spandex manufactured by Bayer, or any other applicable spandex yarn. In some embodiments of the invention the spandex yarn is covered with a bi-component yarn such as described above or with nylon yarns as shown in FIG. 8A and FIG. 8B. In some embodiments of the invention the spandex yarn can be covered with one (so-called single covered as shown in FIG. 8A) or two layers (double covered as shown in FIG. 8B) of nylon or bi-component yarn.
[0036] The fragmentary view A of a portion of fabric structure in the leg section 11 of the stocking (FIG. 4) is illustrates a first preferred embodiment of the therapeutic stocking of this invention as if the fabric were stretched in both coursewise and walewise directions. As shown in FIG. 4, each course (C- 40 , C- 42 , C- 44 , C- 46 and C- 48 ) of the therapeutic stocking is knit with a crimped bi-component yarn. Courses (C- 41 , C- 43 , C- 45 , C- 47 and C- 49 ) of inlay yarn are spandex. Courses of inlay yarn are laid in at least every three courses. It should be understood, however, that if more compression is needed the inlay courses may be used more frequently as shown by inlay yarns in every course in FIG. 4. It was found that the combination of bi-component yarns and spandex enabled the reduction in size of the spandex core used in the inlay courses and maintain the desired compression.
[0037] As shown in the second embodiment, that of FIG. 5 illustrating a fragmentary view A if a portion of fabric structure in the leg section 11 of the stocking, the therapeutic stocking is knit with alternating rows of jersey knit stitches of crimped bi-component polyurethane yarn. The intervening rows are courses of covered elastic yarn. A covered elastic yarn is a single covered elastic yarn, such as spandex with a covering yarn singly or double wound around the elastic yarn. Any polyamides such as nylon 6 and nylon 66, which are used for common polyamide fibers, can be used as the material of the polyamide filaments constituting the covering yarn. As shown in FIG. 5, every other course (C- 50 , C- 53 , and C- 56 ) of the therapeutic stocking is knit with a crimped bi-component yarn. The intervening courses (C- 52 , C- 55 and C- 58 ) are of covered elastic yarn. Courses (C- 51 , C- 54 and C- 57 ) of inlay yarn are spandex.
[0038] In FIG. 6 there is shown a third embodiment of the fabric structure A in the leg section 11 of FIG. 1 used to knit the therapeutic stockings of the present invention. In this embodiment every course (C- 60 , C- 61 , C- 63 , C- 64 and C- 66 ) of the knit stocking is a bi-component yarn. Each course of inlay yarn (C- 61 and C- 65 ) is comprised of spandex covered with a bi-component yarn. Such construction enables the reduction in the size of spandex in each course.
[0039] There is shown in FIG. 7 a fourth embodiment of the fabric structure A used to knit the therapeutic stockings of the present invention. As shown in FIG. 7, every other course (C- 70 , C- 73 and C- 76 ) of the therapeutic stocking is knit with a crimped bi-component yarn. The intervening course (C- 72 and C- 75 ) are of covered elastic yarn. Courses (C- 71 and C- 75 ) of inlay yarn are spandex covered with a bi-component yarn. Preferred yarns are shown in FIG. 8A and FIB. 8 B.
[0040] In FIG. 8A there is shown a spandex yarn core covered with two bi-component yarns used in the inlay courses of the therapeutic stockings of the fourth embodiment of the present invention. As shown in FIG. 8A, the yarn 80 has a spandex yarn component 81 . The spandex yarn is covered with one layer of bi-component yarn 82 wound in one direction and then a second bi-component yarn 83 wound in the other direction. In FIG. 8B, there is also shown another embodiment of the inlay yarn 85 having a spandex core 86 covered with a single layer of bi-component yarn used in the inlay courses of the therapeutic stockings of the fourth embodiment of the present invention.
EXAMPLE 1
[0041] A therapeutic stocking was knit with a jersey knit structure on a conventional circular knit hosiery machine. The leg yarn was a crimped bi-component yarn having a polyurethane core with a polyamide sheath in each course as shown by the fabric structure of FIG. 4. The inlay yarn was bare spandex. This stocking was then compared to the stocking presently on the market. The result is shown in Table 1.
TABLE 1 Property Prior Art 1 Invention Knit structure Jersey with bare spandex inlay Jersey with bare spandex inlay Leg yarn Covered, polyurethane core Bi-component, and polyamide over wrap polyurethane core with polyamide sheath 2 Total (Sum) linear density โ50 โ50 of leg yarn Denier (Linear Density) โ20 โ25 Weight of polyurethanecore part (yarn) Denier (Linear Density) of โ30 โ25 cover part (yarn) (double covering with 15 den (sheath) nylon) Linear density of inlay yarn 105 den polyurethane yarn 4 70 den polyurethane yarn 3 Total linear density of 125 โ95 polyurethane yarns Pressure at ankle โ18.5 โ21.6 Donning force at ankle, kg 5 โ3.3 โ2.5 Weight, g, one leg size โ26 โ17.8 medium Suppleness/stiffness - Less supple Very supple. Not stiff. expert evaluation Thin Hand Not silky, feels harsher than Smooth, silky, cool, not prototype, slightly rubbery rubbery especially inside a stocking Air permeability, ASTM- 730 876 737 cm 3 /s/cm 2
EXAMPLE 2
[0042] To further demonstrate advantages in donning, and fabric's air-permeability and suppleness the stockings were knitted from bi-component and conventionally covered yarns. Yams of similar deniers were used and conditions of knitting were adjusted to produce stockings with similar pressure values.
TABLE 2 Property Prior Art 1 Invention Knit structure Jersey with bare spandex inlay Jersey with bare spandex inlay Leg Yarn 20 den Lycra double covered Bi-component with 20 den nylon Total leg yarn denier โ60 โ50 Denier of inlay yarn 140 140 Total linear density of 160 165 polyurethane yarns Pressure at ankle โ25.1 โ23.9 Donning force at ankle, kg โ3.7 โ2.3 Air-permeability 598 746 Stiffness, g, ASTM โ18.5 โ9.2
[0043] Again it can be easily seen that use of bi-component yarn results in significant improvements in stocking's donning, and fabric's air-permeability and suppleness.
[0044] As can be seen from the results obtained, the first embodiment provides a therapeutic stocking that has superior properties, which is very supple and has a smooth silky cool hand.
[0045] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A knitted therapeutic medical compression stocking made from courses of bi-component fibers inlaid courses of spandex yarn. The use of bi-component yarns, in particular, crimped yarns having an elastomeric core preferably of a polyurethane and a thermoplastic sheath preferably of a polyamide when knit with inlaid courses of bare spandex, covered spandex, or spandex covered with a bi-component yarn forms therapeutic medical stockings that provide excellent compression control. In addition, these therapeutic stockings are more transparent than conventional therapeutic stockings. The therapeutic stockings of the present invention may be knit on a conventional circular hosiery knitting machine.
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This is a continuation of application Ser. No. 08/628,699, filed on Apr. 17, 1996, which was abandoned upon the filing hereof which claims benefit of international application PCT/EP94/03420, filed Oct. 17, 1994.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is relative to a method for the directed modification of enzymes, modified enzymes and their use.
2. Background Information
Enzymes can usually be modified either by chemical modification of the amino acids forming the enzyme or by mutation of the gene coding the enzyme. Chemical modifications are frequently non-specific, so that the directed modifying of the enzyme structure by directed mutation of the gene has advantages over the chemical modification.
Modified enzymes frequently exhibit improved properties as regards activity, specificity or stability in comparison to the unmodified enzymes. Previous activities in this area were frequently limited to improving global properties of the enzyme such as e.g. stability vis-a-vis reaction media. Thus, for example, alkaline proteases were stabilized against the oxidizing action of bleaching agents. However, the problem of changing the specificity of enzymes in order to convert previously defined substrates has hardly been treated. One exception is the work of H. M. Wilks et al. (H. M. Wilks et al., Science 1988, 242, 1541-1544) in which the substrate specificity of a lactate dehydrogenase with lactate as preferred substrate is transformed to a malate dehydrogenase with malate as preferred substrate.
The selectivity for producing enantiomerically pure compounds is especially desirable for enzymes. The enantioselectivity is especially prominent in the case of amino-acid dehydrogenases, among others. Thus, amino-acid dehydrogenases were screened from a number of organisms. The most important enzymes for use in organic synthesis are alanine dehydrogenase (AlaDH, E.C. 1.4.1.1.), phenylalanine dehydrogenase (PheDH; still no E.C. number) and, especially, leucine dehydrogenase (LeuDH, E.C. 1.4.1.9.). However, the best-investigated enzyme of the group is the ubiquitous glutamate dehydrogenase (GluDH, E.C. 1.4.1.2.-4.), which forms an important branch point between carbon metabolism and nitrogen metabolism. GluDH catalyses the NAD (P) + -dependent, oxidative deamination of L-glutamate to 2-oxoglutarate and ammonia: ##STR1##
Amino-acid dehydrogenases generally catalyze the reversible reductive amination of prochiral keto acids to L-amino acids ((S) configuration) and the reverse reaction of the oxidative deamination of L-amino acids to oxo acids.
In most instances, including all NAD + -dependent GluDH'es, the enzyme has six identical subunits of approximately 48 kD each. A considerable homology is found in the polypeptide chain of the hexameric GluDH'es; in particular, the glutamate binding pocket and the active center display a remarkable similarity (Britton, K. L., Baker, P. J., Rice, D. W. and Stillman, T. J., Eur. J. Biochem. 1992, 209, 851-859).
The degree of similarity between the structures of the members of the family of amino-acid dehydrogenases from different organisms is so great that a single superfamily of enzymes is assumed in the case of amino-acid dehydrogenases, which superfamily was produced by divergent evolution (S. Nagata, K. Tanisawa, N. Esaki, Y. Sakamoto, T. Ohshima, H. Tanaka and K. Soda, Biochemistry 1988, 27, 9056-62; H. Takada, T. Yoshimura, T. Ohshima, N. Esaki and K. Soda, J. Biochem. 1991, 109, 371-6).
The three-dimensional structure of the glutamate dehydrogenase from Clostridium symbiosum is known (Baker, P. J. et al., Proteins 1992, 12, 75-86). The gene of this enzyme was cloned and overexpressed in Escherichia coli (Teller, J. K. et al., Eur. J. Biochem. 1992, 286, 151-159). However, it has not been successful in the past to modify the enzymatic structure in such a manner by directed mutation of the gene that even certain substrates selected before the mutation were converted.
SUMMARY OF THE INVENTION
The invention therefore has the problem of making available a method for the directed modification of enzymes in which desired substrates can be converted independently of the natural substrate specificity of the enzyme. A further object of the invention is to indicate a modified enzyme which is altered at its substrate binding site so that a desired substrate which is generally not preferred is converted by the modified enzyme with sufficient activity, selectivity and stability.
This method solves the problem of the invention by carrying out in succession the steps indicated in claim 1. As a result of the fact that:
The structure of at least two enzymes from a group of enzymes is elucidated,
The binding pockets of the enzymes with elucidated structure from a group are compared,
The amino acids are determined which are necessary for the binding of a substrate preferred for the unmodified enzyme,
The amino acids in the binding pocket of the unmodified enzyme with elucidated structure are selected, which are to be modified for the binding of a desired substrate not preferred by the unmodified enzyme,
The selected amino acids are modified by the mutation of a gene belonging to the enzyme, and
The mutated gene is expressed and the purposefully modified enzyme isolated, it is possible to expand the substrate spectrum to new target structures vis-a-vis the unmodified enzyme. As a result thereof, an advantageous activity, selectivity or stability can be expanded to a larger number of substrates.
According to the invention the term "a group of enzymes" denotes all members of a sub-subclass according to E.C. nomenclature (E.C.=Enzyme Commission). The type of sub-subclass is not subject to any particular limitation. The preferred sub-subclasses include NAD (P) + -dependent redox reactions with amines (group 1.4.1. according to E.C. nomenclature), serine proteases (group 3.4.21. according to E.C. nomenclature) and carboxylester hydrolases (group 3.1.1. according to E.C. nomenclature).
Within the framework of the invention the term "structural elucidation" denotes the determination of the spatial structure of an enzyme. It is basically necessary to obtain information about the structure of two enzymes from a group. All methods known to the expert in the art for the structural elucidation of enzymes can be used with advantage thereby for the method of the invention. It is especially preferable if the analysis of the amino-acid sequence is carried out for at least one enzyme of a group, an associated enzyme substrate complex is crystallized thereby and the spatial structure of the enzyme substrate complex elucidated. If the sequence of a second enzyme of the group is highly homologous to the structure of the first one, this is sufficient as regards the structure of the second enzyme of the group as information for carrying out the modifications on the enzyme. The term "highly homologous" denotes in this connection an at least 50% agreement of the sequence of two enzymes.
In the second step of the method of the invention the binding pockets of the enzymes of a group whose structure was elucidated in the first step of the method of the invention are compared with each other. The term "binding pocket" denotes in this connection the three-dimensional surroundings of the binding site of a substrate on the enzyme for the final purpose of conversion by the enzyme; the binding pocket is formed from amino acids which do not necessarily lie adjacent to each other in the sequence of the enzyme. When comparing the binding pockets of the enzymes, the influence of the individual amino acids of the binding pockets is tested as regards analogy for polarity, charge and steric demand on the substrate.
Then, taking into consideration the result obtainable in the analogy testing, the amino acids are determined which are necessary for the binding of a substrate preferred for the enzyme. The position of these amino acids in the sequence is also determined. This is then followed by the selection of those amino acids in the binding pocket of enzymes with elucidated structure which are to be modified for the binding of a desired substrate not preferred by the unmodified enzyme. The amino acids selected are preferably modified in such a manner by mutation of the corresponding triplet of the associated gene that the modified triplet codes the amino acid necessary for binding the desired substrate. The mutated gene is expressed in a suitable organism, the modified enzyme isolated from the organism and tested for the binding of the desired substrate as well as for activity, selectivity and stability.
It is advantageous to use a newly developed technology in this connection for testing the modified enzymes. For the screening and optimizing of the mutants the testing is carried out on microtiter plates which permit the testing of many mutants (in rows) on many substrates (lines). In the case of group 1.4.1. of the amino-acid dehydrogenases the oxidative deamidization is used as screening reaction; to this end the reactants (amino acid and cofactor) are brought together with an artificial electron acceptor as mediator (phenazine methosulfate) as well as with a colored terminal electron acceptor (tetrazolium dye). The activity of a mutated enzyme is indicated by a coloring.
The method of the invention has proven to be especially useful if amino-acid dehydrogenases of group 1.4.1 are used as enzymes and 2-oxo acids differing only in their group are used as substrates preferred both by the unmodified enzyme and by the modified enzyme. It was found in this manner that in the case of glutamate dehydrogenase from Clostridium symbiosum the following amino acids of the sequence of the enzyme exert a particular influence in the binding of the substrate: Valine 377, serine 380, threonine 193, lysine 89 and alanine 163; it was furthermore found that the following amino acids exert an additional influence: glutamine 110, aspartate 114, methionine 121 and arginine 205.
According to the method, a binding pocket with the groups valine 377, serine 380, threonine 193, lysine 89 and alanine 163 is then modified by mutating a gene belonging to the enzyme in order to produce enzymes for the stereospecific, reversible reaction of the oxidative deamination of an L-amino acid or reductive amination of an oxo acid in the case of an enzyme from the group with the E.C. number 1.4.1.
The invention also makes novel enzymes available. These enzymes preferably have a binding pocket which is modified at least in respect to one group in such a manner that a desired substrate which is not preferred by the unmodified enzyme is converted with sufficient activity, selectivity and stability. It is advantageous, especially for the binding of a substrate which is not preferred by the unmodified enzyme and is for the stereospecific reaction of the oxidative deamination of an L-amino acid or reductive amination of an oxo acid if the binding pocket displays at least one modification on the groups valine 377, serine 380, threonine 193, lysine 89 and alanine 163 with the consequence that the desired substrate can be bound and converted in an improved fashion by the modified enzyme.
Among other things, 2-oxo acids can be converted in high enantiomeric yield for the production of L-alpha-amino acids with the method of the invention and with the novel enzymes modified in accordance with the invention.
It is also advantageous to use the enzymes modified at least as regards one group in the binding pocket for converting L-alpha-amino acids for the production of 2-oxo acids. Moreover, it is highly advantageous to use the modified enzymes for converting DL-alpha-amino acids in order to product 2-oxo acids and D-alpha-amino acids.
The use of DL-alpha-amino acids as substrates makes enantiomerically pure D-amino acids accessible after conversion with enzymes of group 1.4.1. Economical L-alpha-amino acids can thus be reacted under extremely advantageous conditions to oxo acids.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
The three-dimensional crystalline structure of glutamate dehydrogenase from Clostridium symbiosum is known from the literature both as a complex with glutamate (T. J. Stillman et al., J. Mol. Biol., 1993, 234, pp. 1131-1139) and also in free form as well as a complex with the cofactor NAD + (P. J. Baker et al., Proteins, 1992, 12, pp. 75-86).
It is also known from the literature that the substrate specificity of glutamate dehydrogenase from Clostridium symbiosum stems from interactions with the side chains of the amino acids Lys 89, Ser 380, Gly 90, Ala 163 and Val 377 (T. J. Stillman et al., J. Mol. Biol., 1993, 234, pp. 1131-1139; the numeric designation of the amino acids refers to the position of the particular amino acid in the sequence of glutamate dehydrogenase from Clostridium symbiosum, calculated from the N terminal).
The specific interaction with the ฮณ-carboxyl group of the glutamate substrate is exerted by the lysine pendant group in position 89 of the glutamate dehydrogenase from Clostridium symbiosum (K. L. Britton et al., J. Mol. Biol., 1993, 234, pp. 938-945).
A replacement of this side chain in position 89 by an uncharged and non-polar group therefore drastically reduces the activity of glutamate dehydrogenase from Clostridium symbiosum vis-a-vis glutamate and the activity vis-a-vis non-polar amino acids increases.
The wild type of glutamate dehydrogenase from Clostridium symbiosum is specific as concerns glutamate as substrate: At pH 7.0 and 25ยฐ C. in 0.1 molar phosphate buffer, with 1 mmole/1 NAD + and 40 mmoles/l amino acid, the specificity constant k cat /K M with L-glutamate as substrate was able to be determined at 5.1ยท10 3 lยทmole -1 ยทs -1 and an activity of 11.2 U/mg, whereas L-norleucine and L-methionine display no measurable activity under the same conditions (activity<10 -4 U/mg).
The gene coding the glutamate dehydrogenase from Clostridium symbiosum was point-specifically mutated by using mismatch oligonucleotide primers and subsequently selected according to the uracil DNA method for mutated DNA, both as described in Kunkel T. A. et al., Proc. Nat. Acad. Sci., 1985, 82, pp. 488-492 and in Kunkel T. A. et al., Methods in Enzymology, 1987, 154, pp. 367-382, cloned with the polymerase chain reaction, the DNA sequence analysis carried out and expression in Escherichia coli performed (J. K. Teller et al., Eur. J. Biochem., 1992, 206, pp. 151 to 159).
The enzyme expressed in Escherichia coli was immobilized on sepharose 6B by chromatography on remazol brilliant red GG as described in Syed S. E. H et al., Biochim. Biophys. Acta, 1990, 1115, pp. 123-130, isolated and, as described in T. J. Stillman et al. (J. Mol. Biol., 1993, 234, pp. 1131-1139), crystallized and subjected to X-ray structural analysis.
Result:
The glutamate dehydrogenase from Clostridium symbiosum in position 89 was modified by the above-described procedure by directed mutagenesis from lysine to leucine (Lys89Leu, K89L). In the case of the enzyme modified in position 89 in the sequence the activities with the same substrates as in the case of the wild type were determined.
The following relative activities (U/mg) were measured hereby under the same assay conditions as above:
______________________________________ rel. activity (U/mg)______________________________________L-glutamate 0.001L-norleucine 0.012L-methionine 0.005______________________________________
Thus, whereas the wild type of glutamate dehydrogenase from Clostridium symbiosum only converts glutamate but not norleucine or methionine, the enzyme Lys 89 Leu (K89L) mutated in position 89 converts the three amino acids norleucine, glutamate and methionine in a ratio of k cat /K M values of 1.2:1.1:0.5 U/mg.
EXAMPLE 2
The three-dimensional crystalline structure of glutamate dehydrogenase from Clostridium symbiosum is known from the literature both as a complex with glutamate (T. J. Stillman et al., J. Mol. Biol., 1993, 234, pp. 1131-1139) and also in free form as well as a complex with the cofactor NAD + (P. J. Baker et al., Proteins, 1992, 12, pp. 75-86).
It is also known from the literature that the substrate specificity of glutamate dehydrogenase from Clostridium symbiosum stems from interactions with the side chains of the amino acids Lys 89, Ser 380, Gly 90, Ala 163 and Val 377 (T. J. Stillman et al., J. Mol. Biol., 1993, 234, pp. 1131-1139; the numeric designation of the amino acids refers to the position of the particular amino acid in the sequence of glutamate dehydrogenase from Clostridium symbiosum, calculated from the N terminal).
By means of an additional comparison of the amino-acid sequences, known in the literature (K. L. Britton et al., J. Mol. Biol., 1993, 234, pp. 938-945), of the four amino-acid dehydrogenases
Glutamate dehydrogenase from Clostridium symbiosum,
Leucine dehydrogenase from Bacillus stearothermophilus,
Phenylalanine dehydrogenase from Thermoactinomyces intermedius and
Phenylalanine dehydrogenase from Bacillus sphaericus
the groups Leu 89, Gly 90, Ala 163, Val 377 and Val 380 in the amino-acid sequence of leucine dehydrogenase were recognized as decisive for the substrate specificity (K. L. Britton et al., J. Mol. Biol., 1993, 234, pp. 943 and 944). Likewise, the groups Leu 89, Gly 90, gly 163, Leu 377 and Val 380 in the amino-acid sequence of phenylalanine dehydrogenase were recognized as decisive for the substrate specificity (K. L. Britton et al., J. Mol. Biol., 1993, 234, pp. 943 and 944). The numbering of the position of the amino acids always refers here to the numeric position of the particular amino acid in the sequence of glutamate dehydrogenase from Clostridium symbiosum.
However, since the substrate specificity of leucine dehydrogenase and phenylalanine dehydrogenase is totally different (K. L. Britton et al., J. Mol. Biol., 1993, 234, pp. 943 and 944) the substrate specificity of phenylalanine dehydrogenase from Bacillus sphaericus is altered by mutation of the groups Gly 163 and Leu 377 and modified in the direction of the substrate specificity of a leucine dehydrogenase.
The gene coding the phenylalanine dehydrogenase from Bacillus sphaericus was point-specifically mutated by using mismatch oligonucleotide primers and subsequently selected according to the uracil DNA method for mutated DNA, both as described in Kunkel T. A. et al., Proc. Nat. Acad. Sci., 1985, 82, pp. 488-492 and in Kunkel T. A. et al., Methods in Enzymology, 1987, 154, pp. 367-382, cloned with the polymerase chain reaction, the DNA sequence analysis carried out and expression in Escherichia coli performed (J. K. Teller et al., Eur. J. Biochem., 1992, 206, pp. 151 to 159).
The enzyme expressed in Escherichia coli T61 was purified as described in Syed S. Y. K. et al., FEBS Letters 370 (1995), 93-96.
Result:
The phenylalanine dehydrogenase from Bacillus sphaericus was modified by the above-described procedure in two positions in the amino-acid sequence: Instead of the amino acids Gly 163 and Leu 377 the mutated enzyme exhibited the amino acids Ala 163 and Val 377 at the corresponding location in the sequence. In the case of the enzyme modified in two positions in the sequence the activities were determined with different potential substrates under assay conditions like those in Y. Asano et al. (J. Biol. chem. 1987, 262, pp. 10346-10354) at pH 10.4 and 25ยฐ C. in 0.1 molar glycine NaOH buffer with 2.5 mmoles/l NAD + and 10 mmoles/l L-amino acid. The results are as follows:
______________________________________Amino acid Wild type mutant______________________________________L-Leu 1.5% 3.0%L-Val 1.7% 6.4%L-Met 2.6% 3.8%L-Nva 2.9% 3.2%L-Ile 1.0% 5.5%L-Phe (for comparison) 100.0% 7.7%______________________________________
The Phe activity of the wild type corresponds to 87.6 U/mg protein, measured under the same assay conditions as in Y. Asano et al. (J. Biol. Chem., 1987, 262, pp. 10346-10354) at pH 10.4 and 25ยฐ C. in 0.1 molar glycine NaOH buffer with 2.5 mmoles/l 1 NAD + and 10 mmoles/l L-amino acid.
It can therefore be determined that not only the relative activity of the mutant in the case of the aliphatic L-amino acids comes close to the activity vis-a-vis L-phenylalanine but that the absolute activity of the mutant vis-a-vis aliphatic L-amino acids is greater than the activity of the wild type vis-a-vis these substrates. This means that the specificity has been significantly modified toward that of a leucine dehydrogenase.
EXAMPLE 3
0.4 mmoles (0.52 g) 2-ketocaproate (=2-oxonorleucine) was dissolved in 100 ml 0.1 molar phosphate buffer with pH 7 and 0.05 mole (2.68 g) ammonium chloride as well as 0.1 mmole (66.3 mg) NAD + added. Then, 4.5 mg of a glutamate dehydrogenase modified in position 89 from lysine to leucine were added and allowed to react under magnetic stirring. The measured activity of the enzyme modified in position 89 was 1.3 U/mg. After 96 hours 100 ml ethanol were added to the batch and the batch evaporated to low bulk on a rotary evaporator. The precipitated product was washed once with 10 ml cold water and once with ethanol and dried at 50ยฐ C. in a vacuum. The enantiomeric purity was determined by GC over chirasil-Val.
Yield of L-norleucine: 0.41 g (78% of theory)
Enantiomeric purity: >99.8% L-amount
Further embodiments of the invention will become apparent from the following patent claims.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 1(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 449 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: protein(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Clostridium symbiosum(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:SerLysTyrValAspArgValIleAlaGluValGluLysLysTyrAla151015AspGluProGluPheValGlnThrValGluGluValLeuSerSerLeu202530GlyProValValAspAlaHisProGluTyrGluGluValAlaLeuLeu354045GluArgMetValIleProGluArgValIleGluPheArgValProTrp505560GluAspAspAsnGlyLysValHisValAsnThrGlyTyrArgValGln65707580PheAsnGlyAlaIleGlyProTyrLysGlyGlyLeuArgPheAlaPro859095SerValAsnLeuSerIleMetLysPheLeuGlyPheGluGlnAlaPhe100105110LysAspSerLeuThrThrLeuProMetGlyGlyAlaLysGlyGlySer115120125AspPheAspProAsnGlyLysSerAspArgGluValMetArgPheCys130135140GlnAlaPheMetThrGluLeuTyrArgHisIleGlyProAspIleAsp145150155160ValProAlaGlyAspLeuGlyValGlyAlaArgGluIleGlyTyrMet165170175TyrGlyGlnTyrArgLysIleValGlyGlyPheTyrAsnGlyValLeu180185190ThrGlyLysAlaArgSerPheGlyGlySerLeuValArgProGluAla195200205ThrGlyTyrGlySerValTyrTyrValGluAlaValMetLysHisGlu210215220AsnAspThrLeuValGlyLysThrValAlaLeuAlaGlyPheGlyAsn225230235240ValAlaTrpGlyAlaAlaLysLysLeuAlaGluLeuGlyAlaLysAla245250255ValThrLeuSerGlyProAspGlyTyrIleTyrAspProGluGlyIle260265270ThrThrGluGluLysIleAsnTyrMetLeuGluMetArgAlaSerGly275280285ArgAsnLysValGlnAspTyrAlaAspLysPheGlyValGlnPhePhe290295300ProGlyGluLysProTrpGlyGlnLysValAspIleIleMetProCys305310315320AlaThrGlnAsnAspValAspLeuGluGlnAlaLysLysIleValAla325330335AsnAsnValLysTyrTyrIleGluValAlaAsnMetProThrThrAsn340345350GluAlaLeuArgPheLeuMetGlnGlnProAsnMetValValAlaPro355360365SerLysAlaValAsnAlaGlyGlyValLeuValSerGlyPheGluMet370375380SerGlnAsnSerGluArgLeuSerTrpThrAlaGluGluValAspSer385390395400LysLeuHisGlnValMetThrAspIleHisAspGlySerAlaAlaAla405410415AlaGluArgTyrGlyLeuGlyTyrAsnLeuValAlaGlyAlaAsnIle420425430ValGlyPheGlnLysIleAlaAspAlaMetMetAlaGlnGlyIleAla435440445Trp__________________________________________________________________________
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Enzymes with modified substrate specificity and methods of obtaining same by the steps of a) determining the structure of two or more enzymes in the same group, b) comparing the structure of the substrate binding sites of the enzymes, and c) modifying selected amino acids by genetic mutation so that the substrate preference of one of the enzymes is altered. The methods are particularly useful for the stereospecific interconversion of oxyacids and aminoacids.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/536,164 to Michael J. Daneman, Berhang Behin, and Satinderpall S. Pannu, filed Mar. 25, 2000 and entitled โApparatus and method for 2-Dimensional Steered-Beam NรM Optical Switch Using Single-Axis Mirror Arrays and Relay Opticsโ, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to fiber optic communications. More particularly, the invention relates to optical routing.
BACKGROUND ART
[0003] Modern fiber optical communications systems direct optical signals over multiple fibers. Such systems require optical switches to direct light beams from any given fiber in an input fiber array to any given fiber in an output array. One class of optical switches uses an approach called beam steering. In beam steering, the light from the fiber is selectively deflected or steered by one or more movable optical element from the input fiber to the output fiber. Suitable optical elements include microelectromechanical system (MEMS) mirrors. MEMS mirrors are usually actuated by magnetic interaction, electrostatic, or piezoelectric interaction. Typically, two sets of moveable mirrors are used to steer the beam. Each fiber has a small โacceptance windowโ. The fiber only efficiently couples light that is incident within a narrow range of angles and positions. Although a single mirror will generally direct the beam from an input fiber to the correct output fiber, two mirrors ensure that the light beam enters the output fiber at the correct angle. If the beam makes too large an angle with the axis of the fiber, light from the beam will not couple properly to the fiber, i.e. there will be high losses.
[0004] Optical switches using the steering-beam approach have been demonstrated in two primary implementations. The first uses linear arrays of mirrors with a single angular degree of freedom. Combining two such mirror arrays as shown in FIG. 1 allows an implementation of an NรN optical switch, where the number of input and output channels is equal to the number of mirrors in each array. The first array steers an optical beam from an input fiber to the appropriate mirror on the second array, which then steers the beam into the corresponding output fiber. This implementation uses simple single-axis mirrors; however, it is limited in its scalability since the optical path between fibers becomes unreasonably large for large port counts (e.g. >32ร32), increasing the loss of the switch.
[0005] The second implementation depicted in FIG. 2 uses two sets of 2-dimensional mirror arrays, each mirror having two angular degrees of freedom. The input and output fibers are each also arranged in a 2-dimensional grid with the same dimension as the mirror arrays. The mirrors in the first mirror array steer the optical beams from the fibers onto the appropriate mirror in the second mirror array which then steers the beam into the corresponding fiber. This approach is considerably more scalable, since, due to its 2-dimensional layout, the size of the mirror and fiber arrays grows as the square root of the number of input/output ports, which is much slower than in the case of a 1-dimensional grid. Therefore, switches with much larger port count (>2000ร2000) are possible. However, this implementation requires the mirrors to rotate about two different axes. Such mirrors are considerably more difficult to design, fabricate, and control.
[0006] Prior art beam steering approaches as shown in FIG. 1 typically deflect light ห90 degrees to another deflector which deflects the light at an offset of 90 degrees such that input and output fiber arrays are substantially parallel. Such beam steering optical switches deflect photons from an input to the output mirror array where the deflected light from the input mirror array causes the beam to be substantially perpendicular to the input fiber array. These designs are not modular, are limited in the number of ports they can physically occupy, and are subject to a fixed geometry.
[0007] Another disadvantage of existing optical switches is that they tend to be monolithic in design, i.e., the mirror arrays are fixed components of the switch that are neither removable nor interchangeable. As a result, a prior art switch cannot easily be reconfigured or repaired.
[0008] There is a need, therefore, for a beam steering apparatus that overcomes the above disadvantages.
SUMMARY
[0009] These disadvantages associated with the prior art may be overcome by a beam steering module. The steering module generally comprises first and second NรM arrays of single axis mirrors. The mirrors in the first array rotate about a particular axis while the mirrors in the second array rotate about an axis different from the first axis (. Relay optics may be disposed between the two arrays image the first mirror array onto the second mirror array such that the beam angle may be controlled with respect to both axes by adjusting the angle of the appropriate mirrors in the first and second mirror grids.
[0010] Two steering modules may be combined to form a beam steering system. With two modules, it is possible to completely determine, at the plane of the output fiber grid, the position and angle of an optical beam emerging from any of the input fibers.
[0011] Embodiments of the steering modules of the present invention may be used to selectively couple light from an input fiber in an NรN input fiber module array to any output fiber in an MรM output fiber module array, or from an input fiber to an output fiber in an NรN module array. The beam steering modules of the present invention may be used interchangeably to achieve full-duplex operation modules functioning as inputs and outputs.
BRIEF DESCRIPTION OF THE FIGURES
[0012] [0012]FIG. 1 depicts a one-dimensional beam steering apparatus according to the prior art;
[0013] [0013]FIG. 2 depicts an isometric view of a two-dimensional beam steering apparatus according to the prior art;
[0014] [0014]FIG. 3 depicts a beam steering module according to a first embodiment of the present invention;
[0015] FIGS. 4 depicts an isometric view of a beam steering apparatus according to a second embodiment of the present invention;
[0016] [0016]FIG. 5 depicts a schematic diagram depicting a modular optical switch according to a first alternative version of a third embodiment of the invention;
[0017] FIGS. 6 A- 6 B depicts a modular optical switch according to a second alternative version of the third embodiment of the invention;
[0018] [0018]FIG. 7A depicts a schematic diagram of a modular optical switch employing stacked beam steering modules according to a third alternative version of the third embodiment of the invention;
[0019] [0019]FIG. 7B depicts a schematic diagram of a modular optical switch employing offset stacked beam steering modules according to a fourth alternative version of the third embodiment of the invention;
[0020] [0020]FIG. 7C depicts a schematic diagram of a modular optical switch employing beam steering modules distributed along a curve according to a fifth alternative version of the third embodiment of the invention;
[0021] [0021]FIG. 7D depicts a schematic diagram of a modular optical switch employing offset beam steering modules distributed along a curve according to a sixth alternative version of the third embodiment of the invention;
[0022] [0022]FIG. 7E depicts a schematic diagram of a modular optical switch employing stacked beam steering modules with a fold deflector according to a seventh alternative version of the third embodiment of the invention;
[0023] [0023]FIG. 7F depicts a schematic diagram of a modular optical switch employing stacked beam steering modules with a curved fold deflector according to a eighth alternative version of the third embodiment of the invention;
[0024] [0024]FIG. 7G depicts a schematic diagram of a modular optical switch employing a curved array of beam steering modules with a fold deflector according to a ninth alternative version of the third embodiment of the invention;
[0025] [0025]FIG. 7H depicts a schematic diagram of a modular optical switch employing a curved array of beam steering modules with a curved fold deflector according to a tenth alternative version of the third embodiment of the invention;
[0026] [0026]FIG. 8 depicts a schematic diagram of a first alternative version of an optical module according to a fourth embodiment of the invention;
[0027] [0027]FIG. 9 depicts a schematic diagram of a second alternative version of an optical module according to the fourth embodiment of the invention;
[0028] [0028]FIG. 10 depicts a cross-sectional schematic diagram of a third alternative version of an optical module according to the fourth embodiment of the invention.
[0029] [0029]FIG. 11 depicts a cross-sectional schematic diagram of a fourth alternative version of an optical module according to the fourth embodiment of the invention;
[0030] [0030]FIG. 12 depicts a cross-sectional schematic diagram of a fifth alternative version of an optical module according to the fourth embodiment of the invention;
[0031] [0031]FIG. 13 depicts a cross-sectional schematic diagram of a sixth alternative version of an optical module according to the fourth embodiment of the invention;
[0032] [0032]FIG. 14 depicts a cross-sectional schematic diagram of a seventh alternative version of an optical module according to the fourth embodiment of the invention;
[0033] [0033]FIG. 15 depicts an isometric schematic diagram of a eighth alternative version of an optical module according to the fourth embodiment of the invention;
[0034] [0034]FIG. 16 depicts an isometric schematic diagram of an optical switch employing two modules of the type shown in FIG. 15.
[0035] [0035]FIG. 17 depicts a cross-sectional schematic diagram of an optical switch according to a first alternative version of a fifth embodiment of the present invention;
[0036] [0036]FIG. 18 depicts a cross-sectional schematic diagram of an optical switch employing a fold deflector according to a second alternative version of a fifth embodiment of the present invention;
[0037] [0037]FIG. 19 depicts a cross-sectional schematic diagram of an optical switch employing dual axis deflectors with a fold deflector according to a fourth alternative version of a fifth embodiment of the present invention;
[0038] [0038]FIG. 20 depicts a simplified schematic diagram of an optical beam steering module according to an embodiment of the present invention;
[0039] [0039]FIG. 21 depicts a simplified schematic diagram of an optical switch according to an embodiment of the present invention;
[0040] [0040]FIG. 22 depicts a simplified isometric diagram of an optical switch according to an embodiment of the present invention; and
[0041] [0041]FIG. 23 depicts a cross-sectional diagram of the optical switch of FIG. 23.
DETAILED DESCRIPTION
[0042] Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following preferred embodiment of the invention is set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
[0043] The optical switch system according to embodiments of the present invention may switch light from any of a set of input fibers into any of a set of output fibers in a non-blocking fashion using beam steering modules.
[0044] Steering modules can switch a plurality of paths independent of the current configuration of the switch. FIG. 3 depicts a steering module 10 according to a first embodiment of the present invention. Module 10 may generally comprise beam steering element 12 configured with at least one pair of deflective elements 14 . Photons may enter the module through a collimator 16 and coupled through a first deflective element 18 which may steer the photons along an axis to a second deflective element 20 which may also steer the photons along a second axis. FIG. 4 shows an alternate configuration having one fixed deflective element 22 coupled to a double-gimbaled deflector 24 . Both module configurations are capable of steering photons along two axis in a manner substantially parallel to the orientation of the input collimator.
[0045] Generally, the deflective elements are individually addressable, created using MEMs fabrication methods and actuated using a variety of known actuation methods, including but not limited to, electrostatic and magnetic types.
[0046] The present invention includes a third embodiment directed to a modular optical switch. By way of example, FIG. 5 schematically depicts a modular switch 500 according to first alternative version of the third embodiment. The switch 500 may generally comprise a first beam steering module 502 optically coupled to a second beam steering module 504 . First and second sets of optical fibers 501 , 505 may be respectively coupled to the first and second modules 502 , 504 e.g., via one or more I/O ports. The beam steering modules 502 , 504 may respectively include one or more beam steering elements 506 , 508 . The I/O ports may include individual or arrayed collimators to facilitate couple of optical signals between the fibers 501 , 505 and the beam steering elements 506 , 508 . The beam steering elements 506 , 508 may deflect one or more optical signals 503 in two dimensions such that an optical signal may be selectively routed between any of the first fibers 501 to any of the second fibers 505 . The beam steering elements 506 , 508 may be configured such that the modules 502 , 504 are substantially horizontally opposed, e.g., with the I/O ports on the first module 502 substantially parallel to the I/O ports on the second module 504 .
[0047] The first and second modules 502 , 504 may be operated under the direction of a controller 510 . The controller may be coupled to the beam steering elements 506 , 508 by electrical optical or mechanical linkage. The controller may be implemented in hardware, software, firmware or some combination of these. The controller 510 may provide control signals to the beam steering elements to allow selective coupling of the optical signals 503 between the first module 502 and the second module 503 or vice versa.
[0048] The modules 502 , 504 can co-operate interchangeably with each other, and with fixed or movable deflector elements, in several ways. First, the modules 502 , 504 may be removably attached to a frame, housing or substrate such that may be replaced to facilitate repair or upgrade. Second, the modules 502 , 504 may be of a standardized configuration, e.g. with standardized dimensions, numbers of I/O ports, to facilitate design of new optical switches and other beam steering devices. Third, the beam steering elements 506 , 508 may be removably attached to the modules 502 , 504 to facilitate repair or upgrade. Fourth, the beam steering elements may be of a standardized configuration to facilitate the design of new optical switches and other devices.
[0049] Although, FIG. 5 depicts a switch having horizontally opposed modules, the invention is in no way limited to this configuration. By way of example, FIG. 6A depicts an optical switch 600 according to a second alternative version of the third embodiment. The optical switch 600 may generally include a first beam steering module 602 optically coupled to a second beam steering module 604 via a fold deflector 610 . First and second sets of optical fibers 601 , 605 may be respectively coupled to the first and second modules 602 , 604 e.g., via one or more I/O ports. The beam steering modules 602 , 604 may respectively include one or more beam steering elements 606 , 608 optically coupled to each other via the fold deflector 610 . The beam steering elements 606 , 608 may deflect one or more optical signals 603 in two dimensions such that an optical signal may be selectively routed between any of the first fibers 601 to any of the second fibers 605 via the fold deflector 610 .
[0050] The fold deflector 610 may be a reflective element, such as a flat or curved mirror. Alternatively, the fold deflector 610 may be a refractive element such as a prism or a diffractive element such as a grating. Furthermore, the fold deflector 610 may include some combination reflective, refractive and diffractive elements. The fold deflector 610 may allow flexibility in the spatial positioning of the modules 602 , 604 within the switch 600 . Alternatively, as shown in FIG. 6B a fold deflector 624 may be used with a single module 622 to provide an optical switch 620 . Fold deflector 624 may be made of a partially transparent material to allow a small percentage of light to pass behind the mirror into a photodetector array, and the photodetector array may be connected to a switch control 510 for controllably operating the input and output beam steering elements in response to the power monitoring signals generated therefrom said photodetector array.
[0051] One alternative method for controllably operating the input and output beam steering elements in response to power monitoring includes an array of photodetectors clusters situated around each collimator. This arrangement may track photons not coupled into an output collimator and provide beam steering telemetry to the switch control for calibrating the input and output beam steering elements for maximum coupling. A photodetector array can be designed with a mask that centers each cluster array at referential points at locations corresponding to each collimator. A cluster may be comprised of a plurality of photodetectors, CCD, three or four individually addressable detectors. When using individually addressable photodetectors, optical insertion losses can be minimized by drilling or etching holes in precise referential locations corresponding to the location of the collimators on the module to allow the light to pass through the center of the cluster into the collimator.
[0052] Although FIG. 5 and FIG. 6 depict switches having only two modules, the present invention is in no way limited to these particular configurations. By way of example, FIG. 7A depicts an optical switch 700 according to a third alternative version of the third embodiment. The optical switch 700 may generally comprise a first stack 701 of N beam steering modules 702 1 , 702 2 . . . 702 N , where N is an integer greater than or equal to 1. The modules in the first stack 701 may be optically coupled to a second stack 703 of M beam steering modules 704 1 , 704 2 . . . 704 M , where N is an integer greater than or equal to 1. M and N may be the same or they may be different numbers. Note that if each of the modules is capable of a sufficiently large angle of deflection of optical signals 705 any module in the first stack may be coupled to any module in the second stack. Although one-dimensional stacks 701 , 703 are depicted in FIG. 7A for the sake of clarity, the modules may alternatively be arranged in two-dimensional arrays.
[0053] [0053]FIG. 7A depicts a modular switch in which the beam steering elements may scan to the left and right of a center rest position. An example of such a beam steering element could include an array of MEMs mirrors that operate by โpush-pullโ actuation. Alternatively, the beam steering elements may scan โone way,โ i.e., only in a sector to the left, or only to the right, of an end rest position. In such a case it may be desirable to offset the alignment of the first and second stacks of modules. FIG. 7B depicts an optical switch 710 according to a fourth alternative version of the third embodiment wherein the beam steering modules are offset. The optical switch 710 may generally comprise a first stack 711 of N beam steering modules 712 1 , 712 2 . . . 712 N , where N is an integer greater than or equal to 1. The modules in the first stack 711 may be optically coupled to a second stack 713 of M beam steering modules 714 1 , 714 2 . . . 714 M . The modules in the second stack 713 may be in an offset alignment with respect to the modules in the first stack. The offset alignment may compensate higher density port count when steering optical signals 715 with โone wayโ scanning capability in the beam steering modules. Optical signals corresponding to the rest and maximum deflections are shown for modules at opposite ends of the two stacks. Note that if each of the modules is capable of a sufficiently large angle of deflection of the optical signals 715 any module in the first stack may be coupled to any module in the second stack. Although one-dimensional stacks 711 , 713 are depicted in FIG. 7B for the sake of clarity, the modules may alternatively be arranged in two-dimensional arrays.
[0054] The modular switches depicted in FIGS. 7A, 7B may have substantially linear stacks or planar arrays of modules. In some applications, if the number of modules N becomes sufficiently large modules at opposite ends of the stacks may not be able to โseeโ one another. In such applications it may be desirable to distribute the stacks along one or more curves. FIG. 7C depicts an optical switch 720 according to a fifth alternative version of the third embodiment wherein the beam steering modules in at least one stack are distributed along a curve. The optical switch 720 may generally comprise a first stack 721 of N beam steering modules 722 1 , 722 2 . . . 722 N , distributed substantially along a curve 727 where N is an integer greater than or equal to 1. The modules in the first stack 721 may be optically coupled to a second stack 723 of M beam steering modules 724 1 , 724 2 . . . 724 M . The modules in the second stack 723 may be distributed along a second curve 729 . The curved stacking of the modules can facilitate coupling between modules at extreme opposite ends of the stacks. By way of example, the curves 727 , 729 may be in the shape of a segment of a circle, parabola, ellipse, hyperbola, cycloid, or any other suitable curved shape. Alternatively, one of the curves 727 , 729 could be a segment of a straight line.
[0055] Although one-dimensional curved stacks are depicted in FIG. 7C for the sake of clarity, the switch 720 may employ two-dimensional curved arrays of modules, e.g. distributed across a curved surface. By way of example, the shape of the curved surface may be cylindrical, spherical, paraboloidal, ellipsoidal, hyperboloidal or any other suitable curved three-dimensional shape. Alternatively, one of the arrays of modules could be arranged in a planar array.
[0056] [0056]FIG. 7D depicts an optical switch 730 according to a sixth alternative version of the third embodiment wherein offset beam steering modules distributed along a curve. The optical switch 730 may generally comprise a first stack 731 of N beam steering modules 732 1 , 732 2 . . . 732 N , distributed substantially along a curve 737 . The modules in the first stack 731 may be optically coupled to a second stack 733 of M beam steering modules 734 1 , 734 2 . . . 734 M . N and M are integers greater than or equal to 1. The modules in the second stack 733 may be distributed along a second curve 739 . The first and second curves 737 , 739 may be in an offset alignment with respect to each other to facilitate coupling between modules at extreme opposite ends of the stacks By way of example, the curves 737 , 739 may be in any shape, and not limited to those described above with respect to FIG. 7C.
[0057] Multiple beam steering modules may be incorporated into an optical switch with a fold deflector. FIG. 7E depicts a schematic diagram of a modular optical switch 740 employing multiple beam steering modules with a fold deflector according to a seventh alternative version of the third embodiment of the invention. By way of example, the switch 740 includes first and second arrays 741 , 743 of N and M modules 742 1 - 742 N , 744 1 - 744 M respectively, where N and M are integers greater than or equal to 1. The modules in the arrays 741 , 743 may be optically coupled to each other via a fold deflector 746 . In the exemplary version depicted in FIG. 7E, the fold deflector 746 may be flat surface coated mirror. Alternatively the fold deflector 746 may be a refractive element, such as one or more prisms.
[0058] The fold deflector may alternatively be curved. FIG. 7F depicts a schematic diagram of a modular optical switch 750 that combines stacked beam steering modules with a curved fold deflector according to a eighth alternative version of the third embodiment of the invention. By way of example, the switch 750 may include first and second arrays 751 , 753 of N and M modules 752 1 - 752 N , 754 1 - 754 M respectively, where N and M are integers greater than or equal to 1. The modules in the arrays 751 , 753 may be optically coupled to each other via a curved fold deflector 746 . In the exemplary version depicted in FIG. 7F, the fold deflector 756 is a curved surface coated mirror. Alternatively the fold deflector 756 may include a refractive element, such as one or more prisms.
[0059] Fold deflectors may also be combined with modules displaced along a curve or spline. By way of example, FIG. 7G depicts a schematic diagram of a modular optical switch 760 that employs a curved array of beam steering modules with a fold deflector according to a ninth alternative version of the third embodiment of the invention. By way of example, the switch 760 may include first and second arrays 761 , 763 of N and M modules 762 1 - 762 N , 764 1 - 764 M respectively, where N and M are integers greater than or equal to 1. The modules in the arrays 761 , 763 are distributed along curves 767 , 769 respectively. The curves 767 , 769 may have any 2-dimensional or 3-diemensional curved shape, including those described above with respect to FIG. 7C. Alternatively, the modules 762 1 - 762 N , 764 1 - 764 M may be distributed along the same curved surface or different portions of the same curved surface. The modules in the arrays 761 , 763 may be optically coupled to each other via a fold deflector 766 . In the exemplary version depicted in FIG. 7G, the fold deflector 766 is a flat mirror. Alternatively the fold deflector 766 may include a refractive element, such as one or more prisms.
[0060] Fold deflector 766 may be made of a partially transparent material to allow a small percentage of light to pass behind the mirror into a photodetector array, and the photodetector array may be connected to a switch control 510 for controllably operating the input and output beam steering elements in response to the power monitoring signals generated therefrom said photodetector array.
[0061] Multiple modules may be displaced along a curve or spline and alternatively be combined with a curved fold deflector. FIG. 7H depicts a schematic diagram of a modular optical switch 770 employing a curved array of beam steering modules with a curved fold deflector according to a tenth alternative version of the third embodiment of the invention. By way of example, the switch 770 may include first and second arrays 771 , 773 of N and M modules 772 1 - 772 N , 774 1 - 754 M respectively, where N and M are integers greater than or equal to 1. The modules in the arrays 771 , 773 may be distributed along curves 777 , 779 respectively. Alternatively, the modules 772 1 - 772 N , 774 1 - 774 M may be distributed along the same curved surface or different portions of the same curved surface. The curves 777 , 779 may have any 2-dimensional or 3-diemensional curved shape, including those described above with respect to FIG. 7C. The modules in the arrays 771 , 773 may be optically coupled to each other via a fold deflector 776 . In the exemplary version depicted in FIG. 7H, the fold deflector 776 may be a flat surface coated mirror. Alternatively the fold deflector 776 may include a refractive element, such as one or more prisms.
[0062] Fold deflector 776 may be made of a partially transparent material to allow a small percentage of light to pass behind the mirror into a photodetector array, and the photodetector array may be connected to a switch control 510 for controllably operating the input and output beam steering elements in response to the power monitoring signals generated therefrom said photodetector array.
[0063] Many different architectures are possible for the beam steering modules depicted in FIGS. 5 - 7 H. According to a fourth embodiment of the invention a beam steering module may include one or more beam steering elements that deflect optical signals in two dimensions. Such modules can cooperate interchangeably with one or more optical components in an optical beam steering device such as an optical switch, adaptive optics, steered beam optical display, or disk drive. The beam steering elements may include a first deflector array optically coupled to a second deflector array, wherein the first and second deflector arrays co-operate to steer an optical signal in two dimensions.
[0064] [0064]FIG. 8 depicts a schematic diagram of a first alternative version of an optical module 800 according to a first version of the fourth embodiment of the invention. By way of example, the module 800 may generally include one or more beam steering elements, e.g., a stack of N beam steering elements 801 1 . . . 801 N . Each beam steering element may include a first array of one or more deflectors optically coupled to a second array of one or more deflectors. In the embodiment depicted in FIG. 8 the arrays may extend perpendicular to the plane of the drawing. The Module 800 may be coupled to one or more optical fibers 810 1 . . . 810 N , e.g., via individual collimators or by a collimator array.
[0065] In the exemplary embodiment depicted in FIG. 8, first array may be an LรM array of x-deflectors 802 11 . . . 802 LM configured to deflect light with respect to one or more first axes 804 . The second array may be a LโฒรMโฒ array of y-deflectors 806 11 . . . 806 LM configured to deflect optical signals 811 with respect to one or more second axes 808 . L, M, Lโฒ and Mโฒ are all integers greater than or equal to one. According to one variation L=Lโฒ and M=Mโฒ, however this need not be the case. The x-deflectors 802 11 . . . 802 LM may deflect the optical signals 811 from the fibers 810 to one or more of the y-deflectors 806 11 . . . 806 LโฒMโฒ . The y-deflectors 806 11 . . . 806 LโฒMโฒ may deflect the optical signals 811 from the x-deflectors 802 11 . . . 802 LM toward some other optical component, such as another module or a fixed fold mirror in the case of an optical switch. In the exemplary embodiment depicted in FIG. 8 the optical signals 811 enter and exit the modules 801 i along substantially parallel paths. For the purposes of the present application, substantially parallel means that in traversing the modules 801 i the angle of deflection of the optical signals 811 is less than 90ยฐ. This is particularly advantageous where, for example it is desired to configure two or more modules in horizontal opposition.
[0066] By way of example and without loss of generality, the deflectors 802 11 . . . 802 LM , 806 11 . . . 806 LโฒMโฒ may be mirrors that rotate about axes 804 , 808 as shown by the arrows 805 , 809 respectively. The first and second axes 804 , 808 may be perpendicular to each other and may be referred to as the x- and y- axes respectively. The invention is not limited to the specific configuration of the x- and y- axis shown in FIG. 8. For example, the relative positions of the x-deflectors and the y-deflectors may be interchanged.
[0067] Where two sets of deflectors are configured to rotate separately about different axes it is often desirable to optically couple relay optics to the deflectors. The relay optics may be placed between the x-deflectors and the y-deflectors. Such relay optics may include one or more lenses 820 1 . . . 820 N or any of the alternative relay optics described above with respect to FIG. 2. In the particular version of the fourth embodiment depicted in FIG. 8, the deflectors 802 11 . . . 802 LM , may be in a one to one correspondence with the deflectors 806 11 . . . 806 LโฒMโฒ . For the purposes of the present applications a one-to-one correspondence means that each x-deflector 802 11 . . . 802 LM is optically coupled to a different one of the y-deflectors 806 11 . . . 806 LM .
[0068] The present invention is not limited to modules having single axis deflectors. Modules may be based on dual axis deflectors. FIG. 9 depicts a schematic diagram of an optical module 900 that employs dual axis deflectors according to a second alternative version of the fourth embodiment of the invention. By way of example, the module 900 may generally include one or more beam steering elements, e.g., a stack of N beam steering elements 901 1 . . . 901 N . The module 900 may be coupled to one or more optical fibers 910 1 . . . 910 N , e.g., via collimators. Each beam steering element 901 i may include an LรM array of dual axis deflectors 902 11 . . . 902 LM optically coupled to an LโฒรMโฒ array of fixed deflectors 906 11 . . . 906 LโฒMโฒ . L, M, Lโฒ and Mโฒ are all integers greater than or equal to one. According to one variation L=Lโฒ and M=Mโฒ, however this need not be the case. The deflectors 902 11 . . . 902 LM may be mirrors that rotate about x-axes 804 , and y-axes 808 as shown by the arrows 905 , 909 respectively. The first and second axes 904 , 908 may be perpendicular to each other and may be referred to as the x- and y- axes respectively. The fixed 906 11 . . . 906 LโฒMโฒ deflectors do not rotate, and may be comprised of one continuous deflector. By way of example, and without loss of generality, beam steering element 901 N is depicted as including a single continuous deflector 907 coupled to all of the deflectors in an array 909 of dual axis deflectors. Furthermore, the invention is not limited to the specific configuration of the fixed and dual axis deflectors shown in FIG. 9. For example, the relative positions of the fixed deflectors and the dual axis deflectors may be interchanged.
[0069] The dual axis deflectors 902 11 . . . 902 LM may deflect one or more optical signals 911 from the fibers 910 to one or more of the fixed deflectors 906 11 . . . 906 LโฒMโฒ . The fixed deflectors 906 11 . . . 906 LโฒMโฒ may deflect the optical signals 911 from the x-deflectors 902 11 . . . 902 LM toward some other optical component, such as another module in the case of an optical switch. The optical signals 911 may enter and exit the modules 901 i along substantially parallel paths.
[0070] Many variations are possible on the optical switches described with above with respect to FIGS. 8 and 9. For example the beam steering elements may include double-sided deflectors. FIG. 10 depicts a cross-sectional schematic diagram of an optical module 1000 that employs double sided deflectors according to a third alternative version of the fourth embodiment of the invention. The module 1000 may generally comprise a stack of N of beam steering elements 1001 containing double-sided arrays 1002 of deflectors 1003 . The deflectors 1003 in the double-sided arrays 1002 may include appropriate combinations of single axis deflectors, dual axis deflectors, or fixed deflectors.
[0071] [0071]FIG. 11 depicts a cross-sectional schematic diagram of an optical module 1100 according to a fourth alternative version of the fourth embodiment of the invention. In this version, the module 1100 may include the beam steering elements 1201 having an array 1102 of double-sided elements single-axis 1103 sandwiched between two opposing arrays 1104 , 1106 of single-sided elements. In the alternative version shown in FIG. 11, each of the double-sided elements 1102 may include an x-deflector 1105 on one side and a y-deflector 1107 on the other side. The x-deflector 1105 on the double-sided element 1103 may face a single sided y-deflector 1108 in the array 1104 . The y-deflector 1107 on the double-sided element 1103 may face a single sided x-deflector 1110 in the array 1106 . The arrays 1102 , 1104 , 1106 may extend perpendicular to the plane of the drawing M deflectors deep. Although a 1รM array is depicted in FIG. 11, the beam steering elements may alternatively contain LรM arrays. N beam steering elements may be stacked in the module to produce an NรLรM beam steering module.
[0072] Other configurations of double-sided deflector arrays are possible. FIG. 12 depicts a cross-sectional schematic diagram of an optical module 1200 according to a fifth alternative version of the fourth embodiment of the invention. In this version, the module 1200 may include beam steering elements 1201 having an array 1202 of double-sided dual-axis elements 1203 sandwiched between two opposing arrays 1204 , 1206 of single-sided fixed deflector elements. In the alternative version shown in FIG. 12, each of the double-sided dual-axis elements 1203 may include a first gimbaled xy-deflector 1205 on one side and a second gimbaled xy-deflector 1207 on the other side. The gimbaled xy-deflectors 1205 , 1207 may face single sided fixed deflectors 1208 , 1210 in the arrays 1204 , 1206 . The fixed deflector arrays 1204 , 1206 may each contain a single continuous deflector or individual deflectors coupled to the gimbaled xy deflectors 1205 , 1207 in a one-to-one correspondence. The arrays 1202 , 1204 , 1206 may extend perpendicular to the plane of the drawing M deflectors deep. Although a 1รM array is depicted in FIG. 12, the beam steering elements may alternatively contain LรM arrays. N beam steering elements may be stacked in the module to produce an NรLรM beam steering module.
[0073] The configuration depicted in FIG. 12 may be reversed. FIG. 13 depicts a cross-sectional schematic diagram of an optical module 1300 according to a sixth alternative version of the fourth embodiment of the invention. In this version, the module 1300 may include beam steering elements 1301 having an array 1302 of double-sided fixed elements 1303 sandwiched between two opposing arrays 1304 , 1306 of single-sided dual-axis deflector elements. In the alternative version shown in FIG. 13, each of the double-sided fixed elements 1303 may include a first fixed deflector 1305 on one side and a second gimbaled fixed deflector 1307 on the other side. The fixed deflectors 1305 , 1307 may face single sided gimbaled dual-axis (xy) deflectors 1308 , 1310 in the arrays 1304 , 1306 . The fixed deflector array 1302 may contain a single continuous deflector or individual deflectors coupled to the gimbaled xy deflectors 1308 , 1310 in a one-to-one correspondence. The arrays 1302 , 1304 , 1306 may extend perpendicular to the plane of the drawing M deflectors deep. Although a 1รM array is depicted in FIG. 13, the beam steering elements may alternatively contain LรM arrays. N beam steering elements may be stacked in the module to produce an NรLรM beam steering module.
[0074] There are still other variations on the beam steering modules of the fourth embodiment of the invention. FIG. 14 depicts a cross-sectional schematic diagram of a beam steering module 1400 according to a seventh alternative version of the fourth embodiment of the invention. The beam steering module 1400 may generally include a frame 1401 with first beam steering element having arrays of deflectors 1402 mounted to a first side 1411 of the frame 1401 and a second beam steering element having arrays of deflectors 1404 mounted to a second side 1413 of the frame 1401 opposite the first side 1411 . The first and second beam steering elements may be oriented in a staggered configuration that allows optical signals to between the arrays of deflectors 1402 , 1404 . The frame 1401 may include a first set of holes 1403 opposite the beam steering elements 1402 that transmit optical signals through the first side of the frame 1401 . The frame 1401 may include a second set of holes 1405 opposite the beam steering elements 1404 that transmit optical signals. The deflectors 1402 , 1404 may be of any of the types discussed above. For example the deflectors 1402 , 1404 may respectively be x-deflectors and y-deflectors or vice versa. Alternatively, the deflectors 1402 , 1404 may respectively be gimbaled dual-axis (xy) deflectors and fixed deflectors or vice versa.
[0075] [0075]FIG. 15 depicts an isometric schematic diagram of an optical module 1500 that may use linear arrays of deflectors according to an eighth alternative version of the fourth embodiment of the invention. In this version, the module 1500 may include beam steering elements 1501 having a 1รM double-sided array 1502 containing deflectors 1505 , 1507 sandwiched between two opposing 1รM arrays 1504 , 1506 of single-sided deflectors 1508 , 1510 . The arrays 1502 , 1504 may be coupled to optical fiber arrays 1520 A , 1520 B e.g. via lens arrays 1530 A , 153 B .
[0076] The deflectors 1505 , 1507 may face single sided deflectors 1508 , 1510 in the arrays 1504 , 1506 . The deflectors 1505 , 1507 may be optically coupled to the single-sided deflectors 1508 , 1510 in a one-to-one correspondence. N beam steering elements 1501 may be stacked in the module to produce an NรM beam steering module 1500 . The deflectors 1503 , 1505 , 1508 , 1510 may be of any of the types discussed above. For example the deflectors 1505 , 1507 may respectively be x-deflectors and y-deflectors or vice versa. If so, the deflectors 1508 , 1510 may respectively be y-deflectors and x-deflectors or vice versa. Alternatively, the deflectors 1505 , 1507 may gimbaled dual-axis (xy) deflectors and the deflectors 1508 , 1510 may be fixed deflectors or vice versa. Alternatively the double-sided deflectors 1503 may contain various mixed pairs of x-deflectors, y-deflectors, dual-axis deflectors and fixed deflectors with the single sided deflectors 1508 , 1510 containing appropriate corresponding deflectors.
[0077] Modules of the type depicted in FIG. 15 may be incorporated into an optical switch. FIG. 16 depicts an isometric schematic diagram of an optical switch employing two modules of the type shown in FIG. 15. The switch 1600 may generally include a first module 1601 and a second module 1651 . The first and second modules may contain, respectively, NรM double-sided arrays 1602 , 1652 sandwiched between opposing 1รM single-sided deflector arrays 1604 , 1606 , 1654 , 1656 . The arrays 1602 , 1604 , 1652 1654 may be coupled to optical fiber arrays 1620 A , 1620 B , 1670 A , 1670 B e.g. via lens arrays 1630 A , 1630 B , 1680 A , 1680 B . The beam steering modules 1601 , 1651 may selectively couple optical signals between any one of the fibers in the fiber arrays 1620 A , 1620 B and any one of the fibers in the fiber arrays 1670 A , 1670 B .
[0078] Although much of the previous discussion had focused on modular switches, other embodiments of the application include switches that are non-modular. For example, according to a fifth embodiment of the invention, modular or non-modular beam deflectors may be combined with a curved distribution of I/O ports to increase port count in an beam steering optical switch. FIG. 17 depicts a cross-sectional schematic diagram of an optical switch 1700 according to a first alternative version of a fifth embodiment of the present invention. The switch 1700 generally comprises a first set of optical input/output (I/O) ports 1702 distributed across a first curve 1704 , a second set of optical I/O ports 1706 distributed across a second curve 1708 , and one or more sets of beam steering elements 1710 , 1712 optically coupled between the first set of I/O ports and the set of I/O ports. First and second sets of optical fibers 1714 , 1716 may be optically coupled respectively to the first and second sets of I/O ports 1702 , 1706 . The beam steering elements each may contain one or more deflectors 1711 , 1713 . By way of example and without loss of generality, the deflectors 1711 , 1713 may be single axis deflectors, dual-axis deflectors, fixed deflectors, or some combination of any or all of these. In the case where single axis deflectors are used, the switch 1700 may include relay optics, e.g. as described elsewhere herein.
[0079] The curved distribution of the I/O ports allows a greater number of ports to be coupled closer together, thereby increasing the port count for the optical switch 1700 . By way of example, the curves 1704 , 1708 may be in the shape of a segment of a circle, parabola, ellipse, hyperbola, cycloid, or any other suitable curved shape. Alternatively, one of the curves 1704 , 1708 could be a segment of a straight line. Although one-dimensional curved I/O port distributions are depicted in FIG. 1700 for the sake of clarity, the switch 1700 may employ two-dimensional curved arrays of I/O ports, e.g. ports distributed across a curved three-dimensional surface. By way of example, the shape of the curved surface may be cylindrical, spherical, paraboloidal, ellipsoidal, hyperboloidal or any other suitable curved three-dimensional shape. Alternatively, one of the arrays of I/O ports could be arranged in a planar array. Furthermore, although beam steering elements having planar arrays of deflectors are depicted in FIG. 17, the invention is in no way limited to this particular configuration. The beam steering elements may alternatively be curved arrays of deflectors. Furthermore, the deflectors may scan โone wayโ or โtwo wayโ as required by the specific application of the switch 1700 .
[0080] [0080]FIG. 18 depicts a cross-sectional schematic diagram of an optical switch 1800 that may employ a fold deflector according to a second alternative version of the fifth embodiment of the present invention. The switch 1800 may generally comprise a first set of optical input/output (I/O) ports 1802 distributed across a first curve 1804 , a second set of optical I/O ports 1806 distributed across a second curve 1808 , and one or more sets of beam steering elements 1810 , 1812 optically coupled between the first set of I/O ports and the set of I/O ports. First and second sets of optical fibers 1814 , 1816 may be optically coupled respectively to the first and second sets of I/O ports 1802 , 1806 . The beam steering elements may each contain one or more deflectors 1811 , 1813 . The second set of I/O ports may be coupled to the beam steering elements 1810 , 1812 via a fold deflector 1815 . The fold deflector may allow the first and second sets of I/O ports to be arranged on the same side of the beam steering elements. By way of example and without loss of generality, the deflectors 1811 , 1813 may be single axis deflectors, dual-axis deflectors, fixed deflectors, or some combination of any or all of these. In the case where single axis deflectors are used, the switch 1800 may include relay optics, e.g. as described below. Although a planar fold deflector is depicted in FIG. 18, the fold deflector may alternatively be curved, in a manner analogous to that depicted in FIG. 7F. By way of example, the shape of the fold deflector 1815 may be cylindrical, spherical, paraboloidal, ellipsoidal, hyperboloidal or any other suitable curved three-dimensional shape. Such a curved fold deflector may be convex fold deflector 1815 B as shown in phantom or a concave fold deflector 1815 C as shown in phantom.
[0081] There may be certain advantages in the particular case that an optical switch according the fifth embodiment of the invention includes dual-axis deflectors. FIG. 19 depicts a cross-sectional schematic diagram of an optical switch 1900 employing dual-axis deflectors according to a third alternative version of the fifth embodiment of the present invention. The switch 1900 may generally comprise a first set of optical input/output (I/O) ports 1902 distributed across a first curve 1904 , a second set of optical I/O ports 1806 distributed across a second curve 1908 , and one or more of beam steering elements 1910 containing dual-axis deflectors 1911 optically coupled between the first set of I/O ports and the set of I/O ports. First and second sets of optical fibers 1914 , 1916 may be optically coupled respectively to the first and second sets of I/O ports 1902 , 1906 . The dual-axis deflectors may be employed without relay optics.
[0082] The above embodiments may use relay optics. An example of a beam steering module 100 using relay optics according to a first embodiment of the invention is depicted in FIG. 20. The steering module 100 generally comprise two 2-dimensional mirror arrays 110 , 130 and relay optics 120 disposed along an optical path between the mirror arrays. The mirror arrays 110 , 130 each typically comprise NรM arrays of single axis mirrors 112 , 132 . Generally N and M are integers greater than one. In the special case of square arrays, N=M.
[0083] In the present application, a single axis mirror refers to a moveable mirror configured to rotate about a single axis. Mirrors 112 and 132 rotate about axes 114 , 134 that are different. Typically, mirrors 112 and mirrors 132 rotate about axes 114 , 134 that are substantially orthogonal to each other. For example, mirrors 112 are configured to rotate about axes 114 , oriented in a substantially horizontal plane. Mirrors 132 are configured to rotate about axis 134 oriented in a substantially vertical plane.
[0084] An input light beam 101 from a input fiber in a given row and column of an NรM input fiber array (not shown) impinges on a given mirror 112 in array 110 . Mirrors 112 and 132 deflect the light beam 101 towards a fiber in an NรM output fiber array (not shown). Those skilled in the art will recognize that because the propagation of light is reversible, the role of input and output fibers may be reversed.
[0085] In an exemplary embodiment, relay optics 120 comprises a first focusing element 122 and a second focusing element 124 in a confocal configuration. For the purposes of this application the โfocusing elementโ encompasses optical elements capable of focusing light. Such elements include refractive elements such as lenses, reflective elements such as mirrors, diffractive elements and micro-optical elements. Lenses include simple lenses and compound, i.e. multiple element lenses, graded refractive index (GRIN) lenses, ball lenses, and the like. Diffractive elements include Fresnel lenses and the like. In a confocal configuration, focusing elements 122 and 124 are characterized by the substantially same focal length f and separated from each other by a distance substantially equal to 2f. Furthermore, array 110 is located a distance f from focusing element 122 and array 130 is located a distance substantially equal to f away from focusing element 124 .
[0086] Relay optics 120 image mirror array 110 onto mirror array 130 . The angle of beam 101 may be controlled with respect to both axes 114 and 134 by adjusting the angle of the appropriate mirrors in the arrays 110 and 130 . For example, beam 101 emerges from mirror array 110 at an angle ฯ with respect to the object plane of relay optics 120 . The object plane of relay optics 120 is typically located proximate mirror array 110 . The image plane of relay optics 120 is typically located proximate mirror array 130 . Relay optics 120 are configured to ensure that beam 101 impinges on the image plane of relay optics 120 at the same angle ฯ. In other words, light beam 101 enters and leaves relay optics 120 at the same angle. Furthermore, parallel light entering relay optics 120 leaves as parallel light. Alternatively the angle beam 101 makes with the image plane may be related to the angle beam 101 makes with the object plane by some other predetermined relationship.
[0087] Steering module 100 may be used for beam steering in small port-count switches or if loss is not critical. Alternatively, module 100 may be used to switch beam 101 from input fibers in an NรM array to a grid or array of photodetectors. Mirrors in array 110 deflect light beam 101 to the row containing the desired output fiber or detector. Mirrors in array 130 deflect beam 101 to the desired column on that row.
[0088] [0088]FIG. 21 depicts a steered beam switching system 200 according to a second embodiment of the invention. If port count becomes sufficiently on module 100 , large losses may occur due to light entering the fibers at two great an angle. To overcome this, the system 200 that utilizes two modules of the type shown in FIG. 21 to ensure that beam 101 enters the output fiber at the correct angle.
[0089] The system 200 generally comprises a first module 210 coupled to an NรM input fiber array 202 and a second module 220 coupled to an output fiber array 204 . Modules 210 and 220 determine, at the plane of output fiber array 204 , the position and angle of an optical beam emerging from any of the input fibers in input fiber array 202 . Modules 210 and 220 have features in common with module 100 of FIG. 21. Module 210 comprises single axis mirror arrays 212 , 214 and relay optics 216 . Mirrors in arrays 212 and 214 rotate about mutually orthogonal axes. Module 220 comprises single axis mirror arrays 222 , 224 and relay optics 226 . Mirrors in arrays 222 and 224 rotate about mutually orthogonal axes.
[0090] In the exemplary embodiment depicted in FIG. 22 mirrors in arrays 214 and 222 rotate about substantially parallel axes. A light beam 201 from a fiber 203 in input fiber array 202 couples to a corresponding mirror 213 in mirror array 212 . Mirror 215 steers light beam 201 to a mirror 215 in array 214 . Relay optics 216 preserve the angle that light beam 201 makes at with respect to an image plane of relay optics 216 . Mirror 215 deflects light beam 201 to a mirror 223 on array 222 . Mirror 223 steers light beam 201 to a mirror 225 in array 224 . Relay optics 226 preserve the angle that light beam 201 makes at with respect to an image plane of relay optics 226 . Mirror 225 deflects light beam 201 to a corresponding fiber 205 in output fiber array 204 .
[0091] Those skilled in the art will recognize that by suitable manipulation of mirrors 213 , 215 , 223 , and 225 any fiber in input array 202 may be coupled to any fiber in output array 204 .
[0092] An exemplary embodiment of an optical switch 2300 employing various features described above is depicted in FIGS. 22 and 23. The switch 2300 generally comprises a plurality of beam steering modules 2302 attached to a case 2301 . The modules are disposed along a curved upper surface of the housing 2301 . Each beam steering module 2302 includes beam steering elements made up of alternating stacked arrays x-axis and y-axis beam steering mirrors 2304 2308 . By way of example the beam steering mirrors 2304 may be single axis mirrors that alternately rotate about x and y axes. The beam steering mirrors 2304 may be electrically connected to a controller by ribbon cables 2305 , which are not considered part of the modules 2302 . Optical signals from optical fibers 2303 are coupled to the beam steering elements by NรM groups of collimators 2306 disposed in holes in housings 2307 mechanically coupled to modules and optically coupled to beam steering elements. For clarity, some of the housings are have been removed to expose the beam steering elements. The modules are optically coupled to each other via a fold mirror 2310 , which is fixed to the case 2301 .
[0093] It will be clear to one skilled in the art that the above embodiment may be altered in many ways without departing from the scope of the invention. For example, although in the above embodiments, the mirrors are described as MEMS mirrors other mirrors such as bulk mirrors or large-area deformable mirrors may be used. Accordingly, the scope of the invention should be determined by the following claims and their legal equivalents.
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A beam steering module comprised of a mirror stack array in close proximity to a collimator array controllably steers photons along two axis and in a direction substantially less than 90 degrees to the collimator orientation. Several configurations of the module are described using single and double axis mirror rotation and relay optics. Optical telecommunications switches are shown using modules coupled to each other along flat and curved surfaces, with and without use of fold mirror and enabling a plurality of configuration options including photodetector optical power monitoring schemes that require no external power taps.
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BACKGROUND
[0001] Car heaters are used to warm the interior of a car during cold season and to defrost/defog windows if needed. FIG. 1 shows an exemplary prior art system for heating the interior of a vehicle. Conventional car heaters have three main parts: the cooling system, the heater core and the blower fan and duct system.
[0002] Conventional internal combustion vehicles come with a cooling system with a radiator, hoses, coolant and water. The coolant in the block heats up, until it becomes hot enough for the thermostat to open. Once the thermostat opens, the water flows through the radiator. The radiator consists of tubes that make multiple passes and has aluminum fins which cool the passing air. The average water temperature is 200 degrees or maybe higher. This heat is more than enough to heat the whole passenger compartment of a vehicle. This system is pressurized to raise the boiling point of water, allowing the car or vehicle to run hotter than 200 degrees, without boiling over. The coolant travels toward the firewall of the vehicle through heater hoses. Heater hoses are smaller and thicker than radiator hoses. The coolant is directed into the heater core directly from the water pump of the engine. Then, it passes through the heater core. This heater core is designed like a tiny radiator with tubes and fins for cooling. This is usually located behind the firewall and above the area where passengers place their legs. The coolant flow is generally as follows: The coolant is picked up at about mid-engine head and then is routed through an aluminum intake manifold. The coolant passes out of the aluminum intake manifold through an outlet and is then routed through an automatic choke and finally by metal tubing and rubber hose to the heater core. The remaining heat in the coolant is then dissipated, and the coolant is returned to the engine water pump by way of metal tubing and rubber hose. As a result of this coolant circulation arrangement, the coolant which is supplied to the heater core already has had a substantial amount of heat dissipated from it. Hot air is created by the coolant in the heater core. This air is then blown through the air duct system of the vehicle by the blower fan. The blower fan has adjustable speeds to satisfy the needs of the passengers and driver at the time. The end of each duct is located where it enters the passenger compartment. These ends have vents that open and close to let more or less hot air.
[0003] In a parallel trend, the rising cost of oil and global warming indications have sensitized manufacturers and consumers to the need to be energy efficient and environmentally responsible. As a result, modern electric cars are becoming popular again. One type of electric car provides a hub wheel motor in each wheel. The advantage of this design is that no additional transmission system is needed, thereby increasing the efficiency of the drive system. However, it is difficult to capture heat from the electric hub wheel motors to warm up the cab or defrost the wind shield.
SUMMARY
[0004] In one aspect, an electric vehicle includes a frame having a cab; a plurality of hub wheel motors mounted to the frame, each hub wheel motor rotating a wheel; and a heater and a fan thermally coupled to the cab, wherein the heater has an independent fuse to prevent a heater problem from shutting down the electric vehicle.
[0005] Implementations of the above aspect can include one or more of the following. The fan can provide heat to the cab through a defrost vent, a driver vent, and a passenger vent. A battery voltage sensor can be used to sense battery voltage to shut down the heater in case of low battery. A cabin temperature sensor can be used to adjust cab temperature to a desired range. A battery temperature sensor can be used to detect excessive current drawing by the heater and other electrical/electronics in the vehicle that can damage the battery. A secondary battery can be provided to provide independent power to the heater so that the main battery can be focused on propulsion power requirements. A solar cell can be provided to recharge the main or secondary battery or to power the heater. The heater includes a heating element that converts electricity into heat through Joule heating. The heating elements can be a Nichrome 80/20 (80% nickel, 20% chromium) wire, ribbon, or strip. In another embodiment, the heating element can have a Positive Thermal Coefficient of resistance.
[0006] In another aspect, a method for operating an electric vehicle includes providing a plurality of hub wheel motors to a frame with a cab, each hub wheel motor rotating a wheel; and heating the cab using an electric heater with an independent fuse to prevent a heater problem from shutting down the electric vehicle.
[0007] Advantages of the system may include one or more of the following. The electric heater provides a highly efficient, rapid warming system for vehicle occupants. The system can be programmed to come on whenever the user wants, the electric heater passes their warmth
[0008] The system can preheat the cabin to normal operating temperature, de-mist and defrost the windows and preheat the car's interior, all with the engine switched off. In cold environments, the user can remotely turn on the heater to avoid scraping ice and struggling with steamed-up windows. The timer on the dashboard can be used program when the user wants the heater to start so that, by the time the user drives off, the windscreens and windows are thawed, the temperature inside is nice and warm and the engine is warmed up and ready to go. The system also enables the user to keep the temperature constant even when the electric hub wheel motor or engine is off due to traffic jam. The system enables driving in winter to be safer by preventing windows from steaming up and providing excellent all-round visibility.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows an exemplary conventional car heater system.
[0010] FIG. 2A is a block diagram of the vehicle heater.
[0011] FIG. 2B is a block diagram showing high voltage control of a vehicle heater.
[0012] FIG. 3 shows an exemplary heater with housing and cab duct outputs.
[0013] FIG. 4 shows an exemplary electric heater/fan used in an electric vehicle with hub wheel motors.
[0014] FIG. 5 shows an exemplary environmentally friendly vehicle control system.
DESCRIPTION
[0015] The following description of various disclosed embodiments is provided to enable any person skilled in the art to make or use the present disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
[0016] FIG. 2A is a block diagram of the vehicle heater of the present invention. The power is supplied to a heater activate/deactivate circuit 108 from the car battery, not shown, when a switch 102 is placed in the on position. The switch 102 can be a 3 way switch to turn on only heater, only fan, or both heater and fan. Alternatively, the switch 102 can provide the user with a fine grain control of the fan speed to precisely adjust the cabin temperature. Power is also supplied by a battery 104 within the housing when the switch connects the battery 104 to the heater control circuit 108 . The control circuit 108 can turn on a heater 111 and/or a fan 112 . Additionally, a solar panel 106 can directly power the heater 111 and the fan 112 or the solar panel can recharge the internal battery 104 . When power is supplied to the heater activate/deactivate circuit 108 the power indicator light 110 and the heater 111 and fan 112 are turned on. The fan 112 is adapted to generate a flow of air through vents in a passenger compartment of the vehicle only during the receipt of a voltage. The heater 112 includes a heating element or a coil assembly situated in the ventilation system downwind of the fan 112 .
[0017] The battery sensor 114 and temperature sensor 116 constantly monitor the battery power of the internal battery 104 and car battery and the temperature of the outside air, respectively. When either the battery power gets too low or the temperature gets too high the sensors 114 or 116 causes an indicator light 118 to be turned on to inform the user of a problem. To protect the car and heater 111 , the heater 111 has its own fuse. Thus, when the heater 111 draws too much power, the heater fuse will trip to shut down the heater 111 without shutting down the rest of the vehicle. The fuse can be a time delayed fuse in one embodiment.
[0018] In one embodiment, the vehicle has a main battery pack that powers the entire vehicle as well as a low voltage auxiliary battery pack. In this embodiment, the heating coil of the heater 111 receives voltage from the main large battery pack. The main pack can supply voltages that can be as low as 36 volts or as high as 360 volts or any suitable voltages. The heater fan 112 may be powered by either a 12 volt auxilliary battery, or a power converter such as a dc to dc converter, or the main battery pack. The heater 111 has a heating element that converts electricity into heat through the process of Joule heating. Electric current through the element encounters resistance, resulting in heating of the element. In one embodiment, the heating elements can use Nichrome 80/20 (80% nickel, 20% chromium) wire, ribbon, or strip. Nichrome 80/20 has a relatively high resistance and forms an adherent layer of chromium oxide when it is heated for the first time. Material beneath the wire will not oxidize, preventing the wire from breaking or burning out. Alternatively, a resistance wire can be used, and the wire may be wire or ribbon, straight or coiled. The wires can be Kanthal (FeCrAl) wires, Nichrome 80/20 wire and strip or Cupronickel (CuNi) alloys for low temperature heating.
[0019] In another embodiment, the heating element can be a PTC ceramic which has a Positive Thermal Coefficient of resistance. The PTC ceramics (often barium titanate and lead titanate composites) has a highly nonlinear thermal response, so that it becomes extremely resistant above a composition-dependent threshold temperature. This behavior causes the material to act as its own thermostat, since current passes when it is cool, and does not when it is hot.
[0020] Other embodiments can use screen-printed metal-ceramic tracks deposited on ceramic insulated metal (generally steel) plates. Tubular (sealed element) can also be used, where a fine coil of Nickel chrome wire in a insulating binder (MgO, aluminia powder), sealed inside a tube made of stainless steel or brass. In another embodiment, the heater 111 can be a heat lampโa high-powered incandescent lamp usually run at less than maximum power to radiate mostly infrared instead of visible light.
[0021] In one embodiment, the processor keeps track of time by using a dedicated clock/timer chip or alternatively by internally counting clock pulses and translating the clock pulses to seconds, minutes, and hours. The user can provide instruction to the processor to turn on the heater at a predetermined time and duration to provide deicing/defrosting operation to the wind shield. The user can also specify the cabin temperature to be maintained. Thus, if the user plans to drive at 8 am, then the user can program the heater to be turned on at 7:50 to decide/defrost and to warm the cab temperature so that the vehicle is ready for use at 8 am.
[0022] In one embodiment, the heater 111 and fan 112 can be provided as a retro-fit for existing vehicles. In such embodiment, a plurality of mounting brackets can be provided to mount the heater 111 and fan 112 to an existing vehicle.
[0023] In the event the existing vehicle is a gas powered car, such retrofit can provide advantages by warming up the engine. Cold starts increase engine wear and put unnecessary strain on the battery. By reducing fuel consumption and permitting a smooth engine start without the usual coughs and splutters and excessive exhaust fumes, a preheater saves plenty of time, trouble and money. Catalytic converters are also more efficient when the engine is warmed up in advance.
[0024] FIG. 2B is a block diagram showing high voltage control of a vehicle heater. A switch 154 is used to turn on or off the heating function. The switch 154 can be an ignition switch for the car, or can be a heater on/off switch. The switch 154 connects a low voltage power supply 148 to a relay 150 . In this case, the low voltage power supply 148 is the car's 12V battery. The relay 150 is also connected to a high voltage power supply 158 , in this case a 72V battery. The supply 158 can be other voltages such as 120V or 360V, among others. The high voltage power supply 158 is connected to a fuse 160 which in turn is connected to ground. Upon user command, the relay 150 gates the high voltage power output to the heater 111 .
[0025] The heater relay/contractor 150 serves the purpose of a switch to close the circuit when the heater switch 148 is turned on. In one embodiment, the car ignition switch should be turned on for the heater to operate. However, in other embodiments, the heater can be turned on independent of the ignition switch. Instead of a switch with a rating of 120V between the main battery pack and the heater, the relay is included to control the 72V or 120V heater using the 12V side. The 12V coil side of the relay can be connected to the heater switch on the dashboard and the 72V or 120V side will be connected to the heater. In this manner, when the heater switch is turned on, the 12V side is energized inside the relay and closes the 72V or 120V side and heater will function. The relays/contactors are made by companies like Cole Hersee, White Rodgers, Stancor, Ametek, Prestolite, among others.
[0026] In one implementation, the heating system consists of a 72/120V heater, 12V fan, 12V switch, fuse, and a 12V relay as shown in the attachment. The 12V switch located on the dash is used to control the heater system on/off. The 12V switch in turn powers the heater fan and 12V relay leading to the 72V heater. As the 12V relay coil energizes in the relay the 72V switch closes activating the 72V heater.
[0027] The embodiment of FIG. 2B applies the entire battery voltage of the 72 volts battery, and can be upscalable to apply 120 volts or even 360 volts to the heater. By applying the high voltage supply to the heater, the heating system is more efficient and can provide more wattage for heating purposes. Due to the high voltage rail, the system keeps connecting wires to a minimal size to be cost-effective.
[0028] FIG. 3 shows an exemplary heater with housing 200 and cab duct outputs. The housing 200 includes a fan cover 202 , a defrost vent 204 , a driver vent 206 and a passenger vent 208 . Vents 202 - 208 are connected to cab air ducts to heat the interior of the cab as well as defrost the wind shield.
[0029] The control circuit 108 can be a wired control using discrete components, or alternatively can be microcontroller based. During use, the heater coil serves to generate heat only during the receipt of a voltage. Mounted on a control panel of the vehicle is a temperature control dial for selecting a temperature. Associated therewith is an activation switch mounted on the control panel for transmitting an activation signal upon the depression thereof. Finally, control means, in form of the control circuitry is connected between the fan, heating element or heater coil, temperature control dial, and activation switch. In use, the control means transmits a predetermined voltage amount to both the fan and the heater coil only during the receipt of the activation signal. It should be noted that the predetermined voltage is proportional to the temperature selected by way of the temperature control dial. In a microcontroller implementation, the user selects the temperature control through a digital input such as a keypad or an analog input such as a touch screen that is digitized. The microcontroller interprets the user selection and generates the appropriate voltage to control the fan. Alternatively, if the fan is controlled by pulse widths, the microcontroller causes appropriate PWM signals to control the fan speed. The fan 112 in turn generates an amount of heat and air flow that are a function of the duty cycle of the pulses from the pulse width modulator.
[0030] FIG. 4 shows an exemplary electric heater/fan 300 used in an electric vehicle with hub wheel motors 302 - 308 . The motors 302 - 308 and the heater/fan 300 are controlled by a vehicle processor 310 to provide transportation to passengers located in a cab 320 . The temperature of the cab 320 is controlled to provide environmental comfort to the passengers. The hub motor of FIG. 4 is designed to be small in size. The compact motor assembly is mounted in conjunction with the hub of the car. The motor assembly includes a self contained unit which includes a rotationally driven motor housing that is connected directly to the tire supporting rim of the car wheel. Rotation of the motor housing will result in similar rotation of the tire supporting rim of the wheel. The motor housing has an internal chamber and within that internal chamber is located a stator and a rotor. The stator is fixedly mounted onto a center shaft which passes through the motor housing which is fixedly mounted to the car. The rotor is to be rotated by the electrical energy being supplied to the stator with this rotation being transferred through the drive shaft.
[0031] The exemplary hub wheel motor system includes a motor enclosed by a hub cap and a tire supporting rim. A rubber wheel can be mounted on the rim. The back of the hub cap has an opening through which a cable is inserted therethrough to provide power as well as control signals to the motor. The motor has outer, ring-shaped permanent magnets (stator) that rotate while the inner metallic core (rotor) is fixed. When the motor is switched on, the static rotor stays still while the stator spins around it. A tire is attached to the motor, and as the outer part of the motor rotates, the wheel (or wheels) powers the vehicle forward.
[0032] Since the motors are hub-wheel motors, the independent heater/fan 300 can provide defrosting as well as heating capability to the cab to provide comfort to the vehicle occupants while they are using the vehicle.
[0033] The electric car with hub-wheel motors can be the Alias, available from ZAP, Inc. of Santa Rosa, Calif. The Alias is 100% electric, 100% of the time. Recharging is simple and effortless via any 110V outlet at home or on the road. The Alias has aerodynamic contours, low profile, wide stance with double-wishbone suspension, and sport styling. The vehicle can also be a truck with hub-wheel motors called ZAP Truck XL. Roomy, durable, rugged yet whisper quiet, the ZAPTRUCK XL is the affordable green solution for fleet operations. The electric truck is a utilitarian workhorse providing a roomy cab for two and a convertible bed/platform for moving up to 1600 lbs. of cargo during off-road use. The vehicle is ideal for corporate campuses, warehouses, universities, factories, municipal operations and around the ranch or farm.
[0034] FIG. 5 shows an exemplary environmentally friendly vehicle control system. FIG. 5 shows how a central controller receives various inputs, draws on necessary information (driving profiles, vehicle specifications and navigation information), and produces the appropriate outputs. The central controller makes use of a range of inputs from sensors. The central controller combines this information with driver inputs received through a โuser interface.โ Typically, these driver inputs include braking, steering, accelerator and the various switch controls. The central controller can then combine these inputs with stored driving profiles, vehicle specifications, and navigation information. Based on all this information, the central controller optimizes for best performance. This requires sending control signals to the motors to continuously control motor torque and speed.
[0035] The system can preheat the cabin to normal operating temperature, de-mist and defrost the windows and preheat the car's interior, all with the engine switched off. In cold environments, the user can remotely turn on the heater to avoid scraping ice and struggling with steamed-up windows. The timer on the dashboard can be used program when the user wants the heater to start so that, by the time the user drives off, the windscreens and windows are thawed, the temperature inside is nice and warm and the engine is warmed up and ready to go. The system also enables the user to keep the temperature constant even when the electric hub wheel motor or engine is off due to traffic jam. The system enables driving in winter to be safer by preventing windows from steaming up and providing excellent all-round visibility.
[0036] In one embodiment, the central controller senses temperature conditions and issues a command to maintain constant temperature given the weather condition and the occupant's desired temperature range. The central controller linearly ramps down the fan when the temperature is too high and vice versa. The user, through the user interface, can override the processor when conditions change or for any reason. In this manner, the vehicle can increase its efficiency and user comfort while minimizing environmental pollution.
[0037] The software controlling the heater and fan 111 / 112 or 300 can be tangibly stored in a machine-readable storage media or device (e.g., program memory or magnetic disk) readable by a general or special purpose programmable computer, for configuring and controlling operation of a computer when the storage media or device is read by the computer to perform the procedures described herein. The inventive system may also be considered to be embodied in a computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner to perform the functions described herein.
[0038] Portions of the system and corresponding detailed description are presented in terms of software, or algorithms and symbolic representations of operations on data bits within a computer memory. These descriptions and representations are the ones by which those of ordinary skill in the art effectively convey the substance of their work to others of ordinary skill in the art. An algorithm, as the term is used here, and as it is used generally, is conceived to be a self-consistent sequence of steps leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of optical, electrical, or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
[0039] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, or as is apparent from the discussion, terms such as โprocessingโ or โcomputingโ or โcalculatingโ or โdeterminingโ or โdisplayingโ or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical, electronic quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
[0040] The system has been described in terms of specific examples which are illustrative only and are not to be construed as limiting. In addition to control or embedded system software, the system may be implemented in digital electronic circuitry or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention may be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a computer processor; and method steps of the invention may be performed by a computer processor executing a program to perform functions of the invention by operating on input data and generating output. Suitable processors include, by way of example, both general and special purpose microprocessors. Storage devices suitable for tangibly embodying computer program instructions include all forms of non-volatile memory including, but not limited to: semiconductor memory devices such as EPROM, EEPROM, and flash devices; magnetic disks (fixed, floppy, and removable); other magnetic media such as tape; optical media such as CD-ROM disks; and magneto-optic devices. Any of the foregoing may be supplemented by, or incorporated in, specially-designed application-specific integrated circuits (ASICs) or suitably programmed field programmable gate arrays (FPGAs).
[0041] The present invention has been described in terms of specific embodiments, which are illustrative of the invention and not to be construed as limiting. Other embodiments are within the scope of the following claims. The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention.
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An electric vehicle includes a frame having a cab; a plurality of hub wheel motors mounted to the frame, each hub wheel motor rotating a wheel; and a heater and a fan thermally coupled to the cab, wherein the heater has an independent fuse to prevent a heater problem from shutting down the electric vehicle.
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FIELD OF THE INVENTION
This invention relates generally to archery apparatus and particularly to apparatus for assisting the archer in steadying the bow at the moment of arrow release.
BACKGROUND OF THE INVENTION
Archery has continued to increase in popularity as a sport and recreational activity for both target shooting and hunting. The apparatus used in archery has been continuously developed to a substantial level of sophistication. Increased power and accuracy of archery apparatus has been achieved as practitioners have developed a variety of stronger and more powerful types of bows. One of the most powerful type of bows developed has been that generally referred to as a compound bow. In a typical compound bow, an elongated rigid riser defines a handle grip and supports a pair of extending flexible resilient limbs at opposed ends. The outer ends of each limb support a rotatable eccentric wheel or cam to which a pair of cables and a bow string are secured. An arrow rest is supported upon the riser to support the forward portion of the arrow shaft as the bow is drawn and aimed.
While arrows initially were formed of simple wooden shafts having feather fletchings and fixed arrow heads or points, modern arrows are usually formed of hollow aluminum alloy shafts or composite materials having threaded inserts at the forward end for installing removable points or heads. The remaining end of the arrow shaft typically supports a molded plastic arrow nock which defines a slot for engaging the bow string. The arrow fletchings are most commonly formed of plastic vanes or the like.
The shooting operation is carried forward as the archer selects an arrow and fits the hock to the bow string at a point referred to as the hocking point. The shaft of the arrow is rested upon the arrow rest as the arrow hock and bow string are drawn back flexing the bow limbs and rotating the eccentric wheels to store energy in the bow. Once the bow is drawn, the nocking point on the bow string and the arrow rest define an axis known as the shooting axis along which the arrow is launched once the drawn bow string is released.
Regardless of the different shooting techniques used by various archers, the moments in the shooting operation in which the drawn bow is aimed at the target are the most critical moments in determining the accuracy of the archer. While a number of devices have been provided by practitioners in the art for assisting the archer in maintaining a steady bow position during the final moments prior to arrow release, difficulty in maintaining a steady bow position often plagues even the most experienced of archers.
Despite the advances in archery apparatus directed toward assisting the archer in maintaining a steady bow during aiming and arrow release, there remains nonetheless a continuing need in the art for evermore improved and effective apparatus for achieving a steady aim during the critical moments prior to arrow release.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide an improved archery apparatus for steadying an archer's bow prior to arrow release. It is a more particular object of the present invention to provide an improved archery apparatus which interacts with the bow string of a drawn bow to aid the archer in steadying the bow prior to arrow release.
In accordance with the present invention, there is provided for use in steadying an archery bow having a bow string, a steadying device comprises: an outer envelope having an interior cavity and a front surface; means for securing the fabric envelope to an archer's waist; and resilient means received within the outer envelope for resiliently supporting the front surface, the steadying device being worn by an archer proximate the archer's hip such that the front surface extends outwardly and provides a resilient surface against which an archer may press a portion of a drawn bow string to steady a drawn bow.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements and in which:
FIG. 1 sets forth a perspective view of a typical archer and bow utilizing a waist supported bow string steadying device constructed in accordance with the present invention;
FIG. 2 sets forth a perspective view of the present invention waist supported bow string steadying device in a relaxed position;
FIG. 3 sets forth a partial perspective view of the present invention waist supported bow string steadying device in the inflated or extended position;
FIG. 4 sets forth a perspective view of an alternate embodiment of the present invention waist supported bow string steadying device in its extended position;
FIG. 5 sets forth a section view of the alternate embodiment of the present invention waist supported bow string steadying device taken along section lines 5--5 in FIG. 4;
FIG. 6 sets forth a partially sectioned side view of a further alternate embodiment of the present invention waist supported bow string steadying device;
FIG. 7 sets forth a section view of a still further alternate embodiment of the present invention waist supported bow string steadying device; and
FIG. 8 sets forth a perspective view of a still further alternate embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 sets forth a perspective view of a typical archer generally referenced by numeral 40 utilizing a compound bow 10 in combination with the present invention waist supported bow string steadying device generally referenced by numeral 50. Compound bow 10 is constructed in accordance with conventional fabrication techniques and includes a generally rigid riser 11 defining a grip 14 and an arrow rest (not seen). Compound bow 10 further includes a pair of flexible resilient limbs 12 and 13 each supporting an eccentric wheel 20 and 21 respectively at the outer ends thereof. A pair of shafts 22 and 23 rotatably support eccentric wheels 20 and 21. A pair of cables 25 and 26 are coupled to eccentric wheels 20 and 21 in accordance with conventional fabrication techniques. A bow string 24 extends between eccentric wheels 20 and 21 in accordance with conventional fabrication techniques. Compound bow 10 further includes an elongated cable guard 35 supported by riser 11 and having a slidably movable cable guide 36 received upon cable guard 35 and having a pair of cable slots 37 and 38 formed therein. Slots 37 and 38 receive cables 25 and 26 in accordance with conventional fabrication techniques. An arrow 30 having an elongated shaft 31 and an arrow point 32 also constructed in accordance with conventional fabrication techniques is shown coupled to bow string 24 and resting upon the arrow rest (not seen) of compound bow 10.
In the position shown, archer 40 has drawn arrow 30 and bow string 24 bending limbs 12 and 13 and rotating eccentric wheels 20 and 21 to store energy within bow 10 in preparation for launching arrow 30. The moment depicted in FIG. 1 corresponds to the final aiming moments in which the steady control of the bow is critical in achieving accurate shooting.
In accordance with the present invention, steadying device 50 is received and supported upon belt 42 encircling waist 41 of archer 40. Steadying device 50 is positioned at the approximate hip location of archer 40 and extends toward bow string 24. Steadying device 50 is described below in greater detail. However, suffice it to note here that in accordance with the present invention, steadying device 50 defines a resilient fabric layer 51 having a frontal surface 52, a seam 54 and as is better seen in FIG. 3 an elastic bladder 58 supported within fabric layer 51. In further accordance with the present invention, a resilient bulb 55 having a conventional valve 56 coupled thereto is coupled to bladder 58 within fabric layer 51 by a flexible tube 57. In its preferred form, resilient bulb 55 and valve 56 are fabricated in accordance with conventional fabrication techniques used in providing a convenient hand actuated air pump used in apparatus such as a blood pressure testing device or the like.
In further accordance with the present invention, steadying device 50 has been inflated using resilient bulb 55 and valve 56 to expand fabric layer 51 and bladder 58 to position frontal surface 52 at the desired distance from waist 41 of archer 40. The resilient structure steadying device 50 provided by the inflated internal bladder and resilient fabric layer surrounding it provides a front surface 52 which when pressed by bow string 24 in the manner shown in FIG. 1 deforms inwardly forming a bow string impression 53. The degree of bow string impression resulting from archer 40 holding bow string 24 against front surface 52 varies with user preference and is controlled by the degree of inflation of bladder 58 (seen in FIG. 3).
In accordance with an important aspect of the present invention, archer 40 is able to utilize the contact between bow string 24 and steadying device 50 to provide a controlling contact between the archer and bow string 24 which aids in maintaining the steady position of compound bow 10 at the critical moments directly preceding arrow release or launch. It will be recognized by those skilled in the art that different archers having different shooting styles and different physiology as well as utilizing a variety of bow structures will require different degrees of inflation of steadying device 50. Thus, in its preferred form, steadying device 50 is fabricated of sufficiently resilient material and a sufficiently expandable interior bladder to assume a wide range of dimensions as the degree of bladder inflation is varied. To achieve a greater degree of dimensional control and stability, steadying device 50 may be fabricated using a resilient fabric layer 51 which exhibits a greater elasticity in the portion forming front surface 52 and a lesser degree of elasticity in the portion resting against the archer's torso. In such case, a seam 54 is formed to join the two different resilient fabric materials.
FIG. 2 sets forth a perspective view of steadying device 50 in the compacted or relaxed position in which bladder 58 (seen in FIG. 3) has been virtually entirely deflated. More specifically, steadying device 50 includes a resilient fabric outer layer 51 having a seam 54 formed therein and defining a front surface 52. Steadying device 50 further includes a pair of belt loops 60 and 61 on the rear surface thereof which receive a conventional belt 42. Alternatively, belt 42 may be secured directly to the rear surface of fabric layer 51 without departing from the spirit and scope of the present invention. As described above, fabric layer 51 is preferably formed of a resilient expandable material such as spandex or the like to facilitate substantial dimensional change during the above-described inflation. As is seen in FIG. 3, an inflatable bladder 58 is received within the interior of fabric layer 51 and is coupled to a resilient bulb 55 by a flexible tube 57. A conventional valve 56 is provided between tube 57 and bulb 55 to facilitate the inflation and deflation of bladder 58 (seen in FIG. 3). In its compacted state as shown in FIG. 2, steadying device 50 may be worn without imposing substantial inconvenience or difficulty upon the wearer during periods between shooting.
FIG. 3 sets forth the present invention steadying device in the fully inflated configuration. As can be seen, steadying device 50 having fabric layer 51, seam 54 and frontal surface 52 formed therein surrounds inflated bladder 58 and is substantially expanded from the noninflated position shown in FIG. 2. Bulb 55, valve 56 and tube 57 are coupled to bladder 58 in accordance with conventional fabrication techniques by which bulb 55 may be utilized to inflate or deflate bladder 58 to expand or contract steadying device 50. Belt loops 60 and 61 secure fabric layer 51 to belt 42.
FIG. 4 sets forth a perspective view of an alternate embodiment of the present invention bow string steadying device generally referenced by numeral 70. Steadying device 70 includes a fabric envelope 71 formed of a flexible portion 72 and a resilient portion 73 joined by a binder strip 74. In its preferred form, flexible portion 72 is formed of a non-expanding material such as canvas or the like while resilient portion 73 is formed of a material which undergoes a high degree of expansion such as spandex or the like. Binder 74 provides a sewn seam structure which securely joins flexible portion 72 to resilient portion 73. Resilient portion 73 defines a front surface 75 which as described above provides a resilient steadying surface for bow string 24 (seen in FIG. 1). A pair of belt loops 80 and 81 are secured to the rear surface of flexible portion 72 and are preferably formed of a nonresilient material such as canvas or the like. As is better seen in FIG. 5, steadying device 70 includes an internal expandable bladder 82 preferably formed of a material such as rubber or the like which is coupled to a tube 57 extending through a convenient aperture in flexible portion 72. A bulb 55 and valve 56 constructed in accordance with conventional fabrication techniques is coupled to tube 57 for providing inflation and deflation of bladder 82 (seen in FIG. 5).
In the expanded position shown in FIG. 4, the interior bladder of steadying device 70 has been inflated using bulb 55 and is maintained in an inflated condition by closing valve 56. The inflation of the interior bladder within fabric envelope 71 causes resilient portion 73 to expand outwardly from binder 74. Thus, the outward dimension or degree of expansion of resilient portion 73 is determined by the pressure or the degree of inflation of the internal bladder. As a result, the user is able to control the outward dimension of resilient portion 73 and position front surface 75 at the desired distance to suit the archer's style, physiology and equipment. Once steadying device 70 is no longer to be used, valve 56 is opened releasing the pressure within the interior bladder of steadying device 70 and permitting resilient portion 73 to contract.
FIG. 5 sets forth a section view of steadying device 70 taken along section lines 5--5 in FIG. 4. As described above, steadying device 70 includes a fabric envelope 71 formed of a flexible nonexpanding portion 72 and a resilient expandable portion 73 joined by a binder seam 74. A pair of belt loops 80 and 81 (the latter seen in FIG. 4) are secured to flexible portion 72. Resilient portion 73 extends, in its preferred fabrication, beneath flexible portion 72 and is secured to flexible portion 72 at a sewn seam 83. An inflatable bladder 82 formed of a rubber material or the like is received within resilient portion 73 and as described above is coupled to bulb 55 and valve 56 by a flexible tube 57. In the position shown in solid-line representation in FIG. 5, bladder 82 has been inflated to a substantial degree extending front surface 75 outwardly a substantial distance. In the event, however, bladder 82 is deflated, the resilient structures of bladder 82 and resilient portion 73 cause contractions thereof and change the degree of extension of front surface 75. For example, the positions of resilient portion 73 and bladder 82 are shown alternatively in dashed-line configuration at a substantially contracted position which results from partial deflation of bladder 82. Between the dashed-line positions shown in FIG. 5 and the solid-line fully extended position shown in FIG. 5, intermediate positions are readily obtainable by simply inflating bladder 82 as desired. Thus, in accordance with an important aspect of the present invention, the extension of front surface 75 from the wearer's hip may be adjusted to suit the needs of a wide variety of archers. It will be apparent to those skilled in the art that the entire structure of steadying device 70 may be completely deflated and may thereafter be conveniently folded or compacted for easy storage or convenient wearing during periods of nonuse.
FIG. 6 sets forth a partially sectioned view of a further alternate embodiment of the present invention bow string steadying device generally referenced by numeral 90. Steadying device 90 includes a fabric envelope 91 having a rear portion 92 formed of a flexible material and defining an interior cavity 99. A belt loop 98 is secured to the rear surface of rear portion 92. An elongated zipper 96 provides a closeable opening in rear portion 92 providing access to interior cavity 99. A plurality of articles 101 through 105 are conveniently stored within interior cavity 99 of rear portion 92. Steadying device 90 further includes a resilient portion 93 secured to rear portion 92. A binding 100 extends between rear portion 92 and resilient portion 93 to provide secure attachment therebetween. An inflatable bladder 95 preferably formed of a rubber material or the like is received within resilient portion 93. A conventional inflating bulb 110 having a valve 111 is coupled to bladder 95 by a flexible tube 92.
Steadying device 90 is worn upon the archer's hip in the manner shown in FIG. 1 for steadying device 50. Steadying device 90 differs from the above-described embodiments in that it provides an inflatable expanding portion having a front surface 94 for bow string contact and steadying together with a rear portion having an interior cavity for convenient storage of various articles. Bulb 110 and valve 111 may be utilized in the manner described above to inflate bladder 95 and expand resilient portion 93 to the extent desired to provide the position of front surface 94 which meets the user's needs in steadying the bow string during shooting. The added advantage of providing article storage is provided by using zipper 96 to gain access to interior cavity 99. It will be recognized by those skilled in the art that the relative sizes of interior cavity 99 dedicated to material storage and resilient portion 93 accommodating bladder 95 may be varied to suit the user's preference without departing from the spirit and scope of the present invention.
FIG. 7 sets forth a section view of a still further alternate embodiment of the present invention bow string steadying device generally referenced by numeral 120. Steadying device 120 includes a resilient expandable fabric envelope 121 formed of a rear portion 122 and a front portion 123 joined along a common junction 124. Steadying device 120 further includes an outer layer 130 secured to the rear surface of rear portion 122 by a sewn seam 127. A belt loop 131 is secured to the rear portion of outer layer 130. Rear portion 122 further defines an elongated zipper 138 which provides access to the interior of rear portion 122. A resilient foam pad 125 is enclosed within front portion 123 and provides resilient support for front surface 126 of portion 123. A plurality of foam inserts preferably formed of a resilient material or other lightweight foam 135, 136 and 137 are received within rear portion 122 of fabric envelope 121 through zipper 138.
In accordance with the embodiment of FIG. 7, bow string steadying device 120 may be worn upon the archer's hip in the same manner set forth above in FIG. 1 for steadying device 50. In such case, front surface 126 provides a resilient bow string steadying surface in the manner described above. The degree of extension of steadying device 120 from the user's hip may be adjusted by varying the number of foam inserts within rear portion 122. Thus, with foam inserts 135, 136 and 137 in place, front surface 126 is maximally extended from the user's hip. A lesser extension is obtained by the user simply removing one of the foam inserts from rear portion 122. In such case, the resilient fabric of rear portion 122 contracts reducing the overall extension of steadying device 120. It will be apparent that removal of both inserts 136 and 137 permits rear portion 122 to further contract and further reduces the extension of front surface 126. Alternatively, the user may remove foam insert 135 and utilize the interior of rear portion 122 for convenient article storage in a manner similar to that set forth above in FIG. 6.
FIG. 8 sets forth a perspective view of a still further alternate embodiment of the present invention steadying device generally referenced by numeral 150. Steadying device 150 is preferably formed of a resilient foam material such as closed or open cell rubber or plastic or its equivalent. Steadying device 150 defines a body 151 having a generally cylindrical front surface 152 and generally planar side surfaces. Body 151 further defines a curved body surface 155 which is nonsymmetrically positioned upon body 151. As a result, body surface 155 generally conforms to the torso of the archer wearing steadying device 150 which is secured to the archer's torso by a pair of flexible belts 154 and 153. Belts 154 and 153 are shown truncated in FIG. 8 but should be understood to include conventional fastening elements suitable for securing the belts about the archer's torso in the manner set forth above. Steadying device 150 may be worn having long side 156 positioned about the back portion of the archer's torso and short side 157 along the front portion of the archer's torso or, if preferred, the position of steadying device 150 may be inverted by simply rotating body 151 and belts 153 and 154 and refastening the device to the archer's torso such that long side 156 extends along the front portion of the archer's torso with side 157 along the rear portion of the archer's torso. The important aspect of steadying device 150 is the provision of the resilient body portion of body 151 beneath curved surface 152 for steadying the bow string in the manner described above and shown particularly in FIG. 1. Thus, the user is able to secure steadying device 150 to the user's waist and torso using belts 153 and 154 in the most comfortable position and thereafter in the manner shown in FIG. 1 and in similarity to the user's application of steadying device 50 shown therein place bow string 24 against curved surface 152 of body 151 thereby providing the steadying action and improving the archer's skill.
What has been shown is a convenient, easy to use and lightweight waist supported bow string steadying device for use by an archer. The device is worn upon the user's belt and is preferably positioned upon the archer's hip to provide a resilient bow string rest surface which may be used to steady the bow at the critical moments prior to arrow launch. Embodiments are shown which provide a fully inflatable waist support as well as other embodiments in which a portion of the steadying device may receive and support various articles for convenient storage. When fully deflated and compacted, the bow string steadying device may be conveniently stored or carried using little or no space and providing little or no weight to the user.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A waist supported bow string steadying device for an archer includes a fabric envelope within which a resilient bladder is supported to provide a size variable somewhat resilient member for contact with the bow string of a drawn bow prior to release. In several embodiments, the resilient member includes an inflatable bladder having a captive air volume therein which inflates to various degrees to provide bow string arrow rests of varying sizes. In alternate embodiments, a portion of the steadying device is provided with a storage cavity in which articles of convenience may be stored. In still further embodiments, the interior of the fabric envelope is provided with one or more resilient foam pads to impart shape and size to the fabric envelope and the desired dimension to the bow string steadying device.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a cyclocomputer attachable to a bicycle.
[0003] 2. Description of the Background Art
[0004] Japanese Utility Model Laying-open No. 02-83574 discloses displaying on a display device installed in a vehicle a variety of information that is stored in an IC card brought into the vehicle.
[0005] A cyclocomputer attached to a bicycle and displaying a variety of information such as a travelling speed in a manner visible by the rider, has also been conventionally known.
[0006] In recent years, near field communication (NFC) technology is increasingly prevalent. A basic study of the NFC technology has been started with the technology under the name of Felica (registered trademark). The basic study of the NFC was started in the late 1980's, and the technology, started by Sony Corporation, has been standardized in recent years as contactless IC card communication (or the NFC communication). While NFC communication includes Felica, ISO/IEC 14443 TypeA (MIFARE (registered trademark)), ISO/IEC 14443 TypeB, and ISO15693 for differences in communication specifications, a chip embedded in a card accommodating all specifications (an NFC LSI chip) and a reader writer have appeared in recent years. The NFC communication is put in practical use as a commutation ticket for public transportation facilities, or electronic money used to pay small sums of money and also having a function as a commutation ticket, or Suica (registered trademark) (Felica) and taspo (registered trademark) (TypeA). In Japan, the technology has also been applied to driver's license, and the NFC standard of the TypeB specification has been applied thereto. The NFC standard of the ISO15693 specification is used for a tag for business use and the like. In Japan, a My Number Card, a successor to a basic resident registry card, is scheduled to be introduced in January, 2016, with an NFC LSI chip embedded therein.
[0007] A cyclocomputer is attached to a bicycle, and accordingly, it is desirable that the cyclocomputer be small in size. On the other hand, it is desirable that the cyclocomputer have a display having a size of some extent to display information. As the small-size cyclocomputer is required to ensure a display having an area of a size of some extent, the cyclocomputer is limited in terms of the size of a user interface used for input to and output from the cyclocomputer. For example, it is difficult to provide the cyclocomputer at an external surface thereof with numeric key pads, as it is necessary to ensure the display's area.
[0008] Accordingly, cyclocomputer dealers have a setting device installed in their shops and dedicated to cyclocomputers for initializing them, such as inputting data such as a cumulative travelled distance, a circumferential length of a tire of a bicycle, a current time, a date, and the like. The setting device can be used to input predetermined information to a new cyclocomputer device.
[0009] Furthermore, some riders may ride different bicycles for different purposes, and in such a case, it is desirable that a cyclocomputer can be shared among the different bicycles. Sharing a cyclocomputer among different bicycles, however, requires rewriting information such as a tire's circumferential length stored in the cyclocomputer, and it is unrealistic to visit a dealer whenever such a rewriting operation is required. Conventionally, such rewriting necessitates using a limited user interface, such as a few number of switches. For example, when a user is required to use two switches to enter a 4-digit number, the user must press the switches repeatedly. As a result, it is difficult to share a single cyclocomputer among a plurality of bicycles or rewrite information such as a tire's circumferential length.
[0010] Furthermore, a cyclocomputer is attached to a bicycle, which is human-powered, and accordingly, the cyclocomputer is required to be lightweight. Sometimes, a bicycle travels hundreds of kilometers for tens of hours at once, and while the bicycle is thus traveling, the cyclocomputer cannot be removed from the bicycle, and accordingly, the cyclocomputer is required to operate on a small-size power source such as a coin cell battery.
SUMMARY OF THE INVENTION
[0011] The present invention contemplates a cyclocomputer that facilitates inputting and outputting information and is also miniaturized and lightweighted, and continues to operate for a long period of time without exchanging batteries or charging a battery.
[0012] The present cyclocomputer is attachable to and detachable from a bicycle.
[0013] In one aspect, the present cyclocomputer includes: a body; a display provided on an upper surface of the body and displaying prescribed information; a storage provided in the body and storing therein data including at least a portion of the prescribed information; and an NFC tag provided in the body and allowing data communication with an NFC reader writer incorporated in a mobile wireless communication terminal. The NFC tag is composed of an NFC LSI chip and an antenna coil, and often has them both laminated for better handlability. The NFC tag may have the NFC LSI chip and the antenna coil unlaminated.
[0014] The above NFC LSI chip is composed of an interface with a microcomputer (e.g., UART, I2C, synchronous serial), an RF front end circuit, a microcomputer, a memory (ROM, RAM, EEPROM), and a power feeding capacitor. The NFC LSI chip can receive electric power from the NFC reader writer and communicate therethrough, via the antenna coil that is connected to the NFC LSI chip. The NFC LSI chip can also receive electric power from a battery of the cyclocomputer. The NFC LSI chip is only required to operate when it receives electric power, and no power source is connected to the NFC tag.
[0015] โMobile wireless communication equipmentโ as referred to herein includes a multifunctional mobile phone such as a smart phone, a tablet computer, and a setting device dedicated to the cyclocomputer.
[0016] The cyclocomputer can perform data communication with a mobile wireless communication terminal, the mobile wireless communication terminal can extract data that is stored in the storage of the cyclocomputer via the NFC LSI chip, and the cyclocomputer can receive, via the NFC reader writer of the mobile wireless communication terminal, data that is stored in the mobile wireless communication terminal or input to the mobile wireless communication terminal via an operation unit of the mobile wireless communication terminal.
[0017] The present invention allows a mobile wireless communication terminal's operation unit to be used to perform the above described data communication, and thus allows information to be easily input and output without the necessity of providing the cyclocomputer with an operation unit. More specifically, the present invention facilitates initializing the cyclocomputer and accordingly, sharing the cyclocomputer among a plurality of bicycles having tires with different circumferential lengths.
[0018] In one embodiment, the cyclocomputer has a function to indicate that the cyclocomputer has completed data communication with the mobile wireless communication terminal, or a function to cause the mobile wireless communication terminal to indicate that wireless communication is completed. This can facilitate confirming that the data communication is completed.
[0019] When the cyclocomputer is provided with the function to indicate that the data communication is completed, the function can be implemented for example by flashing the display of the cyclocomputer, operating a piezoelectric buzzer, a vibration function and/or the like incorporated in the cyclocomputer, and/or the like. The cyclocomputer provided with the above function allows the user to be informed that the communication is completed while the user holds the bicycle by one hand and operates the mobile wireless communication device by the other hand.
[0020] When the mobile wireless communication terminal is provided with the function to indicate that the data communication is completed, the function can be implemented for example by flashing a display of the mobile wireless communication terminal, operating any of a vibration function, a flash function and a speaker function incorporated in the mobile wireless communication terminal, and/or the like.
[0021] In one embodiment, the cyclocomputer establishes the data communication to transmit information including at least one of a circumferential length of a tire of a bicycle, a cumulative travelled distance, a cumulative travelling time, a current time, an average speed, a maximum speed, a cadence, and GPS information.
[0022] โGPS informationโ as referred to herein includes information regarding satellite orbits (almanac data), and information regarding a locus of movement. For example, transmitting almanac data from the mobile wireless communication terminal to the cyclocomputer immediately after the cyclocomputer is powered on allows the cyclocomputer to rapidly determine a current position. Furthermore, transmitting to the mobile wireless communication terminal a locus of movement that is accumulated in the cyclocomputer having a GPS function incorporated therein allows the mobile wireless communication terminal to be used to visually observe the locus of movement.
[0023] In one embodiment, the cyclocomputer includes the display to be capable of implementing a first display state to display first information, and a second display state to display second information, and pushing the body downward to tilt the body allows one of the first and second display states to be switched to the other of the first and second display states.
[0024] This allows a display of a limited size to display more information and thus the cyclocomputer to be miniaturized. Furthermore, tilting the body allows a display state to be switched to another, and the cyclocomputer is thus not required to have the body with an upper surface provided with a switch button, and can thus further be miniaturized.
[0025] In another aspect, the present cyclocomputer includes: a body; a display provided on an upper surface of the body and displaying prescribed information; a storage provided in the body and storing therein data including at least a portion of the prescribed information; and an NFC tag provided in the body and allowing data communication with an NFC reader writer of a mobile wireless communication terminal.
[0026] 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
[0027] FIG. 1 shows a bicycle to which a cyclocomputer according to one embodiment of the present invention is attached.
[0028] FIG. 2 shows a sensor device, which is attached to the bicycle together with the cyclocomputer shown in FIG. 1 , secured to a chain stay of the bicycle.
[0029] FIG. 3 shows the cyclocomputer being attached to a fixture for securing the cyclocomputer to the bicycle.
[0030] FIG. 4 shows the cyclocomputer completely attached to the fixture.
[0031] FIG. 5 shows the cyclocomputer secured to the bicycle.
[0032] FIG. 6 is a functional block diagram of the cyclocomputer when it performs data communication.
[0033] FIG. 7 is a functional block diagram of a mobile wireless communication terminal when it performs data communication.
[0034] FIG. 8 shows the cyclocomputer and the mobile wireless communication terminal communicating data therebetween.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Hereinafter, the present invention will be described in embodiment. Note that identical or corresponding components are identically denoted and may not be described repeatedly.
[0036] In describing the following embodiments when a number, an amount and the like are referred to, the present invention is not necessarily limited thereto in scope unless otherwise specified. Furthermore, in the following embodiments, each component is not necessarily essential to the present invention unless otherwise specified.
[0037] FIG. 1 shows a bicycle to which a cyclocomputer according to the present embodiment is attached.
[0038] With reference to FIG. 1 , a bicycle 1 includes a front wheel 2 and a rear wheel 3 , a chain wheel and crank 4 rotating with a pedal, and a chain stay 5 . Bicycle 1 has a cyclocomputer 100 attached thereto.
[0039] FIG. 2 shows a sensor device, which is attached to the bicycle together with a display device shown in FIG. 1 , secured to the chain stay of the bicycle. With reference to FIG. 2 , a sensor device 200 includes a speed sensor 210 and a cadence sensor 220 . Rear wheel 3 has a spoke with a magnet 3 A attached thereto and chain wheel and crank 4 has a magnet 4 A attached thereto. Speed sensor 210 senses passage of magnet 3 A, and cadence sensor 220 senses passage of magnet 4 A. At what speed bicycle 1 travels and at what pace it is pedaled are thus sensed. More specifically, as magnet 3 A passes, rear wheel 3 โฒs rotation period T (sec) is detected and bicycle 1 's travelling speed V (m/sec) is calculated from rotation period T and rear wheel 3 's circumferential length L (m) as V=L/T.
[0040] When sensor device 200 is attached to bicycle 1 , speed sensor 210 is pivoted in a direction indicated by an arrow DR 210 , and cadence sensor 220 is pivoted in a direction indicated by an arrow DR 220 . This can adjust a spacing between speed sensor 210 and magnet 3 A and that between cadence sensor 220 and magnet 4 A.
[0041] Appropriately adjusting the spacings allows speed sensor 210 to sense passage of magnet 3 A appropriately, and cadence sensor 220 to sense passage of magnet 4 A appropriately.
[0042] FIG. 3 shows cyclocomputer 100 being attached to a fixture 300 for securing cyclocomputer 100 to the bicycle. Furthermore, FIG. 4 shows cyclocomputer 100 completely attached to fixture 300 .
[0043] With reference to FIG. 3 and FIG. 4 , cyclocomputer 100 is attached to bicycle 1 via fixture 300 . Cyclocomputer 100 includes a body 110 and a display 120 . Fixture 300 includes a fixture body 310 , a band 320 , an engagement portion 330 , and a rotary operation unit 340 . The cyclocomputer 100 body 110 is slid in a direction indicated by an arrow shown in FIG. 3 , to detachably engage an engagement portion 110 A of body 110 with engagement portion 330 of fixture 300 to attach cyclocomputer 100 to fixture 300 .
[0044] Cyclocomputer 100 causes display 120 to for example display a cumulative travelled distance, a cumulative travelling time, a current time, a current speed, an average speed, a maximum speed, a cadence, GPS information, and other similar information. These pieces of information may or may not be displayed on display 120 all at once. When a plurality of pieces of information are not displayed all at once, display 120 implements a โfirst display stateโ to display a portion of the plurality of pieces of information, and a โsecond display stateโ to display other information. Note that the present invention is not limited to two display states and can implement any plurality of display states.
[0045] Note that as shown in FIG. 3 and FIG. 4 , fixture 300 is a worm gear type-fixture having rotary operation unit 340 . In other words, rotary operation unit 340 can be rotated to tighten/loose band 320 .
[0046] FIG. 5 shows cyclocomputer 100 secured to the bicycle via fixture 300 . As shown in FIG. 5 , fixture 300 has band 320 wound on and thus clamping a bar 400 of the bicycle to attach the display device to the bar.
[0047] Note that while the FIG. 5 example shows cyclocomputer 100 attached to bar 400 extending along bicycle 1 (e.g., a stem), cyclocomputer 100 may be attached to a bar extending across the bicycle (e.g., a handle bar).
[0048] Cyclocomputer 100 has body 110 supported on fixture 300 such that body 110 can be tilted in directions DR 1 and DR 2 . When switching an indication to another on the display of cyclocomputer 100 , body 110 is pressed downward and thus tilted in direction DR 1 . This allows a switch button (not shown) that is provided at a lower surface of body 110 to be pressed by fixture 300 into body 110 to activate a switch to switch a display state to another. When the user removes his/her hand from body 110 , body 110 tilts back in direction DR 2 to its initial state.
[0049] When a rider purchases a new cyclocomputer, it is necessary to input prescribed data such as a circumferential length of a tire of a bicycle, a cumulative travelled distance, a current time and the like to that new cyclocomputer (i.e., initialize the cyclocomputer). Furthermore, if the rider rides different bicycles for different purposes, it is necessary to re-initialize the cyclocomputer whenever the rider rides a different bicycle. With a tire's circumferential length referred to to calculate speed and travelled distance, if the rider rides bicycles having tires with different circumferential lengths, in particular, failing to re-initialize the cyclocomputer will result in the cyclocomputer displaying an erroneous indication. On the other hand, cyclocomputer 100 is also required to be simplified in structure and reduced in size, which necessitates cyclocomputer 100 to have a simplified operation unit for entering information. The simplified operation unit is poor in operability for initialization.
[0050] Accordingly, the present embodiment provides cyclocomputer 100 to be capable of communicating data with a smart phone to communicate information therewith to allow the smart phone's operation unit to be utilized to initialize cyclocomputer 100 . Furthermore, a smart phone can be carried by a rider when the rider leaves for a bicycle tour, and information (time information, positional information, and the like) obtained via the smart phone during the tour can also be transmitted to cyclocomputer 100 . Furthermore, the information can also be shared by a plurality of cyclocomputers 100 via the smart phone.
[0051] FIG. 6 and FIG. 7 are functional block diagrams of cyclocomputer 100 and a smart phone (or mobile wireless communication terminal) 500 , respectively, performing data communication.
[0052] As shown in FIG. 6 , cyclocomputer 100 includes body 110 and display 120 , and in addition, a storage 130 internal to body 110 , a wireless communication unit 140 (a radio frequency, wireless circuit unit 140 A, and an analog front end, analog-to-digital/digital-to-analog conversion processing unit 140 B), and a control unit 150 that controls display 120 , storage 130 , and wireless communication unit 140 operatively. Storage 130 stores data displayed on display 120 . Wireless communication unit 140 is a component that performs data communication with speed sensor 210 and cadence sensor 220 . NFC tag 160 communicates data that is stored in storage 130 with an NFC reader writer 540 in accordance with a specification of NFC communication.
[0053] As shown in FIG. 7 , smart phone 500 includes an operation unit 510 operated by a user to input prescribed operation information, and a display 520 that displays prescribed information. For example, a touch-sensitive liquid crystal display may serve as both operation unit 510 and display 520 .
[0054] Storage 530 is a component that stores prescribed information, and NFC reader writer 540 is a component that performs data communication with NFC tag 160 of cyclocomputer 100 . Wireless communication unit 560 is a component that establishes physical connection with a mobile phone communication network or a WiFi communication network. Control unit 550 operates in response to how operation unit 510 is operated and the like to control display 520 , storage 530 , and wireless communication unit 560 operatively.
[0055] NFC tag 160 of cyclocomputer 100 receives from smart phone 500 via NFC reader writer 540 data that is stored in smart phone 500 at storage 530 or input to smart phone 500 via operation unit 510 . The received data is transmitted to storage 130 .
[0056] FIG. 8 shows cyclocomputer 100 and smart phone 500 communicating data therebetween. As shown in FIG. 8 , smart phone 500 is held still near cyclocomputer 100 for a period of time (for example of about 0.5 second) to perform designated, desired wireless data communication. Once the data communication has been completed, cyclocomputer 100 and/or smart phone 500 inform/informs the user accordingly. For example, displays 120 , 520 may be flashed or turned on or a flash function, a vibration function, and/or the like may be used.
[0057] Note that the above wireless data communication's contents, e.g., a tire's circumferential length, a current time, a cumulative traveled distance, and the like, are designated on smart phone 500 . In order to do this operation, it is necessary to previously install dedicated application software in smart phone 500 .
[0058] Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the scope of the present invention being interpreted by the terms of the appended claims.
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A cyclocomputer includes: a body; a display provided on an upper surface of the body and displaying prescribed information; a storage provided in the body and storing therein data including at least a portion of the prescribed information; and an NFC tag provided in the body and allowing data communication with an NFC reader writer incorporated in a mobile wireless communication terminal. The cyclocomputer can transmit via the NFC tag to the mobile wireless communication terminal at least a portion of the data stored in the storage, and the cyclocomputer can receive from the mobile wireless communication terminal via the NFC tag at least a portion of other data stored in the mobile wireless communication terminal or input to the mobile wireless communication terminal via an operation unit of the mobile wireless communication terminal.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates to the production of optical components and preferably to the production of optical components that comprise a movable micromechanical device with a light shaping unit.
DESCRIPTION OF RELATED ART
In the production of optical components and preferably components comprising micromechanical positioning devices it is known to use a lens in such an arrangement, see for example U.S. Pat. No. 5,734,490 and U.S. Pat. No. 5,923,480.
In U.S. Pat. No. 5,734,490 it is also described how the production of a lens and micromechanics can be achieved. Here the micromechanical structure comprises arms that are connected to a lens from the side. The lens is formed first followed by the forming of the mechanical structure. This is possible since the arms stretch out on the side of the lens. The lens is here formed from the same transparent material as the arms.
In U.S. Pat. No. 5,923,480 an example is provided on how to produce a lens and structure. Here the forming of a part of the micromechanical structure in the form of arms holding the lens is taking place together with the forming of the lens, followed by the forming of the rest of the micromechanical structure. Also here, the arms and lens are formed from the same material. In this document it is furthermore hard to vary the lens structure, which is in the form of a cylinder. In order to provide a light passage channel below the lens, it is also required that this is formed when the material that is to become the lens and arms is deposed on a substrate.
U.S. Pat. No. 6,074,888 and U.S. Pat. No. 5,097,354 describe lenses that are used in optical systems, but without being arranged as a compact component also including micromechanics.
U.S. Pat. No. 6,054,335 describes a movable laser in a component that can also include a lens. The lens is however presumably placed on the structure after the forming of the other parts of the structure.
SUMMARY OF THE INVENTION
The present invention is directed towards solving the problem of providing a way to produce a movable structure for a light shaping unit that enables simplified production of the light shaping unit on a micromechanical compared with the prior art.
This is achieved through a method of producing a compact movable structure for a light shaping unit comprising the steps of: forming a light shaping unit from a material provided on a carrier of another material, and forming a micromechanical structure from the carrier, whereby the forming of the light shaping unit is performed before the forming of the micromechanical structure.
Through the production method according to the invention compatibility demands between micromechanics and light shaping unit that are otherwise hard to meet are simplified. Through the method according to the invention later assembly of the light shaping unit is also avoided, which can be an expensive processing step.
Because the light shaping units are, according to one embodiment of the present invention, produced through embossing, these can be produced using mass production, which lowers the cost of the structure.
The general idea of the invention is thus based on the fact that in the production of a movable structure for a light shaping unit, a light shaping unit is first formed on a substrate and only thereafter the micromechanics is formed.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will in the following be described with reference being made to the accompanying drawings, where
FIG. 1 schematically shows a perspective view of an optical component having a first type of micromechanical construction,
FIG. 2 shows a top view of a second type of micromechanical construction,
FIG. 3 schematically shows a sectional view of a complete component,
FIG. 4-13 show sectional views on different production steps in the production of a component according to the invention,
FIG. 14 schematically shows the embossing of a lens,
FIG. 15 shows the embossed lens on a substrate, and
FIG. 16 shows a flow chart of different production steps in the method according to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
The present invention relates to the production of a movable light forming unit in the form of a lens and then preferably of a lens with a corresponding micromechanical structure that moves the lens such that light from an optical component that is connected to the movable lens can be deflected.
FIG. 1 schematically shows a circuit 10 produced according to the invention in a perspective view. An optical component in the form of a laser, optical detector or optical fibre (not shown) is provided in a wafer 26 , on which wafer a micromechanical device is provided comprising a rectangular intermediate plate 14 and two opposed side plates 22 . A lens 12 is provided on the intermediate plate. The intermediate plate is equipped with teeth 18 that mate with cavities between corresponding teeth 16 on the two side plates 22 . The side plates 22 each comprise a contact 20 that is used for controlling the micromechanical device. The intermediate plate 14 is suspended by two opposite supporting points 29 via two elastic arms 28 , which supporting points and arms also form part of the micromechanical structure. The teeth 18 are disposed on two opposing sides of the rectangular intermediate plate, while the elastic arms 28 are disposed on the two remaining opposite sides of the intermediate plate 14 . In the figure the arms have a straight structure.
FIG. 2 shows a top view of a preferred embodiment of the micromechanical structure. The difference from FIG. 1 is that each side of the intermediate plate 14 that has arms 28 , has arms with a folded zigzag structure in order to simplify resilience when moving the intermediate plate 14 . In a corresponding manner each arm is provided with a corresponding support point. The construction according to FIG. 2 thus has four supporting points 29 .
FIG. 3 schematically shows a sectional view of the device according to FIG. 1 or 2 . Here the wafer 26 is shown, which includes a semiconductor laser 24 . The micromechanical device is placed with the two side plates 22 and the intermediate plate 14 above the laser. The lens 12 is placed on the intermediate plate 14 , which plate is provided with a cavity or light passage channel between lens and laser, in order to allow light to be sent from the laser and focussed by the lens 12 . In operation the intermediate plate can be made to move in a horizontal direction because of electrical voltages that have been applied on the contacts 20 and because of the elasticity of the arms shown in FIGS. 1 and 2 . In this way the lens can ensure that the laser beam is deflected or scanned in different directions. This can be performed either in the right direction or in the left direction in dependence of how the intermediate plate 14 is moved. The component according to the invention can therefore be used in a multitude of ways, of which some will be mentioned later.
How the device is produced according to a preferred method will now be described with reference being made to FIG. 4-13 that show sectional views of different substrates and layers in the production of the micromechanics and lens.
First a layer of lens material 30 with a thickness of about 3-5 ฮผm is applied on a carrier or a substrate. The carrier comprises a first silicon layer 32 of thickness 10 ฮผm. Under the first silicon layer 32 there is a layer 34 of silica with a thickness of about 1-2 ฮผm. Under the silica 34 there is a second silicon layer 36 of thickness 500 ฮผm. Under the second silicon layer there is a layer of backside oxide 38 . The lens material 30 is preferably in the form of a polymer and in the preferred embodiment CYTOP. An alternative to CYTOP is Parylene. A preferred way to apply the lens material is through spin coating, although other ways are of course also possible, such as for example chemical deposition or spray coating. The carrier with lens material 30 is shown in FIG. 4 .
Thereafter the lens is formed in the lens material 30 , which is preferably done through embossing. In the embossing, the lens material is heated to about 80-110 degrees centigrade and then the lens is embossed using a stamp. The lens can for instance have a diffractive structure, although also other types of lens structures are possible such as pure convex or pure concave lenses.
Thereafter a photo resist is applied over the lens material, for instance AZ-4562. The photo resist is printed through photolithography, i.e. it is illuminated. After development of the photo resist, resist in the form of a mask remains only above the areas that are to remain, i.e. the lens itself. Hereafter etching of the lens material follows using an O 2 -plasma in order to remove superfluous lens material. After the etching the mask is removed, for instance using acetone. The finished lens 12 is left on the carrier, which is shown in FIG. 5 . What has been described here is thus normal photolithography.
After the lens has been finalised, the method of production continues with metallization of contacts. Metal is applied in the form of gold/chromium or alternatively aluminium over the whole wafer, for instance through a vaporisationโor sputtering process. Metal contacts are thereafter created using a photolithography process, i.e. through putting a mask on the areas that are to remain (positive resist). The superfluous metal is then etched away using a suitable metal etch. FIG. 6 shows the contacts 20 provided in this way together with the lens 12 on the carrier with the two silicon layers 32 and 36 as well as oxide layers 34 and 38 .
Thereafter an opening is formed through the backside of the carrier using photolithography and etching, i.e. through providing a mask on the outer parts of the backside oxide 38 and then etching away oxide in the middle. The mask is removed after the etching. The structure after the etching is shown in FIG. 7 .
Thereafter it is time to form the mechanical pattern in the form of the finger structure and the resilient legs that appear in FIGS. 1 and/or 2 . The micromechanical structure is thus formed now, but without releasing the intermediate plate. It can thus not yet be moved after this step. This is performed through applying a resist 40 on the top of the carrier on the parts 20 , 12 where material is not to be removed. The resist is then placed where the mechanical pattern is to be obtained. This is shown in FIG. 8 .
After such a mask has been formed, the non-covered silicon material is etched away using plasma etching. As is apparent from FIG. 9 a large part of the silicon layer 32 above the oxide layer 34 has been etched away. In this way the structure shown in FIGS. 1 and/or 2 has been obtained with the intermediate plate 14 and elastic arms 28 that connect the intermediate plate 14 with the side plates 22 . After this the resist is stripped away in a known way.
Hereafter a temporary protective layer is mounted on the topside of the structure. First a resist layer 42 and then a silicon layer 44 . This is in the preferred embodiment performed through โgluingโ a wafer comprising silicon layer 44 and resist layer 42 on the lens and micromechanics. By this operation the lens 12 and contacts 20 are fixed with the aid of the resist layer 42 . After this follows etching from below in order to create a cavity under the inner oxide layer 34 . In this etching, the lower oxide layer 34 functions as a mask. Thereafter a resist 43 is applied through spraying, for instance maP-215s with ethyl acetate, on the bottom side with the exception of an area straight under the lens, in order to allow the creation of a passage for a laser beam. The structure with this resist layer is shown in FIG. 10 .
Thereafter the cavity up to the lens 10 is created, first through oxide etching through the oxide layer 34 followed by silicon etching through the intermediate plate 14 . The etching is normally performed in such a way that the whole structure is dipped in an oxide etch. After this etching the resist layer 43 is stripped away. The result of this is shown in FIG. 11 . A light passage channel has thereby been created through the micromechanical structure up to the lens and that can be used by a later provided optical component. The lens has here functioned as an etch stop, thus making extra stop layers unnecessary.
Thereafter follows an oxide etching from below so that the lowest oxide layer 38 is removed and non-covered parts of the in-built oxide layer 34 are removed. The result is shown in FIG. 12 .
Finally the resist layer 22 is removed through dipping the construction in acetone. The uppermost silicon layer 44 is then provided in the form of a wafer, which can be lifted off. The result is shown in FIG. 13 , which thus shows the final micromechanical structure with the lens.
The structure is rinsed in water, dipped in IPA (Isopropanole alcohol) and dried. Thereafter the obtained structure is mounted on an optical component, which is substrate 26 comprising a laser 24 , optical detector or an optical fibre, depending on which type of device that is needed, see FIG. 3 , and the structure is bonded.
A more detailed description of the embossing process will now be given with reference being made to FIG. 14 , which schematically shows two hot plates 50 a and 50 b , between which a silicon wafer 50 or carrier, on top of which a polymer film has been spun, and a nickel mould 54 facing the lens material have been placed. This carrier corresponds to the carrier shown in FIG. 4 . The nickel mould 54 is formed as a plate with a cavity corresponding to the lens structure the resulting lens is to have. The embossing process is carried out in such a way that first the nickel mould 54 is inserted between the two hot plates 50 a and 50 b and thereafter the silicon wafer 52 with the lens material 30 is directly inserted against the mould 54 between the two hot plates 50 a and 50 b with the lens material facing the mould 54 . Thereafter pressure is applied against the two hot plates 50 a and 50 b , which gives as a result that the wafer 52 with lens material 30 is pressed against the mould 54 . The temperature of the hot plates 50 a and 50 b is increased, which gives as a result that the lens material is starting to soften and adapt to the mould 54 , i.e. is pressed into the cavity of the mould 54 . Thereafter the temperature is decreased and the pressure is lowered such that the silicon wafer 52 with polymer material 30 can be removed from the mould 54 . In this way the lens material receives the inverted curvature of the mould, which curvature is shown in FIG. 15 .
The final device can be a laser source where a laser beam generated by the laser is scanned, an optical detector that receives a laser beam or an optical fibre that transmits a laser beam generated by a laser all depending on the application.
The device according to the invention has many applications. It can be used for scanning a laser beam, which can be useful when detecting fluorescence in DNA or cell analysis. The invention can also be used when testing retinas in a hand-held ophthalmoscope. Another field of use is to have one ore more such devices in an optical exchange.
Finally the method of production will be schematically described with reference being made to FIG. 16 , which shows a flow chart of the method of production.
First the lens material in the form of a polymer is spun on a carrier or a substrate, step 56 . Thereafter the lens is embossed in the lens material and superfluous lens material is removed, step 58 . The micromechanical structure is thereafter formed in the substrate or carrier from the topside of the structure, i.e., from the side the lens is placed on, step 60 . This is followed by the forming of a light passage channel through the structure or substrate from the underside, i.e. up to the lens, step 62 . When the light passage channel is finished the intermediate plate is released such that it can be moved, step 64 . Finally the lens and the micromechanical structure is mounted on an optical component and bonded, step 66 .
It is apparent that several alternative ways of proving the micromechanical structure are possible than what has been described. There are also several alternative ways to apply the lens material than through spin coating. Metal contacts can for example be provided afterwards when the micromechanical structure has already been formed. The light passage channel can also as an alternative be created through wet etching instead of plasma etching.
The lens material and micromechanical structure are suitable selected according to the wavelength area that the optical component to be employed uses. The used lens material is preferably a polymer.
Above was described the movement of the lens in one dimension between a left and a right position through the micromechanical structure. It is also possible to provide the micromechanical structure in such a way that the lens can be moved in two dimensions through the provision of further teeth and cavities on the other sides of the intermediate plate.
The embossing process can also be varied. The mould does for instance not have to be a nickel mould, but also other metals can be used. The order in which mould and substrate are inserted between the hot plates can also be varied. They can also be inserted simultaneously.
Through the production method according to the invention, where the forming of the light shaping unit in a material takes place before the forming of the micromechanical structure in another material, it is possible to form a light shaping unit with an underlying micromechanical structure in a simple way and that does not have any difficult compatibility requirements between forming of micromechanics and forming of light shaping unit. Expensive later mounting of individual elements in the light shaping unit is also avoided.
Through using different materials for the light shaping unit and micromechanics these can be optimised for best performance considering the optical properties and robustness/reliability of the mechanics.
The material for the light shaping unit is preferably a polymer and then preferably CYTOP, which makes it possible to mass produce the light shaping units through embossing, a very cost-efficient technique.
The light shaping unit is in the preferred embodiment a lens. However, other types of units are also possible like gratings, diffractive optical components, Fresnel lenses, phase holograms or kinoforms.
The light passage channel is in the described embodiment provided as a cavity where light can pass freely. It can however as an alternative be provided in the form of a waveguide.
The micromechanical structure is preferably formed from silicon because of its low cost. Other materials can however of course also be contemplated.
The present invention is only to be limited by the following claims.
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The invention relates to a method of producing a movable lens structure that comprises the steps of: forming a lens from a lens material disposed on a carrier of another material (step 58 ), and forming a micromechanical structure from the carrier (step 60 ), wherein the forming of the lens takes place before the forming of the micromechanical structure. With this method a simplified production method is obtained that simplifies difficult compatibility requirements between micromechanics and lens that can otherwise be hard to meet.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention is directed to a physiologically ingestible composition comprising microstructured water consisting essentially of hydrogen and oxygen atoms and having a melting point lower than double distilled water, and uses thereof.
[0003] 2. Background of the Related Art
[0004] Water supplies are becoming polluted at an alarming rate and the aquifers that haven't been contaminated are now under duress. Pristine aquifers are disappearing as demand for good, clean, drinkable water increases. Water has been taken for granted for the last seventy five years, and because so-called clean potable water has been so easily and readily available from our kitchen tap, the importance of water and water conservation has been lost to the masses. Several of our larger cities and many smaller ones cannot pass clean water tests. More and more chemicals are added to municipal water supplies to enable these water supplies to pass โsafeโ levels for consumption. Adequate chemical levels are consistently being increased to accommodate the higher chemical levels found in municipal water supplies. Mining, farming, and industrial wastes have formed an intricate overlap of contaminants that in most cases cannot be cleaned out of water supplies sufficiently enough to make the water safe to bathe in, much less drink.
[0005] Water treatment facilities inadvertently add pollutants to their water at the same time it is being โpurifiedโ. Chlorine reacts with organic substances in the water to form trihalomethanes (THM's), a known group of carcinogens. In 1975, an EPA survey of eighty cities' water supplies was the first official alarm that there was a definite and serious problem. One particular THM, chloroform, was found in all the samples tested, with three other THM's found in most of the samples tested. In 1980, a study showed that cancer rates were extremely higher in cities that chlorinated their municipal water supplies. This was again attributed to the influence of โTHM's. People who drank chlorinated water were found to have 53% greater chance of contracting colon cancer and up to 93% greater chance of contracting rectal cancer. These figures are according to a report by the Presidents Council on Environmental Quality. Also noted as a common additive to water and in the same report, fluoride was reported to cause bone and kidney damage when found in quantities that were considered to be much more than adequate.
[0006] This is just the tip of the iceberg regarding clean water. In addition, a variety of contaminants can enter municipal water supplies as the water travels from the treatment plant to the kitchen tap. Many water supply systems are well over one hundred years old and are full of holes. As water mains deteriorate, asbestos, lead, and many other toxic metals and substances are released into the water. Inhibitors added to the water to slow down deterioration of the pipes are sometimes themselves toxic. Estimates indicate that there are more than 400,000 miles of asbestos-cement/clay pipe still being used everyday in the U.S.A. alone. An estimated 65 million people drink out of these water systems daily. A 1979 official test survey by the EPA found twenty percent of the cities examined had more than one million asbestos fibers per liter of water, with eleven percent of the cities having more than ten million fibers per liter of water. Studies in California and Canada link the ingestion of asbestos with an increased risk of cancer in the abdominal tract leading one to deduce that much colon cancer could be reduced and/or prevented by simply reducing or, even better, eliminating the amount of water borne asbestos from municipal pipes.
[0007] The human body is composed of from 70% to 80% water and requires a minimum of two quarts of water per day. Two quarts is what one uses up per day through urination, defecation, evaporation through the skin, and overall dehydration. This is the loss of water from an inactive individual. An athlete uses at least twice this amount or roughly at least four quarts per day. Depending on which informational research source is used, one researcher estimates that 75% of Americans are dehydrated and that 37% mistake thirst for hunger. A mere 2 percent drop in body water can trigger fatigue and mental dysfunction.
[0008] Steven Kay of the International Bottled Water Association said, โFor this and other reasons, bottled water sales in the United States increased from 3.1 billion in 1995 to 4.6 billion in 1999.โ In 2000, water sales topped 5.4 billion. The sweetheart of water sales from 2000 to 2001 was oxygenated water, which increased in sales by 45 percent. This culminated in over 100 million bottles being sold by the end of 2001. This unique niche of bottled water, with recent increased advertising and customer education on research regarding oxygenated waters' benefits to the body, may leave expectations of sales in the dust and push actual sales beyond anyone' wildest dreams. Coupled with humankinds' creation of urban deserts in many of today' cities, all water and beverage sales are poised to skyrocket.
[0009] With over 70,000 chemicals, all created by man and in use daily, and with an estimated 1000 new chemicals being developed each year, it is obvious why we are living in a chemical bath of our own creation. A recent study by the Clean Water Network reported that one-third of our rivers, one-half of our estuaries, and more than one-half of our lakes are not fit for fishing and swimming-forget the idea of drinking the water.
[0010] According to the Center for Disease Control, every year an estimated 120 million Americans drink tap water contaminated with waterborne diseases and known cancer causing chemicals. After undertaking one of the most comprehensive water research studies ever conducted, the Natural Resources Defense Council in 1993, found that each year more than 900,000 people in the U.S. became ill. As many as 900 of these people actually die from these waterborne diseases. The United States Environmental Protection Agency (EPA) lists over 700 toxic chemicals that can be found in our nations' tap waters. Beginning in 1976, the EPA has monitored the amount of toxins in the fat tissue of Americans; on a consistent basis, thirteen very highly toxic compounds are found in 100 percent of all the people analyzed. The EPA continues to conduct this analysis every year.
[0011] The EPA and several other governmental agencies state that they only permit chemical levels that are considered โsafeโ in our public water supplies. It is interesting that at every urban EPA office there is always bottled water available for drinking. The fact that our government cannot adequately protect everyone who drinks publicly supplied water is one of the main reasons that bottled water and in-home water filters have become such a huge booming business.
[0012] Over the next twenty years, the Water Infrastructure Network has estimated that $490 billion dollars will be necessary to repair and maintain public drinking water systems throughout the United States. What most Americans and people in general do not know about is the disaster that has already begun in our oldest cities. The clay pipes, many laced with asbestos to hold the clay together, have eroded to the degree that dirt and contaminants are entering into the water system. The asbestos has been tested at 70 parts per million in one liter of water in several locations. It is obvious why the bottled water business made over 7 billion dollars last year by the peoples' effort to avert drinking water problems, some not even discussed herein.
[0013] Oxygen, the most vital element of life itself, is also the key to good health. We can live without water for weeks and go without food for months, but we can survive for only minutes without oxygen. Oxygen is the life-giving, life sustaining element. Approximately 90% of the body's energy is created by oxygen. All of the activities of the body, from brain function to elimination, are regulated by oxygen. Our ability to think, feel and act comes from the energy created by oxygen. The best way to optimize health is to be sure that we oxygenate every cell in our body. The more oxygen we have in our system, the more energy we produce. This is more important today than ever before, because of a general deficiency of oxygen intake directly related to the overall lack of exercise for the average person.
[0014] One of the many reasons for a lack of oxygen is our polluted atmosphere. Other reasons for oxygen depletion in the body include: planetary deforestation; devitalized soil; processed foods and poor diet; a clogged colon; automobile emissions; vitamin and mineral deficiencies; lack of exercise; chlorinated water; bacterial and fungal infections in the body; chemical pollutants; stress; poor posture and breathing habits; and electronic smog.
[0015] There is less oxygen today (on an average) in our bodies' systems to enable production of vital metabolic energy than ever recorded. It is extremely important that we increase our intake of oxygen if we are going to function on a level that gives our brain and body a chance to operate at peak levels.
[0016] The power of added oxygen in water was first evidenced over twenty years ago when European athletes dominated the world sports arena with the Soviet Union clearly leading the pack. Chilled water with oxygen added under pressure enabled the Soviet athletes to increase the oxygen level in their bloodstream and lower pulse rates by as much as 2 to 15 beats per minute. In addition, these athletes increased overall energy levels, biological performance, and stamina. When oxygen content is low in the body, the body becomes tired, weaker, and endurance is compromised. The Soviets outperformed the American athletes and we did not know how this was achieved at the time. It took several years for us to catch up to what the Soviets knew in the early 1970's. Knowledge of oxygenation and water structure are the keys to understanding water's biological behavior.
[0017] Blood plasma holds approximately three percent dissolved oxygen and red blood cells (hemoglobin) hold ninety seven percent. From the red blood cells the oxygen passes out into the plasma and is transferred to cells that need oxygen during metabolic processes. These cells pass CO 2 back to the plasma where it is then picked up by the red blood cells. Free oxygen in the blood then becomes the purging agent to clean and purify the blood. However, there must be enough free oxygen in the blood to enable this process. Many times, there is too much environmental pollution to allow for this excess free oxygen in the blood, and this is where OSIRIS water/liquid has a tremendous place in the market of oxygenated water (virtually including almost every person in the world).
SUMMARY OF THE INVENTION
[0018] An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
[0019] To adequately and sufficiently oxygenate and structure water insofar that when consumed, whether by internal or external absorption, there is a distinct and definite increase in hydration, oxygenation and healthy metabolic changes regarding organic life processes.
[0020] In various embodiments, a physiologically ingestible composition comprising microstructured water consisting essentially of hydrogen and oxygen atoms and having a melting point lower than double distilled water is used. The composition may further include dissolved oxygen, and the dissolved oxygen may be present in an amount of 20 ppm to 150 ppm.
[0021] In a first embodiment, the physiologically ingestible composition is administered to a mammal to inhibit the changes in the heart rate of a mammal undergoing stress.
[0022] In a second embodiment, the physiologically ingestible composition is administered to a human or a horse.
[0023] In a third embodiment, the physiologically ingestible composition is administered at an amount that is at least approximately 500 ml.
[0024] In a fourth embodiment, the administered physiologically ingestible composition can cause a reduction of at least 10%.
[0025] In the fifth embodiment, administering of the physiologically ingestible composition occurs by at least one of oral, topical, parenteral, and/or any combination thereof.
[0026] In the sixth embodiment, the administering of the physiologically ingestible composition occurs at least one of before, during, after, or any combination thereof a physical activity.
[0027] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
[0029] FIG. 1A is a block diagram of a system for making and tuning super-oxygenated and structured water, in accordance with an embodiment of the invention;
[0030] FIGS. 1B-1C are flow charts of methods for making super-oxygenated and structured water, in accordance with an embodiment of the invention;
[0031] FIG. 1D is a flow chart of a method for tuning super-oxygenated and structured water, in accordance with an embodiment of the invention;
[0032] FIG. 2A is a block diagram of a system for preparing water with a stable negative ORP, in accordance with an embodiment of the invention;
[0033] FIG. 2B is a flow chart of a method for preparing water with a stable negative ORP, in accordance with an embodiment of the invention;
[0034] FIG. 2C is a block diagram of a water preconditioning system, in accordance with an embodiment of the invention;
[0035] FIG. 2D is a flow chart of a method for preconditioning water, in accordance with an embodiment of the invention;
[0036] FIG. 3A is a schematic side view of a magnetic structuring stage for a water preconditioning system, in accordance with an embodiment of the invention;
[0037] FIG. 3B is a graph of magnetic field strength versus location for donut rings of a magnetic structuring stage, in accordance with an embodiment of the invention;
[0038] FIG. 4A is a block diagram of an oxygen/water combining system, in accordance with an embodiment of the invention;
[0039] FIG. 4B is a flow chart of an oxygen/water combining method, in accordance with an embodiment of the invention;
[0040] FIG. 5A is a block diagram of a structured oxygen generating machine, in accordance with an embodiment of the invention;
[0041] FIG. 5B is a flow chart of a method for producing structured oxygen, in accordance with an embodiment of the invention;
[0042] FIG. 5C is a perspective/cross sectional view of the oxygen enhancer shown in FIG. 4A , in accordance with an embodiment of the invention;
[0043] FIG. 5D is a front view of a screen shown in FIG. 5C ;
[0044] FIGS. 5E-5G are front and side views of a ring shown in FIG. 5C ;
[0045] FIG. 6A is a schematic side view of a first magnetic structuring stage for a structured oxygen generating machine, in accordance with an embodiment of the invention;
[0046] FIG. 6B is a schematic side view of a second magnetic structuring stage for a structured oxygen generating machine, in accordance with an embodiment of the invention;
[0047] FIG. 7A is a schematic block diagram of a cone system, in accordance with an embodiment of the invention;
[0048] FIG. 7B is a schematic side view of an exemplary cone structure, in accordance with an embodiment of the invention;
[0049] FIG. 7C is a schematic top view of the cone structure of FIG. 7B ;
[0050] FIG. 7D is a flow chart of a method for spinning oxygen using a cone system, in accordance with an embodiment of the invention;
[0051] FIG. 8A is a schematic side view of a coil system, in accordance with an embodiment of the invention;
[0052] FIG. 8B is a schematic top view of the coil system of FIG. 8A ;
[0053] FIG. 8C is a flow chart of a method of using the coil system of FIGS. 8A-8B ;
[0054] FIGS. 9A and 9B are, respectively, schematic top and side views of a multi-coil system, in accordance with an embodiment of the invention;
[0055] FIG. 9C is a schematic side view of the multi-coil system of FIG. 9A ;
[0056] FIGS. 9D and 9E are schematic plan and side views of a pipe entry point into a coil set, according to an embodiment of the invention;
[0057] FIG. 9F is a flow chart of a method of using the multi-coil system of FIGS. 9A-9C ;
[0058] FIG. 10A is a block diagram of a structured ozone machine, in accordance with an embodiment of the invention;
[0059] FIG. 10B is a flow chart of a method structuring ozone, in accordance with an embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0060] The process and apparatus of the present invention are also suitable for use in aerobic processes and other processes such as therapeutic processes advantageously employing oxygen containing liquids.
[0061] As used throughout the specification and the claims, reference to an โaerobicโ process generally includes all chemical and microbiological processes in which such a process is carried out or is promoted in a liquid medium in the presence of oxygen. As used throughout the specification and the claims โtherapeuticโ processes involve the oxygenation of the body or its parts by treatment with an agent in a liquid vehicle containing dissolved oxygen.
[0062] Suitably aerobic processes in which water oxygenated in accordance with the present invention can be employed include, for example, processes in which heretofore water has been aerated such as by bubbling air thereinto, and also in situ or ex situ bioremediation of contaminated (e.g. with petroleum products) surface and ground waters; wastewater, sludge, and animal waste treatment, both by fixed film and by suspended growth methods; rehabilitation of atrophying lakes; biochemical oxygen demand (BOD) measurement techniques; fresh water aquaculture (e.g. fish farming); odor suppression barriers for anaerobic processes; and insolubilization of dissolved contaminants (e.g. Fe., and Mn ions) for removal by filtration or sedimentation.
[0063] In view of the particularly good oxygen retention of liquids oxygenated by the present invention kept in containers, a particularly advantageous new aerobic use of those liquids was discovered. In accordance with a further feature of the present invention, such oxygenated liquids can be advantageously employed as the fermentation liquor of all kinds of fermentation processes, such as drug production or food processing by microorganisms.
[0064] Microorganisms, such as bacteria, consume massive quantities of oxygen in the process of assimilating or breaking down waste. The rate at which oxygen can be introduced into the biomass is a substantial limiting factor on how quickly a breakdown by oxygenation can be achieved. The problem with known process technologies is that oxygen introduction by aeration is highly inefficient because air contains only 21% percent oxygen. Thus, 79% percent of the energy used by aerators is wasted in pumping useless nitrogen. Therefore, the use of highly oxygenated water, in accordance with the present invention, in such aerobic processes is expected to be about 5 times more efficient, also to obtain thereby a like extent of energy efficiency improvement. The dissolved oxygen content of water treated with embodiments of the present invention can be greater than 20 ppm, can be greater than 40 ppm, can be greater than 60 ppm, can be greater than 80 ppm, can be greater than 100, ppm, can be greater than 120 ppm, and can be greater than 140 ppm. Thus, the infusion of water with 40-50 mg/l of oxygen allows for a considerably more efficient and much more rapid aerobic treatment, compared to 7-10 mg/l for the normal oxygen content of water, and just slightly more when a conventional bubbling aerator is used with 20% oxygen containing air. Furthermore, as the equilibrium oxygen content of water is used up, its dissolved oxygen content rapidly decreases.
[0065] Another property of embodiments of the water involves its increased density. The increased density can be described using the term โcluster factorโ, that can be defined by relative density to double distilled water minus 1.0, then multiplied by 100,000. The cluster factor of water treated with embodiments of the present invention can be greater than 150, can be greater than 200, can be greater than 250, can be greater than 300, and can be greater than 350.
[0066] Another property of embodiments of the water involves its pH. The pH of water treated with embodiments of the present invention, as measured by litmus paper, can be between 7.5 and 8.5. The pH of water treated with embodiments of the present invention, as measured by a standard glass electrode pH meter, can be between 9.2 and 9.5.
[0067] Suitable therapeutic processes in which liquids made in accordance with the present invention can be advantageously employed include, for example, increasing the oxygen content of blood and tissues; oxygenation of wounds to increase the rate of healing and to reduce infections; oxygenated organ transplant storage media; tumor oxygenation for radiation therapy and chemotherapy; lung bypass by oxygenated liquids in case of pulmonary deficiencies; carbon monoxide poisoning; mouthwashes; dentifrices; topical, including cosmetic, treatment media; contact lens treating solutions; and cell level therapeutic applications.
[0068] In view of the especially good oxygen retention of liquids oxygenated by the present invention kept in containers, a particularly advantageous new therapeutic product of those liquids was discovered. In accordance with a further feature of the present invention, such oxygenated liquids can be employed as solvents for physiological saline isotonic solutions, especially when kept in sealed, sterile containers.
[0069] In cosmetics and toiletries, the liquids of the present invention may be incorporated into a beauty product in process by addition, mixing, wetting and other methods in the course of production of the beauty product.
[0070] In this case, the state and form of the cosmetics and toiletries are not specifically limited. For example, the liquids of the present invention may be used as is, may be used in a state diluted with double distilled water, alcohol or the like, and may be used in a gel or paste state obtained by adding a thickener, which processing are conducted for improvement on handle-ability, and in other states and forms in use. The water may be mixed into a beauty product in a liquid state as is, or it may be diluted or concentrated prior to the use as desired.
[0071] The state and form as a commodity of a beauty product in the present invention is not specifically limited as far as the beauty product is a beauty product into which a liquid of the present invention is mixed, and a beauty product of the present invention has only to be processed in a similar state and form to those of a known beauty product. Concrete examples thereof in which the liquid can be used include a non-drug product, a skin-care product, a makeup product, a hair care product, fragrance, a body care product, an oral care product and the like.
[0072] Examples thereof further include a face cleansing cream, a toilet lotion, a milky lotion, cream, gel, essence, pack, mask, foundations, lip sticks, cheek rouges, a brow, eye beauty product, manicure enamels, a shaving lotion, a hair washing product, a hair raising agent, a hair makeup product, a perfume, cologne, soap, a liquid body cleaning agent, a sun care product, a hand care product, a bath product, a tooth paste, and an oral cleaning agent.
[0073] The cosmetics and toiletries of the present invention contain a liquid of the present invention mixed therein as a feature, while no specific limitation is placed on other components, and additives currently used in cosmetics and toiletries can be properly mixed in.
[0074] Concrete examples of other components include hydrocarbons, such as squalane, liquid paraffin and the like; animal/vegetable oils, such as olive oil, beef tallow and the like; esters, such as isopropyl myristate, cetyl octate and the like; natural animal/vegetable waxes, such as carnauba wax, beeswax and the like; surfactants, such as glycelyl stearate, and sorbitan stearate; silicone oils, such as dimethylpolysiloxane, methylphenylpolysiloxane and derivative thereof; fluorine containing resins, such as perfluoropolyether and the like; alcohols, such as ethanol, ethylene glycol, glycerin and the like; water-soluble polymers, such as carboxyvinyl polymer, carrageenan, carboxymethyl cellulose sodium and the like; proteins, such as collagen, elastin and the like and hydrolyzates thereof; powders of titanium dioxide, zinc oxide, talk, mica, silicic anhydride, nylon powder, alkyl polyacrlylate, powder of alumina, iron oxide and the like; an ultraviolet absorbent; vitamines; an antiphlogistic agent; amino acids and derivative thereof; lecithin; a colorant; a perfume; an antiseptic agent; an antioxidant and the like.
[0075] The extent of cosmetics and toiletries in the sense of words has been extended because of recent diverse requirements therefor, and cosmetics and toiletries of the present invention are not necessarily strictly restricted in respect of the definition thereof. That is, cosmetics and toiletries of the present invention means cosmetics and toiletries in a general sense into which an activating agent of the present invention is properly mixed. Therefore, cosmetics and toiletries of the present invention include all products by which a liquid of the present invention is taken into the body of an organism in a manner of transdermal or endermic absorption.
[0076] Food additives related to the present invention are characterized by that in which a liquid of the present invention is mixed thereinto and a food additive is added, mixed or incorporated by wetting or similar method into a food or a beverage in the course of production of the food or the beverage for the purpose of processing or preservation of the food or the beverage. A state and a form of a food additive is not specifically restricted to a particular pair and, for example, the water may be used in mixing into a sweetner, a sourness flavoring, a bitterness flavoring, a deliciousness flavoring, an oiliness flavoring and the like at a proper content. The water may also be used in a gel or paste state processed by adding a thickener or the like for improvement on handle-ability, may be used in a liquid state of 100%, or may be used in a dilute or concentrated state as well.
[0077] To be more detailed, a food additive related to the present invention can be to satisfy a person's preference and to prevent modification, or rotting of a food. That is, the food additives may be necessary for production, improvement on quality, preservation of quality and nutrition enhancement, while a state and a form in processing may be similar to those of known food additives. Concrete examples thereof include flavorings, such as a saline solution, salt, a sauce, drips, a soupe, an original broth and the like; a preserving agent; a production auxiliary; a filtering auxiliary; a clarificant; a quality sustaining agent; a sterilizing agent; an antimicrobial agent; a disinfectant and the like.
[0078] Note that in order to further improve a quality of a food additive of the present invention, the inventive water agent is preferably processed into the food additive in a working condition, in which the intermediate is brought into contact to the external air (oxygen) on the lowest possible level or in a low temperature condition. For example, the processing is preferably conducted in a condition in which no activity of mineral components is degraded, such as in a nitrogen atmosphere, at a low temperature or in a freeze drying condition. The food additive as processed is preferably immediately and in a short time packed, so as to be brought into contact with oxygen on the lowest possible level, for example in a vacuum package, in a nitrogen-filled package or in gas-tight package with an antioxidant therein. Such packages are preferably adopted, since the beneficial effects of the inventive water can be sustained over a long term.
[0079] A food related to the present invention is a food in which a liquid or a food additive of the present invention is added as a feature. Since foods can be mixed with a liquid or a food additive under various categories, such as an agricultural food, a livestock food, a fishery food, a fermented food, a canned food, an instant food and the like, according to states and forms of respective food additives described above, no specific limitation is imposed on a kind, and state and form of food related to the present invention. Concrete examples of foods that can be named include breads, noodles, bean curd, a dairy product, a meat processed product, soy source, miso, edible fat and oil, an oil and fat processed product, a fish paste product, sweet stuff, vegetables, pickles and the like. Concrete examples of addition methods and products applied therewith that can be named include: soy source obtained by mixing inventive water into soybean, wheat and seed koji to ferment them and miso obtained by mixing processed inventive water into soybean, rice and barley to ferment them.
[0080] Further examples of foods of the present invention include bean curd obtained by using the inventive water as a brine for coagulation of soybean milk, pickles obtained by using the inventive water as a salty component in a solution, a food added with an inventive liquid or a food additive for retaining freshness and a food immersed in an inventive liquid or a food additive for retaining freshness.
[0081] Still further examples of foods of the present invention include nutritional supplements and the like such as health foods in states and forms including liquid, powder, a tablet, a capsule, in which the inventive liquid or food additive is incorporated.
[0082] A beverage related to the present invention is a beverage in which a water of the present invention and/or a food additive of the present invention is added as a feature. Since, as to a kind, state and form of beverages related to the present invention, a inventive liquid or a food additive can be added to various kinds of beverages according to a kind, state and form thereof, no specific limitation is imposed on a kind, state and form of beverage. Examples thereof that can be named include alcoholic beverages such as brewed sake, synthetic sake, shochu, sweet sake, beer, whisky, liqueur, fruit liquor and the like, and favorite soft beverages or refreshing beverages such as fruit juice, concentrated fruit juice, nectar, soda pop, cola beverage, teas, coffee, black tea and the like.
[0083] Note that in order to further improve a quality of a food and a beverage related to the present invention, the inventive liquid is preferably processed into foods or beverages in a working condition in which the intermediate is brought into contact to the external air (oxygen) on the lowest possible level or in a low temperature condition. For example, the processing is preferably conducted in a condition in which no activity of mineral components is degraded, such as in a nitrogen atmosphere, at a low temperature or in a freeze drying condition. Preferably, the food additive as processed is immediately and in a short time packed so as to be brought into contact with oxygen on the lowest possible level, for example in vacuum package, in nitrogen-filled package or in gas-tight package with an antioxidant therein. Such packages are preferably adopted since the benefits of the inventive liquid can be sustained over a long term.
[0084] The boundaries between a food additive, a food and a beverage in the sense of words have been ambiguous because of recent diverse requirements for foods. For example, since miso, soy source and the like are flavorings (food additives) and foods, sake classified in alcoholic beverages is a food and a beverage, and sweet sake classified in alcoholic beverage is also flavoring (food additive). Therefore, the boundaries in a food additive, a food and a beverage related to the present invention are not necessarily strictly restricted in respect of the definition thereof. That is, food additives, and foods and beverages of the present invention in principle means food compositions in a general sense into which a liquid of the present invention is properly mixed. Accordingly, food compositions of the present invention include all products through which an inventive liquid is taken into the body of an organism in a manner of oral uptake.
[0085] It will be recognized by those skilled in the art that the water/liquids of the present invention can be further modified in any number of ways. For example, following formation of structured water, the water may be oxygenated as described herein, further purified, flavored, distilled, irradiated, or any number of further modifications known in the art and which will become apparent depending on the final use of the water.
[0086] In another embodiment, the present invention provides methods of modulating the cellular performance of a tissue or subject. The inventive water (e.g., oxygenated microcluster water) can be designed as a delivery system to deliver hydration, oxygenation, nutrition, medications and increasing overall cellular performance and exchanging liquids in the cell and removing edema.
[0087] It is also contemplated that the water of the present invention provides beneficial effects upon consumption by a subject. The subject can be any mammal (e.g, equine, bovine, porcine, murine, feline, canine) and is preferably human. The dosage of the water (or oxygenated water) will depend upon many factors recognized in the art, which are commonly modified and adjusted. Such factors include, age, weight, activity, dehydration, body fat, etc. Typically 0.5 liters/day of the water of the invention provide beneficial results. In addition, it is contemplated that the water of the invention may be administered in any number of ways known in the art including, for example, orally, topically, buccally, sublingually, parenterally, intramuscularly or intravenously, either alone or mixed with other agents, compounds and chemicals. It is also contemplated that the water of the invention may be useful to irrigate wounds or at the site of a surgical incision. The water of the invention can have use in the treatment of infections. For example, infections by anaerobic organisms may be beneficially treated with the oxygenated forms of the water. In another embodiment, the water of the invention can be used to lower free radical levels and, thereby, inhibit free radical damage in cells.
[0088] In one embodiment, the water may contain a sweetener (i.e., a compound that imparts a sweet taste but does not increase the blood glucose levels of the patient). Examples include a sugar alcohol and non-nutritive sugars. As used herein, the term sugar alcohol refers to reduced sugars. The preferred sugar alcohol are mono-saccharide alcohols and disaccharide alcohols. The monosaccharide alcohols have the formula HOโCH2 (CHOH)n-CH2OH, wherein n is 2-5. They also include tetritols, pentitols, hexitols and heptitols. Examples of sugar alcohols include erythritol, theritol, ribitol, arabinitol, xylitol, allitol, dulcitol, glucitol, sorbitol, mannitol, altritol, iditol, maltitol, lactitol, isomalt, hydrogenated starch hydrolysate and the like. The sugar alcohols, especially the monosaccharide alcohols, may be utilized as a racemic mixture or in the D or L form.
[0089] The non nutritive sweeteners are patentably sweet but are non-caloric. Examples include L-sugars, aspartame, alitame, acesulfame-K, cyclamate, stevioside, glycyrrhizin, sucralose, neohesperidin, dihydrochalcone, thaumatin saccharin and its pharmaceutically acceptable salts (e.g., calcium), and the like.
[0090] In one embodiment of the present invention, it is preferred that the sweetener be present in the water in amounts ranging from about 40% to about 80% by weight and more preferably from about 50% to about 70% and most preferably from about 55% to about 65%. In addition, it is preferred that the weight ratio of sweetener to alkyl hydroxyethyl cellulose, when present, ranges from about 400 to about 800, and, most preferably, from about 500 to about 600.
[0091] Other optional ingredients which may be present in certain waters of the present invention include buffers, such as citric acid or its corresponding salts or acetic acids and its salts, flavoring agents, such as peppermint, oil of wintergreen, orange, or cherry flavoring, and the like, surfactants, thickeners, preservatives, such as methyl and propyl parabens, and the like, anti-oxidants, such as benzoate salts, and the like, chelating agents, such as EDTA and its salts and the like.
[0092] In certain embodiments, the waters of the present invention can be administered to a mammal in need thereof by topical, systemic, subscleral, transscleral, or intravitreal delivery. Intravitreal delivery may include single or multiple intravitreal injections, or via an implantable intravitreal device that releases the water in a sustained capacity. Intravitreal delivery may also include delivery during surgical manipulations in treatment for retinal detachments, diabetic retinopathy, or macular degenerations as either an adjunct to the intraocular irrigation solution or applied directly to the vitreous during the surgical procedure.
[0093] Minimally invasive transscleral delivery can be used to deliver an effective amount of the water to the retina with negligible systemic absorption. Transscleral delivery utilizes the sclera's large and accessible surface area, high degree of hydration that renders it conductive to water-soluble substances, hypocellularity with an attendant paucity of proteolytic enzymes and protein-binding site, and permeability that does not appreciably decline with age. An osmotic pump loaded with the inventive water can be implanted in a subject so that the active compounds are transsclerally delivered to the retina in a slow-release mode. (Ambati, et al., Invest. Ophthalmol. Vis. Sci., 41: 1186-91 (2000)).
[0094] The inventive waters may also be administered topically by administering the active compounds to a patient by any suitable means, but are preferably administered by a liquid or gel suspension of the water in the form of drops, spray or gel. Alternatively, the water may be applied, for example to the eye, via liposomes. Further, the water may be infused into the tear film via a pump-catheter system. Another embodiment of the present invention involves the water contained within a continuous or selective-release device, for example, polymeric ocular inserts for the administration of drugs. (Alza Corp., Palo Alto, Calif.), or in the intra-vitreal implant for the gradual release of pharmaceuticals for the treatment of eye conditions (Bausch & Lomb, Claremont, Calif.).
[0095] As an additional embodiment, the inventive water can be contained within, carried by, or attached to contact lenses that are placed on the eye. Another embodiment of the present invention involves the water contained within a swab or sponge that can be applied to the desired surface. Another embodiment of the present invention involves the water contained within a liquid spray that can be applied to any desired surface, such as the ocular surface.
[0096] The inventive water may be administered systemically. The term โsystemicโ as used herein includes subcutaneous injection, intravenous, intramuscular, intraesternal injection, infusion, inhalation, transdermal administration, oral administration, and intra-operative instillation.
[0097] Liquid formulations containing water of the present invention may be sterile and non-sterile injectable formulations. For instance, the formulation may be an aqueous or oleaginous suspension. The suspensions may be formulated according to techniques known in the art using suitable dispersing or wetting agents and suspending agents.
[0098] The injectable formulation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptible diluent or solvent. Suitable diluents and solvents for injectable formulations include 1,3-butanediol, Ringer's solution and isotonic sodium chloride solution. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. Suitable fixed oils include, but are not limited to, synthetic mono- or di-glycerides, fatty acids, such as oleic acid and its glyceride derivatives, and natural pharmaceutically-acceptable oils, such as olive oil, castor oil, and polyoxyethylated derivatives thereof. (Sigma Chemical Co.; Fisher Scientific) According to a preferred embodiment, oil containing injectable formulations contain a long-chain alcohol diluent.
[0099] Topical formulations of the present invention are typically in the form of an ointment or suspension. Such formulations may be administered for diseases of the eye, the skin, and the lower intestinal tract. Suitable suspending agents, diluents, and dosing vehicles for such formulations include, but are not limited to, mineral oil, liquid petrolatum, white petrolatum, propylene glycol, polyoxyethylene, polyoxypropylene compound and emulsifying wax. (Sigma Chemical Co.; Fisher Scientific) Alternatively, the topical formulation can be in the form of a lotion or cream. Suitable suspending agents, diluents, and dosing vehicles for such formulations include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60 cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, and benzyl alcohol. (Sigma Chemical Co.; Fisher Scientific) Topical application for the lower intestinal tract can be effected in a rectal suppository formulation or in a suitable enema formulation. The formulation may also be administered via a transdermal patch as known in the art.
[0100] The liquid formulation containing the inventive water may also be applied ophthalmically. A preferred ophthalmic formulation of the present invention is a micronized suspension in isotonic, pH adjusted sterile saline. A preservative, such as benzalkonium chloride, may be included in the formulation but is not necessary as a preservative due to the nature of the invention. Alternatively, the ophthalmic formulation is in an ointment, for example, containing petrolatum.
[0101] Nasal aerosol and inhalation formulations of the invention may be prepared by any method in the art. Such formulations may include dosing vehicles, such as saline, preservatives, such as benzyl alcohol, absorption promoters to enhance bioavailability, fluorocarbons used in the delivery systems, e.g., nebulizers, etc., solubilizing agents, dispersing agents, or any combination of any of the foregoing.
[0102] The formulations of the present invention may be administered systemically. The term โsystemicโ as used herein includes parenteral, topical, oral, spray inhalation, rectal, nasal, bucal, and vaginal administration. The term โparenteralโ as used herein includes subcutaneous, intravenous, intramuscular, intra-articular, intra-synovial, intrasternal, intrathecal, intrahepatic, intralesional and intracranial administration. Preferably, the compositions are administered orally, intraperitoneally or intravenously.
[0103] One systemic method involves an aerosol suspension of respirable particles comprising the inventive water, which the subject inhales. The water would be absorbed into the bloodstream via the lungs, and subsequently contact the lacrimal glands in a pharmaceutically effective amount. The respirable particles are preferably liquid, with a particle size sufficiently small to pass through the mouth and larynx upon inhalation. In general, particles ranging from about 1 to 10 microns, but more preferably 1-5 microns, in size are considered respirable.
[0104] Another method of systemically administering the active compounds to the eyes of a subject involves administering a liquid/liquid suspension in the form of eye drops or eye wash or nasal drops of a liquid formulation, or a nasal spray of respirable particles that the subject inhales. Liquid pharmaceutical compositions containing the inventive water for producing a nasal spray or nasal or eye drops may be prepared by combining the inventive water with a suitable vehicle, such as sterile pyrogen free water or sterile saline by techniques known to those skilled in the art.
[0105] The inventive water may also be systemically administered to eyes through absorption by the skin using transdermal patches or pads. In this embodiment, the inventive water is absorbed into the bloodstream through the skin.
[0106] Other methods of systemic administration of the inventive water involves oral administration, in which compositions containing the inventive water are in the form of lozenges, aqueous or oily suspensions, viscous gels, chewable gums, emulsion, soft capsules, or syrups or elixirs. Additional means of systemic administration of the inventive water to the eyes of the subject would involve a suppository form of the water, such that a therapeutically effective amount reaches the eyes via systemic absorption and circulation.
[0107] Further means of systemic administration of the inventive water involve direct intra-operative instillation of a gel, cream, or liquid suspension form of a therapeutically effective amount of the water.
[0108] For topical application, a solution containing the inventive water may contain a physiologically compatible vehicle, as those skilled in the ophthalmic art can select, using conventional criteria. The vehicles may be selected from the known ophthalmic vehicles which include, but are not limited to, saline solution, polyethers such as polyethylene glycol, polyvinyls such as polyvinyl alcohol and povidone, cellulose derivatives such as methylcellulose and hydroxypropyl methylcellulose, petroleum derivatives such as mineral oil and white petrolatum, animal fats such as lanolin, polymers of acrylic acid such as carboxypolymethylene gel, vegetable fats such as peanut oil, polysaccharides such as dextrans, glycosaminoglycans such as sodium hyaluronate, and salts such as sodium chloride and potassium chloride.
[0109] For systemic administration, such as injection and infusion, the pharmaceutical formulation is prepared in a sterile medium. The inventive water, depending on the vehicle and concentration used, can either be suspended or dissolved in the vehicle. Adjuvants such as local anaesthetics, preservatives and buffering agents can also be dissolved in the vehicle. The sterile injectable preparation may be a sterile injectable solution or suspension in a non-toxic acceptable diluent or solvent. Among the acceptable vehicles and solvents that may be employed are saline solution or Ringer's solution.
[0110] For oral use, an aqueous suspension may be prepared by addition of the inventive water to dispersible powders and granules with a dispersing or wetting agent, suspending agent, one or more preservatives, and other excipients. Suspending agents include, for example, sodium carboxymethylcellulose, methylcellulose and sodium alginate. Dispersing or wetting agents include naturally-occurring phosphatides, condensation products of an allylene oxide with fatty acids, condensation products of ethylene oxide with long chain aliphatic alcohols, condensation products of ethylene oxide with partial esters from fatty acids and a hexitol, and condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anydrides. Preservatives include, for example, ethyl, and n-propyl p-hydroxybenzoate. Other excipients include sweetening agents (e.g., sucrose, saccharin), flavoring agents and coloring agents. Those skilled in the art will recognize the many specific excipients and wetting agents encompassed by the general description above.
[0111] Formulations for oral use may also be presented as soft gelatin capsules wherein the inventive water is administered alone or mixed with an oil medium, for example, peanut oil, liquid paraffin or olive oil. Formulation for oral use may also be presented as chewable gums by embedding the active ingredient in gums so that the inventive water is slowly released upon chewing.
[0112] For rectal administration, the compositions in the form of suppositories can be prepared by mixing the inventive water with a suitable non-irritating excipient that is solid at ordinary temperatures but liquid at the rectal temperature and will therefore melt in the rectum to release the water. Such excipients include cocoa butter and polyethylene glycols.
[0113] FIG. 1A is a block diagram of a system for making and tuning super-oxygenated and structured water, in accordance with one embodiment of the present invention. The system 1 includes system 10 for producing or making super-oxygenated and structured water coupled via pipe 27 to a system 20 for tuning super-oxygenated and structured water. The term pipe refers to any component configured to provide fluid or gaseous communication between two components. The pipe may be, for example, a PVC pipe, a crystal pipe, flexible tubing, or other type of conduit.
[0114] System 10 includes a water preparation system 103 coupled to an oxygen/water combining system 113 via a holding tank 109 . Oxygen/water combining system 113 is in turn coupled to a cone system 121 via holding tank 109 . System 20 for tuning super-oxygenated and structured water includes a coil system 123 coupled to a structured ozone machine 125 and multi-coil system 127 .
[0115] Water preparation system 103 includes a water preconditioning system 100 and an electrolysis machine 101 coupled by a pipe 75 , which together comprise a system for preparing water with a stable negative oxidation reduction potential (ORP). Output of system 103 , in particular, from electrolysis machine 101 , is either alkaline water, which is output via a pipe 105 to holding tank 109 , or acidic water, which is output via a pipe 107 to an acid water tank 110 . Both the alkaline water output via pipe 105 and the acidic water output via pipe 107 have a stable negative oxidation reduction potential (ORP). The alkaline water is input to holding tank 109 , which is in turn output via a pipe 111 to the oxygen/water combining system 113 . Holding tank 109 may be a single tank or a plurality of tanks, for example, three tanks arranged in series. A pump 523 and pressure gauge 519 are preferably provided between the holding tank 109 and the oxygen/water combining system 113 to control the flow of water from the holding tank 109 to the oxygen/water combining system 113 .
[0116] The oxygen/water combining system 113 includes a structured oxygen generating machine 600 and a diffusion chamber 115 . The structured oxygen generating machine 600 outputs oxygen via a pipe 117 , which is coupled to pipe 111 and pipe 118 by a valve 119 . Water and oxygen flow together from valve 119 to the diffusion chamber 115 via pipe 118 . The oxygen/water combining system 113 outputs oxygen enriched water to cone system 121 via pipe 25 .
[0117] As set forth above, the system for tuning super-oxygenated and structured water 20 is coupled to the system for producing super-oxygenated and structured water 10 via pipe 27 . The system for tuning super-oxygenated and structured water 20 includes coil system 123 , structured ozone machine 125 , and multi-coil system 127 . Coil system 123 receives the oxygen enriched water from system 10 via pipe 27 , and combines and outputs oxygen enriched water via a pipe 29 . Structured ozone machine 125 outputs structured ozone via a pipe 31 , which is coupled to pipe 29 and pipe 35 by a valve 33 . The structured ozone from structured ozone machine 125 is combined with the super-oxygenated and structured water in pipe 29 at valve 33 and the combination of structured ozone and super-oxygenated and structured water is directed via pipe 35 to multi-coil system 127 .
[0118] Coil system 123 tunes water received via pipe 27 , and multi-coil system 127 tunes the combined water and ozone received via pipe 35 to yield super-oxygenated and structured water that is output via pipe 37 . Pipe 37 returns the super-oxygenated and structured water to holding tank 109 , from which the water may be, for example, bottled for human consumption or other uses.
[0119] Water preconditioning system 100 , oxygen/water combining system 113 , including structured oxygen generating machine 600 and diffusion chamber 115 , cone system 121 , coil system 123 , structured ozone machine 125 , and multi-coil system 127 will be described in more detail below.
[0120] FIG. 1B is a flow chart of a method for producing super-oxygenated and structured water, in accordance with one embodiment of the present invention, and FIG. 1C is a flow chart of a more detailed method for producing super-oxygenated and structured water, in accordance with one embodiment of the present invention. Referring to FIG. 1B , step S 202 involves receiving water from pipe 148 by system 103 for preparing water with stable negative ORP. Water preconditioning system 100 in system 103 preconditions water for electrolysis at step S 204 . Electrolysis machine 101 performs electrolysis at step S 206 . System 103 for preparing water with a stable negative ORP outputs alkaline water with its stable negative ORP via pipe 105 into holding tank 109 at step S 208 . At step S 210 water with a stable negative ORP is received from holding tank 109 and is combined with oxygen at oxygen/water combining system 113 . At step S 212 , the combined oxygen/water is received and spun by cone system 121 . Finally, at step S 214 , oxygen enriched structured water is output from cone system 121.
[0121] FIG. 1C is a flow chart of a mote detailed method for producing super-oxygenated and structured water, in accordance with one embodiment of the present invention. In particular, step S 204 from FIG. 1A includes two substeps S 204 a and S 204 b for preconditioning water. In particular, step S 204 for preconditioning water involves adding ozone to the water at step S 204 a , followed by subjecting the water to magnetic fields at step S 204 b.
[0122] Step S 210 of FIG. 1B , during which water is combined with oxygen, is subdivided in FIG. 1C into step S 210 a , in which ozone treated alkaline water is combined with oxygen, followed by step S 210 b , in which oxygen enriched ozone treated alkaline water is forced through the diffusion chamber 115 .
[0123] Step 212 of FIG. 1B , during which water is spun, is shown in FIG. IC as step S 212 โฒ, in which oxygen enriched structured water is received from the diffusion chamber 115 and input into the cone system 101 .
[0124] The system for tuning super-oxygenated and structured water 20 performs the steps shown in FIG. 1D as follows. At step S 224 spun water is received from the system for producing super-oxygenated and structured water 10 , and is input into coil system 123 . The water output from the coil system 123 via pipe 29 is then combined with structured ozone received from structured ozone machine 125 via pipe 31 at step S 228 . The combination of water from coil system 123 and the structured ozone from structured ozone machine 125 is input to multi-coil system 127 via pipe 35 at step S 232 . Finally, at step S 236 , super-oxygenated, tuned, and structured water is output from the system 20 and, in particular, from multi-coil system 127 .
[0125] FIG. 2A is a block diagram of the system for preparing water with a stable negative ORP 103 . System 103 includes water preconditioning system 100 and electrolysis machine 101 . As discussed above, water preconditioning system 100 outputs water preconditioned for electrolysis machine 101 via pipe 75 . A cut off valve 75 A may be provided on pipe 75 to control the flow of the water. The preconditioned water is, in turn, received by electrolysis machine 101 , and electrolysis is performed thereon to yield both alkaline water output through pipe 105 to holding tank 109 and acidic water output through pipe 107 to acidic water tank 110 . As discussed above, both the alkaline water and acidic water have a stable negative ORP.
[0126] The acidic water output via pipe 107 is not designed for consumption, but it has many other uses and advantages. For example, acidic water can be used for cleaning many things, such as pipes, etc. It can also be mixed with hair rinse. The mixture can vary from pH 4.0 to pH 6.5 (6.7) and preferably between ห4 parts per volume of water to ห1 part per volume of hair rinse all the way to ห1 part per volume of water to ห4 parts per volume of hair rinse, and more preferably ห1 part per volume of water with ห1 part per volume of hair rinse. It can also be used in the same manner mixed with shampoo because it acts as a reagent and helps clean oils out of hair.
[0127] Typically, when water is output from an electrolysis system, the negative ORP that is created does not stay very long. It typically only remains for minutes at a time. The negative ORP of water treated with embodiments of the present invention can be less than โ100. For both the alkaline and the acidic water at pipes 105 and 107 , respectively, typically the negative ORP begins at ห183 ORP. However, as the water settles out, some of the electrons are given off due to a variety of reasons, and it ultimately settles out at approximately หโ170 ORP to หโ173 ORP. Both the alkaline and acidic water can maintain หโ170 to หโ173 ORP for 6 months to up to ห2 years or more depending on the electromagnetic environment next to or near the storage area. Water in this state gives a multitude of free electrons which then can become an antioxidant in the blood. At this point the water, both the alkaline water and the acidic water, have structure. If the water in holding tank 109 is not processed within ห24 hours, the structure begins to deteriorate, although the negative ORP remains, as discussed above. Accordingly, for structure purposes, it is advantageous to continue processing the alkaline water in holding tank 109 as quickly as possible. That is, it is advantageous to proceed to output the alkaline water in holding tank 109 via pipe 111 to the oxygen/water combining system 113 as quickly as possible.
[0128] FIG. 2B is a flow chart of a method for preparing water with a stable negative ORP, in accordance with one embodiment of the present invention. System 103 for preparing water with a stable negative ORP performs the following steps:
[0129] At step S 412 , water is preconditioned for electrolysis, and at step S 414 electrolysis is performed before outputting alkaline and/or acidic water at step S 416 . Water preconditioning system 100 performs step S 412 and electrolysis machine 101 performs step S 414 . At step S 412 , system 103 outputs alkaline water to holding tank 109 via pipe 105 and acidic water to acid water tank 110 via pipe 107 . Step S 412 for preconditioning water involves performing steps S 402 , S 404 , S 406 , S 408 , and S 410 , discussed below in connection with FIG. 2D .
[0130] FIG. 2C shows a water preconditioning system 100 for conditioning water for electrolysis, according to one embodiment of the present invention. Water preconditioning system 100 includes a filter system 104 , a UV system 108 , a circulating tank 112 , an ozone machine 116 , and a magnetic structuring stage 120 .
[0131] System 100 for preconditioning water operates generally as follows. First, high quality water is received by filter system 104 . High quality water may be water received from water source 152 , for example, an aquafier well, preferably an aquafier well located in certain geographic areas throughout the world, such as northern New Mexico and, more specifically, New Mexico, Missouri and Hawaii.
[0132] For example, a pump 140 , such as a pressure pump, can be used to pump the water from a well house 144 to filter system 104 via a pipe 148 . The aquafier well 152 may be deep, for example, ห850 feet deep.
[0133] Water received by filter system 104 via pipe 148 is then filtered by filter system 104 and output via a pipe 156 to UV system 108 . Water output from UV system 108 via pipe 146 is then input to circulating tank 112 , which in turn is coupled via a pipe 136 to an ozone machine 116 . Pipe 1063 is provided to allow water to circulate between the circulating tank 112 , the ozone machine 116 and the magnetic structuring stage 120 . The ozone machine 116 is selectively activatable. A valve 186 and bypass pipe 1062 are provided for selective bypass of the magnetic structuring stage 120 . After passing through magnetic structuring stage 120 , preconditioned water may be output via a pipe 164 .
[0134] Filter system 104 may be, for example, a four-stage filtering system which includes a ห10 ฮผm filter 124 , followed by a ห5 ฮผm filter 128 , followed by a ห0.5 ฮผm filter 132 , followed by a carbon filter 134 .
[0135] UV system 108 preferably includes a UV chamber carbon block filter (10โณ0.5 micron), and a UV #10 lamp (120V, 0.420 amp unit).
[0136] The operation of system 100 will be explained with reference to FIG. 2D , which is a flow chart of a method for preconditioning water. Water from water source 152 is received by system 100 for preconditioning water at step S 402 . The water is filtered by filtering system 104 at step S 404 . Step S 406 involves subjecting the water to ultraviolet radiation with UV system 108 . Steps S 408 -S 410 involve circulating water between circulating tank 112 , ozone machine 116 to add ozone to the water, and magnetic structuring stage 120 to preferably subject the water to a series of magnetic fields. Ozone machine 116 can be set between 1 mm/liter 10 SCFH and 1.2 mm/liter 15 SCFH, and the water is preferably exposed to ozone less than ห15 seconds per ห100 gallons to prevent burning, more preferably approximately between หtwo and 10 seconds per ห100 gallons, and most preferably ห5-8 seconds per 100 gallons. Step S 412 involves outputting water from magnetic structuring stage 120 as preconditioned water, which can then be input to electrolysis machine 101 . A residual of 0.1-0.4 PPM of ozone is typically left in the treated water.
[0137] As discussed above, circulating tank 112 is coupled via pipe 136 to ozone machine 116 , which is in turn coupled to magnetic structuring stage 120 via pipe 160 . Pipe 1063 connects magnetic structuring stage 120 to circulating tank 112 to form a complete circulation loop.
[0138] As discussed above, ozone machine 116 is preferably operated for ห5-8 seconds for every ห100 gallons contained in circulating tank 112 . However, ozone machine 116 may operate for up to ห15 seconds for every ห100 gallons in circulating tank 112 . However, operation should not exceed ห15 seconds for every ห100 gallons of water in circulating tank 112 in order to prevent burning. This essentially saturates and shocks the water. Typical ozone machine operations are between ห0.08 to ห0.8 mm per liter, which is not sufficient to saturate/shock the water. Exceeding ห15 mm per liter results in essentially โburningโ the water as mentioned above, so that the water tastes as if it were boiled. Burned water has an unnatural taste and, when one drinks it, is so caustic that it can strip out saliva from the mouth. It has utility in that it can โclear outโ one's pipes and has very powerful antibacterial effect in that it can strip bacteria out that most people have a difficult time ridding from their system. For example, iron bacteria in domestic wells is a significant problem. Many believe that the only way to kill them is with excessive chlorine, but that really does not do a complete job. With this system, ห12 seconds per 100 gallons of ozonated water kills iron bacteria.
[0139] Magnetic structuring stage 120 is shown in FIG. 3A . Water flows from pipe 160 into pipe 162 at location 200 and flows out at location 204 . Pipe 162 includes a series of magnetic donut rings 163 . According to a preferred embodiment of the invention, other magnet shapes might include north pole bar magnets or other magnets. In this embodiment, there are preferably 14 such donut rings 163 a - 163 n evenly spaced over a distance โdโ of approximately 7 feet, such that their central longitudinal axis are spaced apart a distance โaโ of ห6.46โณ. Donut ring 163 a preferably has a magnetic field strength of ห350 Gauss, while the magnetic field strength of donut ring 163 b linearly increases by a difference of ห91.66 Gauss to ห441 Gauss. Further, the magnetic field strength of each subsequent donut ring preferably increases by the same amount linearly until it reaches a maximum value of ห900 Gauss. The magnetic field strength of donut rings 163 g and 163 h are both preferably ห900 Gauss. The remaining magnets 163 i through 163 n preferably have magnetic field strengths or flux that are also linearly decreased by ห91 Gauss.
[0140] FIG. 3B is a graph showing the magnetic flux of the magnetic donut rings of an exemplary magnetic structuring stage plotted versus distance or position of the donut rings. In FIG. 3B , the lowest value โLGaussโ of magnetic flux for a donut ring is ห350 Gauss, while the highest value โHGaussโ of magnetic flux is ห900 Gauss. However, HGauss value can be varied, for example to ห1200 Gauss. When HGauss is ห1200 Gauss, the water can become too clarifying to the colon. In another embodiment of the invention, HGauss can be varied as high as ห1800 Gauss. The value of HGauss depends on the flow rate of the water through pipe 162 . As HGauss is increased, the maximum flow rate is preferably decreased. If the flow rate is too slow, the water breaks down.
[0141] The purpose of magnetic structuring stage 120 is to structure the water as it passes through the series of magnets 163 . The number and shape of magnets 163 can be varied. The flow rate is controlled by the pressure of the water entering location 200 of pipe 162 , which pressure can vary anywhere from ห22 psi up to ห30 psi. At ห31 psi, there is a break over point. Water output at location 204 is considered structured water. When HGauss is ห1200 Gauss, the water can hold more oxygen. The flow rate of the water preferably increases as the value of HGauss is increased in order to maintain equilibrium pressure/gauss.
[0142] FIG. 4A is a block diagram of an oxygen/water combining system, according to one embodiment of the present invention. Ozone treated alkaline water input to holding tank 109 via pipe 105 is then output from holding tank 109 to oxygen/water combining system 113 via pipe 111 . A pump 523 and pressure gauge 519 are preferably provided on pipe 111 to control water flow.
[0143] Oxygen/water combining system 113 includes a structured oxygen generator 600 , which outputs structured oxygen via pipe 117 , which is combined and coupled to pipe 111 at valve 119 . The ozone treated alkaline water is mixed with the structured oxygen from pipe 117 at valve 119 , and both are then directed via pipe 118 to diffusion chamber 115 .
[0144] Structured oxygen generating machine 600 outputs high pressure oxygen at pipe 117 . For example, structured oxygen generating machine 600 may output structured oxygen at up to ห300 PSI changing pressures change electron ring formulation in molecule via pipe 117 before combining with the ozone treated alkaline water in pipe 111 . Pipe 111 may be, for example, an ห1 inch pipe.
[0145] The combination of water and oxygen in pipe 118 is then sprayed into the diffusion chamber 115 via a pipe 504 in fluid communication with a spray nozzle 503 . The spray nozzle 503 has a very small orifice, for example, less than ห0.1 inches and preferably less than ห0.01 inches and more preferably ห0.0078 inches in diameter.
[0146] Diffusion chamber 115 includes a cylinder 507 capable of generating a type of tornado or vortex 511 in diffusion chamber 115 . Diffusion chamber 115 may be, for example, a modified water filter rated to 250 psi with the top of the water filter replaced with a small set of fittings, for example, หโ
inch brass fittings, that go through a ห1 inch orifice, where a pipe for the water filter would normally be located. At the end of pipe 504 is spray nozzle 503 . Spray nozzle 503 may be หยผ inch in diameter and preferably has a spray fan which is designed to have a spray fan angle that creates a strong vortex of the oxygen-water combination in chamber 115 . The resulting spray fan angle is preferably ห15ยฐ. The oxygen-water combination at the input of pipe 504 is preferably under a pressure of ห60 PSI.
[0147] The tornado 511 is essentially a clockwise vortex that is created in cylinder 507 . The tornado 511 has a cream-like appearance due to the fine oxygen bubbles. That is, the tornado 511 is essentially white because all of the oxygen is pulled into the center of the vortex. The width of the tornado or vortex 511 is preferably หยพ inch and extends all the way to the bottom of the preferably 18โณ to 24โณ cylinder 507 . At the bottom of cylinder 507 is a pressure escape valve 513 which is coupled to a pipe 515 A which, in a preferred embodiment, is หยฝ inch in diameter. The pipe 515 A which is coupled to holding tank 109 . Pipe 515 B also couples diffusion chamber 115 to holding tank 109 . Pipe 25 connects oxygen/water combining system 113 to cone system 121 , with a pressure gauge 25 A and cut off valve 25 (See FIG. 1A ) provided on pipe 25 to control water flow. Pressure escape valve 513 and pipe 515 A provide pressure relief for the system.
[0148] Oxygen is mixed with water at location 119 . It is desirable to saturate the water with oxygen so that there is an abundance of oxygen. Because there is a saturation of oxygen, it can actually add oxygen to the water rather than pull oxygen out of the water.
[0149] FIG. 4B is a flow chart of an oxygen/water combining method, according to one embodiment of the present invention, performed by the oxygen/water combining system 113 . Step S 531 involves receiving ozone treated alkaline water via pipe 111 . Step S 533 involves mixing oxygen with ozone treated alkaline water at valve 119 . Step S 535 involves forcing the mixture of oxygen and ozone treated alkaline water through spray nozzle 503 in diffusion chamber 115 to create tornado/vortex 511 . Step S 537 involves outputting oxygen enriched structured water from diffusion chamber 115 . Step S 539 involves outputting the oxygen enriched structured water from oxygen/water combining system 113 via pipe 25 .
[0150] FIG. 5A is a block diagram of a structured oxygen generating machine 600 according to one embodiment of the present invention. Structured oxygen generating machine 600 includes a compressor 604 , which is coupled via a pipe 608 to an oxygen generator 612 . Compressor 604 may be, for example, a ห25 horsepower compressor which outputs refrigerated and cleaned air at ห250 PSI to oxygen generator 612 . Oxygen generator 612 may be, for example, an OGS oxygen generator. Oxygen generator 612 outputs oxygen via a pipe 614 at, for example, ห70 PSI to an oxygen storage tank 616 . Oxygen storage tank 616 in turn outputs oxygen at high pressure (up to ห300 PSI) through a high pressure pipe 620 to an oxygen enhancer 622 . The oxygen is then directed to a valve 624 , which in turn directs the oxygen through either a first magnetic structuring stage 628 or a second magnetic structuring stage 632 . When valve 624 is in a first position, oxygen output from oxygen enhancer 622 passes through pipe 626 to first magnetic structuring stage 628 , shown in more detail in FIG. 6A . That is, oxygen from oxygen enhancer 622 is input to first magnetic structuring stage 628 via pipe 626 and, after passing through first magnetic structuring stage 628 , is output through pipe 631 to pipe 117 as structured oxygen. When valve 624 is in a second position, oxygen from oxygen enhancer 622 passes through pipe 630 to the second magnetic structuring stage 632 , shown in more detail in FIG. 6B . That is, oxygen from oxygen enhancer 622 is input to second magnetic structuring stage 632 via pipe 630 and is output via pipe 634 to pipe 117 as structured oxygen.
[0151] FIG. 5B is a flow chart of a method for producing structured oxygen, according to one embodiment of the present invention. At step S 670 , refrigerated and cleaned air is input to the oxygen generator 612 under pressure. Oxygen generator 612 , in turn, outputs highly pressurized oxygen to oxygen storage tank 616 via pipe 614 at step S 674 . At step S 678 , highly pressurized oxygen is input to either first magnetic structuring stage 628 or second magnetic structuring stage 632 . At step S 682 , magnetically structured oxygen is output from either the first magnetic structuring stage 628 or the second magnetic structuring stage 632 .
[0152] FIG. 5C is a longitudinal cross sectional view of the oxygen enhancer 622 shown in FIG. 5A . The oxygen enhancer 622 preferably has a substantially tubular body portion 6200 , and is preferably formed of a non-conductive material, such as, for example, high pressure plastic. In one embodiment of the present invention, the body portion 6200 may be between 14 and 17 inches long, and approximately 3 inches in diameter. However, other dimensions for the body portion 6200 may also be used. Ends of the body portion 6200 are preferably tapered so as to form an inlet 6210 and an outlet 6220 , which accommodate incoming and outgoing pipes 6215 and 6225 , respectively. In one embodiment of the present invention, the incoming and outgoing pipes 6215 and 6225 preferably have a ยฝ inch diameter, and some length thereof (e.g., ยฝ inch) may extend into the body portion 6200 . However, other diameters may also be used.
[0153] Ring type devices 6230 and 6240 , such as, for example, a washer, are preferably positioned at the inlet 6210 and outlet 6220 to secure and properly align the pipes 6215 and 6225 , respectively, in place. The body portion 6200 are preferably filled with a filtering material 6250 , such as, for example, carbon, to scrub the oxygen processed therethrough and absorb any contaminants that may be present. The carbon chips 6250 may vary in size, and preferably fall within an average size of between โ
and 1/32 inch. Carbon creates a pure, clean oxygen that is readily accepted into the water.
[0154] First and second mesh screens 6270 and 6280 , respectively, are preferably positioned in the body portion 6200 as shown in FIG. 5C , preferably with a void 6290 formed therebetween. The screens 6270 and 6280 may be made of any type of suitable metallic material, such as silver, platinum or gold. In one embodiment of the present invention, the screens 6270 and 6280 are preferably made of a gold mesh material. However, other materials, such as, for example, copper and brass, could also be used. The mesh size of the screens 6270 and 6280 may also be varied. In one embodiment of the present invention, the mesh size may preferably fall within a range of between 150 and 200 microns, and is most preferably 200 microns.
[0155] A plurality of magnets are provided on each of the first and second screens 6270 and 6280 , with a first set of magnets 6275 preferably provided on a surface of the first screen 6270 facing the inlet 6210 , and a second set of magnets 6285 preferably provided on a surface of the second screen 6280 facing the outlet 6220 . Wires 6260 , preferably made of a conductive material, such as, for example, copper, extend from the first set of magnets 6275 to the inlet ring 6230 , and from the second set of magnets 6285 to the outlet ring 6240 . The wires 6260 may be attached to the rings 6230 and 6240 by any suitable means such as, for example, soldering.
[0156] A front view of an exemplary mesh screen 6300 is shown in FIG. 5D . This exemplary mesh screen 6300 is shown with nine magnets attached thereto, with a center magnet 6310 being preferably slightly larger than surrounding magnets 6320 . However, other numbers of magnets, relative sizes, strengths, and arrangements on the mesh screen 6300 may also be used. The magnets may be made of any appropriate magnetic material. In one embodiment of the present invention, the magnets are preferably button magnets, and most preferably germanium button magnets, that are less than ยฝ inch in diameter, and preferably โ
inch in diameter, and with a strength of between 300 and 550 Gauss. Based on this type of magnet arrangement on each of the first and second screens 6270 and 6280 shown in FIG. 5C , an appropriate width for the void 6290 is approximately ยฝ inch. However, the number, arrangement, and strength of the magnets may be varied, and an appropriate width of the void 6290 may be determined based on the resulting strength of the magnetic flux produced by the magnets.
[0157] In FIG. 5C , the first set of magnets 6275 is preferably oriented with a north side 6276 facing the inlet 6210 , and a south side 6277 adjacent the first screen 6270 , while the second set of magnets 6285 is preferably oriented with a north side 6286 facing the outlet 6220 , and a south side 6287 adjacent the second screen 6280 . This opposing polarity arrangement causes the oxygen to โsnapโ as it passes through the void 6290 , thus initiating the structuring process by aligning and preparing the oxygen for further structuring as it subsequently passes through either the first or second structuring stages 628 or 632 .
[0158] FIGS. 5E and 5F are front and side views, respectively, of a ring 6291 which is preferably positioned within the void 6290 . The ring 6291 preferably includes a plurality of magnets 6292 positioned along a circumference of the ring 6291 , adhered to the ring 6291 by any suitable means. In one embodiment of the present invention, fourteen germanium magnets 6292 are preferably adhered along a circumference of the ring 6291 with a silicone based compound. In this embodiment, each of the magnets 6292 may be between ยฝ and โ
inch in diameter, and each have a strength of approximately 200 Gauss. However, it should be understood that many other combinations of type, number, and strength of the magnets may be used to provide a suitable effect. Similarly, a width W of the ring 6291 may be varied based on a corresponding width of the void 6290 formed between the screens 6270 and 6280 .
[0159] As shown in FIGS. 5E-5G , a south pole S of each of the magnets 6292 is preferably flush with an outer circumference 6293 of the ring 6291 , while a north pole N of each of the magnets 6292 preferably extends from an inner circumference 6294 of the ring 6291 and toward the center of the ring 6291 . Accordingly, when configured as such and positioned in the void 6290 formed between the screens 6270 and 6280 , the south poles S of the magnets 6292 and the outer circumference 6293 of the ring 6291 contacts an inner surface of the body portion 6200 , while the left and right faces 6295 and 6296 , respectively, of the ring 6291 contact the screens 6270 and 6280 , respectively. In one embodiment of the invention, the width W of the ring 6291 is approximately ยฝ inch to match the corresponding width of the void 6290 .
[0160] FIG. 6A is a schematic side view of a first magnetic structuring stage for a structured oxygen generating machine, according to one embodiment of the present invention. First magnetic structuring stage 628 includes N donut magnets 1 , 2 , 3 . . . N all arranged along pipe 626 . Each of the donut magnets 1 หN preferably has a strength of up to ห3,300 Gauss. The spacing between central longitudinal axes of the donut magnets 1 and 2 of first magnetic structuring stage 628 is preferably ห2 inches, and gradually increases to the middle 636 of first magnetic structuring stage 628 at which point the spacing is preferably ห12 inches, and then the spacing between the subsequent donut magnets decreases until the spacing between central longitudinal axes of donut magnets Nโ1 and N is preferably ห2 inches. The middle 636 of first magnetic structuring stage 628 is preferably located 4.5 feet from each end of the first magnetic structuring stage 628 .
[0161] Alternatively, as discussed above, oxygen can be directed by the valve 624 to the second magnetic structuring stage 632 . FIG. 6B is a schematic side view of the second magnetic structure stage for a structured oxygen generating machine, in accordance with one embodiment of the present invention. In this embodiment, there are M central longitudinal axes of donut magnets which are spaced apart distances D 1 , D 2 . . . D M , where distances D i all represent a Fibonacci sequence in inches. Hence, D i =1, 1, 2, 3, 5, 8, 13, . . . , whereby D i =D j-2 +D i-1 . In a preferred embodiment, M is an integer between 1 and 21.
[0162] The structured oxygen, which is output from either the first magnetic structuring stage 628 or the second magnetic structuring stage 632 , may be used to enrich water with oxygen according to processes described herein. When the structured oxygen output from first magnetic structuring stage 628 is mixed with properly prepared water, the resulting water may provide energy to the person or mammal that ingests the water. On the other hand, structured oxygen output from second magnetic structuring stage 632 , when used to enrich water, yields oxygen enriched water which may produce a sedating effect for people or mammals that ingest the oxygen enriched water.
[0163] FIG. 7A is a block diagram of a cone system, in accordance with one embodiment of the present invention. Combined oxygen/water is input via pipe 25 to cone system 121 . A medical grade oxygen machine 803 is coupled to pipe 25 via a pipe 805 at a valve 807 . Medical grade oxygen is output from the medical grade oxygen machine 803 and mixed with the combined oxygen/water from the system 10 at valve 807 , and together are directed via a pipe 523 to a series of cones 809 . The series of cones 809 are shown in FIG. 7A to be 6 cones 811 , 813 , 815 , 817 , 819 and 821 , according to one embodiment of the present invention. However, the number of cones in the series of cones 809 can vary from 1 to N where N can be as high as 24. The combined water/oxygen from system 10 and the medical grade oxygen 803 are mixed by each of cones 811 through 821 , which individually spin the combination, and output a resulting spun water via pipe 27 . In this embodiment, cone 811 is coupled to cone 813 by a pipe 812 , cone 813 is coupled to cone 815 by a pipe 814 , cone 815 is coupled to cone 817 by a pipe 816 , cone 817 is coupled to cone 819 by a pipe 818 , and cone 819 is coupled to cone 821 by a pipe 820 .
[0164] FIG. 7B is a schematic side view of an exemplary cone 811 , and FIG. 7C is a schematic top view of the exemplary cone 811 . Referring to FIG. 7B , pipe 523 is coupled to a tube 831 , for example, a double-bent tube, near the top of cone 811 . In this embodiment, tube 831 is preferably a crystal tube. Tube 831 preferably includes two ห90ยฐ bends 833 and 835 . Bends 833 and 835 are preferably ห90ยฐ, but can vary by plus or minus 45ยฐ. Also, bends 833 and 835 are preferably configured so as to impart a clockwise spin 837 in cone 811 . The combination of oxygen and water input to tube 831 is under high pressure of at least ห30 PSI and more preferably of at least ห34 PSI in order to create clockwise spin 837 in cone 811 . Pipe 812 is coupled to cone 813 in the same manner as pipe 523 is coupled to cone 811 , and this is also true for cones 813 through 821 as well.
[0165] Clockwise spin vortex 837 of the oxygen/water combination will be referred to herein as a clockwise vortex spin 837 . The ratio of the oxygen from medical grade oxygen machine 803 and the oxygen/water combination, together with the water pressure at tube 831 , determines the efficiency of the mixing of oxygen with water at cone 811 , as well as the rest of cones 813 - 821 . Lines 841 in vortex 837 disappear if oxygen from medical grade oxygen machine 803 is turned off. That is, clockwise vortex spin 837 remains but lines 841 disappear.
[0166] In the embodiment discussed above, the inner diameter of tube 523 is preferably หยผโฒ and the outer diameter is preferably หยฝโณ, the inner diameter of tube 831 is preferably หโ
โณ and the outer diameter is preferably หยผโณ. The tube 831 is preferably ห1ยพโณ long and preferably extends to a position หโ
โณ from the edge of cone 811 , and is preferably attached to cone 811 by, for example, a solder joint 811 A. Further, cone 811 preferably has a diameter D i at a top portion of ห6โณ and a diameter D b at a bottom portion of หโ
โณ.
[0167] FIG. 7D is a flow chart of a method for spinning water with oxygen using a cone system, according to one embodiment of the present invention. Step S 861 involves receiving the oxygen/water combination. Step S 863 involves combining the oxygen/water combination with medical grade oxygen. Step S 865 involves inputting the combination of oxygen/water and the medical grade oxygen into cone series 809 . Finally, step S 867 involves outputting spun water as super-oxygenated and structured water, with its negative ORP further enhanced and locked into the water.
[0168] FIG. 8A is a schematic side view and FIG. 8B is a schematic top view of a coil system, according to one embodiment of the present invention. Coil system 123 includes a coil 871 with an outer diameter D. In this embodiment, coil 871 is preferably a crystal coil. The outer diameter D of coil 871 can vary from ห4โณ to ห12โณ, and is preferably between ห5โณ and ห9โณ, and more preferably ห7 inches. Pipe 27 is coupled to tube 871 to form a bend 875 with an angle between ห45ยฐ and ห130ยฐ and preferably between ห65ยฐ and ห95ยฐ and more preferably ห90ยฐ. In particular, pipe 27 is coupled to tube 871 to form bend 875 and water flows through pipe 27 until it reaches bend 875 at which point it is abruptly redirected to the right to begin a clockwise flow down tube 871 until it is output at pipe 29 , as shown in FIG. 8A .
[0169] In this embodiment, tube 871 is preferably cylindrical with a round cross-section. However, other shapes, such as octagonal, hexagonal, or oval, for example, can also be used.
[0170] A crystal 881 is preferably arranged approximately in the center of coil 871 , as shown in FIG. 8A . The size of crystal 881 is preferably 3โณ or 12โณ, but is more preferably 7โณ. However, other crystal sizes may be used. The crystal 881 is arranged in a container 883 , which may contain a tincture or solution 885 . A battery 887 is preferably coupled via a wire 889 to crystal 881 and the other pole of battery 887 is preferably grounded in tincture or solution 885 via a wire 891 . As the water travels in a clockwise pattern down coil 871 it cuts through magnetic flux lines 893 created by the battery 887 and crystal 889 combination. The right hand or clockwise flow of the water pulls electrons into its orbit. If coil 871 is reversed, so as to provide a counterclockwise flow or a left hand spin of the water, then the left hand spin throws electrons out of the orbit. The water resulting from a left hand spin is beneficial for a short time because of detoxifying effects in the body. Independent of crystal 881 , a motion of the water in either a clockwise or counterclockwise fashion creates an electromagnetic field which can be measured, such as any charged particle in motion would create an electromagnetic field. In this embodiment, crystal 881 is preferably a vogel crystal. Solution 885 may contain herbs or any substance depending on the tint for the water. By placing different substances in solution 885 or by changing solution 885 , water output from pipe 29 can be tuned to that particular substance or solution. โTuneโ can refer to the modification of the structure, character and/or property of the water.
[0171] Crystal 881 oscillates at a particular resonance frequency, which can modify the water. These frequencies can vary from ห5 to ห9 Hz, and preferably from ห6 to ห8 Hz, and more preferably from ห6.8 to ห7.8 Hz, and even more preferably from ห7.2 to ห7.8 Hz.
[0172] FIG. 8C is a flow chart of a method performed by the coil system of FIGS. 8A-8B . In particular, FIG. 8C shows step S 893 , which involves creating a magnetic flux, and step S 895 , which involves passing water in a spiral fashion through the magnetic flux. The magnetic flux is preferably created using a crystal, as discussed with respect to FIG. 8A . Also, as water is passed in a spiral fashion, it can be passed in a clockwise spiral fashion through the magnetic flux in order to maintain free electrons in the water or in a counterclockwise fashion in order to give off electrons from the water.
[0173] FIGS. 9A and 9C are, respectively, schematic top and side views of a multi-coil system, according to one embodiment of the present invention. Multi-coil system 127 preferably includes coil sets 901 , 903 , 905 , and 907 . Coil sets 901 and 907 are preferably single coils, while coil sets 903 and 905 preferably contain inner coils 903 a and 905 a , respectively, and outer coils 903 b and 905 b , respectively.
[0174] Super-oxygenated and structured water mixed with structured ozone is input via pipe 35 to multi-coil system 127 . A series of magnets 912 may be optionally placed on pipe 35 prior to entry into multi-coil system 127 . These magnets can be any shape, but are preferably donut magnets and preferably north field magnets surrounding or placed directly on the pipe 35 .
[0175] As shown in FIG. 9A , coil set 901 is coupled to coil set 905 via a pipe 914 , coil set 905 is coupled to coil set 907 via pipe 916 , and coil set 907 is coupled to coil set 903 via pipe 918 . In this embodiment, water preferably enters coil set or coil 901 at a top portion, spirals down to a bottom portion of coil 901 and then passes via pipe 914 to coil set 905 . At coil set 905 , water preferably enters a bottom portion of inner coil 905 a and spirals up against gravity to a top portion of inner coil 905 a . The water then passes into outer coil 905 b and spirals down outer coil 905 b to a bottom portion, where it exits coil set 905 via pipe 916 . The water then preferably passes into a top portion of coil set or coil 907 and spirals downward to a bottom portion, where it exits coil 907 via pipe 918 . The water next preferably enters coil set 903 at a bottom portion of inner coil 903 a , spirals up (against gravity) to a top portion of inner coil 903 a , where it passes into outer coil 903 b before spiraling downward to a bottom portion of 903 b , where it exits coil set 903 and multi-coil system 127 via pipe 37 . The super-oxygenated, tuned and structured water is then directed to holding tank 109 via pipe 37 .
[0176] As shown in FIG. 9C , multi-coil system 127 includes an outer box 941 and an inner box 943 with mica 945 contained in between inner box 943 and outer box 941 . Coil sets 901 - 907 are preferably between ห5โณ and ห17โณ inches wide and preferably between ห14โณ and ห33 inches long, and more preferably ห7 inches wide and ห17 inches long. Inner coils 903 a and 905 a preferably have a diameter in the range of ห2โณ to ห9โณ, and more preferably between ห3โณ and ห5โณ, and most preferably ห3โณ.
[0177] FIG. 9B is a schematic side view of coil set 905 of FIG. 9A . Coil set 905 , includes outer coil 905 b and inner coil 905 a . As viewed from the top, the water spirals up the inner coil 905 a in a clockwise fashion until it reaches a top portion and then spirals down the outer coil 905 b where it exits the coil system 905 . Inner coil 905 a is preferably supported by one or more supports 1070 A, preferably two dowel rods, and the outer coil 905 b is preferably supported by one or more supports 1070 B, preferably a plurality of dowel rods. The supports 1070 A and 1070 B are preferably connected to coils 905 a and 905 b using plastic ties.
[0178] As shown in FIGS. 9D and 9E , the various pipes are connected to the various coils via a tube, preferably with a bend. In this embodiment, the tube is a glass tube with an ห90ยฐ bend. As can be seen in FIG. 9B , a crystal 923 may be placed at a base of the coil set 905 . Crystal 923 is preferably a double terminated quartz crystal, but is not limited to clear quartz. The crystals are centered at the base and extend up inside the coil. Extending the crystal further up into the coil reduces the effects. Coil set 903 also has an arrangement like that shown in FIG. 9B with respect to the coil set 905 . Each coil set 903 , 905 , and 907 also includes a crystal arranged as shown in FIG. 9B .
[0179] As shown in FIG. 9C , magnets 912 may be arranged on pipe 35 prior to entry into multi-coil system 127 , and serve to cancel frequencies that have been input or are otherwise contained in the water prior to input to multi-coil system 127 . Although multi-coil system 127 in this embodiment is shown with four coil sets, it can contain one, two, three or more than four coil sets, with various combinations of single and double coil sets. The inner diameter of the inner and outer coils for coil sets 901 - 907 is preferably ห 5/16 inches. The coils for coil sets 901 - 907 are preferably made of crystal and not pyrex. Crystal 923 , as well as the crystals for the other three coil sets, preferably have dimensions of ห17โณรห18โณ to ห3โณรห1โณ, and more preferably ห8ยฝ inches long and ห3ยฝ inches across double terminated.
[0180] FIG. 9F is a flow chart of a method performed by the multi-coil system of FIGS. 9A-9E . Step S 951 involves inputting water and structured ozone into a top portion of a first coil set or coil arranged in a first magnetic flux. Step S 953 involves passing the water/ozone combination clockwise down the first coil set. Step S 955 involves coupling the water/ozone combination into the bottom of an inner coil of a second coil set arranged in a second magnetic flux. Step S 957 involves passing the water/ozone combination clockwise up the inner coil of the second coil set. Step S 959 involves coupling the water/ozone combination into the outer coil of the second coil set. Step S 961 involves passing the water/ozone combination clockwise down the outer coil of the second coil set. Step S 963 involves coupling the water/ozone combination into a top portion of a third coil set arranged in a third magnetic flux. Step S 965 involves passing the water/ozone combination clockwise down the third coil set. Step S 967 involves coupling the water/oxygen combination into a bottom portion of an inner coil of a fourth coil set arranged in a fourth magnetic flux. Step S 969 involves passing the water/ozone combination clockwise up the inner coil of the fourth coil set. Step S 971 involves coupling the water/ozone combination into the outer coil of the fourth coil set. Step S 973 involves passing the water/ozone combination clockwise down the outer coil of the fourth coil set. Step S 975 involves outputting super-oxygenated, tuned, and structured water.
[0181] FIG. 10A is a block diagram of a structured ozone machine, according to one embodiment of the present invention. Structured ozone machine 125 includes a medical grade oxygen source 746 coupled via a pipe 749 to a standard ozone machine 751 . Medical grade oxygen is output from medical grade oxygen source 746 to ozone machine 751 , which in turn produces ozone, which is output via pipe 31 . Pipe 31 may be, for example, หโ
inch flex tubing. Two low Gauss magnets 753 are arranged on pipe 31 . Although the two low Gauss magnets are shown in this embodiment, a single low Gauss or more than two, including three, four, five, and so forth, low Gauss magnets can be arranged along pipe 31 . Where two low Gauss magnets are arranged on pipe 31 , they are preferably spaced between หยฝโณ and ห3 inches apart, and more preferably ห1 inch apart. In this case, the low Gauss magnets 753 are preferably magnets which are below ห1,000 Gauss, and more preferably below ห500 Gauss and most preferably ห200 Gauss each.
[0182] FIG. 10B is a flow chart of a method performed by the structured ozone machine of FIG. 10A to produce structured ozone. Step S 761 involves inputting medical grade oxygen into structured ozone machine 125 . Step S 763 involves generating ozone using the medical grade oxygen. Step S 765 involves passing the ozone generated from the medical grade oxygen through a magnetic flux to yield structured ozone.
[0183] The water flow throughout the system is preferably controlled to enhance the system'S performance. That is, pipe diameters and pressures at each point P in the system are preferably configured to ensure proper functioning. Referring to FIG. 1A , pipe diameters and water pressure at each point P are preferably as follows.
[0184] At Point P 1 : Pipe diameter is preferably หยฝ to ห3 inch(es), more preferably ห1 to ห1ยผ inch(es), most preferably ห1ยผ inches. Pressure is preferably ห17 to ห36 psi, more preferably ห18 to ห30 psi, most preferably ห27 psi.
[0185] At Point P 2 : Pipe diameter is preferably หโ
to ห1ยฝ inch(es), more preferably หยพ to ห1ยผ inch(es), most preferably ห1 inch. Pressure is preferably ห17 to ห36 psi, more preferably ห18 to ห26 psi, most preferably ห22 psi.
[0186] At Point P 3 : Pipe diameter is preferably หโ
to ห1ยฝ inch(es), more preferably หยพ to ห1ยผ inches(es), most preferably ห1 inch. Pressure is preferably ห12 to ห20 psi, more preferably ห12 to ห15 psi, most preferably ห15 psi.
[0187] At Point P 4 : Pipe diameter is preferably หโ
to ห1ยผ inch(es), more preferably หยฝ to ห1 inch(es), most preferably ห1 inch. Pressure is preferably ห12 to ห20 psi, more preferably ห12 to ห15 psi, most preferably ห15 psi.
[0188] At Point P 5 : Pipe diameter is preferably หยพ to ห1ยฝ inch(es), more preferably หยพ to ห1 inch(es), most preferably ห1 inch. Pressure is preferably ห40 to ห80 psi, more preferably ห40 to ห60 psi, most preferably ห69 psi.
[0189] At Point P 6 : Pipe diameter is preferably หยผ to โยพ inch(es), more preferably หยผ to หโ
inch(es), most preferably หโ
inch. Flow rate should be preferably 5 liters per minute. (Pressure preferably ห22 to ห60 psi, more preferably ห30 to ห45 psi, most preferably ห44 psi.)
[0190] At Point P 7 : Pipe diameter is preferably หยผ to ห1ยผ inch(es), more preferably หยฝ to หยพ inch(es), most preferably หยฝ inch. Pressure is preferably ห50 to ห75 psi, more preferably ห49 to ห69 psi, most preferably ห69 psi.
[0191] At Point P 8 : Pipe diameter is preferably หยผ to หยพ inch(es), more preferably หยฝ to หโ
inch(es), most preferably หยฝ inch. Pressure is preferably ห5 to ห25 psi, more preferably ห5 to ห10 psi, most preferably ห7-10 psi.
[0192] At Point P 9 : Pipe diameter is preferably หยฝ to ห1 inch(es), more preferably หโ
to หยพ inch(es), most preferably หยพ inch. Pressure is preferably ห18 to โ35 psi, more preferably ห18 to ห25 psi, most preferably ห25 psi.
[0193] At Point P 10 : Pipe diameter is preferably หยผ to หยพ inch(es), more preferably หยผ to หยฝ inch(es), most preferably หยฝ inch. Pressure is preferably ห18 to ห35 psi, more preferably ห30 to ห42 psi, most preferably ห40-42 psi.
[0194] At Point P 11 : Pipe diameter is preferably หยผ to หยพ inch(es), more preferably หโ
to หยฝ inch(es), most preferably หยฝ inch. Pressure is preferably ห15 to ห50 psi, more preferably ห20 to ห40 psi, most preferably ห34 psi.
[0195] At Point P 12 : Pipe diameter is preferably ห 1/16 to หยผ inch(es), more preferably ห 1/16 to หโ
inch(es), most preferably หโ
inch. Flow rate is preferably โ
liter per minute.
[0196] At Point P 13 : Pipe diameter is preferably ห 1/16 to หยพ inch(es), more preferably หโ
to หยฝ inch(es), most preferably หยฝ inch. Pressure is preferably ห10 to ห25 psi, more preferably ห10 to ห18 psi, most preferably ห15-18 psi.
[0197] At Point P 14 : Pipe diameter is preferably ห 1/16 to หยพ inch(es), more preferably หโ
to หยฝ inch(es), most preferably หยฝ inch. Pressure is preferably ห15 to ห35 psi, more preferably ห18 to ห22 psi, most preferably ห22 psi.
[0198] At Point P 15 : Pipe diameter is preferably ห 1/16 to หยพ inch(es), more preferably หโ
to หยฝ inch(es), most preferably หยฝ inch. Pressure is preferably ห15 to ห75 psi, more preferably ห22 to ห60 psi, most preferably ห30-40 psi.
EXAMPLE 1
Heart Rate and Excercise Performance
[0199] The present example is provided to demonstrate the utility of the present invention for maintaining and/or restoring a desired physiological fluid oxygen level in an animal. In particular aspects, the present example will also demonstrate the utility of the present compositions for maintaining, and in some aspects normalizing, a reduced oxygenated blood level in an animal subsequent to a blood oxygen-lowering effect activity, such as what typically occurs in an animal, such as a human, after an oxygen-consuming activity, such as exercise. Changes in these physiologically measurable parameters are typically attendant an increase in physical activity, stress or other fatigue-inducing event.
[0200] The parameters that were measured in the present study were changes in subjects consuming the oxygen-enriched, microstructured water preparations verses subjects consuming conventional bottled water. The changes in these two subject populations were monitored for changes in heart rate, changes in oxygen saturation, changes in blood lactate, changes in oxygen consumption, and changes in fatigue assessment by a patient in response to a defined exercise regimen after having consumed a defined quantity of the oxygen-enriched, structured and/or microstructured water, or after consuming a conventional bottled water.
[0201] The present study was a randomized, double blind crossover study. Subjects were recruited from training facilities in Montreal. Subjects were tested on four different days during a two-week period. The subjects comprised a group of males and females of at least 18 years in age in good physical condition. None of the test subjects had any history of serious chronic disease. Each of the test subjects had been in physical training during the previous year, training at least 2 times per week, during the time preceding their participation in the present study.
[0202] The test subjects were randomly assigned to a group to receive the oxygen enriched, structured and microstructured water preparation verses a preparation of conventional tap or bottled water (Placebo).
[0203] The total duration of the study was 14 days, comprised of four (4) evaluation visits. Each subject, depending on the group assigned, was asked to drink 500 ml of the oxygen-enriched structured and microstructured water or 500 ml of the bottled Santa Fe municipal city water. Each subject was then asked to sit for 5 minutes. After 5 minutes, a baseline physiological set of measurements were recorded for each subject. These measurements included heart rate, blood pressure, blood oxygen, blood oxygen saturation, and blood lactate.
[0204] Once recorded, the subject began a 5-minute warm-up on a treadmill. After this warm-up period, the subject began a multi-stage VO 2 -max test. Each subject then underwent a standardized five-step exercise tolerance test to fatigue. During this test, each subject was asked to consume 500 ml of the oxygen-rich, microstructured water or bottled spring water, according to the initial test group to which they were originally assigned. (Total consumption by each test subject was between ยฝ and ยพ liter).
[0205] The multi-stage VO 2 -max test commenced at a speed of 11.3 km/hr (7.02 miles/hr) and a slope of 2 degrees. The slope was then progressively increased by 2 degrees every minute. At the end of each stage, heart rate, blood pressure and blood oxygen saturation were measured. Upon maximal exertion, VO 2 max was calculated and blood lactate was measured. A visual analog scale was used to assess perceived fatigue (i.e., maximal exertion), at the end of the VO2 max. For this determination, the subject was asked to place an โXโ on a 10 cm line indicating how tired they felt at the end of the VO 2 max test with one end of the line indication no fatigue (0), and the other end indication exhaustion (10). This routine was repeated with the same product 2 days later. A third visit took place one week later when subjects were asked to return to the gym.
[0206] Each subject then completed the same protocol of exercise a second time, this time consuming the opposite product (i.e., Group 1-Bottled Santa Fe Municipal City Water (Placebo) consumed (ยฝ to ยพ liter) during Exercise Test Session 1; Group 1-Oxygen-enriched, Structured and Microstructured water (AGFW) consumed (ยฝ to ยพ liter) during Exercise Test Session 2) (Group 2-Bottled Spring Water (Placebo) consumed (1 Liter) during Exercise Test Session 1 (1 Liter); Group 2-Oxygen-enriched, Microstructured Water (AGFW) during Exercise Test Session 2).
[0207] As demonstrated in the data presented at Tables 1, 2 and 3, the performance parameters that were assessed and compared in response to consumption of the oxygen-enriched, microstructured water preparations were heart rate, oxygen saturation, blood lactate, and oxygen consumption and fatigue assessment. As used in this study and others described throughout this application, โfatigueโ is defined as the length of physical exertion needed for the subject to assess subjectively an exhaustion level of at least 7 on a scale of 0 to 10.
[0208] Table 1 presents the data collected from the subjects at a first visit and at a second visit. Table 2 presents the change demonstrated in each of the performance parameters. Table 3 presents an analysis of the differences between the changes observed in each of the performance parameters examined.
TABLE 1 Exercise Performance Parameters by Visit and Treatment Period Visit 1 Visit 2 Parameter: AGFW Placebo P-Value AGFW Placebo P-Value Change in Mean (SD) 86.93 (18.15) 76.00 (15.60) 0.001 76.25 75.76 0.999 Heart Rate (14.70) (13.64) 95% C.I. 81.38, 92.49 71.22, 80.78 71.76, 71.60, 79.96 80.75 Change in Mean (SD) โ2.05 (2.53) โ1.90 (2.32) 0.377 โ2.22 โ1.85 (2.37) 0.198 Oxygen (1.67) Saturation 95% C.I. โ2.82, โ1.27 โ2.61, โ1.19 โ2.73, โ2.58, โ1.13 (%) โ1.71 Blood Mean (SD) 11.30 (3.64) โ9.43 (3.52) 0.007 10.29 โ9.44 (4.05) 0.125 Lactate (3.09) 95% C.I. 10.19, 12.41 โ8.35, 10.50 โ9.34, โ8.20, 10.68 11.23 Calculated Mean (SD) 66.37 (4.23) 66.05 (4.47) 0.407 66.39 66.59 (4.92) 0.750 Oxygen (4.50) Consumption 95% C.I. 65.07, 67.66 64.68, 67.42 65.01, 65.08, 68.09 67.77 Fatigue Mean (SD) 11.94 (2.36) 11.94 (1.89) 0.539 11.94 11.82 (2.17) 0.744 Assessment (2.25) 95% C.I. 11.18, 12.66 11.36, 12.52 11.25, 11.16, 12.49 12.63
[0209]
TABLE 2
Change in Exercise Performance Parameters between Visits by
Treatment Period
AGFW
Placebo
P-Value
P-Value
P-Value
Within
Within
Between
Parameter:
Estimate
Treatment
Estimate
Treatment
Treatment
Change in
Mean (SD)
โ10.68
0.932
โ0.22 (13.17)
0.081
0.002
Heart Rate
(16.11)
95% C.I.
โ15.61, โ5.75
โ4.25, 3.81
Change in
Mean (SD)
โโ0.17 (2.13)
0.067
โ0.05 (2.72)
0.070
0.519
Oxygen
95% CI.
โโ0.83, 0.48
โ0.78, 0.88
Saturation
(%)
Blood
Mean (SD)
โโ1.01 (4.08)
0.604
โ0.01 (3.89)
0.814
0.241
Lactate
95% C.I.
โโ2.26, 0.23
โ1.18, 1.20
Calculated
Mean (SD)
โ0.02 (2.41)
0.040
โ0.54 (2.51)
0.001
0.267
Oxygen
95% C.I.
โโ0.71, 0.76
โ0.23, 1.31
Consumption
Fatigue
Mean (SD)
โ0.00 (2.80)
0.342
โ0.12 (2.19)
0.852
0.632
Assessment
95% C.I.
โโ0.85, 0.86
โ0.79, 0.55
[0210]
TABLE 3
Difference in Change in Exercise Performance Parameters
between Treatment Periods
Absolute
Percent
P-Value
P-Value
Between
Between
Parameter:
Estimate
Treatment
Estimate
Treatment
Change in
Mean
10.46, 19.43
0.002
โ0.65 (4.95)
0.038
Heart Rate
(SD)
95%
โ4.51, 16.41
โ2.18, 0.89
C.I.
Change in
Mean
โ0.22 (3.65)
0.519
โ1.43 (1.74)
0.041
Oxygenation
(SD)
(%)
95%
โ0.89, 1.34
โ2.04, โ0.82
C.I.
Blood
Mean
โ1.03 (4.75)
0.241
โ0.26 (8.17)
0.001
Lactate
(SD)
95%
โ0.43, 2.48
โ2.24, 2.76
C.I.
Calculated
Mean
โ0.51 (3.31)
0.267
โ0.49 (1.84)
0.002
Oxygenation
(SD)
95%
โ0.50, 1.53
โ1.23, 0.25
C.I.
Fatigue
Mean
โ0.12 (3.29)
0.632
โ0.59 (4.79)
0.050
Assessment
(SD)
95%
โ1.13, 0.89
โ2.08, 0.90
C.I.
[0211] Results:
[0212] The following efficacy outcome measures were defined to assess the effect of consuming the oxygen-enriched water preparations on exercise performance in the subject participants.
[0213] For each parameter, the measurement at each visit was determined as Pl1 (Placebo, first visit), Pl2 (Placebo, visit 2), AGFW1 (Oxygen-enriched water, visit 1), and AGFW 2 (oxygen-enriched water, visit 2).
[0214] For each subject, the following variables were calculated:
CHANGE BETWEEN VISIT 2 AMD VISIT 1 FOR PLACEBO:
DPl 2-1 : Pl 2โ Pl 1
CHANGE BETWEEN VISIT 2 AND VISIT 1 FOR OXYGEN-ENRICHED PRODUCT (AGFW):
DAGFW 2โ1 : AGFW 2 โAGFW 1
CHANGE BETWEEN AGFW AND PLACEBO:
DAGFW 2-1 โDP 2-1
PERCENT CHANGE BETWEEN AGFW AND PLACEBO:
100% ร(DAGFW 2-1 โDPl 2-1 )/DPl 2-1
[0219] The primary outcome variable for the studies was the latter variable that measures the percent difference in the effect between the oxygen-enriched water and the placebo.
[0220] Statistical Methods:
[0221] Given that each subject used both the placebo and the oxygen-enriched preparations, and the fact that the distribution of the study outcomes deviated from normal due to the small sample size, the Kolmogorov-Smirnov paired, non-parametric tests were used to assess the statistical significance of the different water regimens. The null hypothesis tested was the mean change between the oxygen-enriched preparations (AGFW) and the placebo was zero. Two tailed significance testing was used. When the distribution of the variable deviated from the normal, the non-parametric was used.
[0222] Change in Heart Rate:
[0223] At visit one, a significant difference was observed in the heart rate of patients consuming the oxygen-enriched, structured and microstructured water, compared to subjects who consumed conventional tap water. At visit 1, a significant difference was observed in heart rate.
[0224] Heart rate (HR) is proportional to the work rate in physical activities with anaerobic energy supply. The relationship between HR and workload is highly reproducible for any individual (1). The simple way of registering HR has made it the most widely used estimate of metabolic strain in training or competition for many types of exercise (2-4). The measurement of heart rate in this study was based on the change in pulse between the beginning and the end of the exercise test defined as 80% maximum capacity. The reduction of change in heart rate during exercise until fatigue indicates that subjects who consumed the oxygen-enriched water increased their endurance by significantly reducing the increase of pulse by 65%.
[0225] The mean (SD) percent change was 0.65 (4.95), indicating that when subjects consumed the oxygen-enriched water, the change in heart rate during exercise to fatigue was reduced by 65% when compared to placebo.
EXAMPLE 2
Change in Oxygen Saturation
[0226] The present example demonstrates the utility of the present compositions and methods for inhibiting and/or onset of fatigue in a human. The maintenance of oxygen saturation levels (i.e., decreasing the change in oxygen saturation levels attendant exercise) in response to exercise is also demonstrated.
[0227] Oxygen saturation measurements were taken during the exercise periods. The change in oxygen saturation between beginning of the exercise and the end was used for the determination of effect on oxygen saturation.
[0228] When subjects consumed the oxygen-enriched water product, the change in blood oxygen saturation after a period of exercise was significantly less than the dramatic drop in blood oxygen saturation demonstrated after exercise in subjects that consumed the bottled Santa Fe municipal city water (placebo).
[0229] The results show that when the subjects used the oxygen-enriched preparations, the drop in oxygen saturation was less by a factor of 1.5 (150% ), in comparison to the drop in oxygen saturation demonstrated in subjects consuming the Santa Fe Municipal City bottled water preparations (placebo). This effect is statistically significant (P=0.041).
EXAMPLE 3
Blood Lactate
[0230] The present example demonstrates the utility of the present compositions and methods for inhibiting and/or reducing the increase in levels of blood lactate attendant exercise in a human. In addition, and because blood lactate level may be directly correlated with lactic acid accumulation in muscle attendant exercise, the present example also demonstrates the utility of the presently described methods and compositions for reducing muscle soreness, and for reducing lactic acid accumulation in muscle as indicated by blood lactate levels. The present study demonstrates that consumption of the defined oxygen enriched preparation significantly inhibited (i.e., reduced) the typical increase in blood lactate levels saturation typically attendant exercise.
[0231] Patients were treated and monitored as outlined in Example 1. Blood lactate levels were obtained from all subjects. The data from these studies is presented in Tables 1, 2 and 3.
[0232] Blood Lactate:
[0233] Blood lactate levels were at least 89.95% lower in subjects consuming the oxygen-enriched water preparations, compared to blood lactate levels in subjects consuming the bottled water preparation (Placebo), after the defined exercise regimen. This difference is statistically significant (P=0.010).
[0234] Lactic Acid:
[0235] Lactate in the blood can be correlated with the accumulation level of lactic acid in muscle tissue; the present data also provides indication that the consumption of the oxygen-enriched water preparations as defined herein can significantly reduce lactic acid accumulation in tissues. It is thus further expected that the use of the oxygen-enriched water preparations as herein defined can significantly reduce the muscle soreness/burning typically attendant periods after extreme exercise.
EXAMPLE 4
Calculated Oxygen Consumption:
[0236] The present example is presented to demonstrate the utility of the present methods for reducing and/or inhibiting the significant and sudden increase on oxygen consumption attendant exercise n a human.
[0237] Subjects were treated according to the regimen outlined in Example 1. The oxygen consumption data collected from the subjects that consumed the oxygen-enriched microconstructed water (AGFW) or the bottled spring water (Placebo) is presented at Tables 1, 2 and 3.
[0238] The study demonstrated that consumption of the defined oxygen enriched preparation significantly inhibited (i.e., reduced) the characteristic increase in oxygen consumption levels saturation typically attendant exercise.
[0239] Over a period of three days of consumption the oxygen-enriched water preparations, a much more static, conservative and constant amount of oxygen consumption was achieved by the body. This is contrasted by the significant increase in oxygen consumption illustrated by the significant increase in oxygen consumption. Oxygen consumption was reduced by 50%. This change was also statistically significant (P=0.004).
EXAMPLE 5
Enhanced Endurance/Fatigue Onset Assesment
[0240] The present example is presented to demonstrate the utility of the present methods and compositions for reducing and/or inhibiting the onset of fatigue in response to exercise in a human.
[0241] Subjects were treated according t the regimen outlined in Example 1. The fatigue assessment data from the subjects that consumed the oxygen-enriched microstructured water (AGFW) or the bottled Santa Fe Municipal City water (Placebo) is presented at Tables 1, 2 and 3.
[0242] The mean standard deviation (SD) percent change was 0.65 (4.95), indicating that when subjects consumed the oxygen enriched preparations, the change in heart rate during exercise to fatigue was reduced by 65 % when compared to placebo.
[0243] A statistically significant difference with respect to subjective assessment of fatigue by a factor of 59% in subjects consuming the oxygen-enriched preparations. (P=0.04).
EXAMPLE 6
Increase in Blood Oxygen
[0244] The present example is presented to demonstrate the utility of the present methods and compositions for increasing and/or replenishing available oxygen in the blood stream by consuming the oxygen-enriched microstructured water preparations.
[0245] The present studies were conducted on humans using a medical oximeter. In these studies, it was demonstrated that consumption of the oxygen-enriched, microstructered component containing water compositions of the present invention greatly increased the availability of oxygen in the bloodstream. Using the oximeter, it is shown that a person'S blood oxygen levels taken at high altitude (over 5,000 feet) can be increased within two minutes of consuming the enriched oxygen, microstructured water. The overall increase in oxygen in the blood at high altitudes usually increases from three (3) to six (6) points after drinking either ounces of the oxygen enriched, microstructured water. A medical grade oximeter provides an accurate analysis of blood oxygen levels that is not invasive to the patient and that is immediately detectable. The accuracy of the device is +/โ2%. The device is slipped over the top of, for example, a finger, and allowed to moniter and take a reading of the patient/subject both before and after consuming the appropriate amount of the oxygen enriched, microstructured water.
[0246] The medical grade oximeter used in the present example demonstrated a measurable increase in the blood hemoglobin levels of the patient. These results demonstrate the utility of using the presently disclosed methods and compositions for the treatment of a variety of conditions associated and/or linked with low blood oxygen, such as altitude sickness. In addition, it is anticipated that the present compositions are also useful as a preferred beverage for consumption by professional athletes and/or those persons involved in any competitive sport, and provide for an enhancement of the persons endurance and performance as a result of the increase in available blood oxygen.
EXAMPLE 7
Blood Oxygen Stability in Open (Non-Pressurerized) Conditions
[0247] The present example demonstrates that the oxygen-enriched preparations herein are capable of retaining a higher concentration and/or amount of oxygen under open-air (i.e., open container) conditions. Absent the microstructured nature of the present preparations, the oxygen concentration would decrease and leak/evaporate away.
[0248] A WTW 300 DO meter was used to test and determine oxygen content and stability in the oxygenated alkaline structured water (this water was 6 months old). The oxygen content was tested at 76 ppm and tested every hour on the hour for three days. The water was placed in a 4 inch open beaker in a warehouse that had no air conditioning. Temperatures ranged from 74ยฐ F. at night to 101ยฐ F. during the day. Even after agitating the water in the four inch wide beaker every hour after three days, the first hour of the fourth day there was approximately 30 ppm of oxygen in the water. When the water was subsequently boiled, frozen and shaken, the water still was just as effective biologically even though the oxygen was reduced to 30% of its original levels using a DO meter.
[0249] The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the invention. The present teaching can be readily applied to other types of apparatuses. The description of the invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures.
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A physiologically ingestible composition comprising microstructured water consisting essentially of hydrogen and oxygen atoms and having a melting point lower than double distilled water is used. The physiologically ingestible composition may be administered to inhibit changes in the heart rate of a mammal undergoing stress.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The disclosure of Japanese Patent Application No. 2012-056272 filed on Mar. 13, 2012, and on which this application claims priority, is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a chain transmission device including an endless, flexible, transmission chain in mesh with a set of sprockets, the chain having alternating, interconnected, guide rows and link rows, each guide row having guide plates.
[0003] The chain can be a silent chain or any of various other kinds of transmission chains. The chain transmission device can be used as a timing chain in an automobile engine, or as a power transmission chain in a vehicle or in other kinds of machines such as industrial machinery.
BACKGROUND OF THE INVENTION
[0004] A conventional chain transmission device includes an endless chain in which a plurality of guide rows and a plurality of link rows are arranged alternately in the longitudinal direction of the chain and connected to one another flexibly. Each of the guide rows has a pair of guide plates and one or more link plates arranged between the pair of guide plates in the widthwise direction of the chain. Each of the link rows has a plurality of second link plates. The transmission includes a plurality of sprockets around which the chain is wrapped. An example of such a transmission is described in United States Patent publication 2004/0166978, published on Aug. 26, 2004.
[0005] As shown in FIGS. 11 and 12 , a chain transmission 500 includes a chain 530 which has a wrapping portion 531 wrapped around and engaging with a sprocket 510 of a sprocket set. A pair of guide plates 540 of a guide row G 5 of the chain 530 guide first and second link plates 560 and 570 along the longitudinal direction of the chain. In the wrapping portion 531 , the pair of guide plates 540 may come into contact with side surfaces 512 of the sprocket 510 to restrict sideslip, i.e., movement of the chain 530 in the widthwise direction.
[0006] Noise is generated when the guide plates 540 come into contact with the sprocket side surfaces 512 . In addition, power transmission efficiency is impaired by friction between the guide plates 540 and the sprocket side surfaces 512 .
[0007] Furthermore, when a plurality of the guide rows G 5 are regularly arranged in a chain longitudinal direction, the guide plates 540 come into contact with the sprocket side surfaces 512 at regular intervals, causing generation of periodic sounds.
[0008] This invention addresses the above problems. It is an object of the invention to provide a chain transmission in which some of guide rows of a chain have non-contact guide plates which do not come into contact with side surfaces of the sprockets in order to decrease noise and friction caused by contact between guide plates of the guide rows and the side surfaces of the sprockets, and to reduce the weight of the chain.
SUMMARY OF THE INVENTION
[0009] The chain transmission according to the invention comprises a chain and a plurality of sprockets, at least one of the sprockets being in driving relationship with the chain, and at least one of the sprockets being in driven relationship with the chain. The chain is elongated in a lengthwise direction and has a width in a widthwise direction perpendicular to the lengthwise direction. The chain comprises a plurality of guide rows and a plurality of link rows, the guide rows and link rows being arranged alternately along the lengthwise direction of the chain and flexibly interconnected to one another. Each of the guide rows has a pair of guide plates spaced from each other in the widthwise direction and at least one first link plate disposed between the pair of guide plates. Each of the link rows has a plurality of second link plates. At any time during the operation of the transmission, the chain has a plurality of wrapping portions, a wrapping portions being in engagement with, and extending around, a portion of each of the sprockets. Each of guide plates of each of the guide rows is a guide plate from the group consisting of contact guide plates, which are able to come into contact with side surfaces of the sprockets when in a wrapping portion of the chain, and non-contact guide plates, which do not come into contact with sprocket side surfaces when in the wrapping portion of the chain. The guide rows of the chain include at least one contact guide row having at least one contact guide plate, and at least one non-contact guide row having only non-contact guide plates.
[0010] The contact guide plates of the contact guide rows restrict sideslip of the chain. However, because some of the guide rows of the chain are non-contact guide rows having only non-contact guide plates, the number of the guide rows that come into contact with side surfaces of the sprockets and the sprocket teeth is reduced. Consequently, noise and friction caused by the contact between guide plates and the sprocket side surfaces are reduced, and power transmission can take place more efficiently. In addition, because the non-contact guide plates are lighter in weight than the contact guide plates, impact noise generated when the contact guide plates come into contact with the sprocket side surfaces is reduced. The weight of the chain is also reduced, and therefore the overall weight of the machinery of which the chain is a part is reduced.
[0011] According to a second aspect of the invention, at least one of the wrapping portions of the chain always includes at least one contact guide row having at least one contact guide plate, and a plurality of non-contact guide rows each having only non-contact guide plates. Here, because at least one of the wrapping portions always includes a contact guide row, it is possible to restrict sideslip of the chain. Because at least one of the wrapping portions always includes a plurality of the non-contact guide rows, the weight of the wrapping portions is reduced, and impact noise and friction loss are reduced.
[0012] According to a third aspect of the invention, in each of the wrapping portions, the number of non-contact guide rows is always greater than the number of contact guide rows. Here, because the wrapping portions always include a larger number of non-contact guide rows than contact guide rows, the weight of the wrapping portions is still further reduced. Thus, it is possible to realize a further decrease in impact noise and friction.
[0013] According to a fourth aspect of the invention, the pair of guide plates of each of the guide rows consists of a first and second guide plates opposed to each other in the widthwise direction and provided on opposite sides of the chain. The contact guide rows of the chain comprise at least one first contact guide row, the first and second guide plates of which are contact guide plates, and a plurality of second contact guide rows one of the first and second guide plates of which is a contact guide plate and the other of the first and second guide plates of which is a non-contact guide plate. The plurality of second contact guide rows consists of guide rows from the group consisting of type 1 contact guide rows the first and second guide plates of which are respectively contact guide plates and non-contact guide plates and type 2 contact guide rows the first and second guide plates of which are respectively non-contact guide plate and contact guide plates.
[0014] At least one of the wrapping portions always includes at least one guide row from the group consisting of: (a) at least one first contact guide row, (b) at least one first contact guide rows and at least one second contact guide row; and (b) at least one said type 1 contact guide row and at least one said type 2 contact guide rows.
[0015] With this configuration the chain is restricted against chain sideslip bidirectionally.
[0016] According to a fifth aspect of the invention, the pair of guide plates of each of the guide rows consists of a first and second guide plates opposed to each other in the widthwise direction and provided on opposite sides of the chain. Each of the contact guide rows is a guide row from the group consisting of a type 1 contact guide row the first and second guide plates of which are respectively a contact guide plate and a non-contact guide plate, and a type 2 contact guide row the first and second guide plates of which are respectively a non-contact guide plate and a contact guide plate, and at least one of the wrapping portions always includes at least one type 1 contact guide row and at least one type 2 contact guide row.
[0017] Here, because at least one of the wrapping portions always includes at least one type 1 contact guide row and at least one type 2 contact guide row, it is possible to restrict sideslip of the chain bidirectionally.
[0018] According to a sixth aspect of the invention, each of guide plates of each contact guide row is a contact guide plate. Here again, because each of guide plates of the contact guide row is a contact guide plate, it is possible to restrict sideslip bidirectionally in the wrapping portion.
[0019] According to a seventh aspect of the invention, one of the pair of guide plates of at least one of the contact guide rows is a contact guide plate and the other guide plate of the pair is a non-contact guide plate. Here it is possible not only to restrict sideslip of the chain, but also to reduce the weight of the wrapping portions, and to decrease impact noise and friction.
[0020] According to an eighth aspect of the invention, a plurality of the contact guide rows are arranged randomly in the lengthwise direction of the chain. Here, because contact between the guide plates and the sprocket side surfaces does not occur at regular intervals, periodic contact noise is decreased.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is an elevational view illustrating a chain transmission device in accordance with a first embodiment of the invention;
[0022] FIG. 2 is an enlarged view, partly in section, of a part of the chain in the transmission of FIG. 1 , as viewed in the direction of arrow 2 in FIG. 1 ;
[0023] FIG. 3 is a cross sectional view of the chain transmission of FIG. 1 , taken on section plane 3 a - 3 a or section plane 3 b - 3 b in FIG. 1 ;
[0024] FIG. 4 is an elevational view of a part of the chain of FIG. 3 , as viewed in the direction of arrow 4 in FIG. 3 ;
[0025] FIG. 5 is an elevational view illustrating a chain transmission device in accordance with a second embodiment of the invention;
[0026] FIG. 6 is a cross-sectional view of the second embodiment shown in FIG. 5 , taken on section plane 6 - 6 in FIG. 2 ;
[0027] FIG. 7 is an elevational view illustrating a chain transmission device in accordance with a third embodiment of the invention;
[0028] FIG. 8 is a sectional view, corresponding to FIG. 6 , illustrating the third embodiment shown in FIG. 7 ;
[0029] FIG. 9 is an elevational view illustrating a chain transmission device in accordance with a fourth embodiment of the invention;
[0030] FIG. 10 is a sectional view, corresponding to FIG. 6 , illustrating the fourth embodiment shown in FIG. 9 ;
[0031] FIG. 11 is a view, corresponding to FIG. 2 , illustrating a part of a chain transmission of the prior art; and
[0032] FIG. 12 is an elevational view of a part of the chain of FIG. 11 , as viewed in the direction of arrow 12 in FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] In the following description, the term โguide plateโ should be understood as referring to a plate in the position of a guide plate, whether or not it Is capable of coming into contact with the side of a sprocket. The invention can be embodied in any chain transmission comprising a chain and a plurality of sprockets, at least one of the sprockets being in driving relationship with the chain, and at least one of the sprockets being in driven relationship with the chain. For example, the chain may be a silent chain or any chain having link plates corresponding to a pair of guide plates.
[0034] The chain transmission can be utilized not only in an automobile engine, but also in industrial machinery, conveying or carrying machines, and other machines that utilize a chain for transmission of power. While a typical chain transmission has one driven sprocket and one driving sprocket, the chain transmission can have more than one driven sprocket and can have more than one driving sprocket. The driving sprocket or sprockets can be operated by an internal combustion engine, an electric motor, or any of various other kinds of power generating devices for rotating a sprocket.
[0035] The transmission device 100 shown in FIG. 1 , which can be a timing drive in an automobile engine (not shown), comprises an endless silent chain 130 . Referring to FIGS. 1 , 2 and 4 , the chain transmission 100 also has a sprocket set 101 in mesh with the chain. The sprocket set 101 includes a driving sprocket 110 and a driven sprocket 120 . The driving sprocket 110 is rotated by the crank shaft of an engine, and the driven sprocket 120 rotates a valve-operating camshaft in the engine or the drive shaft of an engine accessory such as an oil pump. The sprockets 110 and 120 respectively have sprocket teeth 111 and 121 which are capable of meshing engagement with the chain 130 .
[0036] Referring to FIGS. 1 to 4 , the chain 130 includes a plurality of guide rows G, a plurality of link rows L, and a plurality of connecting pins 150 ( FIG. 2 ), which connect the guide rows G with the link rows L. The guide rows G are arranged alternately with the link rows L and the connecting pins allow relative articulation of the guide rows and link rows.
[0037] Each of the guide rows G includes a pair of guide plates 140 , and one or more first link plates 160 disposed between the pair of guide plates. In the chain shown in FIGS. 2 and 3 , each guide row includes a plurality of first link plates 160 . Each first link plate 160 has a pair of pin holes 161 spaced from each other in the longitudinal direction of the chain, and a pair of teeth 162 ( FIG. 4 ) capable of engaging with the sprocket teeth.
[0038] Each of the link rows L includes a plurality of second link plates 170 , which are arranged in spaced, side-by-side relationship in the widthwise direction of the chain. The number of second link plates in each link row L exceeds by one the number of first link plates 160 in each guide row G. The second link plates 170 in each of the link rows L extend into a space between a pair of guide plates 140 of a first adjacent guide row and into a space between a pair of link plates in another adjacent guide row. Each second link plate has a pair of second pin holes 171 , spaced from each other in the longitudinal direction of the chain, and a pair of teeth 172 capable of engaging the sprocket teeth 111 and 121 .
[0039] Each of the connecting pins 150 is a rocker joint pin composed of a first pin 151 and a second pin 152 , which is shorter than the first pin 151 . The first and second pins 151 and 152 are inserted together through the first and second pin holes 161 and 171 and extend through the first and second link plates 160 and 170 in the widthwise direction of the chain.
[0040] Each of the guide plates 140 of a guide row G has a pair of pin-holding holes 149 , spaced from each other in the longitudinal direction of the chain, for holding the first pins 151 . By insertion into the pin-holding holes, each first pin 151 is fixed to the guide plates 140 at both ends thereof. Although the connecting pins in the embodiment illustrated are rocker joint pins, as an alternative, each of the connecting pins can be a single cylindrical pin.
[0041] As shown in FIG. 1 , the chain 130 includes wrapping portions 131 and 132 which respectively extend in arcs around parts of sprockets 110 and 120 , and engage the sprocket teeth 111 and 121 . The portions of the chain that are not wrapped around the sprockets are free span portions 133 that extend from one sprocket to the other.
[0042] Referring to FIG. 2 , the pair of guide plates 140 of each of the guide rows consists of a first guide plate 141 provided at one end of the guide row, and a second guide plate 142 at the other end of the guide row, these two guide plates being in opposed relation to each other and spaced from each other in the widthwise direction of the chain. It does not matter which of the guide plates 140 is the first guide plate 141 or the second guide plate 142 ; when one of the pair of guide plates 140 is the first guide plate 141 , the other is the second guide plate 142 . Each of the first and second guide plates 141 and 142 of each of the guide rows G is either a contact guide plate P 1 (indicated by dark hatching in FIG. 1 ) or a non-contact guide plate P 0 (indicated by light hatching in FIG. 1 ).
[0043] A contact guide plate P 1 is able to come into contact with a side surface of sprocket 110 and with a corresponding side surface of sprocket 120 . Depending on a running condition of the chain 130 , a contact guide plate P 1 may or may not come into contact with a side surface 112 or 122 of a sprocket. When restricting sideslip of the chain, which includes the prevention of meandering of the chain, a guide plate P 1 comes into contact with a sprocket side surface, e.g., side surface 112 a or 122 a of the respective sprockets or with a sprocket side surface 112 b or 122 b , depending on the direction of the chain sideslip ( FIG. 3 ). The sprocket side surfaces 112 and 122 include at least side surfaces 113 and 123 of the sprocket teeth 111 and 112 , respectively.
[0044] A non-contact guide plate P 0 does not come into contact with the sprocket side surfaces 112 and 122 while the chain 130 is running, and is smaller and lighter than a contact guide plate P 1 .
[0045] In order to avoid coming into contact with the sprocket side surfaces 112 and 122 , the non-contact guide plate P 0 has a shape such that no part thereof can overlap a sprocket tooth. In the embodiment shown, in the wrapped portions 131 and 132 of the chain, the entire non-contact guide plate is positioned radially outward of the sprocket teeth 111 and 121 . This configuration reduces the weight of the non-contact guide plate P 0 . This configuration also prevents the non-contact guide plate P 0 from coming into contact not only with the sprocket side surfaces 112 and 122 , but also with the sprocket teeth 111 and 121 in the direction of the radius of a sprocket. Although the entire plate P 0 is positioned radially outward of the sprocket teeth in the embodiment shown, it is possible for portions of a non-contact guide plate that come into register with the spaces between sprocket teeth to extend radially inward relative to the tips of the sprocket teeth.
[0046] Referring to FIG. 1 , all of the guide rows G of the chain 130 are categorized as either a contact guide row G 1 , in each of which at least one of the first and second guide plates 141 and 142 is a contact guide plate P 1 , or as a anon-contact guide row G 0 , in each of which both the first and second guide plates 141 and 142 are non-contact guide plates P 0 .
[0047] The chain 130 includes one or more non-contact guide rows G 0 . In the embodiments shown, the number of non-contact guide rows G 0 exceeds the number of contact guide rows G 1 . The weight of the chain is reduced when the number of non-contact guide rows is increased.
[0048] One or more non-contact guide rows G 0 are arranged between successive contact guide rows G 1 . In the embodiment shown in FIG. 1 four non-contact guide rows are arranged between successive contact guide rows. The number of non-contact guide rows between successive contact guide rows in the chain can be a constant predetermined number, e.g., two or more, in which case the contact guide rows G 1 are arranged at regular intervals along the longitudinal direction of the chain.
[0049] In the embodiment shown in FIG. 1 , all of the contact guide rows G 1 are first contact guide rows G 11 in which each of the first and second guide plates 141 and 142 ( FIG. 2 ) is a contact guide plate P 1 .
[0050] As is apparent from FIG. 1 , each of the wrapping portions 131 and 132 always includes at least one first contact guide row in the embodiment of FIG. 1 , each of the wrapping portions includes a plurality of first contact guide rows G 11 and a larger number of non-contact guide rows G 0 .
[0051] The weight of the chain is reduced with an increasing number of non-contact guide rows G 0 in the wrapping portions 131 and 132 . However, a minimum number of the contact guide rows G 1 in the wrapping portions is required to restrict sideslip of the chain. In the wrapping portions 131 and 132 , the number of non-contact guide rows G 0 can be more than twice as many as the number of contact guide rows G 1 .
[0052] Each of the guide plates 140 of each of the guide rows G is either a contact guide plate P 1 or a non-contact guide plate P 0 .
[0000] Each of the guide rows G of the chain 130 may be categorized as a contact guide row G 1 , having at least one contact guide plate P 1 , or a non-contact guide row G 0 , having only non-contact guide plates P 0 .
[0053] It is possible to restrict sideslip of the chain by utilizing a contact guide row G 1 having a contact guide plate P 1 . Because some of the guide rows G are non-contact guide rows G 0 , both guide plates 140 of which are non-contact guide plates, the number of the guide rows G that come into contact with the sprocket side surfaces 112 and 122 is decreased, and noise and friction caused by the contact between the guide plates 140 and the side surfaces 112 and 122 of the sprockets are reduced. Reduction of friction reduces power loss and improves transmission efficiency. Because the non-contact guide plates P 0 can be made lighter than the contact guide plates P 1 , the wrapping portions 131 and 132 of the chain 130 become lighter. Thus, it is possible to decrease impact and friction generated when the contact guide plates P 1 come into contact with the sprocket side surfaces 112 and 122 , and to reduce noise and frictional loss. Furthermore, the weight of the chain 130 as a whole is decreased, which contributes to reduction of the overall weight of the machine in which the chain transmission 100 is incorporated.
[0054] Each of the wrapping portions 131 and 132 always includes a plurality of contact guide rows G 1 and a plurality of non-contact guide rows G 0 . Because the wrapping portions 131 and 132 always include a plurality of contact guide rows G 1 , it is possible to restrict sideslip of the chain by contact between the guide plates P 1 of the contact guide rows G 1 and sprocket side surfaces 112 and 122 .
[0055] Because the wrapping portions 131 and 132 always include a plurality of non-contact guide rows G 0 , the weight of the wrapping portions 131 and 132 is decreased, and impact noise and friction generated when contact guide plates P 1 come into contact with the sprocket side surfaces 112 and 122 are also reduced.
[0056] If a guide row G 1 is a first contact guide row G 11 having a pair of contact guide plates P 1 , it is possible in each of the wrapping portions 131 and 132 to restrict chain sideslip bidirectionally in the widthwise direction of the chain. If each of the wrapping portions 131 and 132 includes a plurality of first contact guide rows G 11 , the bidirectional restriction of the chain against sideslip is enhanced.
[0057] If each of the wrapping portions 131 and 132 always includes a larger number of non-contact guide rows G 0 than contact guide rows G 1 , the weight of the wrapping portions 131 and 132 is further decreased. Thus, it is possible to decrease impact noise and friction generated when the contact guide plates P 1 come into contact with the sprocket side surfaces 112 and 122 .
[0058] In the following description of second to fourth embodiments, the same reference numerals as the first embodiment are basically used for members are used to designate components that correspond to components of the embodiment described above.
[0059] In the chain transmission 100 of a second embodiment, the chain 230 includes contact guide rows G 1 , which can be first contact guide row G 11 , or second contact guide row G 12 , one of the first and second guide plates 141 and 142 of which is a contact guide plate P 1 , and the other of the first and second guide plates of which is a non-contact guide plate P 0 . The chain 230 includes one or more first contact guide rows G 11 and one or more second contact guide rows G 121 . In the embodiment shown, the chain includes one first contact guide row G 11 , and a plurality of second contact guide rows G 121 .
[0060] Each of the second contact guide rows G 121 in the chain 230 is either a type 1 contact guide row G 121 , the first and second contact guide plates 141 and 142 of which are respectively a contact guide plate P 1 and a non-contact guide plate P 0 , or a type 2 contact guide row G 122 whose first and second guide plates 141 and 142 are respectively a non-contact guide plate P 0 and a contact guide plate P 1 .
[0061] Specifically, the chain 230 includes one or more type 1 contact guide rows G 121 and one or more type 2 contact guide rows G 122 . In the embodiment shown, the chain includes a plurality of type 1 contact guide rows G 121 and a plurality of type 2 contact guide rows G 122 .
[0062] One or more (one in the embodiment shown in FIG. 5 ) first contact guide rows G 11 or type 1 contact guide rows G 121 are arranged between two successive type 2 contact guide rows G 122 in the longitudinal direction of the chain. The number of guide rows G arranged between a first contact guide row G 11 and a succeeding type 2 contact guide row G 122 , and between two successive type 2 contact guide rows G 122 is constant.
[0063] As is apparent from FIGS. 5 and 6 , each of the wrapping portions 231 and 232 always includes one or more (one in the present embodiment) first contact guide rows G 11 and one or more second contact guide rows G 122 , or one or more type 1 contact guide rows G 121 and one or more type 2 contact guide rows G 122 .
[0000] Each of the wrapping portions 231 and 232 always includes a larger number of non-contact guide rows G 0 than contact guide rows G 1 .
[0064] In this second embodiment, the contact guide rows G 1 included in the chain 230 consist of one first contact guide row G 11 and a plurality of second contact guide rows G 12 . The plurality of the second contact guide rows G 12 consists of a plurality of the type 1 contact guide rows G 121 and a plurality of the type 2 contact guide rows G 122 . Each of the wrapping portions 231 and 232 always includes one first contact guide row G 11 and a plurality of second contact guide rows G 12 , or one or more of the type 1 contact guide rows G 121 and one or more of the type 2 contact guide rows G 122 .
[0065] With this configuration, because each of the wrapping portions 231 and 232 always includes at least one first guide plate 141 , which is a contact guide plate P 1 , and at least one second guide plate 142 , which is a contact guide plate P 1 , it is possible to restrict the chain sideslip bidirectionally in the widthwise direction of the chain.
[0066] Because each of the wrapping portions 231 and 232 always includes a second contact guide row G 12 , one of the pair of guide plates 140 of which is a contact guide plate P 1 and the other of which is a non-contact guide plate P 0 , it is possible not only to restrict sideslip, but also to reduce the weight of the wrapping portions 231 and 232 . Thus, it is possible to decrease impact noise and friction generated when the contact guide plate P 1 comes into contact with the sprocket side surfaces 121 and 122 .
[0067] In a third embodiment, shown in FIGS. 7 and 8 , the chain transmission 100 includes a chain 330 . All of the contact guide rows G 1 in the chain 330 are first contact guide rows G 11 . The number of non-contact guide rows G 0 arranged between two successive first contact guide rows G 11 differs depending on the positions of the first contact guide rows G 11 in the longitudinal direction of the chain. Thus, the first contact guide rows G 11 in the chain 330 are arranged randomly in the longitudinal direction of the chain, i.e., at two or more different intervals.
[0068] Each of wrapping portions 331 and 332 always includes one or more (a plurality in the present embodiment) first contact guide rows G 11 , and a plurality of the non-contact guide rows G 0 the number of which exceeds the number of guide rows G 11 .
[0069] The contact guide rows G 11 of the chain 330 constitute one or more consecutive guide row sets and one or more single contact guide rows. The consecutive guide row set includes a plurality of first contact guide rows G 11 that are consecutive except for the link row L connecting successive guide rows. The single contact guide row includes one first contact guide row G 11 .
[0070] Each of the wrapping portions 331 and 332 always includes a plurality of first contact guide rows G 11 , and each of the wrapping portions 331 and 332 always includes the first and second guide plates 141 and 142 , both of which are contact guide plates P 1 . Thus, it is possible to restrict sideslip of the chain bidirectionally in the widthwise direction, and to increase the restriction of sideslip compared to the case in which some of the guide rows G 1 in the wrapping portions 331 and 332 are second contact guide row G 12 .
[0071] Because the first contact guide rows G 11 are arranged randomly in the chain longitudinal direction, the guide plates 140 do not come into contact with the sprocket side surfaces 112 and 122 at regular intervals when the chain 330 engages with the sprockets. Thus, periodic noise is decreased.
[0072] The chain transmission 100 of the fourth embodiment, shown in FIGS. 9 and 10 , includes a chain 430 . All of the contact guide rows G 1 in the chain 430 are second contact guide rows G 12 , or more specifically, type 1 contact guide rows G 121 and type 2 contact guide rows G 122 . The arrangement of the non-contact guide rows G 0 with reference to the contact guide rows G 1 is the same as that of the third embodiment. Each of the wrapping portions 431 and 432 of the chain 430 always includes one or more type 1 contact guide rows G 121 , one or more type 2 contact guide row G 122 , and a plurality of non-contact guide rows G 0 the number of which is greater than the number of contact guide rows G 1 included therein.
[0073] If the guide rows G 1 are arranged randomly, the same effects as the first and third embodiments can be achieved. In addition, the following effects can be achieved.
[0074] Because each of the wrapping portions 431 and 432 always includes one or more type 1 contact guide rows G 121 and one or more type 2 contact guide rows, it is possible to restrict sideslip bidirectionally in the widthwise direction of the chain.
[0075] Because the contact guide row G 1 included in each of the wrapping portions 431 and 432 is always a second contact guide row G 12 , the weight of each of the wrapping portions 431 and 432 is reduced. Thus, it is possible to decrease impact noise and friction.
[0076] Many variations of the above described embodiments are possible. For example, the non-contact guide plate P 0 may have a shape such that a part is positioned radially inward of the radius of the tips of the sprocket teeth, as long as the non-contact guide plate P 0 does not come into contact with the sprocket teeth 111 and 121 , including the side surfaces 113 and 123 thereof.
[0077] As variations of the first embodiment, all of the guide rows G 1 of the chain 130 may consist of other combinations of first guide rows G 11 and second guide rows G 12 . In other words, all of the guide rows G 1 of the chain 130 may consist of or more first contact guide rows G 11 , one or more type 1 contact guide rows G 121 and one or more type 2 contact guide rows G 122 , one or more first contact guide rows G 11 and one or more type 1 contact guide rows G 121 , or one or more first contact guide rows G 11 and one or more type 2 contact guide rows G 122 .
[0078] Alternatively, all of the guide rows G 1 of the chain 130 may consist of only second contact guide rows G 12 . In other words, all of the guide rows G 1 of the chain 130 may consist of one or more type 1 contact guide rows G 121 and one or more type 2 contact guide rows G 122 , only the type 1 contact guide rows G 121 or only the type 2 contact guide rows G 122 .
[0079] Similarly, in the second, third and fourth embodiments, all of the guide rows G 1 of the chains 230 , 330 and 430 may consist of any of the combinations of the first contact guide row G 11 and the second contact guide row G 12 , or only the second contact guide rows G 12 , described in the above variations of the first embodiment. In any of the variations, a plurality of the contact guide rows G 1 may be arranged either at regular intervals or randomly along the longitudinal direction of the chain.
[0080] In each of the embodiments, it is sufficient that all, or at least one, of the wrapping portions, always include one or more first contact guide rows G 11 , one or more first contact guide rows G 11 and one or more second contact guide rows G 12 , or one or more type 1 contact guide rows G 121 and one or more type 2 contact guide rows G 122 .
[0081] In the second embodiment, the first contact guide row G 11 and the type 2 contact guide row G 121 may exist between two type 2 contact guide rows 122 mutually adjacent in the longitudinal direction of the chain.
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In a transmission chain, guide plates are provided on opposite ends of guide rows. In a guide row, both of the guide plates can be contact guide plates arranged to contact sides of the transmission sprocket teeth. However, some of the guide rows are formed with one guide plate configured for contact with the sprocket teeth and the opposite guide plate configured so that it does not contact the sprocket teeth. The sprocket tooth-contacting plates can be on one side of the chain in some of the guide rows and on the opposite side of the chain in other guide rows. The guide plates in still other guide rows are configured so that they never contact the sides of the sprockets.
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BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a positioning device or dowel attached to an engine block of an internal combustion engine for setting a location of a gasket.
When engine parts are assembled with a gasket, a lower engine part is placed on a floor or a platform. Since the lower engine part is provided with dowels for setting a location of the gasket, the gasket is placed on the lower engine part so that the dowels are located in dowel holes of the gasket. Then, an upper engine part is placed above the gasket, and the two engine parts are tightened together by bolts.
In order to easily assemble the gasket on the lower engine part, the diameter or size of the dowel hole of the gasket is slightly larger than the diameter of the dowel. Therefore, in case the lower engine part with the gasket is shaken, the gasket may disengage from the lower engine part.
Especially, in a V engine, gasket attaching surfaces of the lower engine part inclines downwardly. Therefore, even if gaskets are installed on the gasket attaching surfaces of the lower engine part, the gaskets are liable to disengage from the lower engine part.
In an automatic assembly line of engines, engines are continuously or consecutively moved. When the upper engine part is assembled on the lower engine part with the gasket, in some cases, the engine parts are stopped for a while for assembly.
In the V engine, in case the lower engine part with the gasket is consecutively moved and stopped, the gasket may fall from the lower engine part. In the automatic assembly line, it is troublesome to check the gasket in each engine, and install a gasket in case no gasket is placed on the lower engine part.
In a positioning pin or dowel, there has not been made any device for preventing a gasket from disengaging from an engine part.
Accordingly, one object of the invention is to provide a positioning device for preventing accidental disengagement of a gasket from an engine part as well as exactly setting a location of the gasket.
Another object of the invention is to provide a positioning device as stated above, to which a gasket can be easily installed.
A further object of the invention is to provide a positioning device as stated above, which can be easily and economically manufactured.
Further objects and advantages of the invention will be apparent from the following description of the invention.
SUMMARY OF THE INVENTION
A positioning device of the present invention is attached to an engine part, i.e. engine block, of an internal combustion engine for setting a location of a gasket. Generally, at least two positioning devices are attached to the engine part.
The positioning device of the invention includes a positioning pin attached to the engine part to project outwardly from the engine part, and a top plate fixed to a top end of the positioning pin. The positioning pin includes an annular depression adjacent to the top end thereof. Since the top plate extends laterally and outwardly from the top end of the positioning pin, a space is defined around the depression.
When the gasket is accidentally moved on the engine part, a portion of the gasket around the positioning hole is held in the space and is blocked by the top plate to prevent the gasket from accidentally disengaging from the engine part.
When a gasket is installed on the engine part, the positioning holes of the gasket engage the positioning pins on the engine part. When the gasket thus installed abuts against the engine part, the gasket is located in a proper position. When the gasket is accidentally moved outwardly, edges of the gasket around the positioning holes are blocked by the top plate and is retained inside the space or annular depression of the positioning pins to prevent accidental disengagement of the gasket from the engine part.
Especially, in a V type engine, the gasket attaching portion of the engine inclines downwardly. Therefore, when the gasket is slightly moved, the gasket is liable to disengage from the positioning pins. In the present invention, the edge around the positioning hole of the gasket is located in the space or annular depression of the positioning pin when the gasket is moved around the position pin, and the movement of the gasket is restrained by the top plate. Therefore, the gasket is securely retained on the engine part.
The top plate has resiliency and is made larger than the positioning hole of the gasket. Therefore, the top plate can pass through the positioning hole but is prevented from disengaging therefrom.
Also, the top plate may be at least partly bent downwardly to facilitate positioning of the gasket over the positioning device when installed. Also, the top plate may have a plurality of slits at an outer periphery so that the top plate can easily pass through the positioning hole of the gasket.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a part of a gasket installed on a cylinder block;
FIG. 2 is an enlarged section view taken along line 2--2 in FIG. 1, wherein a first embodiment of a positioning device of the invention is shown;
FIG. 3 is a plan view of the positioning device of the first embodiment of the invention;
FIG. 4 is a section view of a second embodiment of a positioning device of the invention;
FIG. 5 is a section view of a third embodiment of a positioning device of the invention; and
FIG. 6 is a plan view of the positioning device of the third embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a part of a steel laminate gasket G installed on a cylinder block X with a positioning device A of the present invention. The gasket G is a cylinder head gasket, and includes a plurality of cylinder bores Hc, water holes Hw, oil holes Ho, bolt holes Hb and push rod holes Hp, as in the conventional gasket.
The gasket G includes two positioning holes Hd (one is shown in FIG. 1). When the gasket G is installed on the cylinder block X, the positioning devices A attached to the cylinder block X are located in the positioning holes Hd of the gasket G to precisely locate the gasket G onto the cylinder block X. The positioning devices A may be used to determine a position of a cylinder head relative to the cylinder block X.
As shown in FIGS. 2 and 3, the positioning device A is formed of a columnar positioning pin A10 and a top plate A11. The columnar pin A10 is fixed to the cylinder block X at a lower part thereof, and projects upwardly from an upper surface of the cylinder block X. The columnar pin A10 includes a top end A10a and a tapered edge A10b around the top end A10a.
The top plate A11 is made of a metal plate with resiliency, and includes an inner portion A11a and an outer portion A11b. The outer diameter of the outer portion A11b is substantially the same as that of the columnar pin A10. The outer portion A11b inclines slightly downwardly from the inner portion A11a, so that when the gasket G is installed on the cylinder block X, the gasket G can be easily aligned with the positioning device A.
The inner portion A11a is fixed to the top end A10a of the pin A10 by spot welding. Consequently, an annular space A12 is defined by the tapered edge A10b and the top plate A11.
When the positioning device A is installed on the cylinder block X, the lower part of the pin A10 is attached or fixed to the cylinder block X in a conventional manner. The upper part of the pin A10 projects outwardly from an upper surface of the cylinder block X.
In the embodiment as shown in Figs. 1-3, the gasket G is a steel laminate gasket including an upper plate 13, a middle plate 14 and a lower plate 15. The size of a hole in the lower plate 15 is substantially the same as the positioning pin A10. Therefore, when the hole of the lower plate 15 engages the positioning pin Al0, the gasket G is located in a proper position.
Also, the width or height of the space A12 is made larger than the thicknesses of the middle and lower plates 14, 15. Accordingly, in case the gasket G slips out of the positioning device A, one of the plates 14, 15, in particular the lower plate 15 in FIG. 2, engages the space A12.
When the gasket G is installed on the cylinder block X, the positioning hole Hd of the gasket G is aligned with the positioning device A, and the gasket G is placed above the cylinder block X so that the positioning hole Hd engages the positioning device A. Since the top plate A11 is slightly bent downwardly, the gasket G can be installed easily.
In case the cylinder block X with the gasket G thus installed is transferred on an assembly line and is stopped, the gasket G may jump up from the cylinder block X. At this time, since the positioning device A is provided with the space A12, the lower plate 15 of the gasket G enters the space A12 and is blocked by the top plate A11. Accordingly, the gasket G is prevented from disengagement from the positioning device A.
FIG. 4 shows a second embodiment B of a positioning device of the invention. The positioning device B includes a positioning pin B10 with an annular step B10b at an upper end thereof, and a top plate B11 fixed to the positioning pin B10. In the top plate B11, an outer portion B11b is bent relative to an inner portion B11a. Also, the diameter of the top plate B11 is slightly larger than the diameter of the positioning pin B10 and the positioning hole of the gasket.
When a gasket G is installed in the positioning device B attached to the cylinder block, after the gasket G is placed on the cylinder block, the gasket G is strongly pushed against the cylinder block. Consequently, the top plate B11 bends slightly into a space B12, and the top plate B11 passes through the positioning hole Hd.
In the positioning device B, even if the gasket G moves on the cylinder block, the gasket G does not disengage from the positioning device B because of the top plate B11 larger than the positioning hole Hd. The position of the gasket G is determined by the positioning pin B10. The gasket G is securely positioned on the cylinder block X.
FIGS. 5 and 6 show a third embodiment C of the positioning device of the invention. The positioning device C includes a positioning pin C10, and a top plate C11 fixed to the positioning pin C10.
The positioning pin C10 has a conical top end C10a, and an annular step C10b. The top plate C11 is also made conical and larger than the positioning pin C10. The top plate C11 includes an inner portion C11a fixed to the top end C10a and an outer portion C11b extending outside the top end C10a to form a space C12 toqether with the annular step C10b. Also, the outer portion C11b includes a plurality of slits C11c to facilitate bending of the outer portion C11b.
In the positioning device C, since the positioning device C has a conical top end, the gasket G can be easily positioned on the cylinder block. Also, since the top plate C11 includes the slits C11c, the gasket G can be easily engaged with the positioning pin when installed. The gasket G does not disengage from the positioning device C even if the gasket G moves on the cylinder block.
In the present invention, the top plate is welded to the positioning pin. But the top plate may be glued onto the positioning pin or may have a cap press-fitting onto the positioning pin.
In accordance with the present invention, the positioning device attached to the engine part is provided with a space under the top plate. When the gasket accidentally slips out of the positioning pin, a part of the gasket is at least located in the space and is blocked by the top plate. Accordingly, accidental disengagement of the gasket from the engine part is securely prevented.
While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative, and the invention is limited only by the appended claims.
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A positioning device of the invention is attached to an engine part for installing a gasket thereon. The positioning device includes a positioning pin with an annular depression adjacent a top end thereof, and a top plate fixed to the top end of the positioning pin. A space is defined by the top plate and the annular depression. When the gasket is moved on the engine part, the gasket is held in the space and is blocked by the top plate to prevent accidental disengagement of the gasket from the engine part.
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RELATED APPLICATION
This is a continuation-in-part of Applicant's application Ser. No. 07/990,046 filed Dec. 14, 1992 now U.S. Pat. No. 5,375,891, issued Dec. 27, 1994, for which all right under 35 U.S.C. 120 is claimed.
INTRODUCTION AND DESCRIPTION OF THE PRIOR ART
The invention disclosed in U.S. Ser. No. 07/990,046 provided a universal hinged connector to connect dissimilarly cross sectioned downspouts and extensions, while still permitting the elevation of the downspout for lawn mowing or whatever purpose required. The connection is achieved by having a tube of approximately circular cross section, or more properly a square cross section with very pronounced rounded corners on the square, hinged with a second tube of approximately square cross section; more properly a square cross section with slightly rounded corners on the square. These are approximations of common forms for both downspouts and drainage extensions; and moreover, the hinged connector in that invention is provided with simple screws with instructions to apply them in appropriate configurations, so that either tube can be connected either on the exterior surface of a downspout or the interior of a drainage extension as required.
This invention is directed towards improvements in the shape of the hinged connector portions; which improvements allow more types of common residential downspouts and extensions to be accommodated by the connector. These improvements take three distinct forms:
1. The two main segments that are joined to form the connector are now each fashioned in differently-sized steps, so that multiple types of tubes will fit within the downspout portion and outside the extension portion, respectively. This will be made more clear with reference to the diagrams herein.
2. In the case of the downspout-fitting segment, the cross sections of the stepped portions are varied to conform to specific industry-standard tubing so that this tubing will be held securely.
3. Again in the case of the downspout-fitting segment, a removable face is fashioned so that one specific size of common tubing, being 21/2"ร21/2" square vinyl, can be accommodated by removal of the face.
With these improvements each end of the hinged connector fits at least six different shapes of industry standard pipe dimensions which are:
3" round metal pipe;
25/8"ร25/8" square metal pipe;
21/2"ร21/2" square vinyl pipe;
21/4"ร3" rectangular vinyl pipe; and
23/4" round vinyl pipe.
The present improved connector is able to accommodate an unusually small downspout or unusually large extension simply by reversal of the connector, or by friction fitting the connector inside the downspout or outside the extension; or both. Further sizes may be accommodated by a small amount of bending of the downspouts, extensions, or connector.
Details of attachment of the connector to the downspout and extension are identical to those disclosed in U.S. Ser. No. 07/990,046 and are not illustrated or repeated herein. Reference to the aforementioned application and incorporation of its disclosure herein is made as if the aforementioned application is a part hereof.
DETAILED DESCRIPTION OF THE INVENTION
For this description, refer to the following diagrams, wherein like numerals refer to like parts;
FIG. 1, the improved hinged connector, perspective view;
FIG. 2, outflow tube segment of the improved hinged connector with ghosted drainage extensions, side elevation view;
FIG. 3A, input tube of the invented hinged connector including removable face exploded, cross section along plane 3A of FIG. 1;
FIG. 3B, input tube of the invented hinged connector, cross section along plane 3B from FIG. 1;
FIG. 3C, input tube of the invented hinged connector, with downspout pipe outlines; end view;
FIG. 3D, input tube of the invented hinged connector with removable panel removed to accommodate alternative downspout; end view;
FIG. 3E, input tube of the invented hinged connector with alternative downspout outline; cross section along plane 3B from FIG. 1;
FIG. 4A, improved hinged connector in usage position during water flow; partial cross section, side elevation; and
FIG. 4B, improved hinged connector in usage position during water flow, with alternative downspout and extension; partial cross section, side elevation.
DESCRIPTION OF THE INVENTION
The preferred embodiment of the improved hinged connector is generally indicated as 10 in FIG. 1. Hinged connector 10 consists of two main sections attached by hinge pins 12; these sections are outflow tube generally indicated at 14 and input tube generally indicated at 18.
Outflow tube 14 has an integral projecting U-flange portion 15 which fits alongside and outside U-flange 19 of downspout tube 18. Note that outflow tube 14 steps down in size, as is obvious in FIG. 2, showing a small drainpipe extension 30 (ghosted) snugly fit over a smaller step 14', and a larger drainpipe extension 32 (also ghosted) snugly fit over the larger step 14".
Input tube 18, to refer again to FIG. 1, can be seen to have similarly larger step 18" and smaller step 18'. In addition, input tube 18 has removable side panel 28, which snaps on or off from larger step 18". The shape of input tube 18 may be more readily appreciated with reference to FIG. 3A, which is a cross section of larger step 18" along the lines 3A from FIG. 1. Similarly, the cross section of small step 18' is shown in FIG. 3B. These shapes will now be explained in conjunction with the use of the improved connector 10.
In FIG. 3C, industry standard 21/4"ร31/4" "rectangular" metal pipe external surface 40 (which actually is made with slightly rounded corners 40') fits snugly into corresponding rounded channels 100 in input tube 18. 21/4"ร3" rectangular vinyl pipe, owing to its thicker wall, will also fit sufficiently snugly in these same channels 100, and so ghosted pipe 40 can be taken to represent the external surface of this size of vinyl pipe also. Also shown on FIG. 3C is 25/8"ร25/8" (approximately square) metal pipe external surface 42, shown ghosted, which fits into lower corners 101 of input tube 18 and underneath removable panel 28. In FIG. 3D, nominal 21/2"ร21/2" square vinyl pipe external surface 43 is accommodated by removal of the panel 28. FIG. 3E, a cross section along 3B from FIG. 1 of smaller step 18' shows 3" round metal pipe external surface 44, ghosted, inserted snugly along channel 104 of input tube 18, 23/4" round vinyl pipe external surface would fit in the same path as this metal pipe external surface 44. Support projections 46 held keep surface 44 firmly in place.
Two of the thirty-six possible combinations are shown schematically in FIGS. 4A and 4B (this thirty-six is calculated by each of the six types being accommodated on both the input tube 18 and the outflow tube 14; the other thirty-four combinations are not shown).
In the example of FIG. 4A, during water flow, connector 10 operates as follows: water flows along path of arrow F from 3" round metal downspout 44, over input U-flange 19, onto output U-flange 15, through outflow larger step 14", through outflow smaller step 14', and into extension 50, which may, for example, be 21/2"ร21/2" square vinyl pipe.
A second illustrated example of the multiple combinations possible is shown in FIG. 4B, where instead the downspout is 21/4"ร3" rectangular vinyl pipe 47 and the extension is 23/4" round vinyl pipe 51. Water flows again along path indicated as arrow F.
As described in detail in the corresponding U.S. Ser. No. 07/990,046 which, as mentioned previously, disclosed a connector without the improvements described herein, storage of extending portion of the system described herein (such as extension 51 and attached outflow tube 14, in FIG. 4A) involves merely pivoting the connector 10 at hinge pins 12. (Such pivoting is not illustrated herein.)
Securement of connector 10 in the pivoted position, as well as secure attachment of the downspout and extensions to the connector 10, are identical to that disclosed in the corresponding U.S. Pat. No. 5,375,891 and are not itemized herein.
Finally, it should be noted that whereas a particular hinged connector 10, such as that shown in FIGS. 1 through 5, is designed to accommodate particular common cross sections of pipe, such a hinged connector 10 will also be fittable by other close sizes and shapes of downspout and drainage extension pipe, with small amounts of adaptation, since such pipe commonly is made of thin metal or plastic that can be easily bent or formed at such a join. Thus virtually all known, and probably many heretofore unknown, residential downspouts and extensions can be fitted to this universal hinged connector.
The foregoing is by example only and the scope of the invention should be limited only by the appended claims.
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An adaptor for eavestrough downspouts has two portions of different cross sections. The first section fits outside the downspout and the other fits inside the drainage extensions. The two portions are hinged together. The adaptor is formed with step-down sized cross sections and a removable panel to allow more sizes of downspouts and extensions to be connected.
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BACKGROUND OF THE INVENTION
The present invention pertains to systems for measuring and indicating the depth of material in a container, such as a bin containing fertilizer.
There are many instances in which it is desirable or necessary to provide a quick measurement of the amount of material stored in a container. In a typical industrial or agricultural setting, a bin or other container is provided for temporary storage of some material, such as fertilizer, grain, feed, cement, carbon black, etc. It is typical for quantities of material to be added to or withdrawn from the container from time to time, and the need arises for knowing the amount of material in the container at any given moment.
It is not realistically possible to provide actual measurement of quantities of material added to and withdrawn from the container, in order to maintain a tally of its actual contents. Such schemes are generally not practical because of the length of time and degree of compleixty involved in making actual measurements of the material. Rather, it is generally preferable to allow for rapid adding or subtracting of material from the container, such as by conveyor, dump truck, auger, or the like, without the necessity of actual measurement of the material so added or removed. This in turn implies a need for an indirect means of measurement, and preferably one which is quickly and accurately made.
Since the total volume of a given container is known, having once been measured or calculated, the simplest method of measuring material in such container involves measurement of the depth of the material at a given time. Because visual inspection is generally inconvenient or impractical, various systems have been proposed in the prior art for measurement of the depth of the material by means of a sensor or sensors placed within the container, and some type of readout means located externally of the bin, such as an office which contains readouts for numerous containers in a given installation.
Sensors for measuring depth of granular material in containers have been proposed which operate electrically, or by fluid pressure. In either case, an elongate sensor or a plurality of sensors may be placed vertically in the container so as to be progressively immersed in the material as it is added to the container.
Prior art fluid type systems have been proposed, which involve the use of an elongate sensor mounted vertically in the bin. The sensor has a movable or flexible portion which is intended to be compressed by the accumulating material in the bin so as to displace a quantity of fluid from within the sensor. The fluid bellow or the like is then provided to measure the displaced fluid.
Regardless of whether operated by mechanical or electrical means, prior art systems have suffered from certain problems and inaccuracy due to the amount of force required to actuate or compress the sensor. This is because most dry products develop horizontal forces which are very low compared to the weight per cubic foot of material. This is especially true of very light materials such as carbon black or sawdust, in which the very low horizontal forces approach the limits of the sensitivity of prior art sensors.
Typical prior art fluid systems use a flexible member or diaphragm defining an air passage, positioned vertically in the container. A fluid communication line from the top of the sensor connects to a bellows, piston, or other displacement indicating device, to which is attached an indicating pointer or other readout means. An example of such a system is found in U.S. Pat. No. 3,401,562, issued to W. A. Reaney. As material in the container causes compression of the sensor, the bellows or piston is caused to move in response. Such systems are subject to a major problem of temperature sensitivity, in addition to the fact of product bridging and the weakness of the horizontal forces developed in the product as discussed above, upon which such systems must rely for compression of their sensors.
In this type of prior art system, the entire fluid system including the sensor, interconnecting line, and the bellows or other readout device must be sealed from the atmosphere. Unfortunately, this renders the system highly susceptible to erroneous readings caused by temperature changes. When the temperature increases, the air in the system expands, giving erroneous readings, and vice versa when the temperature drops. Of course, use of a liquid instead of a gas as the working fluid would help in this respect, but it is generally not feasible to do so, because the density of the liquid would build up a significant pressure head in the elongate vertical sensor, requiring excessive and unrealistic displacement forces to be supplied by the material.
In order to overcome temperature problems, systems have been proposed in the prior art which include elaborate temperature compensating bellows, as shown in U.S. Pat. No. 3,290,938 issued to R. R. Miller for example. Unfortunately, this proposed solution leads to greater complexity and increased costs, and potentially increases the vulnerability of the system to leaks. In addition, it tends to clog.
Because the prior art fluid systems depend upon a completely sealed fluid system, the presence of even a minute leak will seriously affect long term accuracy. Although it is possible to build a system relatively free of gross leaks, the extent of the sensor, and the other tubes and devices involved in the measurement system makes it extremely difficult to guard against long term, slow leaks which will degrade accuracy over a period of weeks or months. As a generality, recalibration in this type of prior art system is not feasible, short of completely emptying or completely filling the container. Also, pressure does not activate these systems.
The present invention solves these and other problems existing in the art by providing an improved depth measurement system which takes advantage of the inherent simplicity and economies of a fluid system, but which works upon a different principle so as to avoid the problems heretofore existing in the art. Clogging of the components of my novel system is virtually non-existent.
SUMMARY OF THE INVENTION
With specific regard to the present invention, I have provided a system for measuring the depth, and hence the quantity of material in a container, such as a bin. My novel component reliably detects the presence or absence of liquid or solid materials ranging from fine powder to large diameter prill. My instrument was designed primarily for use in the dry bulk material industry, with fertilizer being but one example. By monitoring the level of material in cluster bins, multi-celled holding hoppers, above the weigh hoppers, it not only saves the cost of labor but it also eliminates the health hazards associated with humans in close proximity to heavy concentrations of mineral dust.
With regard to the minimization of dust, this is very important in the industry because close tolerance of the material is required by the United States Agricultural Department, and cross contamination, which occurs if one cell of a group overflows into the next, is not acceptable.
One embodiment of my sensor for use in determining the level of fill in a bin being filled comprises a housing or casing of generally Y shaped configuration. This housing has a central chamber, first and second upper orifices, and a single orifice at the bottom of the housing. An elongate primary hose is connected to the bottom orifice, in communication with the central chamber. A secondary hose of relatively small diameter is loosely contained within the primary hose, having a length slightly less than the length of the primary hose, with the remote ends of these hoses being comparatively closely associated, and separated by less than one foot.
One of the upper orifices of the housing is connected to a supply of air under pressure, and the other of the upper orifices is connected to pressure sensing equipment disposed at a remote location. The air under pressure added at one of the upper orifices normally flows outwardly and downwardly from one of the hoses, with such outward flow normally not affecting the pressure condition in the other of the hoses. However, upon the degree of the fill of the bin or container being such that material begins to closely approach the remote end of the primary hose, the air normally flowing out of one of the hoses is caused to be deflected into the remote end of the other of the hoses, and thus causing the pressure in such other hose to increase. Such pressure increase is sensed at the remotely located pressure sensing equipment, with this in turn being utilized to directly affect the rate of fill of the bin.
Regarding the prior art, the industry rarely employs any of the currently available indicators because they are not reliable under the conditions encountered. The working parts of instruments are quickly rendered inoperable by clouds of dust and sticky materials. Often the entire instrument becomes completely encased and they are susceptible to damage by being battered by the flow of material into and out of the bin. When it comes time to clean out a hopper, the standard procedure is to start from above and below by jabbing rods through it to acquire a through hole. This destroys anything in the hopper that is susceptible to destruction.
It is to be noted that electrical components, no matter how carefully sealed, whether in the hopper or located in the contaminated area above, do not last long. Even the placement of instruments presents a problem because what starts out well in a hopper soon gives trouble due to the constant changing of the pile characteristic.
Most indicators of the prior art incur high installation costs, especially in existing plants because of the problems found in just cleaning a hopper sufficiently enough to install a unit, attaching brackets and such, or the impossibility of installing through wall units in multiple celled hoppers. And the installation of electrical circuits in these areas is expensive and troublesome.
By the use of my novel system, all of the known problems of the prior art devices are avoided. The only part subjected to the harsh conditions in the bin is an elongate hose made of non-stick, abrasive resistant material that is self cleaning due to the flow of exhaust air. No moving parts are involved, or anything that can be harmed by either flowing material or cleaning equipment. The elongate hose I utilize in connection with my novel sensor (transducer) presents nothing for the material to cling to or build up on, and it automatically follows the flow path so that it requires no special care in placement or maintenance. Installation consists of dropping the hose operatively associated with my novel sensor into the hopper until it reaches the appropriate depth. There are no electrical components in or near the hopper, only low pressure air hoses. The diaphragm switch, known to the industry, that I utilize to operate signal devices and/or feed machinery is located well away from the contaminated area, taking its signal from a long, low pressure air hose.
Another unique advantage of my novel system is that it can be operated either with air from an air compressor, or from a blower. In fact, my novel sensor requires for its operation such a small amount of air, that a one horsepower blower can handle more than a dozen units. The blower can be located 50 or more feet away from the hopper, and the diaphragm switch can be an additional 50 feet away. Only low voltage, single phase power is required, and even including an indicator lamp, less than one ampere of current per unit is required.
Also important is that both installation and maintenance of my novel device requires no particular skill, but despite its non-complex configuration, it performs the task better, and at much lower cost, than any high tech equivalent.
It is thus a primary object of my invention to provide a sensor of uncomplicated, low cost construction, that can be effectively used for accurately determining the extent of fill in a bin.
It is another important object of my invention to provide a sensor or transducer of uncomplicated, low cost, non-clogging construction, that can be effectively used for accurately determining the extent of fill in a bin adapted to contain a wide range of different fill materials.
It is another object of my invention to provide a bin level sensor adapted to operate at a low level of pressurized air, making it unnecessary to utilize an air compressor for supplying the operating air needed for the operation of the sensor.
It is yet another object of my invention to provide a novel bin level indicator of simple construction, that does not need to be affixed to a wall of a bin for its operation, thus making it possible for my novel device to be used in multicell cluster hoppers, where ready access to the inner cells of the cluster is quite difficult.
It is yet still another object of my invention to present a sensor or transducer utilizing elongate, flexible hoses adapted to be lowered into a bin that contains material whose height or extent of fill is to be measured, which hoses contain no protrusions likely to contain an undesirable buildup of material.
It is still another object of my invention to provide a sensor having components are adapted to be lowered into a bin containing material whose height or extent of fill is to be measured, which sensor utilizes a signal tube that is recessed from the lower tip of the exhaust tube, thus to assure good signal pressure.
It is still another object of my invention to provide a sensor having components adapted to be lowered into a bin containing material whose height or extent of fill is to be measured, which sensor utilizes a signal tube that can be recessed for a variable extent with respect to the lower tip of the exhaust tube, thus to make it possible to obtain the best signal pressure for each different material whose depth in the bin is to be measured.
These and other objects, features and advantages of this invention will become more obvious as the description proceeds.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side elevational view of a primary embodiment of my novel sensor or transducer, with certain portions cut away to reveal internal construction, and with arrows being utilized in order to show typical flow paths around the central chamber of the device;
FIG. 2 is a type of exploded view revealing preferred constructional techniques utilized in connection with the housing portion of my novel sensor or transducer, with this view also showing certain ancillary components utilized in conjunction with my novel sensor or transducer;
FIG. 3 is a simplified view of a typical single bin device, with this figure revealing that an elongate hose is utilized in conjunction with both the upper level and the lower level sensors, in order that information as to the fill of the bin can be transmitted to respective high limit and low limit switches; and
FIG. 4 is a simplified showing of a multiple cell cluster hopper arrangement of the type that may be utilized for the mixing of the desired ingredients to be incorporated into a commercial fertilizer, for example, in a desired ratio.
DETAILED DESCRIPTION
With initial reference to FIG. 1 , a first embodiment of my novel sensor 10 is illustrated, involving a housing or casing 12 in which a central chamber or bore 14 is defined. I may also refer to the device 10 as a transducer. The housing 12 may be of one-piece construction, and may be regarded as generally being in a โYโ shaped configuration and containing several apertures or orifices, to be described shortly. The housing 12 may be made of a suitable metal, or of an industrial grade plastic.
Inasmuch as my novel sensor 10 is typically utilized in a vertical attitude in a bin whose fill level is to be measured on a moment-by-moment basis, I have depicted the sensor 10 in a vertical attitude in FIG. 1 . In FIG. 2 I have presented an exploded view of the housing 12 and its associated components, and in FIG. 3 I have illustrated a typical single bin installation, with which my invention may be used. In FIG. 4 I have depicted a typical multiple bin installation or multicell cluster hopper, as will be discussed hereinafter.
It is to be noted that in the usual instance, my novel sensor is utilized in pairs, with each sensor or transducer being utilized with an elongate hose designed to extend down into a bin whose fill level is to be monitored; note in FIG. 3 that elongate hoses of different lengths are depicted.
In FIG. 1 I have illustrated a portion of an elongate hose 16 , regardable as being the primary hose which, in this instance, is shown to a substantially foreshortened length. The upper end 18 of the hose 16 is fitted tightly in lower aperture or orifice 22 of the housing 12 , where the hose may be secured by a suitable clamp.
The lower end of the elongate primary hose 16 , which is to be understood as disposed at a remote location with respect to the housing 12 , may have an angled lower end 26 , for a reason explained hereinafter. As will become obvious as the description proceeds, the elongate primary hose 16 is preferably flexible, and is intended to be dropped into a large bin being filled with particulate material, such as fertilizer; note FIG. 3 .
A pair of my novel sensors (transducers) are to be observed in FIG. 3 , and the angled lower end 26 of the hose 16 L will be noted to be utilized near the lower part of the bin in FIG. 3 , provided for the purpose of conveying of information regarding the bin becoming substantially empty. On the other hand, the end of the shorter hose 16 U, intended to be used near the upper part of the bin or container depicted in FIG. 3 , serves to convey information pertaining to the bin becoming substantially full.
With reference back to FIG. 1 , which may be regarded as an important embodiment of my invention, this figure illustrates on what may be regarded as the principal axis of the housing 12 , a signal tube 30 . The tube 30 may also be referred to as the secondary hose or the relatively small diameter hose. This hose or signal tube 30 serves an important function insofar as the operation of my sensor is concerned.
A first end 32 of the signal tube, at which a suitable connector is typically used, may be regarded as extending to a remotely located pressure-responsive component or ingredient, such as to a diaphragm switch of a type that is well known in the art. My novel sensor or transducer 10 is intended to function with such a switch, but the diaphragm switch is not illustrated, for it does not itself form an intrinsic part of this invention. An example of the type of switch that may be used with my sensor is a device made by the Cleveland Controls Company of Cleveland, Ohio, Model No. AFS-222.
In accordance with the embodiment of my invention shown in FIG. 1 , the signal tube 30 is designed to fit snugly in aperture 34 located in what may be regarded as the upper end of the sensor housing or body 12 . The aperture 34 will also be hereinafter referred to as the first upper orifice. As will be noted from FIG. 1 , the signal tube 30 extends downwardly the length of the central chamber 14 of the housing 12 , and in addition, the signal tube 30 is of a length sufficient to extend for most of the length of the particular elongate primary hose 16 with which it may be used in a given instance.
Generally in the manner of the configuration of the lower end 26 of the hose 16 , the lower end 36 of the secondary hose or signal tube 30 is preferably configured to have an angle similar to the angle of the lower end of the hose. The angles at which the ends 26 and 36 may be cut is preferably between 20ยฐ and 40ยฐ, with an angle of approximately 30ยฐ to the vertical being preferred. Advantageously, the angled tube ends serve to increase surface area, thereby permitting improved air flow by a factor of 1.5 to 2.0. In addition, the lower ends of hoses 16 and 30 almost never become clogged, as might well have taken place in certain instances when the ends of the primary and secondary hoses had been cut off straight. As will be seen from FIG. 1 , I have designated the distance between the lower angled tip 36 of the secondary hose 30 , and the lower angled tip 26 of the primary hose 16 as recess 50 .
I am not limited to any fixed distance between the lower tip of the signal tube or hose 30 and the lower tip of the primary hose 16 , but a typical distance or recess of 3ยฝ inches usually brings about a good signal pressure. It is important to note that it is within the scope of this invention to provide a scale or indicia 38 on the visible upper end of the signal tube. Such calibrations 38 make it possible for an operator to readily select the optimum distance between the lower tip of the signal tube and the lower tip of the primary hose 16 , without having to attempt to apply a measuring device to these lower components of the sensor.
In accordance with this first embodiment of my invention, air under pressure is to be inserted into a pipe or tube 40 that is attached to a fitting 42 located in an aperture or orifice 44 formed at the upper end of the housing 12 . I will also refer to the orifice 44 as the second upper orifice.
As will be noted from FIG. 1 , the pipe 40 and its fitting are disposed in an offset relationship to the aperture 34 of the housing 12 , and to the previously mentioned principal axis of the housing. The aperture 44 in this offset branch of the housing 12 may be fitted with a plug 46 , disposed in a fluid-tight relationship to the aperture 44 . For example, the plug 46 may be equipped with internal screw threads, so as to tightly accommodate the fitting 42 that is equipped with matching male screw threads 48 .
It is obvious that I am not to be limited to any particular offset, but by way of example, the branch of the housing containing the aperture 44 may be disposed at an angle of 45ยฐ to the principal axis of the housing.
As will be noted from the embodiment of my invention illustrated in FIG. 1 , the path of the air under pressure entering the housing through the pipe 40 is represented by arrows 52 , which indicate that the air under pressure flows downwardly through the chamber 14 and thereafter enters the interior of the primary hose 16 . The curved arrows 54 reveal how the air under pressure may be regarded as flowing in a surrounding relationship to the signal tube or secondary hose 30 . If nothing resides in the vicinity of the angled lower end of the hose 16 , this compressed air will flow downwardly and outwardly, without restraint, through the angled lower end 26 of the primary hose.
It will be noted from a lower portion of FIG. 1 that I have indicated a small quantity of material 56 , this representing a buildup of particulate material, such as fertilizer, in the upper part of the bin or other container in which my novel sensor is being utilized. As the bin continues to be filled with material, the fertilizer, or other such ingredient or material being added to the bin will, quite understandably, gradually approach the location of the angled lower end 26 of the primary hose 16 . In such instance, instead of the air under pressure continuing to flow downwardly, this air under pressure, in the presence of the buildup of material 56 , will be redirected upwardly, into the angled lower end 36 of the signal tube or secondary hose 30 ; note the curved arrow 60 .
The approach of the material 56 to the lower tip 58 may be understood as causing an increase in pressure at the previously mentioned recess 50 . This increase in pressure is sensed at the tip of the signal tube or secondary hose 30 . In accordance with this embodiment, such pressure increase is transmitted up the tube 30 to the remotely located switch. When the switch (not shown) senses a sufficient increase in pressure, the filling procedure is caused, in a well understood manner, to cease.
It is to be noted that in accordance with another embodiment of my invention, the air flow arrangement may be reversed in order to enable a different type of material to be sensed. In accordance with this second embodiment, the previously-mentioned connector in the tube or hose 30 would be opened (broken), so as to be able to properly receive the pipe supplying compressed air at the first upper orifice 34 . Continuing with this modification, the second upper orifice or aperture 44 in the offset portion of the housing 12 would be reconfigured to receive a proper connection to the remotely located pressure switch, or other readout device. I have found that when the level of an item such as pinto beans reside in the bin to be measured, it is advantageous for air to be admitted to the second upper orifice or aperture 44 , as indicated in FIG. 1 , whereas when the height of ground styrofoam residing in a bin is to be measured, it is more advantageous to supply the compressed air at the first upper orifice or aperture 34 , and the remotely located readout device connected to the second upper orifice or aperture 44 .
With reference now to FIG. 2 , it will be seen that here I have shown a typical detector assembly, with FIG. 2 being an exploded view in order to illustrate preferred details of construction of an exemplary form of my invention.
In FIG. 2 the housing 12 is to be seen as receiving at its first upper orifice or aperture 34 , a 1โณ PVC plug 62 that has been bored to a ยฝโณ inner diameter in order to receive the end of the signal tube 30 , also known as the secondary hose. From this figure it will be noted that the signal tube leads to a signal box 64 , disposed at a remote location, that contains an air switch. The signal box 64 is connected to a relay 66 that is in turn connected to a device, such as a screw drive, that is to be energized when the bin is to be filled. Also shown in this figure is an electric plug 68 used to supply electric power to the signal box 64 .
Aperture 44 , associated with the offset portion of the housing 12 , is shown in conjunction with a 1โณ combination nipple 72 , such as of schedule 80 PVC, equipped with threads configured to threadedly engage the threads of the aperture 44 . It will be noted that the end of the nipple 72 opposite the threads is configured to readily receive the end of the earlier-mentioned blower hose or pipe 40 in a fluid tight manner. A suitable clamp 74 may be utilized to assure a tight connection.
In this illustrated instance I have shown the remote end of the blower pipe 40 connected to the outlet 76 of the blower 80 , with the outlet 76 in this instance being associated with the high or upper detector, used to indicate the completion of the fill of the bin. It is to be noted that another connector, connector 82 , is also provided on the blower 80 , to which the hose (not shown) associated with the low detector of the bin is to be connected.
Continuing with FIG. 2 , it will be noted that below the lower aperture 22 of the housing 12 is shown a 1โณ combination nipple 84 , designed to fit tightly inside the lower aperture or orifice 22 of the housing 12 . Also shown in this exemplary figure is a plate 86 , such as of ยผโณ steel, that has an outer diameter of approximately 6โณ. In the interior of this plate I have provided three evenly spaced ยผโณ holes (not shown) that are disposed ยฝโณ from the edge. This plate is utilized for sensor support.
The underside of the nipple 84 is provided with serrations to enable the upper end of the primary hose 16 to be tightly attached. A suitable hose clamp 88 may be used for this purpose.
With reference now to FIG. 3 , it will be noted I have illustrated a pair of my novel sensors or transducers utilized in a typical bin 90 , with transducer or sensor 10 U serving as the high limit or upper detector, and the transducer or sensor 10 L serving as the low limit detector. It will be noted that primary hose 16 U extends downwardly from sensor 10 U for a relatively short distance, whereas primary hose 16 L extends for a relatively large distance downwardly from low limit sensor 10 L. Also shown in this figure is a screw conveyor 94 utilized for loading the bin with the particulate material to be received in the bin or container 90 . Typically the screw conveyor 94 is a two horsepower device which is energized at the time the bin is to be filled, that is, as observed by the low limit sensor 10 L, and then de-energized when the bin is substantially full, as observed by the high limit or upper sensor 10 U.
FIG. 3 involves the embodiment of my invention in which the offset apertures 44 of the sensors or transducers 10 U and 10 L are connected to the supply of air under pressure from the blower 80 . More particularly, the lower end of pipe 40 L connects to the low pressure blower outlet 82 , whereas pipe 40 U connects to the high pressure outlet 76 of the blower 80 . In this way, the normal flow of air through the pipes 40 L and 40 U are supplied to the central chambers 14 of each of the pair of sensors 10 U and 10 L.
With regard to the blower design, I have found that a blower supplying 500 cubic feet of air per minute at a pressure of 10โณ of water will adequately supply my sensors, while drawing only 6.8 amperes of current. This relatively low current consumption is possible because my devices are advantageously designed to operate under low pressure, high volume conditions.
As an alternative to the use of a blower, an air compressor could be used if it can be regulated so as to supply air under low pressure. However, generally speaking, I have found that an air compressor is relatively ineffecient when providing air at low pressure.
Continuing with FIG. 3 , the signal tube 30 L is connected to the low limit switch 96 , whereas signal tube 30 U connects to the upper or high limit switch 98 . A typical single clam gate is shown at 92 .
The embodiment of my invention depicted in FIG. 3 represents an obvious difference from prior art designs, for the elongate hoses 16 U and 16 L present no area or location in which the material contained in the bin 90 can accumulate. Both gravity and the flow of material are significant in keeping the tips of the hoses or pipes clear. As depicted in FIG. 1 , there is virtually no chance of material moving against gravity in order to gain entry to the recessed signal tube tip which, in the typical instance, is recessed approximately 3ยฝโณ from the tip of the primary tube, as previously mentioned. However, I am not to be limited to this distance or measurement.
With reference back to FIG. 1 , the amount of recess 50 is important for the obtaining of proper signal pressure. I have conducted extensive investigations of the relationships of the lower end of the signal tube or hose to the lower end of the primary tube or hose, and I have found that varying the amount of recess 50 can effect the pressure by as much as 0.2 inches of water. I have discovered that as the tip 36 of the signal tube 30 is advanced toward the angled lower end 26 of the primary hose 16 beyond a certain point, the signal pressure steadily decreases. After ascertaining the optimum relationship of the two tubes, which I call the โsweet spot,โ I have also found that the pressure decreases when the signal tube is pulled further away from the exhaust tube 16 . From this it should be clear that I have found that fine grain adjustments of the amount of recess 50 is important for each of the various materials contained in the bin in order that the best signal pressure will be obtained. If desired, and as previously mentioned, it is possible that the easily visible upper end of the signal tube 30 can be calibrated as shown at 38 in FIG. 1 , which of course is near the location where the tube or hose 30 enters the housing 12 .
A most significant aspect of my invention is the fact that with the elongate, flexible primary hoses I use, there is very little likelihood of material sticking to the walls of the bins or hoppers and forming what may be regarded as a โcake.โ When this in the past happened, this caused the failure of instruments which in accordance with prior art design were bolted or otherwise rigidly attached to the walls of the bin or hopper.
Because the high level and low level hoses used in connection with my invention can be dropped into cluster hoppers, they are readily usable in multi-cell cluster hoppers. This of course was not possible in accordance with prior art devices needing to be attached to walls of a bin or hopper, which walls are virtually inaccessible with respect to the inner bins or hoppers of the cluster.
With reference now to FIG. 4 , it is to be seen that high limit and low limit sensors in accordance with my invention may be used in pairs in a number of similar bins. For example, FIG. 4 a schematically shows a twelve cell cluster of hoppers, with it to be understood that each bin or hopper utilizes a pair of my novel sensors.
It is well known in the fertilizer industry that a bag of fertilizer may contain many different ingredients. That these separate ingredients may be mixed in a proper ratio, one cluster hopper may contain murate of potash, whereas other hoppers of the cluster may contain Milorganite, ammonium nitrate, potassium nitrate, manganese, sludge, slag, sulphur, calcium nitrate, triple super phosphate, iron chelate, diammonium phosphate, magnesium, copper sulphate, boron, zinc, peanut hulls, corn cob, vermiculite, and the like.
In the typical instance, these various materials are loaded into the appropriate hoppers by a person operating a front end loader. This person must work rapidly, for the batch man is dropping these materials at a rate of two tons each minute. Consequently, it is most important that a hopper containing a particular ingredient must not be permitted either to run out of material, or become overrun by material.
For the convenience of the front end loader operator, a display is provided containing a number of pairs of indicator lights. The display 100 depicted in FIG. 4 preferably utilizes twelve lights in the left column, associated with the respective bins or hoppers becoming full, and twelve lights in the right column, associated with the respective bins or hoppers becoming empty. The color yellow means a given bin is not quite full, whereas the color red means that a bin is not quite empty. It is the goal of the front end loader operator to keep the lights turned off, thus indicating a normal, desirable operating condition.
Also visible in FIG. 4 is a conventional weigh scale 102 , which is configured and positioned so as to receive the ingredients from the various hoppers or bins of the cluster. These bins may, for example, be 10 ton bins, with a pair of my novel sensors used in each bin; one sensor in each bin to develop the information indicating when a bin is nearing empty, and the other sensor in each bin to develop the information indicating when the bin is nearing a full condition.
When a sufficient weight of the ingredients from the several bins have been released into the weigh scale 102 , the contents of the weigh scale are dropped, by the opening of the clam gate 104 , into the conventional mixer 106 , for subsequent mixing and then packaging.
The blower 108 depicted in FIG. 4 is equipped with a twelve outlet manifold, so that air under pressure may be delivered by respective lines or small conduits to the appropriate upper orifice of each sensor of the cluster. A signal line 110 connects the signal output from each sensor to the appropriate light of the display 100 .
By now it should be apparent that I have provided a novel bin level indicator of simple construction, that does not need to be affixed to a wall of a bin for its operation, thus making it readily and conveniently possible for my novel device to be used in multicell cluster hoppers, where ready access to the inner cells of the cluster is quite difficult. Each of my novel sensors or transducers utilizes a pair of elongate, flexible hoses that can be easily lowered into a bin that contains material whose height or extent of fill is to be measured. Each sensor advantageously contains no protrusions likely to contain or develop an undesirable buildup of material.
It is obvious that the earlier-described modifications, as well as other modifications can be made to my invention, within the spirit and scope of the claims of my invention.
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A sensor involving a housing having a lower orifice to which a primary hose is connected. A secondary hose inside the primary hose is slightly shorter than the primary hose, with these hoses being placed inside a bin for determining fill level. One of two upper orifices in the housing is connected to a supply of air under pressure, with this air normally caused to flow outwardly from one of the hoses. Upon the degree of the fill of the bin being such that the material approaches the remote end of one of the hoses, the air normally flowing from the one hose is caused to be deflected into the remote end of the other of the hoses, causing a pressure increase. This pressure increase is directed through the other upper orifice, for being sensed at remotely located pressure sensing equipment.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to a priority controlled network, wherein a plurality of sensor terminals and at least one display terminal are connected to a network and priority of data from the plurality of sensor terminals to the network are selectively displayed on the at least one display terminal.
2. Discussion of the Prior Art
In a conventional surveillance system using a plurality of TV cameras, at least one display unit, and a network connecting the cameras and display unit, the problem of limited capacity of the network can be troublesome. For example, an operator might not recognize an emergency situation since he cannot simultaneously view all of the iamge data from all the cameras. Also, the total amount of data can readily exceed the capacity of the network so that priority of data is difficult to maintain. Improvement is needed to enable more efficient and reliable use of networks and display of data based on a predetermined priority value.
A conventional network is known which uses a plurality of sensor terminals, such as TV cameras, connected to a network. Each sensor terminal determines the priority of its data. Where the network has a certain capacity, for example, 10 image data, and the number of sensors exceeds the capacity, it has been suggested that the sensor terminal having the least valuable priority, such as the 10th, stop transmitting if it has less than the 10th value priority. Although, such suggested system may solve the immediate problem, there is the disadvantage that the number of sensors at each terminal is fixed, and hence, flexibility of design is reduced.
SUMMARY OF THE INVENTION
Accordingly, an object of the invention is to overcome the aforementioned and other deficiencies, disadvantages and problems of the prior art.
Another object is to provide a priority controlled network, such as used for visual surveillance systems, wherein a selective priority method enables expansion of the priority capacity of the network, and increase flexibility of design.
The foregoing and other objects are attained by the invention, which encompasses a priority controlled network, wherein one or more parameters used at a sensor terminal is supplied to determine priority value and are varied so that priority data are determined by the varied parameters and the sensor terminals having the desired priority values are selected in a network having a capacity of the highest priority value. For example, a network having a capacity of 10 sensors can have more than 10 sensors when the priority values are determined for 10 values of the more than 10 sensors.
The foregoing procedure is applied to a plurality of sensor terminals, at least one display terminal, and control unit interconnected to a network, wherein the control unit supplies the parameters, such as priority calculation algorithm and priority calculation equations, and priority value determination is made by a priority calculation unit in the sensor terminals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram depicting an illustrative embodiment of the priority controlled network of the invention, showing details of the sensor terminals, and one display terminal and using a control terminal as a part of the control means.
FIG. 2 is a block diagram depicting the illustrative embodiment of the priority controlled network of the invention, showing a plurality of display terminals and using an accounting server as a part of the control means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a priority controlled network including a network 8 interconnecting a plurality of sensor terminals T 1 . . . Tn, one display terminal D, and a control unit having a control terminal 1 , therein. Details of the sensor terminal, e.g. T 1 , are shown and are explained below.
FIG. 2 shows a similar controlled network, except that instead of one display terminal D, a plurality of display terminals D 1 . . . Dn are shown. The control unit is shown having an accounting sensor 9 , therein.
As shown in FIG. 1, each of the sensor terminals T 1 . . . Tn comprises a TV (e.g. a closed circuit television) camera 2 , connected to an image processing unit 3 , which is connected to priority calculation unit 5 and to communication unit 4 . Sensors 1 . . . N (labeled 6 , 7 ) are connected to and provide input to the priority calculation unit 5 . The priority calculation unit 5 is connected to the communication unit 5 to receive parameters sent from control terminal 1 through network 8 and through communication unit 4 , and to supply priority signals, such as priority value, to communication unit 4 . Thus, the priority calculation unit 5 receives data from camera 2 , through image processing unit 3 , and data from each of sensors 6 and 7 , and parameters from communication unit 4 . After calculation using the parameters from communication unit 4 and the data from camera 2 and sensors 6 and 7 , a priority signal, such as priority value, is supplied to communication unit 4 , to enable suitable transmission through network 8 to the appropriate single display terminal D (in FIG. 1) or to the plurality of display terminals D 1 . . . Dn (in FIG. 2 ). Sensors 6 and 7 area connected directly to unit 4 for desired use.
As constituted, the visual image from TV camera 2 is supplied through image processing unit 3 to the communication unit 4 for display in the appropriate display terminal D 1 . . . Dn as governed by the priority value calculated for that sensor terminal. The data from the camera 2 is also processed by processing unit 3 and supplied to the priority calculation unit, so that together with data from sensors 6 and 7 , and using the parameters supplied by the communication unit 4 , the priority calculation unit 5 can make the desired priority calculation, and provide a priority signal, such as priority value. Advantageously, the data from a plurality of sensors, such as camera 2 , and sensors 6 , 7 , and through the parameters sent from the control unit 1 , the conditions of all of the sensor terminals can be taken into consideration when assigning priority values.
Connected to the network is the control unit 1 having therein a control terminal 1 , which supplies parameters to the communication unit 4 through network 8 , and then to the priority calculation unit 5 of each of the plurality of sensor terminals T 1 . . . Tn. The parameters sent by control unit 1 , may comprise a priority calculation algorithm and one or more priority calculation operations. The parameters may include conditions of each of the sensor terminals T 1 . . . Tn and the various sensors therein. The control unit 1 continues to monitor conditions of the entire network and the components thereof, and takes these conditions into consideration when providing the parameters to each different sensor terminal. The priority calculation unit 5 comprises a computer and in the calculation process uses such algorithms and operations. When the priority signal is sent to the calculation unit 5 , the priority value is assigned thereto so that in the desired order of priority, the visual images from camera 2 of the desired sensor terminals are displayed in the desired display terminals D 1 . . . Dn.
The sensors 1 . . . N (labeled 6 and 7 ) may be any desired sensor, such as a temperature sensor to measure air temperature, a microphone to sense and transmit sound, etc. The sensor 6 , and 7 and TV camera may be located at a fixed location or may be disposed to be movable from one location to another location. Also, the display terminals may be located at a fixed location, or may be located at different positions. For example, the TV cameras and sensors 6 and 7 may be disposed in fixed locations, such as besides a road, and form part of a road surveillance system for recording traffic accidents. Similarly, the air temperature sensor and/or microphones can be fixed at the same location as the TV camera, or may be disposed at different locations. When the camera, for example, are used, they may be placed in different road side locations, such as one mile apart and cover a certain area. In the same manner, the air temperature sensor and/or microphones can be placed periodically apart along the road for optimal coverage. The display terminal, being real time visual, can be advantageously used to observe a real time event. Thus, the one or more display terminals can be located at the same location or be at different locations, as desired.
The visual images from camera 2 can also be stored in the image processing unit 3 or in the communication unit 4 , with use of a storage unit in such image processing unit 3 and/or communication unit 4 . In this manner, the stored images can be used later as desired, such as for research into causes of vehicle accidents.
When there is only one display terminal D (see FIG. 1 ), the display will display the highest priority value data, or depending on the algorith and equations of the parameters supplied by control unit 1 , the single display D may display the data having a certain priority value,which is not necessarily the highest priority value.
On the other hand, where there are a plurality of display terminals D 1 . . . Dn (as shown in FIG. 2 ), each of the different display terminals D 1 . . . Dn will display data having a priority value within a range of priority values assigned to the plurality of display terminals. For example, when there are signlas having priority 1 through 10 , and there are 10 display terminals and 10 sensors, all of the data wil be displayed. However, if there are more than 10 sensors, such as 15 sensors, and only 10 display terminals, then the sensor terminals having the priority values assigned thereto of 1 - 10 will be shown in the display terminal. By suitable algorithm and equations, in a suitable control signal from control unit 1 , the data having less valued priority can also be continuously shown in the display terminals 1 - 10 . For example, every โMโ minutes, a different set of images can be shown in displays 1 - 10 , but from sensor terminals having assigned priority values 2 - 11 , then next 3 - 12 , then next 4 - 13 , etc. In another embodiment, the images from terminals having priority 5 - 15 , instead of 1 - 10 , can be shown. Thus, with the invention flexibility is obtained, and desired priority is obtained at all times. Also, the images for all sensors can be displayed even though the capacity of the network is limited.
The display terminals may comprise a visual display unit, such as a television monitor, and also comprise appropriate data servers and database, minicomputers and-storage units to perform desired functions. Also, the plurality of sensor terminals may comprise a data server, database, minicomputers and storage unit to enhance the carrying out of the foregoing method.
The control terminal 1 is understood to be a control unit and can comprise a control terminal 1 (see FIG. 1) and/or an accounting server 9 (see FIG. 2 ). They have been labeled as shown in FIGS. 1 and 2 for sake of convenience of description. Also, only one display terminal D is shown in FIG. 1 and a plurality of display terminals are shown in FIG. 2 for sake of convenience of description.
When only one display terminal D (in FIG. 1) is used then the control terminal 1 sends to all sensor terminals T 1 . . . Tn, priority calculation algorithm and equations so that a highest (or other desired priority rank) priority is calculated by the priority calculation unit 5 using the data from the various sensors for one particular sensor terminal and the visual images from the camera 2 therefrom will be caused to be shown on the one display terminal.
On the other hand, using a plurality of sensors and a plurality of display terminals (see FIG. 2 ), the control unit 1 having an accounting server therein 9 , will provide suitable priority calculation algorithm and equations, for example as โparametersโ so that the priority values of the different sensor terminals will cause assignment of the different images from the different sensor terminals to be displayed on the display terminal assigned to that display terminal.
In using an accounting server 9 , as part of the control unit, priority values can be calculated based on fees charged to the different sensor terminals. Thus, for example, based on relative financial values of the different sensor terminals, the priority values can be calculated for each sensor terminal so that commerically, the highest payer will obtain best service in terms. of display on the display terminal. Also, the accounting server can concurrently work up charges for the different sensor terminals reflecting the priority order of displaying.
Advantageously, the capacity of the network can thus be fully utilized continually and concurrently therewith all of the desired data can be displayed in order of priority value. Teh parameters sent by the control unit 1 to the one or more sensor terminals can control the priority of the data, such as visual images from camera 2 , which is obtained in one or more sensor terminals, and the display of the image of a particular priority value in the one or more display terminals. Also, advantageously, the various elements shown in the drawing and/or discussed in the specification, such as servers, TV cameras, sensor terminals, display terminals, image processing unit, priority calculation unit, sensors, communication unit, control terminal, accounting server, etc, are of circuit components known in the art and can be readily obtained and understood from the description herein.
The foregoing description is illustrative of the principles of the invention. Numerous modifications and extensions thereof would be apparent to the worker skilled in the art. All such modifications and extensions are to be considered to be within the spirit and scope of the invention.
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A priority controlled network wherein a plurality of sensor terminals, at least one display terminal, and control circuit are interconnected by a network, and within each sensor terminal is a priority determining unit to which are supplied data from one or more sensors in the sensor terminal, and parameters controlling the priority determining from the control circuit, whereby priority determining by said priority determining unit is obtained by using said data and said parameters so that a particular priority value is determined for each of the plurality of sensor terminals and selected priority value data are displayed in the at least one display terminal and capacity of said network is optimally used where more than one display terminal is provided.
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TECHNICAL FIELD
This invention relates to a flexible coupling and more particularly to a flexible coupling used to interconnect machine components.
BACKGROUND OF THE INVENTION
Known flexible couplings of this kind are often used to connect an engine flywheel to a driven component of the engine for example the gearbox or alternator. These couplings are substantially disc shaped having an inner metallic member connected to an outer metallic ring via a rubber body which is vulcanized to the inner member. The inner member of the coupling is connected to the driven component and the ring is bolted to the engine flywheel. The rubber body provides the torsional flexibility of the coupling.
In one particular known coupling the outer ring has a plurality of equiangularly spaced holes by means of which it is bolted to the flywheel. When the bolts are tightened, the face of the flywheel engages the ring. Resistance against backlash in this coupling is provided by the friction force between the flywheel face and the outer ring. This coupling is of limited flexibility because the rubber body is confined to the space between the inner member and the outer ring. Furthermore, blind assembly in this type of assembly, the flywheel carrying the ring and the driven component with the inner member are brought into engagement by feel without fitting or tightening any fixing elements which may be difficult to access as a result of housing structures in the engine, is not possible with this design as the bolts connecting the coupling to the flywheel need to be tightened.
In another known form of flexible coupling the rubber body has peripheral teeth which engage with corresponding teeth on the outer ring. The teeth on the outer ring and the rubber body allow the coupling to be assembled blind. This type of coupling has several disadvantages. Under load there is a tendency for adjacent engaging teeth to disengage, slip over each other and to re-engage with the next tooth. This causes undesirable wear on the teeth and ultimately can ruin the coupling. In transmitting torque the rubber teeth become compressed causing gaps to appear between the two sets of teeth. When the torque reverses, the presence of the gap causes backlash in the coupling. Furthermore, as a result of centrifugal forces generated during rotation of the coupling, the rubber teeth on the rubber body tend to swell during rotation and grip tightly the outer ring. This induces friction between them and effectively prevents axial movement between the rubber and the outer ring. Axial movement is desirable in flexible couplings to help provide compensation for any misalignment of the coupled components.
DISCLOSURE OF THE INVENTION
It is an object of the present invention to provide a flexible coupling with improved torsional flexibility and provides ease of assembly.
In accordance with the present invention there is provided a flexible coupling for interconnecting machine components comprising a rigid inner annular member for connection to one of the machine components, means for forming an outer annular member for connection to the other of the machine components, and a resilient annular body fixed to the inner and outer annular members, the outer annular means comprises a plurality of arcuately spaced rigid tubes extending generally axially through and embedded in the resilient annular body. A plurality of rigid pins are connected to the other of the machine elements and extend through said tubes. A resilient annular lining is fixed to the inner walls of each of the tubes such that at least a zero clearance exists between the pins and said tubes, whereby the coupling can be assembled by sliding the tubes over the pins with minimum or no backlash.
The above and other related objects and features of the present invention will be apparent from a reading of the following description of the disclosure shown in the accompanying drawings and the novelty thereof pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a part sectioned longitudinal view of half of the flexible coupling according to the present invention together with part of an engine flywheel;
FIG. 1A is an enlarged partial view of the flexible coupling of FIG. 1 showing a tapered section of rubber tubes 10;
FIG. 2 is an end view of a quarter of the coupling in the direction of arrow X of FIG. 1 (flywheel not shown);
FIG. 3 is a perspective view of a reinforcement skeleton forming part of the flexible coupling of the present invention;
FIG. 4 is a sectioned view of the reinforcement skeleton along line A--A of FIG. 2;
FIG. 5 is a part sectioned longitudinal view of a second embodiment of the present invention;
FIG. 6 is a part sectioned longitudinal view of a third embodiment of the present invention; and
FIG. 7 is an end view of FIG. 6 showing a quarter of the coupling.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2 in which for convenience only part of the coupling is shown, the rest of the coupling being the mirror image of the part shown about the center lines, the flexible coupling generally indicated by arrow 1 is connected between a hub 2 and a flywheel 3 of an internal combustion engine (not shown). The hub 2 is machined to fit on to a shaft of a driven component (not shown) of the engine, for example, a gearbox or an alternator. The coupling 1 has a main body of rubber 4 and is connected at its outer end to the flywheel 3.
An inner member 5 of cylindrical shape and having a radially inwardly directed flange 6 is connected to the hub 2 by a plurality of equiangularly spaced screws 7 which pass through the flange. The inner member 5 is vulcanized on its outer surface 5a to the main body of rubber 4.
The main body of rubber 4 is of disc-like configuration having radial end faces 4a and 4b configured so that the axial thickness of the body 4 diminishes radially outwards. The body has embedded in it, adjacent its outer edge, a metal reinforcement skeleton 8 which is shown in detail in FIG. 3. The skeleton 8 comprises a plurality of equiangularly spaced tubes 9 which are linked together by integral arcuate bridges 9a of inverted T-shaped cross section (see FIG. 4) to form a complete ring. The bridges 9a each comprise a radially extending web 9b linking adjacent tubes 9 and an axially extending wall 9c extending between and smoothly flaring into the outer circumference of the tubes 9, as shown especially in FIG. 2.
The inside of each tube 9 is lined with a rubber tube 10 formed from rubber which is harder than the rubber in the main body 4. As particularly shown in FIG. 1A, the rubber tube 10 is internally tapered from both ends 10a to a minimum diameter at the center 10b. Within the rubber tube 10 there is shown a sleeve or pin 11 which is slightly longer than the rubber tube 10. One end of the sleeve 11 has rounded edges 12 and the other end has a boss 13. The minimum inside diameter of the rubber tube 10 is slightly less than the outside diameter of the sleeve 11.
A location ring 14 fits into a recess 15 provided in the flywheel 3 and against a shoulder 15a. The location ring 14 is drilled and counterbored at 14a to match the hole pattern in the flywheel 3. The boss 13 on each sleeve 11 locates in the corresponding counterbore 14a in the location ring.
The coupling 1 is fixed to the flywheel 3 by means of screws 16 which pass through the sleeves 11 and the drillings and counterbores 14a in the location ring 14 to engage in a threaded bore 3a in the flywheel 3. The sleeves 11 may, in an alternative embodiment, be counterbored to receive the head 16a of each screw 16.
The coupling is assembled in the following manner. The location ring 14 and sleeves 11 are attached to the flywheel 3 by means of the screws 16 and the hub 2 is connected to a driven shaft by means of, for example, a key. The coupling 1 comprising the rubber body 4, the inner member 5, the skeleton 8 and the rubber tubes 10 is then connected to the hub 2 by means of screws 7. The rubber tubes 10 are lubricated with, for example, silicon fluid. The coupling 1 and the flywheel 3 can then be assembled blind by bringing them together and aligning the sleeves 11 to their respective tapered holes formed by the rubber tubes 10 in the coupling 1 by feel. The engine and driven machine are then pushed together such that the sleeves 11 enter the rubber tubes 10. The rounded edges 12 of the sleeves 11 and the tapered bores of the rubber tubes 10 facilitate entry of the sleeves 11 into the tubes 10.
In manufacture, the inner member 5 and skeleton 8 are placed within a mold and the rubber 4 is injected into the mold and vulcanized to them to form the main body and the tubes. The rubber body 4 and the rubber tubes 10 are of different rubber compound but are injected simultaneously into the rubber mold. The rubber tubes 10 have a high value of hardness designed to resist deformation and abrasion from the loads imposed by the sleeves 11 whereas the rubber body 4 has a low value of hardness and thus produces a low torsional stiffness in the coupling 1.
The rubber body 4 is tapered as described to provide for uniform torsional strength throughout the coupling.
By virtue of the minimum internal diameter of the rubber tube 10 being less than the outer diameter of the sleeve 11 a precompression is induced in the rubber tube 10.
The arrangement of the sleeves 11 in the tubes 10 provides for a very low axial stiffness for the coupling 1. As the friction force between the sleeves 11 and the rubber tubes 10 is not great the coupling is allowed to slide axially on the sleeves 11 while in use. This axial movement is desirable in couplings to provide compensation for any misalignment of the coupled components. The relatively high radial stiffness of the connection ensures that the torque load or centrifugal stresses do not tend to cause swelling of the rubber tubes 10 and thus they have little or no effect on the axial stiffness.
The skeleton 8 is bonded to the rubber body 4 over a large surface area such that the stress of the rubber to metal bond has a relatively low value. The skeleton 8 acts to reinforce the harder rubber of the tubes and provides a strong connection resistant to localized deformation of the rubber.
The skeleton 8 and the rubber tubes 10 preloaded by the sleeves 11 act to eliminate virtually all backlash. The provision of a rubber body 4 which entirely encompasses the skeleton 8 and therefore the connection holes gives extra flexibility in the coupling compared with known couplings of this kind. This allows the rubber 4 to have a lower stiffness without overstressing the rubber 4.
The bridges 9a of the skeleton 8 provide restraint from centrifugal forces acting on the connection tubes 9 and the associated fixings as the coupling rotates, and help to reduce the stress concentration in its rubber body 4 near each tube 10.
In summary, it can be seen that in the embodiment described the coupling 1 provides extra torsional flexibility while minimizing backlash and allowing blind assembly.
It will be appreciated that the coupling of the present invention can also be used in applications where blind fitting is not required. In such cases the coupling can be bolted to the flywheel once the tubes of the reinforcement skeleton have been aligned to the holes in the flywheel. The backlash in these cases will be zero. Furthermore, there may be applications where the elimination of backlash is not a significant concern in relation to the torsional flexibility requirement, so couplings may be provided which do not have the rubber tubes 10 lining the tubes 9 of the reinforcement skeleton 8.
FIG. 5 shows an alternative embodiment of the present invention in which an alternative connection arrangement between the flexible coupling 1 of FIGS. 1 to 3 and the flywheel is provided to suit other designs of flywheels or driving machines. The same reference numerals but incremented by a value of 100 are used to identify parts common to both embodiments. In this design the location ring 114 is extended radially outwardly. The ring 114 has a plurality of equiangularly spaced outer holes 117a and similarly spaced inner holes 117b counterbored at 117c. The boss 113 of each sleeve 111 locates in the counterbored hole 117c as before and the coupling, indicated generally by arrow 101, is connected to the location ring 114 by a nut and bolt arrangement 118 and 118a respectively. The coupling 101 is connected to the flywheel 103 by a plurality of equiangularly spaced screws 119 which pass through the outer hole 117a in the location ring 114.
FIGS. 6 and 7 show a further alternative embodiment in which parts common to the first embodiment are given the same reference numeral but incremented by a value of 200. For convenience, only part of the coupling is shown, the rest of the coupling being the mirror image of the part shown about the center lines. In this embodiment of the invention the location ring 214 extends radially inwardly from the flywheel 203 connection. An inner limit ring 220 is connected in the same plane as the location ring 214 to the hub 202 and inner member 205 by means of screws 207. The location ring 214 has radially inwardly extending projections which project into the spaces between corresponding outwardly extending projections 222 on the inner limit ring 220. This arrangement acts as a failsafe mechanism. If the rubber of the main body 204 should fail during rotation the degree of relative rotational motion between the hub 202 and the flywheel 203 is limited by the abutment of the projections 221, 222 on the limit ring 220 and location ring 214, respectively. Thus, despite the rubber failure the projections enable the drive to be transmitted by the coupling until the requisite repair action can be taken.
While preferred embodiments of the present invention have been described, it should be apparent to those skilled in the art that it may be practiced in other forms without departing from the spirit and the scope thereof.
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A flexible coupling has an inner member and a resilient body mounted on the hub and connected thereto. A reinforcement ring is embedded within the resilient body. The ring has arcuately spaced tubes with tapered rubber liners. Fasteners for connecting the coupling to the flywheel are locatable within the rubber liners. The taper causes the fixing to induce a precompression in the rubber tubes when the coupling is assembled and fitted in place. The coupling minimizes backlash, provides extra torsional flexibility and permits blind assembly.
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[0001] The present application claims priority benefit under 35 U.S.C. ยง119(e) from U.S. Provisional Application No. 60/665,067, filed Mar. 24, 2005, titled SYSTEMS AND METHODS FOR ENHANCING DIGITAL ACQUISITION DEVICES FOR ANALOG DATA IN LOCAL AS WELL AS REMOTE DEPLOYMENTS, the entirety of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to systems and methods for improving the quality of data acquired by data acquisition devices. The user can be located locally or remotely from the data acquisition device.
[0004] 2. Description of the Related Art
[0005] Data acquisition devices for analog data transform analog data to digital data. A typical example is a scanning device. It takes as input an image printed onto a sheet of paper and outputs a digital representation of the physical image. The quality obtained by the acquisition device depends strongly on using the device with settings that are suited for the specifics of the given analog data. For example, the scanner settings useful to achieve a high quality scanned image of a sunset are rather different from the settings used to scan a picture taken in the broad sunlight of a summer day. Finding better or optimal settings given the specifics of the analog data is a time consuming process that often makes it necessary to acquire the analog data more than once using different settings of the acquisition device. This becomes particularly unpractical and inefficient when the recipient of the digital data and the data acquisition device are at different locations.
[0006] The following example illustrates the inefficiency of the current technology. The recipient of a fax is unsatisfied with the quality of the received fax. In order to obtain a better quality fax, the recipient has to, e.g. by using a phone, inform a person located at the origination of the fax and request to resend the fax with different settings.
[0007] Furthermore, given temporary analog data, the determination of improved acquisition settings using physical reacquisition of the analog data is either impossible or less feasible within a narrow time frame.
[0008] In current remote data acquisition applications, analog data are acquired digitally by using, for example, a scanning device or a digital copy machine. The digitalized data are then sent to a remote recipient via a network. Current methods of remote digital acquisition application do not provide the remote recipient of the acquired data with remote control of the data acquisition device.
SUMMARY OF THE INVENTION
[0009] Embodiments include methods of virtual reacquisition of data for the purpose of quality enhancements. In an embodiment, virtual reacquisition for quality enhancement may be used for scanning devices, and other data acquisition devices, such as, for example, digital copiers, fax machines, multifunctional peripherals, infrared cameras, acoustic cameras, digital cameras, infrared cameras, acoustic cameras, digital cameras, mobile phones with built in digital cameras, and the like. Virtual reacquisition can be used with any analog or digital source including, for example, voice, acoustic measurements for monitoring devices, temperature, video, and the like.
[0010] The input stream of an acquisition device for analog data can be either discrete or continuous. In addition, the input stream can be a function of time or space. Regardless of these modalities, the resulting data are contained in an ordered set of discrete units. The order of the set contains the information of the time or space direction of the input stream. In case of a continuous input stream, the acquisition device generates discrete units by subdividing the continuous input stream in bins. For example, the input to a video camera is continuous, and the resulting data are given by the ordered set of picture frames taken by the camera with each picture frame being an instance of the aforementioned discrete units. A batch of paper sheets fed into a scanning device is an example of a discrete input stream, and the discrete data are defined by the paper sheets.
[0011] One embodiment is an efficient method and system for enhancing the digital data obtained by an acquisition device for analog data. The enhancements are obtained using virtual reacquisition of the analog data. The method of virtual reacquisition stores the raw data acquired by the acquisition device in a cache. The data processor accesses the raw data from the cache allowing the reprocessing of the raw data by the data processor without physically reacquiring the data by the acquisition device.
[0012] An embodiment stores as many of the incoming data units at the cache as possible, given the cache size. In certain embodiments, new storage for incoming data is created by deleting the data units that have resided at the cache the longest. In addition, or in other embodiments, data units are assigned priorities and data units with lower priorities are overwritten with new data units before data units with higher priorities.
[0013] An embodiment has the capability of virtually reacquiring the most current or more currently used data units acquired by the acquisition device. Alternatively, the user can, via a selection mechanism, virtually reacquire the raw data or subsections of the raw data stored at the cache. The method of virtual reacquisition renders unnecessary the time and labor consuming physical reacquisition of the analog data. Furthermore, in instances where physical reacquisition of the data is impossible, e.g. in the case of a time dependant input stream, the application of virtual reacquisition is especially valuable.
[0014] An additional application of virtual reacquisition is given when the acquisition rate of the acquisition device is too high for the output communication system and as default, compressed low resolution data are transferred. Using virtual reacquisition the recipient of the data can selectively access and reprocess the original high-resolution data despite the constraint given by the bandwidth of the transmission.
[0015] In addition, an embodiment of the method and system presented here utilizes virtual reacquisition to efficiently determine improved or optimal acquisition device settings. The improved or optimal settings can be found interactively in real time as well as in non-real time, automatically by the system itself, or using a combination thereof, depending on the specific embodiment. Furthermore, the method and system facilitates the control of digital acquisition devices by alerting the user automatically about potentially low quality digital data or changes in the input stream, that might be of interest to the user, by analyzing the data and comparing the results against some user defined thresholds. This feature is of value, for example, in deployments using or requiring the acquisition of large amounts of analog data.
[0016] In addition, the method of virtual reacquisition in combination with remote deployment, as presented in an embodiment, offers the potential of large efficiency gains in a large variety of business processes, e.g. security surveillance applications. For example, a building is monitored using a video system and, owing to the available bandwidth, as low resolution data are transmitted to a central location. By analyzing the data, the system detects events that are potentially of interest for the person monitoring the system and triggers the transmission of high-resolution data to the user utilizing virtual reacquisition.
[0017] By transferring as default the processed data instead of the raw uncompressed data, the remote application of an embodiment makes efficient use of storage and of the network reducing or minimizing the hardware usage or requirements on storage as well as the network.
[0018] Furthermore, an embodiment of the method and system presented here allows multiple users to share the usage of one or multiple analog acquisition devices. Each user can process the same raw data with different setting of the data processor enabling each individual user to process the raw data according to his or her personal preferences and needs.
[0019] Finally, an embodiment of the method and system can be independently applied to subsections of the acquired discrete data units, i.e. the user can select subsections of the acquired data unit and process the selected subsections differently. For example, given a scanned image displaying an image and text, the user can subdivide the acquired data unit in two zones with one containing the image and the other text and can virtual reacquire the zones using settings most suited or better suited for the selected zone.
[0020] As mentioned above, an embodiment of the method and system presented here has the capability of determining improved or optimal processor settings automatically by deploying potentially one or more analytic engines. For example, a first analytic engine (engine 1 ) takes as input the raw data, whereas a second analytic engine (engine 2 ) uses the processed data as input. The second engine determines the quality of the processed data using a metric. It selects new processor settings either randomly or depending on the quality of the processed data as determined by the metric. The raw data are reprocessed using the new settings. This process continues until convergence, i.e. until the metric cannot detect any improvements in the quality of the processed data. The functions performed by the first analytic engine are, but are not limited to, page boundaries detection, background smoothing, bleed-through detection, color detection, and orientation detection, and the like.
[0021] Page boundaries detection is useful for efficient page skew correction. In an embodiment, the page boundaries detection detects the page against a variety of backgrounds and, thus, allows page skew correction and cropping for white background scanners as well as black background scanners.
[0022] An embodiment of a background smoothing method addresses the need or desire to reduce the number of colors within the backgrounds of an image to improve the appearance of the image as well as decrease the size of the image after compression. An embodiment of the method works as follows. Cluster all or a portion of the colors found in the image and select those that contain enough pixels to be considered backgrounds. These backgrounds are then merged, and all or a portion of the pixels within the image belonging to a background cluster are replaced by the average color within the cluster.
[0023] An embodiment of the bleed-through detection detects bleed-through on otherwise blank sides of scanned documents in order to perform further image processing on these pages. An embodiment of this algorithm uses page boundary detection within front and back scanned images to approximately match side coordinates. Then, the algorithm uses existing color or gray content to fine-tune the mapping. This additional step is useful because of slightly different optics and skews of front and back cameras. If residual (unexplained) content fall below certain density criterion, the page is called blank.
[0024] In an embodiment, the color detection addresses the need or desire to detect the color content in a scanned image and the need or desire to distinguish between the foreground and background color. An embodiment of this algorithm provides a mechanism to eliminate the background color if it is a predominant color or the most predominant color in the document. An embodiment of this algorithm examines pixels in the scanned image and determines if they are a color pixel or a background pixel. This determination uses the saturation and luminance levels of the pixel.
[0025] In an embodiment, orientation detections determine automatically which way to orthogonally rotate a text page for viewing. An embodiment of the algorithm selects possible individual characters from connected components of black within the page and determines their individual orientations by a trained neural network. The algorithm uses the orientation results as votes to decide which orientation of the page is best or an improvement.
[0026] In an embodiment, virtual reacquisition is implemented as software and is independent from the acquisition device. The users of the acquisition device can interactively enhance the quality of the digital representation of the acquired analog data by changing the processor settings. The possible adjustments include, but are not limited to, brightness, contrast, gamma, erosion, orientation, segmentation, color rendering, saturation, resolution, warping angle, out of sequence detection, dilation, speckle removal, and skew angle. The embodiment is of value, for example, in connection with acquisition devices that, owing to their limited hardware capabilities, are generally incapable of producing consistently high quality digital data given, as input, a large variety of analog data. In these instances, the embodiment is a cost effective method to enhance the capabilities and usability of the acquisition device.
[0027] Furthermore, an embodiment allows the users of the acquisition device to acquire the digital data according to their individual preferences and requirements.
[0028] Another advantage, in an embodiment, is virtual reacquisition's independence from the acquisition device. The algorithms employed by virtual reacquisition typically progress on a considerably faster pace than the improvements to the hardware of the acquisition devices. The user can easily take advantage of the algorithmic improvements by simply updating the virtual reacquisition software. This feature is of value, for example, for expensive high-end scanners by reducing or minimizing the scanners depreciation.
[0029] In a further embodiment, the embodiments described above are deployed remotely and, thus, offers the capabilities of virtual reacquisition to one or more remote recipients of the digital data. The implementation may be software, firmware, hardware, or any combination of software, firmware, or hardware.
[0030] An example of an embodiment is within the usage of fax server machines. The data are rendered in high definition analog form, stored at the data cache of the fax communication server, and the binary data, obtained by using default settings and attributes, are sent to their respective destinations. Through a call back protocol, implemented at the fax server machine, the recipient of the fax can select a specific image or a scaled area of an image from the images stored at the fax server and specify the processor settings and attributes for the selected image. The selected image or scaled area of the image is reprocessed according to the specified settings and transmitted to the recipient.
[0031] Image sets are stored in the cache at the fax server. When the cache is full or when the image is fully processed by the user, the images are either erased, replaced by the transmitted image, stored in a database, or any combination thereof. This embodiment enables the recipient of the fax to enhance the quality of the received fax directly on his desktop or application, rendering obsolete the resending of the fax in case of insufficient image quality.
[0032] In addition, the above-mentioned call back protocol allows the recipient to alert the sender to irreversible potential problems such as, white pages. Finally, the sender does not have to guess improved or optimal settings while sending the fax.
[0033] In a further embodiment, virtual reacquisition is enhanced by an analytic engine that takes as input the raw data of the acquisition device. The analytic engine automatically determines improved or close to optimal settings for the acquisition device. Additionally, it automatically monitors the quality of the digital data obtained by the acquisition device and alerts the user when the quality is below a predetermined threshold. The user can adjust the threshold to his or her preferences. In addition, the user can overwrite the acquisition device settings determined by the analytic engine and interactively adjust the settings manually when necessary or desired.
[0034] In an embodiment, the interactive adjustments can be done in non real-time, and thus, do not interrupt the flow of incoming data. This embodiment is of interest, for example, for deployments that use or require the acquisition of large amounts of analog data. It allows a nearly automatic data acquisition and still ensures high quality of the resulting digital data. Typical examples are copier rooms or facilities that electronically archive large amounts of paper documents using scanning devices.
[0035] In an embodiment, virtual reacquisition enhanced by an analytic engine may be implemented as software, firmware, hardware, or any combination of software, firmware, or hardware. The hardware implementation offers advantages with regard to speed compared to the software implementation and allows handling high volumes of data fast and efficient.
[0036] In a further embodiment, the virtual reacquisition enhanced by the analytic engine is deployed remotely. Remotely deployed virtual reacquisition enhanced by an analytic engine may be implemented as software, firmware, hardware, or any combination of software, firmware, or hardware.
[0037] In a further embodiment, the virtual reacquisition is enhanced by a first and a second analytic engine. The second analytic engine analyzes the processed digital data obtained with specific data processor settings from the first analytic engine. Utilizing this information, the second analytic engine estimates a new set of data processor settings and the raw data are virtually reacquired using the new settings.
[0038] In an embodiment, this process is iterated until sufficiently improved settings or the optimal settings have been determined automatically. Virtual reacquisition enhanced by a first and a second analytic engine may be implemented as software, firmware, hardware, or any combination of software, firmware, or hardware.
[0039] In a further embodiment, virtual reacquisition enhanced by a first and a second analytic engine is deployed remotely. Remotely deployed virtual reacquisition enhanced by a first and a second analytic engine may be implemented as software, firmware, hardware, or any combination of software, firmware, or hardware.
[0040] In an embodiment, a data processing system comprises raw or normalized data from a data capture device, where the raw or normalized data is stored in a computer accessible storage medium, and a first acquisition controller in communication with the raw or normalized data. The first acquisition controller is configured to analyze at least portions of the raw or normalized data to determine whether the raw or normalized data is within a first set of parameters. If the raw or normalized data is not within the first set of parameters, the first acquisition controller generates a first set of processor settings. The data processing system further comprises a processor in communication with the first acquisition controller, where the processor is configured to process the raw or normalized data with the first set of processor settings, and a second acquisition controller in communication with the processor. The second image acquisition controller is configured to analyze at least portions of the processed data to determine whether the processed data is within a second set of parameters. If the processed data is not within the second set of parameters, the second acquisition controller generates a second set of processor settings that the processor uses to reprocess the raw or normalized data.
[0041] In another embodiment, a data processing method comprises storing raw or normalized data from a data capture device in a computer accessible storage medium, and analyzing at least portions of the raw or normalized data with a first analytic engine to determine whether the raw or normalized data is within a first set of parameters. If the raw or normalized data is not within the first set of parameters, the method comprises generating with the first analytic engine a first set of processor settings, processing the raw or normalized data with the first set of processor settings, and analyzing at least portions of the processed data with a second analytic engine to determine whether the processed data is within a second set of parameters. If the processed data is not within the second set of parameters, the method further comprises generating with the second analytic engine a second set of processor settings to reprocess the raw or normalized data.
[0042] In yet another embodiment, a data processing system comprises a storing means for storing raw data from a data capture device, a first analyzing means in communication with the raw data for analyzing at least portions of the raw data to determine whether the raw data is within a first set of parameters, and if not, the first analyzing means generates a first set of processor settings. The data processing system further comprises a processing means in communication with the first analyzing means for processing the raw data with the first set of processor settings, and a second analyzing means in communication with the processing means for analyzing at least portions of the processed data to determine whether the processed data is within a second set of parameters, and if not, the second analyzing means generates a second set of processor settings that the processing means uses to reprocess the raw data.
[0043] In a further embodiment, a document processing system comprises document data from a data capture device where the document data is stored in a computer accessible storage medium, and a first acquisition controller in communication with the document data. The first acquisition controller is configured to analyze at least portions of the document data to determine whether the document data is within a first set of parameters. If the document data is not with the first set of parameters, the first acquisition controller generates a first set of processor settings. The document processing system further comprises a processor in communication with the first acquisition controller, where the processor is configured to process the document data with the first set of processor settings, and a second acquisition controller in communication with the processor. The second acquisition controller is configured to analyze at least portions of the processed document data to determine whether the processed document data is within a second set of parameters. If the processed document data is not within the second set of parameters, the second acquisition controller generates a second set of processor settings that the processor uses to reprocess the document data.
[0044] In an embodiment, a document processing method comprises storing document data from a data capture device in a computer accessible storage medium, and analyzing with a first analytic engine at least portions of the document data to determine whether the document data is within a first set of parameters. If the document data is not within the first set of parameters, the method further comprises generating with the first analytic engine a first set of processor settings, processing the document data with the first set of processor settings, and analyzing with a second analytic engine at least portions of the processed document data to determine whether the processed document data is within a second set of parameters. If the processed document data is not within the second set of parameters, the method further comprises generating with the second analytic engine a second set of processor settings to reprocess the document data.
[0045] In another embodiment, a document processing system comprises a storing means for storing document data from a data capture device, a first analyzing means in communication with the document data for analyzing at least portions of the document data to determine whether the document data is within a first set of parameters, and if not, the first analyzing means generates a first set of processor settings. The document processing system further comprises a processing means in communication with the first analyzing means for processing the document data with the first set of processor settings, a second analyzing means in communication with the processing means for analyzing at least portions of the processed document data to determine whether the processed document data is within a second set of parameters, and if not, the second analyzing means generates a second set of processor settings that the processing means uses to reprocess the document data.
[0046] In yet another embodiment, a document processing system comprises a random access cache that receives a document from a scanner, where the document is stored as multiple bands within the random access cache and in a manner that is randomly accessible. The document processing system further comprises a processor in communication with the random access cache, where the processor is configured to obtain the document from the random access cache, the processor having processor control settings that are used to process the document, and an acquisition controller interconnected with the processor. The acquisition controller is configured to analyze the processed document to determine when to use different processor control settings on at least one band within the document and where the processor randomly accesses the at least one band stored in the random access cache to reprocess the band with the different processor control settings.
[0047] In a further embodiment, a document processing method comprises storing a document from a scanner as multiple bands within a random access cache and in a manner that is randomly accessible, obtaining the document from the random access cache, and processing the document with processor control settings. The method further comprises analyzing the processed document with an analytic engine to determine when to use different processor control settings on at least one band within the document, and randomly accessing the at least one band stored in the random access cache to reprocess the band with the different processor control settings.
[0048] In an embodiment, a document processing system comprises a storing means for storing a document received from a scanner as multiple bands within the storing means and in a manner that is randomly accessible, and a processing means for obtaining the document from the storing means and processing the document with processor control settings associated with the processing means. The document processing system further comprises an analyzing means for analyzing the processed document to determine when to use different processor control settings on at least one band within the document, and an accessing means for randomly accessing the at least one band stored in the storing means to reprocess the band with the different processor control settings.
[0049] For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] A general architecture that implements the various features of the invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention. Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements. In addition, the first digit of each reference number indicates the figure in which the element first appears.
[0051] FIG. 1 is a block diagram of an embodiment of a data acquisition and rescanning system.
[0052] FIG. 2 is a block diagram of an embodiment of a remotely deployed data acquisition and rescanning system.
[0053] FIG. 3 is a block diagram of an embodiment of a data acquisition and rescanning system having an analytic engine.
[0054] FIG. 4 is a block diagram of a hardware-implemented embodiment of a data acquisition and rescanning system having an analytic engine.
[0055] FIG. 5 is a block diagram of an embodiment of a remotely deployed data acquisition and rescanning system having an analytic engine.
[0056] FIG. 6 is a block diagram of a hardware-implemented embodiment of a remotely deployed data acquisition and rescanning system having an analytic engine.
[0057] FIG. 7 is a block diagram of an embodiment of a data acquisition and rescanning system having a first and a second analytic engine.
[0058] FIG. 8 is a block diagram of a hardware implemented embodiment of a data acquisition and rescanning system having a first and a second analytic engine.
[0059] FIG. 9 is a block diagram of an embodiment of a remotely deployed data acquisition and rescanning system having a first and a second analytic engine.
[0060] FIG. 10 is a block diagram of a hardware implemented embodiment of a remotely deployed data acquisition and rescanning system having a first and a second analytic engine.
[0061] FIG. 11 is a block diagram of an embodiment of a data acquisition and rescanning system comprising multiple acquisition devices and having multiple users.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0062] FIG. 1 is a block diagram of an embodiment of a data acquisition and rescanning system 150 . The data acquisition and rescanning system 150 comprises a data acquisition device 100 , which comprises a data capture device 101 , a normalization processor 102 , and a communication device 103 . Examples of data capture devices 101 include, but are not limited to scanners, cameras, video recorders, infrared cameras, acoustic cameras, digital cameras, facsimile machines, any devices capable of capturing an image, acoustic sensors, any devices having an acoustic sensor, and the like. Data capture devices 101 can be non-real time devices, such as, for example, scanners, or data capture devices 101 can be real time devices, such as, for example, cameras and video recorders.
[0063] The data acquisition and rescanning system 150 further comprises a user system 110 , which comprises a communication device 104 , which communicates with the communication device 103 , a random access data cache 105 , a data processor 106 , a user interface 107 , and a data display 108 . In an embodiment, the random access data cache stores the data in at least one subsection, zone, band, image strip, data strip, or the like, and in a manner that is randomly accessible.
[0064] The data reacquisition and rescanning system 150 further comprises an application/storage device 109 . Examples of the application/storage device 109 include, but are not limited to computer processors, program logic, controller circuitry, general purpose single-chip or multi-chip microprocessors, digital signal processors, embedded microprocessors, microcontrollers and the like. Data storage examples can include volatile and non-volatile memory, hard drives, DVD storage, CD ROM storage, optical and magneto-optical storage, removable or non-removable flash memory devices, or another memory device.
[0065] Analog data are presented to the acquisition device 100 . The analog capture device 101 measures the analog data. The normalization processor 102 transforms the measured data into normalized data. It calibrates and compensates for known errors and biases introduced by the sensors measuring the analog data to produce normalized data.
[0066] The normalized raw data, referred to as raw data from here on, are transmitted via a fast connection using the communication devices 103 and 104 to the user system 110 and stored at the random access data cache 105 . The raw data are stored as bands, image strips, data strips, or the like in the random access cache 105 . In an embodiment, the random access data cache 105 is partitioned into 64 K byte bands.
[0067] In addition to the raw data, data pertaining to the raw data, or metadata for each band, are also stored at the cache 105 . These metadata comprise, but are not limited to, a tag identifying the data and the location in the cache, a time and date stamp of the acquisition, the sequence number, the beginning of the data band, the end of the data band, height, width, a pointer to the next band, and the like. In some embodiments, tags identify subsections or zones of raw data.
[0068] The data processor 106 processes the raw data using the default data processor settings.
[0069] The order in which the raw data are processed by the data processor 106 is either determined automatically or interactively. In an automatic embodiment, the most current or more current raw data first stored at the cache 105 are processed.
[0070] In an interactive embodiment, the user identifies specific raw data bands or subsections of these for processing utilizing the data tags or metadata. The bands are randomly accessible in the cache 105 . This allows non real-time virtual reacquisition.
[0071] The processed data together with their metadata are displayed at the data display 108 . The default data processor settings are adjustable through the user interface 107 . Changing the settings triggers the data processor 106 to reprocess the selected raw data stored in the random access data cache 105 with the changed settings and to display the reprocessed data at the data display 108 . By interactively readjusting the processor settings, the data are processed until they satisfy the user's preferences.
[0072] In addition to controlling the data processor 106 , the user interface 107 also controls the random access data cache 105 . The user, through the user interface 107 , can access subsections, zones, bands, image strips, or data strips of the raw data as well as selecting specific raw data for non real time interactive processing.
[0073] The user can transmit the processed data to the application/storage device 109 for further processing as well as storage.
[0074] The data acquisition and rescanning system 150 depicted in FIG. 1 supports multiple user usage. The data acquisition device 100 can be accessed by multiple users. In an embodiment, the user system 110 further comprises a computer (not shown). In an embodiment, the user system 110 is implemented, at least in part, as software on the computer.
[0075] FIG. 2 is a block diagram of an embodiment of a remotely deployed data acquisition and rescanning system 250 . The data acquisition and rescanning system 250 comprises the data acquisition device 100 , a storage and processing system 212 , a user system 210 , and the acquisition/storage device 109 .
[0076] The storage and processing system 212 comprises the communication device 103 , the random access data cache 105 , the data processor 106 , and a communication device 203 .
[0077] The user system 210 comprises a communication device 204 , the user interface 107 , and the data display 108 .
[0078] The raw data from the acquisition device 100 are transmitted, via a fast connection using the communication devices 103 and 104 , to the storage and processing system 212 . The raw data and the metadata are stored at the random access data cache 105 . The data processor 106 processes the raw data using the default data processor settings.
[0079] The user system 210 communicates with the storage and processing system 212 via a communication medium 216 using the communication devices 203 and 204 .
[0080] Focusing now on the communication medium 216 , as shown in FIG. 2 , in one embodiment, the communications medium is Internet, which is a global network of computers. In other embodiments, the communication medium 216 can be any communication system including by way of example, dedicated communication lines, telephone networks, wireless data transmission systems, infrared data transmission systems, two-way cable systems, customized computer networks, interactive kiosk networks, and the like.
[0081] The processed data together with their metadata are displayed at the data display 108 . The default data processor settings are adjustable through the user interface 107 . Changing the settings triggers the data processor 106 to reprocess the selected raw data stored in the random access data cache 105 with the changed settings and to display the reprocessed data at the data display 108 . By interactively readjusting the processor settings, the data are processed until they satisfy the user's preferences.
[0082] The user can transmit the processed data to the application/storage device 109 for further processing as well as storage.
[0083] The data acquisition and rescanning system 250 is similar to the data acquisition and rescanning system 150 except the user system 210 is located remotely from the data acquisition device 100 and the storage and processing system 212 . In the remotely deployed system 250 , the data cache 105 is local to the data acquisition device 100 . The user system 210 does not have to be connected to the data acquisition device 100 with a fast connection in order to ensure an effective use of the embodiment. The data acquisition and rescanning system 250 is implemented, at least in part, as software, firmware, or any combination of software and firmware.
[0084] FIG. 3 is a block diagram of an embodiment of a data acquisition and rescanning system 350 comprising an analytic engine. The data acquisition and rescanning system 350 comprises the data acquisition device 100 , a user system 310 , and the application/storage device 109 . The user system 310 comprises the communication device 104 , the random access data cache 105 , the data processor 106 , the user interface 107 , the data display 108 , and an analytic engine 314 .
[0085] Analog data are presented to the acquisition device 100 . The analog capture device 101 measures the analog data. The normalization processor 102 transforms the measured data into normalized raw data. The raw data are transmitted via a fast connection using the communication devices 103 and 104 to the user system 310 . At the user system 310 , the raw data are stored at the random access data cache 105 .
[0086] Selected raw data are analyzed by the analytic engine 314 . In an embodiment, the analytic engine 314 is an acquisition controller 314 . The selection mechanism can be either automatic or interactive as described in the embodiments above. The analysis performed by the analytic engine 314 yields new data processor settings for the selected raw data. Examples of analyses comprise, but are not limited to, page boundary detection, streak detection, page border detection, blank page detection, conversion from RGB color representation to a YCbCr color representation, hue measurement, saturation measurement, luminescence measurement, creating a grayscale intensity histogram, creating a color histogram, geometric analysis, color detection, gamma detection for brightness and color levels, textual orientation, and the like.
[0087] The settings are transferred to the data processor 106 , and the raw data are processed with the new settings. The processed data are displayed at the data display 108 . The data processor settings can be adjusted interactively using the user interface 107 . In addition to determining the data processor settings, the analytic engine 314 also detects automatically raw data that will potentially result in poor quality processed data and alerts the user upon selection of these data through the user system 310 . The corresponding trapping conditions (e.g., user-defined parameters specifying quality thresholds such as brightness range, contrast range, missing corner, blank page, and the like) are accessible to the user through the user interface 107 . The user through the user system 310 is able to control the quality of the acquired data.
[0088] The user system 310 can transmit the processed data to the application/storage device 109 for further processing as well as storage. Additionally the user can, via the user interface 107 , access subsections, or zones of the raw data stored at the random access data cache 105 to be processed at the data processor 106 .
[0089] The data acquisition and rescanning system 350 allows the non real time interactive processing of specific raw data. The data acquisition and rescanning system 350 also supports multiple user usage. The data acquisition device 100 can be accessed by multiple user systems 310 with each data processor 106 having unique processor settings. In an embodiment, the data acquisition and rescanning system 350 further comprises a computer (not shown). In an embodiment, the data acquisition and rescanning system 350 is implemented, at least in part, as software on the computer.
[0090] FIG. 4 is a block diagram of an embodiment of a data acquisition and rescanning system 450 comprising the data acquisition device 100 , a user system 410 , and the analytic engine 314 . The data acquisition and rescanning system 450 implements the data acquisition and rescanning system 350 shown in FIG. 3 as hardware.
[0091] The random access data cache 105 , the data processor 106 , and the analytic engine 314 are implemented at the data acquisition device 100 . The data acquisition device 100 further comprises the data capture device 101 , the normalization processor 102 , and the communication device 103 . The user system 410 comprises the communication device 104 , the user interface 107 , and the data display 108 .
[0092] FIG. 5 is a block diagram of an embodiment of a remotely deployed data acquisition and rescanning system 550 comprising the analytic engine 314 . The data acquisition and rescanning system 550 comprises the data acquisition device 100 , a storage and processing system 512 , a user system 510 , and the acquisition/storage device 109 .
[0093] The storage and processing system 512 comprises the communication device 104 , the random access data cache 105 , the data processor 106 , the analytic engine 314 , and a communication device 503 .
[0094] The user system 510 comprises a communication device 504 , the user interface 107 , and the data display 108 .
[0095] The raw data from the acquisition device 100 are transmitted, via a fast connection using the communication devices 103 and 104 , to the storage and processing system 512 . The raw data and the metadata are stored at the cache 105 . The data processor 106 processes the raw data using the default data processor settings.
[0096] Selected raw data are analyzed by the analytic engine 314 . The analysis performed by the analytic engine 314 yields new data processor settings for the selected raw data. The settings are transferred to the data processor 106 , and the raw data are processed with the new settings.
[0097] The user system 510 communicates with the storage and processing system 512 via the communication medium 216 using the communication devices 503 and 504 . The processed data are displayed at the data display 108 . The data processor settings can be adjusted interactively using the user interface 107 .
[0098] The user, through the user system 510 , can transmit the processed data to the application/storage device 109 for further processing as well as storage. Additionally the user can, via the user interface 107 , access subsections, or zones of the raw data stored at the random access data cache 105 to be processed at the data processor 106 .
[0099] The data acquisition and rescanning system 550 allows the non real time interactive processing of specific raw data. The data acquisition and rescanning system 550 is similar to the data acquisition and rescanning system 350 except the user system 510 is located remotely from the data acquisition device 100 and the storage and processing system 512 . In the remotely deployed system 550 , the data cache 105 and the analytic engine 314 are local to the data acquisition device 100 .
[0100] The data acquisition and rescanning system 550 also supports multiple user usage. The data acquisition device 100 can be accessed by multiple user systems 510 with each data processor 106 having unique processor settings. The data acquisition and rescanning system 550 is implemented, at least in part, as software, firmware, or a combination of software and firmware.
[0101] FIG. 6 is a block diagram of a hardware implemented embodiment of a remotely deployed data acquisition and rescanning system 650 comprising the analytic engine 314 . The data acquisition and rescanning system 650 implements the data acquisition and rescanning system 450 shown in FIG. 4 in a remote deployment. The data acquisition and rescanning system 650 comprises the data acquisition device 100 , a user system 610 , and the application/storage device 109 .
[0102] The random access data cache 105 , the data processor 106 , and the analytic engine 314 are implemented as hardware on the data acquisition device 100 directly. The data acquisition device 100 further comprises the data capture device 101 , the normalization processor, and the communication device 103 . The user system 610 comprises the user interface 107 , the data display 108 , and a communication device 604 .
[0103] The user system 610 communicates with the data acquisition device 100 via the communication medium 216 using the communication devices 103 and 604 .
[0104] FIG. 7 is a block diagram of an embodiment of a data acquisition and rescanning system 750 having a first analytic engine 714 and a second analytic engine 718 . The data acquisition and rescanning system 750 comprises the data acquisition device 100 and a user system 710 . The data acquisition device 100 comprises the data capture device 101 , the normalization processor 102 , and the communication device 103 . The user system 710 comprises the communication device 104 , the random access data cache 105 , the data processor 106 , the user interface 107 , and the data display 108 . The user system 710 further comprises the first analytic engine 714 and the second analytic engine 718 . In an embodiment, the first and second analytic engines 714 , 718 are first and second acquisition controllers 714 , 718 , respectively.
[0105] Analog data are presented to the acquisition device 100 . The data capture device 101 measures the analog data. The normalization processor 102 transforms the measured data into normalized raw data. The raw data are transmitted via a fast connection using the communication devices 103 and 104 to the user system 710 .
[0106] At the user system 710 , the raw data are stored at the data cache 105 . The raw data are stored as bands, image strips, data strips, or the like in the random access data cache 105 . In an embodiment, the random access data cache is partitioned in to 64 K byte bands.
[0107] In addition to the raw data, data pertaining to the raw data, or metadata for each band, are also stored at the cache 105 . These metadata comprise, but are not limited to, a tag identifying the data and the location in the cache, a time and date stamp of the acquisition, the sequence number, the beginning of the data band, the end of the data band, height, width, a pointer to the next band, and the like. In some embodiments, tags identify subsections or zones of raw data.
[0108] Selected raw data are analyzed by the first analytic engine 714 . The selection mechanism can be either automatic or interactive as described in the embodiments above. The analysis performed by the first analytic engine 714 yields an improved or close to optimal data processor settings for the selected raw data. In an embodiment, the first analytic engine 714 performs geometric processing, such as for example, document orientation, background compensation, color compensation, text extraction, text/background separation, page boundary detection, streak detection, page border detection, blank page detection, conversion from RGB color representation to a YCbCr color representation, hue measurement, saturation measurement, luminescence measurement, creating a grayscale intensity histogram, creating a color histogram, color detection, gamma detection for brightness and color levels, and the like.
[0109] The settings are transferred to the data processor 106 , and the raw data are processed given with the settings.
[0110] The processed data are transferred to the second analytic engine 718 . In an embodiment, the processor 106 sends the processed data to the second analytic engine 718 for analysis. In another embodiment, the processor 106 sends the processed data to the first analytic engine 714 and the first analytic engine 714 sends the processed data to the second analytic engine 718 for analysis.
[0111] At the second analytic engine 718 the processed data are analyzed and improved data processor settings are determined. The second analytic engine 718 compares the quality of the processed data to a predetermined metric. The second analytic engine 718 selects new processor settings based on the quality of the processed data as determined by the metric.
[0112] In an embodiment, the second analytic engine performs feature or quality processing, such as, for example, recognizing an area of poor optical character recognition, non-linear gamma, high background noise, character color distortion, and the like. In an embodiment, the second analytic engine replaces, at least in part, the user's data review at the data display 108 and the user's revised processor settings input from the user interface 107 .
[0113] The new settings are transmitted to the data processor 106 and the raw data are reprocessed using the new settings. In an embodiment, the second analytic engine 718 sends the metadata containing the location of the raw data in the random access cache 105 and the new processor settings to the processor 106 . The processor 106 processes the data with the new processor settings.
[0114] In another embodiment, the second analytic engine 718 sends the metadata associated with the data and the new processor settings to the first analytic engine 714 . The first analytic engine 714 receives the metadata containing the location of the raw data in the random access cache 105 and the new processor settings and sends the metadata containing the location of the raw data in the random access cache 105 and the new processor settings to the processor 106 . The processor processes the raw data with the new processor settings.
[0115] In yet another embodiment, the second analytic engine 718 sends the metadata associated with the data to the first analytic engine 714 . The first analytic engine 714 receives the metadata containing the location of the raw data in the random access cache 105 and the new processor settings and processes the band of raw data with the new processor settings.
[0116] The processed data are transferred to the second analytic engine 718 for analysis. In an embodiment, the processor 106 sends the processed data to the second analytic engine 718 for analysis. In another embodiment, the first analytic engine 714 sends the processed data to the second analytic engine 718 for analysis. In another embodiment, the processor 106 sends the processed data to the first analytic engine 714 and the first analytic engine 714 sends the processed data to the second analytic engine 718 for analysis.
[0117] The step of reprocessing the raw data with the revised data processor settings and the step of analyzing the processed data and determining revised data processor settings are repeated until convergence, i.e. until the metric does not detect any improvements in the quality of the processed data. This yields improved or optimal processor settings.
[0118] For example, a scanner scans a document at a resolution of 600 dots per inch (dpi). The document includes text of various font sizes. The raw data are stored in the random access cache 105 in bands, along with the metadata associated with each band of raw data.
[0119] To save processing time and user storage space, the first analytic engine 714 sends the processor 106 settings to process the data at a resolution of 200 dpi, for example, along with other possible geometric processing settings, as describe above.
[0120] The processor 106 processes the raw data using the settings from the first analytic engine 714 . The processed data and the associated metadata are transferred to the second analytic engine 718 .
[0121] The second analytic engine 718 analyzes the processed data using a predefined metric. For example, the second analytic engine 718 determines that a band of the processed data is not recognizable, perhaps because the text size is too small to be recognizable at a resolution of 200 dpi. The second analytic engine 718 sends the metadata associated with the band of unrecognizable data along with new processor setting to process the data at a resolution of 400 dpi to the processor 106 .
[0122] The processor 106 receives the metadata containing the location of the raw data in the random access cache 105 and the new processor settings and processes the band of raw data at 400 dpi. The processor 106 sends the processed band of data and its associated metadata to the second analytic engine 718 for analysis.
[0123] The second analytic engine 718 determines if the processed band of data meets the predetermined metric. If not, the second analytic engine 718 sends the metadata associated with the band along with new processor settings to process the band of raw data to the processor 106 . For example, the second analytic engine 718 determines that the text in the band is unrecognizable even at a resolution of 400 dpi and sends the metadata associated with the band along with new processor settings to process the band of raw data at a resolution of 600 dpi to the processor 106 .
[0124] The process of analyzing the data and reprocessing the raw data with new processor setting occurs until the second analytic engine 718 determines that the processed data meet the predefined metric. Processing parameters can be changed on portions or bands of the raw data without reprocessing all of the raw data. In an embodiment, reprocessing portions of the captured data saves processing time and data storage space.
[0125] The processed data obtained by these steps are displayed at the data display 108 . The data processor settings can be adjusted interactively using the user interface 107 .
[0126] In addition to determining the data processor settings, the first analytic engine 714 and the second analytic engine 718 automatically detect raw data that will potentially result in poor quality processed data. The corresponding trapping conditions, described above, are accessible to the user through the user interface 107 , enabling the user to efficiently control the quality of the acquired data.
[0127] Additionally the user can, via the user interface 107 , access subsections or zones of the raw data stored at the random access data cache 105 to be processed at the data processor 106 .
[0128] The data acquisition and rescanning system 750 also allows the non real time interactive processing of specific raw data. The user can transmit the processed data to the application/storage device 109 for further processing as well as storage. The data acquisition and rescanning system 750 supports multiple user usage. The acquisition device 100 can be accessed by multiple user systems 710 with each data processor 106 having unique processor settings. In an embodiment, the data acquisition and rescanning system 750 further comprises a computer (not shown). In an embodiment, the data acquisition and rescanning system 750 is implemented, at least in part, as software on the computer.
[0129] FIG. 8 is a block diagram of an embodiment of a data acquisition and rescanning system 850 comprising the first analytic engine 714 and the second analytic engine 718 . The data acquisition and rescanning system 850 implements the data acquisition and rescanning system 750 shown in FIG. 7 as hardware.
[0130] The data acquisition and rescanning system 850 comprise the data acquisition device 100 , a user system 810 , and the application/storage device 109 . The random access data cache 105 , the data processor 106 , the first analytic engine 714 , and the second analytic engine 718 are implemented at the data acquisition device 100 . The data acquisition device 100 further comprises the data capture device 101 , the normalization processor 102 , and the communication device 103 . The user system 810 comprises the communication device 104 , the user interface 107 , and the data display 108 .
[0131] FIG. 9 is a block diagram of an embodiment of a remotely deployed data acquisition and rescanning system 950 comprising the first analytic engine 714 and the second analytic engine 718 . The data acquisition and rescanning system 950 comprises the data acquisition device 100 , a storage and processing system 912 , a user system 910 , and the acquisition/storage device 109 .
[0132] The data acquisition device comprises the data capture device 101 , the normalization processor, and the communication device 103 .
[0133] The storage and processing system 912 comprises the communication device 104 , the random access data cache 105 , the data processor 106 , the first analytic engine 714 , the second analytic engine 718 , and a communication device 903 .
[0134] The user system 910 comprises a communication device 904 , the user interface 107 , and the data display 108 .
[0135] The raw data from the acquisition device 100 are transmitted, via a fast connection using the communication devices 103 and 104 , to the storage and processing system 912 . The raw data and the metadata are stored at the cache 105 . The data processor 106 processes the raw data using the default data processor settings.
[0136] At the data storage and processing system 912 , the raw data are stored at the data cache 105 . Selected raw data are analyzed by the first analytic engine 714 . The selection mechanism can be either automatic or interactive as described in the embodiments above. The analysis performed by the first analytic engine 714 yields an improved or close to optimal data processor settings given the selected raw data. The settings are transferred to the data processor 106 , and the raw data are processed with the given settings.
[0137] The processed data are transferred to the second analytic engine 718 . At the second analytic engine 718 the processed data are analyzed and improved data processor settings are determined. The second analytic engine 718 determines the quality of the processed data using a metric. The second analytic engine 718 selects new processor settings depending on the quality of the processed data as determined by the metric. The improved settings are transmitted to the data processor 106 and the raw data are reprocessed. The step reprocessing the processed data with the revised data processor settings and the step of analyzing the processed data and determining revised data processor settings are repeated until convergence, i.e. until the metric cannot detect any improvements in the quality of the processed data, as described above. This yields improved or optimal processor settings.
[0138] The user system 910 communicates with the storage and processing system 912 via a communication medium 216 using the communication devices 903 and 904 . The processed data are displayed at the data display 108 . The data processor settings can be adjusted interactively using the user interface 107 .
[0139] The user, through the user system 910 , can transmit the processed data to the application/storage 109 for further processing as well as storage. Additionally the user can, via the user interface 107 , access subsections, or zones of the raw data stored at the random access data cache 105 to be processed at the data processor 106 .
[0140] The data acquisition and rescanning system 950 allows the non real time interactive processing of specific raw data. The data acquisition and rescanning system 950 is similar to the data acquisition and rescanning system 750 with the user system 910 located remotely from the data acquisition device 100 and the storage and processing system 912 . In the remotely deployed system 950 , the data cache 105 , the data processor 106 , the first analytic engine 714 , and the second analytic engine 718 are local to the data acquisition device 100 .
[0141] The data acquisition and rescanning system 950 also supports multiple user usage. The data acquisition device 100 can be accessed by multiple user systems 910 with each data processor 106 having unique processor settings. The data acquisition and rescanning system 950 is implemented, at least in part, as software, firmware, or a combination of software and firmware.
[0142] FIG. 10 is a block diagram of a hardware implemented embodiment of a remotely deployed data acquisition and rescanning system 1050 comprising the first analytic engine 714 and the second analytic engine 718 . The data acquisition and rescanning system 1050 implements the data acquisition and rescanning system 850 shown in FIG. 8 in a remote deployment. The data acquisition and rescanning system 1050 comprises the data acquisition device 100 , a user system 1010 , and the application/storage device 109 .
[0143] The random access data cache 105 , the data processor 106 , the first analytic engine 714 , and the second analytic engine 718 are implemented as hardware at the acquisition device 100 . The data acquisition device 100 further comprises the data capture device 101 , the normalization processor 102 , and the communication device 103 .
[0144] The user system 1010 comprises the user interface 107 , the data display 108 , and a communication device 1004 . The user system 1010 communicates with the data acquisition device 100 via the communication medium 216 using the communication devices 103 and 1004 .
[0145] FIG. 11 is a block diagram of an embodiment of a data acquisition and rescanning system 1150 comprising a plurality of data acquisition devices 100 and a plurality of user systems 1110 . The plurality of user systems 1110 are located remotely from the plurality of data acquisition devices 100 .
[0146] The data acquisition device 100 comprises the data capture device 101 , the normalization processor 102 , the communication device 103 , the random access data cache 105 , and the data processor 106 . In an embodiment, the data processor 106 is a low processing capability engine.
[0147] The user system 1110 comprises the user interface 107 , the data display 108 , a communication device 1104 , and an analytic engine 1114 . In an embodiment, the analytic engine 1114 is a high performance analytic processor.
[0148] Analog data are presented to the acquisition device 100 . The analog capture device 101 measures the analog data. The normalization processor 102 transforms the measured data into normalized raw data. The data processor 106 is used for transformations of the data. The transformed data are stored at the random access data cache 105 . Examples of data processing include, but are not limited to, document orientation, background compensation, color compensation, text extraction, text/background extraction, threshold, correlation, despeckle, and the like.
[0149] Working in a real time broadcast push mode or upon request from at least one of the user systems 1110 , selected cached data are scaled and compressed by the data processor 106 . The communication device 105 sends the scaled and compressed data, and the associated tag or metadata to the user system 1110 via the communication medium 216 using the communication device 103 .
[0150] In an embodiment, the tag data comprises the capture device address and the data location in the cache 105 . In an embodiment, the metadata comprise, but are not limited to, a tag identifying the data and the location in the cache, a time and date stamp of the acquisition, the sequence number, the beginning of the data band, the end of the data band, height, width, a pointer to the next band, and the like. The tag data is embedded in the communication network protocol of the communication medium 216 .
[0151] The user system 1110 receives the data via the communication medium 216 and the communication device 1104 . The data is analyzed by the analytic engine 1114 . If the analysis detects some relevant data area(s) characterized by analysis results that are outside of a boundary determined by the user, the analytic engine 1114 activates the user interface 107 by sending the tag associated with the data and the location of the area(s) of interest within the data.
[0152] The user interface 107 can be an automatic or a manual operation. The user interface 107 uses the tag content and the area location to request a new data set with new processing settings from the corresponding data capture device 100 . The data processor 106 reprocesses the selected data using the new settings and the data capture device 100 retransmits the reprocessed data to the user system 1110 . This virtual rescan operation is an interactive process, which can use different settings or windows.
[0153] During the interactive process described above, the data continue to be transmitted in real time by the plurality of the capture devices 100 to the plurality of user systems 1110 . In an embodiment, the user, through the data display 108 , can visualize any of the incoming data. In an embodiment, any part of the receiving data can be stored by the application/storage device 109 .
[0154] In an embodiment, the user system 1110 can lock selected data in the data cache 105 of one or more data acquisition devices 100 associated with the selected data. When the user system 1110 receives the selected data at the desired resolution, the user system 1110 unlocks the data. In an embodiment, the user system 1110 has an authorization level in order to lock data. The non-locked data in the data cache 105 is overwritten in a first in first out model.
Exemplary Embodiments
[0155] This section includes exemplary embodiments of a virtual rescan workflow, a detection orientation method, a detect bleed-through method, a color detection method, a background smoothing method, and a detection of scanned page boundaries method.
Exemplary Virtual Rescan (VRS) Workflow
[0156] If, in an embodiment, the user chooses to scan images with VRS processing, the VRS processing initializes the scanner to acquire a raw (unprocessed) master image. The master image is in grayscale if the user chooses to scan in black and white, else the master image is in grayscale or color as the user specifies.
[0157] VRS processing also initializes the scanner using predefined scanner specific settings. These settings help the VRS processing improve performance. For example, one of the settings is to perform overscanning (i.e., scan more than the size requested so VRS can perform a good deskew operation).
[0158] The scanner scans an image, per the specified settings, and the raw image is transmitted from the scanner to a VRS cache.
[0159] The VRS software performs one or more image processing algorithms. In an embodiment, an analytic engine comprises the VRS. One algorithm determines the actual page boundaries within the scanned raw image. In an embodiment, the scanned image contains scanner-introduced background due to overscanning. Determining the page boundaries is done for a variety of backgrounds, such as black, white, grey, and the like. Techniques, such as streak detection, are used, for example, for line streaks introduced by a dirty scanner camera/lamp, rollers, or the like. Other techniques, such as page border shadow detection are used to determine a page boundary.
[0160] Another image processing algorithm determines if the scanned page is blank. A page may contain colors that bleed through from the other side of the page when scanning is done in duplex. If the algorithm determines that the page contains no content, the page can be deleted per the user setting.
[0161] Another image processing algorithm converts the page contents from an ROB color representation to a YCbCr (luminance, hue, and saturation format). This permits many color related operations on the hue and saturation aspects of the page, and hence, results in a speed improvement. If the scanner scans the image in black and white, this step is not performed.
[0162] Yet another image processing algorithm analyzes the image. Possible analyses are performing luminance analysis and extracting the grayscale intensity information into a histogram, extracting color information into a color histogram, performing geometric analysis on the page, and the like.
[0163] Another image processing algorithm detects whether the document has color, based on previous analyses. If there is no color content, the algorithm sets the scanner settings to indicate that the document is a black and white document. If document has background color and that background color is the predominant color, the algorithm sets the scanner settings to indicate that the document is a color document. Additionally, if the document contains color content, the user can adjust the scanner settings to reproduce the color or not to reproduce the color, based on a determination of whether the color content is related to specific document content, or is a predominate characteristic of the document, such as a document on yellow paper.
[0164] Another image processing algorithm performs gamma correction on the image to adjust the brightness and color levels.
[0165] A further image processing algorithm performs deskew and cropping on the page image based on the previous analyses.
[0166] Yet another image processing algorithm detects textual orientation in the image and rotates the image orthogonally, if required.
[0167] Another image processing algorithm performs other operations, such as, for example, barcode detection, line filtering, despeckling, annotating with an endorsement string, or the like.
[0168] A further image processing algorithm performs background smoothing by detecting the background colors and merging them together.
[0169] If the image has problems that cannot be corrected automatically, the image processing software displays the processed image and the settings to the user. The user then determines the settings for the image. As the user changes the settings, the image processing software performs one or more of the image processing algorithms discussed above using the user specified settings and displays the processed image to user. When the user accepts the image, the image processing software re-processes the raw image using the final settings chosen by the user.
[0170] In another embodiment, a second analytic engine performs additional analyses to determine if the processed image meets predetermined requirements. If the image does not meet the predetermined requirements, the second analytic engine determines new settings and reprocess the raw image using the new settings. This process repeats until the image meets the requirements.
[0171] When the image processing is complete, the image processing software sends the image to the application.
Exemplary Detect Orientation
[0172] In an embodiment, the detect orientation algorithm automatically detects which way to orthogonally rotate a text page for viewing. The algorithm selects possible individual characters from connected components of black within the page. The algorithm then determines the orientations of the individual characters by employing a trained neural network. The algorithm uses the orientation results of the neural network to determine a better page orientation.
[0173] The algorithm finds the connected components within the page image. Since some of these components can contain graphic elements, the algorithm uses a number of constraints to filter out non-characters within the page image. Examples of the constraints are the number of pixels exceeds a predetermined threshold; both width and height are large enough; the ratio of height to width does not exceed a predetermined threshold; the ratio of the number of black pixels in the connected component to the area of its bounding box is not too large or too small; the size of the component does not approach the size of the page; and the number of transitions from white to black and back along a line crossing the character in either horizontal or vertical direction is not too large.
[0174] Some of the components passing this test may contain glued characters, pieces of broken characters, and the like. In an embodiment, assuming reasonable image quality, a statistically meaningful majority contains individual characters.
[0175] The algorithm proportionally scales of each of the components to fit into a gray-scale square of 20 by 20 pixels. The algorithm then adds a 2 pixel white margin around the gray-scale square and sends the resulting 24ร24 image to a trained feed-forward neural network for orientation detection.
[0176] The neural network used in the algorithm, in an embodiment, has a preprocessing layer that converts the 576 inputs into 144 features. The features pass through two hidden layers of 180 and 80 nodes, respectively. The result of the neural network is four outputs indicating confidences in โupโ, โdownโ, โleftโ, or โrightโ orientation. This neural network with its rather distinct preprocessing using Gabor Wavelets has been described in the papers, โA Subspace Projection Approach to Feature Extraction The Two-Dimensional Gabor Transform for Character Recognitionโ, Neural Networks, 7 (8), pp. 1295-1301, 1994, and โNeural Network Positioning and Classification of Handwritten Charactersโ, Neural Networks 9 (4), pp. 685-693, 1996. The training of the neural network is not a part of the run-time algorithm and is performed off-line using scaled characters from common business fonts, such as, for example, Arial, Times Roman, Courier, and the like.
[0177] Next, the algorithm decides whether to accept the orientation having the highest confidence level. The algorithm decides based on confidence ratios that exceed predetermined thresholds.
[0178] For increased or maximum accuracy, in an embodiment, the analysis of the page utilizes the components found within it. Typically, for most text pages a small percentage of the components is sufficient to make a confident decision. To achieve a reasonable tradeoff between accuracy and speed, the page is divided into several sets of stripes. The stripes in each set are distributed over the page to make the selection of components quasi-random. If, in an embodiment, the number of good connected components in the first set exceeds a predefined number and the votes confidently determine the winning orientation, the algorithm returns the result. Otherwise, the next set of stripes is processed, then the next, etc., until the end condition is met, or until all or a predetermined percentage of the components on the page have been examined.
[0179] Recognition of character shapes becomes more difficult as the font size and resolution become smaller. For the algorithm to perform well, in an embodiment, the height of binary characters exceeds 16 pixels. The algorithm can show graceful degradation for characters up to 8 pixels in height.
[0180] The algorithm, in an embodiment, may assume that the majority of connected components on the page are individual characters.
[0181] Embodiments of the algorithm have been trained with the Latin alphabet. Since there are many common shapes between Latin and Cyrillic as well as between the Latin and Greek alphabets, the algorithm also performs well for Cyrillic and Latin. The algorithm can be trained specifically for different character sets.
Exemplary Detect Bleed-Through
[0182] An embodiment of the detect bleed-through algorithm addresses automatically detecting bleed-through on sides of scanned documents in order to perform further image processing on these pages. In an embodiment, the algorithm uses page boundary detection within front and back scanned images to approximately match side coordinates. Then, the algorithm uses existing color or gray content to fine-tune the mapping. This additional step can be used because of slightly different optics and skews of front and back cameras. If residual (unexplained) content fall below predetermined density criterion, the algorithm determines that the page is blank.
[0183] In an embodiment, the algorithm detects each side of the page against the background of the scanner. Next, the algorithm runs individual blank page detection on both sides of the page to determine if one or both sides of the page are blank regardless of possible bleed-through. If one or both sides are blank, the algorithm ends.
[0184] If one or both sides are not blank, the algorithm determines the main background of the page on both sides. Next, the algorithm chooses the side with greater volume of content as the front side. Next, the algorithm maps the back side to the front side using corresponding rectangles of the page.
[0185] Dark pixels with color sufficiently different from the background are marked on both sides to form mask images. The algorithm analyzes the mask images locally block by block to determine the local shift relative to the rough mapping. Next, the algorithm uses a Least Mean Squares approximation to finalize the back-to-front mapping. The algorithm cancels content on the back side within a predefined distance of darker content on the front side, and then the algorithm sends the residual image to the blank page detection step.
Exemplary Color Detection
[0186] An embodiment of the color detection algorithm detects the color content in a scanned image and distinguishes between the foreground and background color. The algorithm eliminates the background color if it is the most predominant color in the document. The algorithm examines pixels in the scanned image and determines if the pixel is a color pixel and if the pixel is a background pixel. This determination uses the saturation and luminance levels of the pixel.
[0187] In an embodiment, the algorithm converts the image from an RGB representation to a YCbCr (Luma and Chrominance) representation. The algorithm looks at the saturation component of the pixel to determine the saturation level. Saturation provides a measure of the amount of color in a pixel. The higher the saturation, the more vivid the color. The lower the value, the less color the pixel contains. Saturation is expressed as a number between 0 and 182, which comes from the mathematical formulation used to calculate saturation. A user adjustable color threshold value, in an embodiment, is used to determine if a pixel is a color pixel. If the saturation value is greater than the threshold, the pixel is color, else it is not.
[0188] The algorithm determines if the pixel is a background pixel. When scanner scans a document, the white or black background of the document and/or the scanner can appear as a low saturated light or dark color. For most images, the amount of background pixels is a large percentage of the total area. The color detection algorithm, in order to exclude the contributions of the white and/or black background portions of an image, uses a white background threshold, a black background threshold, and a background saturation threshold to determine background pixel membership. If, in an embodiment, the luminance of a pixel is higher than the white background threshold or lower than the black background threshold, and the saturation of the pixel is lower than the background saturation threshold, then the pixel is a classified as a background pixel. Otherwise, the pixel is non-background pixel.
[0189] The algorithm analyzes the non-background pixels to determine the various color contents by building a histogram of the pixels based on their saturation values. A scanner can introduce some color to the scanned image because of the lamp or the camera. A dirty camera can add color spots, for instance. If a color saturation value of a pixel is below a predetermined threshold, the algorithm determines that the pixel does not have color. Otherwise, the pixel is considered a valid color. If the document contains any valid color, the document is considered a color document.
Exemplary Background Smoothing
[0190] An embodiment of the background smoothing algorithm reduces the number of colors within the backgrounds of an image to improve the appearance of the image as well as decreases the size of the image after compression.
[0191] The algorithm clusters the colors found in the image and selects those that contain enough pixels to be considered backgrounds.
[0192] The algorithm determines the co-occurrence of the background clusters to determine if two or more clusters actually represent a single background. These types of backgrounds are commonly generated by dithering or using micro-dots, which the eye perceives as the averaged color within the background. When the scanner scans the image at a high resolution, the individual colors are seen for each of the pixels. The algorithm merges the co-occurring clusters and calculates an average color for the cluster.
[0193] Then, the algorithm determines if backgrounds have neighboring clusters with colors that are slightly darker or slightly brighter. Often, when scanning, for example, the paper going through the transport will buckle due to the rollers and forces acting on the paper, and can create shadows and highlights within the image. These shadows and highlights can be perceived as different clusters and they can be merged with the main background.
[0194] The algorithm modifies the image pixel by pixel by searching the image and determining if the color of the pixel belongs to one of the background clusters. If the pixel belongs to a background cluster, the algorithm changes the pixel color to the averaged color of the cluster.
Exemplary Detection of Scanned Page Boundaries
[0195] The detection of scanned page boundaries algorithm automatically detects page boundaries within a scanned image. Generally, page skew detection algorithms used in the industry work reliably only for black background scanning where the contrast between very dark background of the scanner and typically white page is difficult to miss. In an embodiment, this algorithm detects the page against any background, thus, performing page skew correction and cropping even for white background scanners.
[0196] Since there may be very small color or gray level differences between the background of the scanner and the background of the page, the differences alone cannot be relied upon to detect the page boundary points. Instead, the algorithm calculates and compares statistics collected in a small window centered on pixels of analysis. The algorithm compares these statistics to the range of the statistics collected in the corners of the scanned image, where the algorithm expects the background of the scanner.
[0197] The algorithm calculates the statistics in the four corners of the scanned image. If some of the corners are not uniform, which can occur when the content of the page is close to the corner, the algorithm does not consider the non-uniform corners.
[0198] If some of the corners are significantly different from the other corners, the algorithm chooses the majority of like corners. If the choice has to be made between equally plausible alternatives, the algorithm compares the corners to the background of the inside of the scanned image in order to disqualify the background of an over-cropped page.
[0199] For qualifying corners, the algorithm aggregates the statistics of the scanner background for later use.
[0200] The algorithm searches rows and columns of the scanned image looking for the first and last pixel with statistical properties significantly different from those of the scanner background. Predetermined thresholds determine the significance of the deviations of the pixel-centered windows from the range of the scanner background.
[0201] The detected first and last non-background pixels can be used to determine candidate edge points. Several constraints are used to filter out outliers. For example, if searching for the left boundary of the page, the candidate edge point has immediate neighbors above and below such that the angles formed by connecting segments are within 45 degrees from the vertical and are close to each other. Candidate edge points are analyzed with a variant of a Least Mean Square approximation to find best straight lines representing the main rectangle of the page. The algorithm assigns a confidence measure to the found rectangle based on the ratio of edge points supporting the rectangle to the maximum possible number of edge points, which may depend on the size of the page, the resolution of the scan, and the like.
[0202] After the algorithm determines the angle of skew, the algorithm, checks if individual edge points outside of the main rectangle of the page have enough support from their neighbors to indicate a tab or another existing deviation from the assumed rectangular shape of the page. Edge points deemed meaningful are used to determine the crop lines.
[0203] In case of dual scanning, the algorithm reconciles the skew angles between the front and back of the page image. If the angles of skew detected on the front side are different from that of the back side, it is likely that one of the two is wrong. In this case, the algorithm uses the angle associated with the higher confidence and recalculates crop lines for the other side.
[0204] Similarly, if the crop lines on the front and back significantly disagree, the algorithm reconciles the crop lines between the front and back of the page image. The algorithm considers the differences between the main rectangle of the page and its crop line to determine and remove extensions due to scanner artifacts.
[0205] In an embodiment, the detection of page boundaries algorithm assumes that the background of the scanner is uniform, that variation in brightness between individual sensors over the width of the scan are not significant, and that there are very few non-functioning or badly calibrated sensors causing streaks.
[0206] While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
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An efficient method and system to enhance digital acquisition devices for analog data is presented. The enhancements offered by the method and system are available to the user in local as well as in remote deployments yielding efficiency gains for a large variety of business processes. The quality enhancements of the acquired digital data are achieved efficiently by employing virtual reacquisition. The method of virtual reacquisition renders unnecessary the physical reacquisition of the analog data in case the digital data obtained by the acquisition device are of insufficient quality. The method and system allows multiple users to access the same acquisition device for analog data. In some embodiments, one or more users can virtually reacquire data provided by multiple analog or digital sources. The acquired raw data can be processed by each user according to his personal preferences and/or requirements. The preferred processing settings and attributes are determined interactively in real time as well as non real time, automatically and a combination thereof.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 09/162,078, filed Sep. 28, 1998, U.S. Pat. No. 5,989,358, in turn a continuation of application Ser. No. 08/722,857, filed Sep. 26, 1996, issued as U.S. Pat. No. 5,813,073.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an improved apparatus for cleaning dust and other surface particulate contaminants from material in sheet form.
BACKGROUND OF THE INVENTION
This invention is an improvement to the sheet cleaning apparatus described in U.S. Pat. No. 5,349,714, the entire contents of which are incorporated herein by reference. These apparatus are typically arranged in a printed circuit board production line, with other, very expensive machines. When the sheet cleaning apparatus needs servicing, typically to clean the sheet cleaning rollers ( 52 , 54 , 56 , 58 , shown e.g. in FIG. 8 ), the apparatus must be disassembled to remove the rollers, or the operator must clean the rollers in place. With either technique, considerable time is required for this maintenance procedure, idling not only the sheet cleaning apparatus but the other, very expensive machines on the production line.
It would therefore be advantageous to provide a sheet cleaning apparatus which can be quickly serviced to minimize the machine down time.
SUMMARY OF THE INVENTION
To overcome the foregoing problems, a sheet cleaning apparatus is described, having one or more sets of cleaning rollers, wherein the rollers are integrated into a removable cartridge assembly. Couplers are provided at roller shaft ends to connect to the roller drive. The cartridge assembly is held in a slide carriage, permitting the cartridge assembly to be readily removed from the apparatus by sliding the carriage out, and lifting the cartridge out from the slide carriage. With this arrangement, the down time for the sheet cleaning apparatus is minimized, since the sheet cleaning apparatus can be provided with two cartridges, and the cartridge needing maintenance can simply be quickly removed and replaced with a fresh cartridge. The production line can quickly be put back into operation, and the removed cartridge can be serviced off line for subsequent use.
BRIEF DESCRIPTION OF THE DRAWING
These and other features and advantages of the present invention will become more apparent from the following detailed description of an exemplary embodiment thereof, as illustrated in the accompanying drawings, in which:
FIG. 1 is a front view of a sheet cleaning apparatus embodying the invention.
FIG. 2 is a side cross-sectional view taken along line 2 โ 2 of FIG. 1 .
FIG. 3 is a side view illustrating the relative orientation of the sheet cleaning rollers and the roller cleaning adhesive rolls.
FIG. 4 is a simplified perspective view illustrating an exemplary motor/gear drive arrangement for driving the roller couplers.
FIG. 5 illustrates the sheet cleaning apparatus with the roller cartridge exposed and removed from the cartridge slide arrangement for replacement.
FIG. 6 is an exploded view of the drive end of the cartridge roller assembly.
FIG. 7 is an isometric view of a roller lifting device employing in the apparatus of FIG. 1 to bias the position of the upper set of sheet cleaning rollers upwardly for separation from the lower set of sheet cleaning rollers when the apparatus is not in use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-7 illustrate an exemplary embodiment of a sheet cleaning apparatus 50 embodying the invention. The apparatus 50 includes two pairs of sheet-contacting cleaning rollers 52 , 54 and 56 , 58 . Rollers 52 and 54 are disposed in vertical alignment adjacent each other to define a nip 62 . The surfaces of the cleaning rollers 52 , 54 , 56 , 58 are defined by a layer of resilient compressible material which has a surface tack or adhesion sufficient to transfer dust and other foreign particulate contamination from a sheet coming into compressive contact with the roller surface. It is also desirable that the roller surfaces be smooth, in order to obtain complete contact with the surface of a sheet pressed against the surface. Typically, the roller surfaces will have a Shore A durometer value of up to 35.
In order to clean the surfaces of the sheet cleaning rollers 52 - 58 , rolls 64 , 66 of adhesive-coated tape are provided. These rolls 64 , 66 are disposed so as to be in contact with respective surfaces of rollers 52 - 58 during sheet cleaning operations, as shown in FIG. 3 . In a general sense, the rolls 64 , 66 are defined by rolls of tape having the adhesive coating on the outward facing sides. The external surface of each of the rolls 64 , 66 has a surface tack which greatly exceeds the surface tack of the sheet cleaning rollers 52 - 58 , in order to transfer the foreign particles from the sheet cleaning rollers 52 - 58 to the surfaces of rolls 64 , 66 .
To the extent just described, the apparatus 50 is similar to that described in U.S. Pat. No. 5,349,714.
The apparatus 50 includes a system for applying a variable preload force, urging roller 64 into engagement with surfaces of rollers 52 and 56 , and urging roller 66 into engagement with surfaces of rollers 54 and 58 . The system includes pneumatic cylinders 100 and 102 which support the lower tape roller 66 , and pneumatic cylinders 104 and 106 which apply pressure to the upper tape roller 64 . Cylinder 100 includes a rod 100 A driven by a cylinder piston to an extended position. The rod is attached to a coupler 100 B which has an opening into which an end of shaft 67 carrying roll 66 is inserted. Cylinder 102 includes rod 102 A driven by a cylinder piston to an extended position. Rod 102 A is attached to a coupler 102 B which has an opening into which the opposed end of shaft 67 is inserted. The roll 66 is therefore supported by the system comprising cylinders 100 and 102 and couplers 100 B and 102 B. The cylinders 100 and 102 are single acting, spring biased devices, wherein the rods are spring biased to the fully retracted position, and the rods are extended against the bias when pneumatic pressure is applied to the cylinders. Further the compression contact force of the roll 66 in relation to the sheet cleaning rollers 54 and 58 is adjustable by adjusting the pneumatic pressure applied to the cylinders 100 and 102 .
The system further includes pneumatic cylinders 104 and 106 which apply pressure to the upper tape roller 64 . Cylinder 104 includes a rod 104 A driven by a cylinder piston to an extended position. The rod is attached to a coupler 104 B which has an U-shaped opening into which a portion of shaft 65 carrying roll 64 and adjacent a shaft end is received. Cylinder 106 includes rod 106 A driven by a cylinder piston to an extended position. Rod 106 A is attached to a coupler 106 B which has an opening into which a portion of shaft 67 adjacent the opposite end of the shaft is received. The cylinders 104 and 106 are single acting, spring biased devices, wherein the rods are spring biased to the fully retracted position, and the rods are extended against the bias when pneumatic pressure is applied to the cylinders. Further the compression contact force of the roll 64 in relation to the sheet cleaning rollers 52 and 56 is adjustable by adjusting the pneumatic pressure applied to the cylinders 104 and 106 .
The shaft 65 is carried by spring-loaded bracket assemblies 72 and 74 . Exemplary bracket assembly 72 is illustrated in FIG. 7, and includes outer bracket fixture 72 A, sliding bracket 72 B which fits within the outer fixture for sliding movement, and bias spring elements 72 D and 72 E. The spring elements bias the relative position of the sliding bracket 72 B to the upper position shown in FIG. 7, and upon application of force, the springs are compressible to permit the bracket 72 B to slide down. Assembly 74 is identical to assembly 72 . Together, these assemblies bias the upper tape roll 64 to an elevated position out of contact with the cleaner rollers 52 , 56 when the machine is idle, i.e. when the pneumatic pressure for the cylinders 104 and 106 is released. This prevents the tape roll surface from adhering to the cleaner roller as a result of extended stationary contact. When the pneumatic pressure is removed from the cylinders 100 , 102 , the lower tape roll 66 drops by force of gravity out of contact with the lower set of cleaner rollers 54 , 58 , and is supported by a V-shaped cradle in brackets 76 , 78 . No spring biasing is employed in connection with brackets 76 , 78 , since such biasing would tend to keep the tape roll surface in contact with the surfaces of the lower cleaner rollers after the pneumatic pressure is released.
In accordance with an aspect of the invention, the cleaner rollers are arranged in an easily removable cartridge assembly 120 . The assembly 120 is mounted on a slide assembly 130 which permits the cartridge assembly to be moved from a working position, with the cleaner rollers in position within the apparatus 50 for operation, and a maintenance position (shown in FIG. 5) with the cleaner rollers and the cartridge assembly slid outside the housing 50 A of the cleaner apparatus 50 for ready replacement of the cartridge 120 .
As shown in FIG. 5, the slide assembly 130 includes a carriage member 132 which receives the cartridge assembly 120 . Four mounting tabs 122 on the cartridge assembly have holes 122 A formed therein. The cartridge assembly 120 is dropped and locked into position on the carriage 132 , with pins 134 extending upwardly from the carriage 132 and received through holes 122 A registering the position of the cartridge 120 on the carriage 132 . The cartridge assembly is locked into position by spring-loaded locking tabs (not shown) formed with the pins 134 , which locking tabs spring out after cartridge assembly has dropped onto the pins to lock the cartridge in position. This prevents the cartridge from being lifted from the carriage by the tackiness of the roll 64 as pressure is released from the pneumatic system. Other types of locking arrangements can readily be employed. The carriage 132 is mounted between a first set of opposed slide rails 136 A, 136 B, which in turn are mounted on a second set of opposed slide rails 138 A, 138 B. The second set of rails 138 A, 138 B are mounted on bearings (not shown) mounted to the housing 50 A to permit the second set of rails to slide outwardly also. The first set of rails is mounted on bearings to permit telescoping of the first and second sets of rails. The slide rails and bearings are parts of a commercially available slide assembly, such as the three-section linear drawer slides marketed by Jonathan Company, Fullerton, Calif., which lock in both the closed and open positions.
The cartridge assembly 120 is shown in further detail in FIG. 6 . Side rails 124 A, 124 B and end rails 126 A, 126 B form a carriage structure which carries the lower set of cleaner rollers 54 , 58 . The rollers rotate on respective shafts 54 A, 58 A which in turn are mounted on bearings fitted in openings formed in the end rails. For example, bearings 126 AA and 126 AB are mounted in end rail 126 A. only the drive end of the cartridge assembly 120 is visible in FIG. 5 . The lower set of rollers are driven by a motor drive 150 (FIGS. 1 and 4) through a drive coupler 160 . The roller shafts 54 A, 58 A have flats 54 AA, 58 AA formed adjacent the shaft ends to form D-shaped shaft ends for mating with corresponding D-shaped openings 162 A, 164 A formed in hexagonal male coupler elements 162 , 164 to prevent rotation of the coupler elements on the shafts, while permitting axial sliding movement of the coupler elements on the shafts. Springs 166 A, 166 B are fitted on the shafts and extend between an end surface of rail 126 A and the coupler elements 162 and 164 to urge the coupler elements away from the end surface of rail 126 A. Snap rings 168 A, 168 B lock into position in grooves 54 AB and 58 AB to lock the coupler elements 162 , 164 onto the shafts, after assembly of the springs 166 A, 166 B and the coupler elements onto the shafts. The coupler elements 162 , 164 are formed with conical end surfaces 162 B, 164 B which act as lead-in surfaces to align the male hexagonal coupler elements with corresponding female driven hexagonal coupler elements 170 , 172 shown in the isolation perspective view of FIG. 4 . The driven coupler elements are mounted on shafts 174 , 176 . Sprocket gears 178 , 180 are mounted on the respective shafts 174 , 176 , and have an endless chain 182 mounted thereon. The shaft 176 also has a beveled gear 184 mounted thereon, which meshes with beveled gear 186 mounted on the motor shaft 188 . The cleaner rollers 54 , 58 are driven in the same direction by the motor drive 150 .
The upper cleaner rollers 52 , 56 are not actively driven. Referring again to FIG. 6, the upper rollers are mounted to the cartridge assembly 120 by upper end rails 127 A, 127 B. The roller shafts 52 A, 56 A are received in corresponding bores (e.g. 127 AA, 127 AB) formed in the upper end rails. The upper end rails are slidably mounted on pins 128 A, 128 B which are received in bores (e.g. bores 127 AC, 127 AD) formed in the upper end rails. Springs (e.g., springs 129 A, 129 B) can be fitted on the pins to provide a bias force tending to separate the upper end rails 127 A, 127 B from the lower end rails 126 A, 126 B. This in turn biases the upper set of cleaner rollers 52 , 56 away from the lower set of rollers 54 , 58 . The upper set of pneumatic cylinders 104 , 106 can exert a force on the tape roll 64 to push the upper set of rollers toward the lower set of rollers. The bias action of the springs, biasing the upper set of rollers away from the lower rollers and therefor tending to increase the nip gap, provides the advantage of facilitating the cleaning of thicker sheets for cleaning without adjusting the apparatus. For some applications, it is preferable to omit the springs fitted on the pins.
The cleaning apparatus employs a pneumatic supply and control system similar to that described in U.S. Pat. No. 5 , 349 , 714 , and illustrated at FIG. 9 . Similarly, the control circuit of FIG. 10 in U.S. Pat. No. 5,349,714 can be employed to control the motor drive 150 . The pneumatic supply and control system and the motor drive control circuit therefore need not be described in further detail herein.
The cartridge assembly 120 can easily be replaced with a fresh cartridge. This can be done by releasing the pressure on the pneumatic cylinders 100 - 106 , so that the tape rolls move out of engagement with the cleaner rollers 52 - 58 . The latch of the slide assembly is then released, and the carriage 132 is pulled from the operating position to the maintenance position shown in FIG. 5 . As the carriage is pulled out away from its operating position, the drive coupler elements 162 , 164 become disengaged from the mating coupler elements 170 , 172 , thereby disconnecting the cartridge from the motor drive 150 . The cartridge 120 is then removed, without the use of tools in this exemplary embodiment, by lifting the assembly up and out of engagement with the pins 134 . Once the cartridge assembly 120 is removed from the carriage 132 , it can quickly be replaced by a fresh cartridge with clean sets of rollers 52 - 58 . Once a fresh cartridge is positioned in the carriage 132 , the operator slides the carriage into the operating position. As the carriage slides into position, the coupler elements 162 , 164 are received within the coupler elements 170 , 172 . There may be some initial rotational misalignment between the hexagonal mating elements. If so, the springs 166 A, 166 B compress as the elements 162 , 164 are pushed toward the end rail 126 A. The conical surfaces 162 B, 164 B tend to align the mating elements by acting as a lead-in surface. Even if the mating elements do not engage as the cartridge is slid into the operating position, the first time the motor drive is actuated, as the outer coupler elements 170 , 172 are turned by the motor drive, the mating elements will come into alignment, and the springs 166 A, 166 B will urge the elements 162 , 164 into an engaged aligned position relative to the outer mating elements 170 , 172 .
The sheet cleaning apparatus can be quickly serviced by replacement of the cartridge assembly 120 , thus minimizing the machine down time. The removed cartridge assembly 120 can be serviced off line. The upper set of rollers 52 , 56 can easily be removed from the cartridge assembly for cleaning, and to expose the lower set of rollers for cleaning.
It is understood that the above-described embodiments are merely illustrative of the possible specific embodiments which may represent principles of the present invention. Other arrangements may readily be devised in accordance with these principles by those skilled in the art without departing from the scope and spirit of the invention.
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A sheet cleaning apparatus having sets of cleaning rollers, wherein the rollers are integrated into a removable cartridge structure. Couplers are provided at roller shaft ends to connect to the roller drive. The cartridge is received in a slide carriage, permitting the cartridge to be readily removed from the apparatus by sliding the carriage out, and lifting the cartridge out from the slide carriage. With this arrangement, the down time for the sheet cleaning apparatus is minimized, since the sheet cleaning apparatus can be provided with two cartridges, and the cartridge needing maintenance can simply be quickly removed and replaced with a fresh cartridge. The production line can quickly be put back into operation, and the removed cartridge can be serviced off line for subsequent use.
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FIELD OF THE INVENTION
The present invention relates generally to apparatus and methods for providing repeatable measurements of volume within an enclosed chamber. More specifically, the present invention provides methods and apparatus for calibrating volume measurement in a plethysmographic measurement system.
BACKGROUND OF THE INVENTION
The assessment of body composition, including measurement of fat and fat-free mass, provides physicians with important information regarding physical status. Excess body fat has been associated with a variety of disease processes, such as cardiovascular disease, diabetes, hypertension, hyperlipidemia, kidney disease, and musculoskeletal disorders. Low levels of fat free mass have been found to be critically adverse to the health of certain at-risk populations, such as the elderly, infants, and those suffering from muscle wasting diseases.
Assessment of body composition has also been found to be useful in the context of evaluating and improving athletic performance. Generally, athletes require a high strength to weight ratio to achieve optimal athletic performance. Because body fat adds weight without a commensurate increase in strength, low body fat percentages have been emphasized within many athletic fields. However, too little body fat can result in deterioration of both health and athletic performance. Thus, accurate measurement of body composition has been found extremely useful in analysis of athletic performance.
A variety of methods are currently used in the assessment of body composition. One common method is a skinfold measurement, typically performed using calipers that compress the skin at certain points on the body. While non-invasive, this method suffers from poor accuracy on account of variations in fat patterning, misapplication of population specific prediction equations, improper site identification for compressing the skin, poor fold grasping, and the necessity for significant technician training to administer the test properly.
Another method employed is bioelectric impedance analysis (โBIAโ). Bioelectric impedance measurements rely on the fact that the body contains intracellular and extracellular fluids that are capable of conducting electricity. By passing a high frequency electric current through the body, BIA determines body composition based on the bodies' measured impedance in passing current, and the known impedance values for human tissue. However, the accuracy of this method is greatly affected by the state of hydration of the subject, and variations in temperature of both the subject and the surrounding environment.
The most common method currently used when precision body mass measurements are required is hydrostatic weighing. This method is based upon the application of Archimedes principle, and requires weighing of the subject on land, repeated weighing of the subject under water, and an estimation of air present in the lungs of the subject using gas dilution techniques. However, hydrodensitometry is time consuming, typically unpleasant for the subjects, requires significant subject participation such as repeated, complete exhalation of air from the subject's lungs, requires considerable technician training and, due to the necessary facilities for implementation, is unsuitable for clinical practice. Further, its application to populations who would particularly benefit from body-mass measurement, such as the obese, elderly, infants, or cardiac patents, is precluded by the above concerns.
One technique offering particular promise in performing body mass measurement is the use of plethysmography. Plethysmographic methods determine body composition through application of Boyle's law to the differentiation in volume between the volume of an empty measurement chamber, and the volume of the chamber with the subject to be measured inside. Examples of this technique are disclosed in U.S. Pat. No. 4,369,652 issued to Gundlach, U.S. Pat. No. 5,450,750 issued to Abler, U.S. Pat. No. 4,184,371 issued to Brachet, and U.S. Pat. No. 5,105,825 issued to Dempster. This procedure, in contrast to hydrodensitometry, generally does not cause anxiety or discomfort in the subject, and due to the ease and non-invasiveness of the technique, can readily be applied to populations for whom hydrodensitometry is impractical.
However, such plethysmographic systems require very exact volume measurements to yield valid body composition results. In particular, calibration of the measurement chamber equipment used to generate the volume measurements for body composition analysis is necessary for achieving accuracy, on account of very small differences in measured volume yielding large differences in computed body composition. Although some efforts have been made in the field of calibration for plethysmographic systems, these methods are typically complicated, inexact, and/or inconvenient for the medical technicians who conduct plethysmographic body composition measurements by requiring manual activation and implementation of the calibration.
For example, Dempster, U.S. Pat. No. 5,108,825, discloses the use of a calibration volume structure that is manually placed in a plethysmographic reference chamber. However, this process is slow, cumbersome, and requires active participation by the medical technician to calibrate the system.
Ganshorn, U.S. Pat. No. 5,626,005, discloses a method of calibration for a plethysmographic chamber for measuring the volume of a subject's thorax-lung system. The method disclosed by Ganshorn involves the use of a harmonically oscillating piston pump that generates pressure fluctuations that simulates a test subject's breathing, and relies on these pressure fluctuations to calibrate a chamber pressure gauge based on the simulated breathing. However, this method is unnecessarily complex and not generally applicable to calibration of plethysmographic chambers used in the measurement of body composition.
Therefore, it would be desirable to provide a computer assisted calibration system for a whole body plethysmographic measurement chamber that provides accurate calibration of the measurement system.
It would further be desirable to provide a computer assisted calibration system for a whole body plethysmographic measurement chamber that does not require active, manual participation of medical technician to conduct the calibration.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a computer assisted calibration system for a whole body plethysmographic measurement chamber that provides accurate calibration of the measurement system.
It is another object of the present invention to provide a computer assisted calibration system for a whole body plethysmographic measurement chamber that does not require active, manual participation of medical technician to conduct the calibration.
These and other objects of the present invention are accomplished by proving computer assisted methods and apparatus for calibration of a plethysmographic measurement system using a calibration volume chamber.
The present invention generally consists of a calibration volume chamber of known, fixed volume coupled to a plethysmographic measurement chamber in a plethysmographic measurement system, wherein a computer system is used to calibrate the measurement system prior to conducting a volume measurement of a test subject, by measuring the chamber volume before and after opening (or alternatively, before and after closing) an electronically controlled valve that connects the controlled calibration volume to the plethysmographic chamber, and comparing the measured chamber volumes based on the known reference volume.
In one embodiment of the present invention, the actuation assembly for opening and closing the valve in response to a signal from the computer system is a cam and motor assembly coupled to a shaft that is mounted to the valve by means of a ball joint.
In a second embodiment of the present invention, the actuation assembly for opening and closing the valve in response to a signal from the computer system is a solenoid coupled to a shaft that is mounted to the valve by means of a ball joint.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
FIG. 1 is a representational view of an adult-sized plethysmographic chamber and control system in which embodiments of the present invention operate;
FIG. 2 is a flow chart describing the calibration sequence of one embodiment of the present invention;
FIG. 3 is a flow chart describing the calibration sequence of a second embodiment of the present invention.
FIG. 4 is a cross-sectional view of one embodiment of the calibration volume chamber and valve actuation assembly of the present invention;
FIG. 5A is a detailed cross sectional view of one embodiment of the valve and valve actuation assembly of the present invention, with the valve in the open position;
FIG. 5B is a detailed cross sectional view of one embodiment of the valve and valve actuation assembly of the present invention, with the valve in the closed position;
FIG. 6 is a representational view of the infant sized plethysmographic chamber in which the present inventions operate;
FIG. 7 is a cross sectional view of a second embodiment of the calibration volume and valve actuation assembly of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a representational view of an adult-sized plethysmographic chamber in which embodiments of the present inventions operate are described.
Plethysmographic measurement system 20 comprises measurement chamber 22 , chamber door 24 , plethysmographic measurement components 26 , and computer 30 . The operation of plethysmographic measurement components 26 is controlled by computer 30 , which computer is operated by the medical technician performing the plethysmographic measurement. (As used herein, the term โmedical technicianโ refers to any individual conducting the plethysmographic measurements of the test subject.)
Measurement components 26 can include such devices as an oscillating diaphragm or speaker, pressure transducers, their respective control systems, and other components necessary to conduct plethysmographic measurements. Further information regarding such plethysmographic measurement components, and the techniques used to derive volume and body composition measurements using them, are described in detail in Dempster, U.S. Pat. No. 5,105,825, assigned to Life Measurement Instruments, the specification of which is hereby incorporated by reference in its entirety. The algorithms used in conducting plethysmographic measurements are likewise well known to one of ordinary skill in the art, and therefore are not disclosed herein.
Housed within measurement chamber 22 is a calibration volume chamber 36 , including an opening 38 , a valve 40 for sealing and unsealing said opening, and valve actuation assembly 42 for opening and closing said valve in response to commands from computer 30 .
When the medical technician initiates a measurement sequence, computer 30 is used to calibrate plethysmographic measurement system 20 prior to measuring the body composition of the test subject. The actual programming of computer 30 to conduct calibration of the plethysmographic measurement system is done in accordance with conventional programming techniques suitable for performing basic calculations and supplying control signals to the measurement components and actuation assembly of the present invention. These techniques are well known to one of ordinary skill in the art, and as such are not disclosed herein.
The calibration of the plethysmographic system can be, but need not be, performed without technician intervention. In a preferred embodiment, the calibration of the plethysmographic measurement system is conducted transparently to the medical technician, such that the calibration occurs automatically upon the technician initiating a plethysmographic measurement sequence.
As illustrated by flow chart 43 in FIG. 2, in a first embodiment of the present invention, computer 30 directs plethysmographic system 20 to first measure the volume of measurement chamber 22 when valve 40 is in the open position (i.e. with calibration reference volume 36 open to measurement chamber 22 ).
Specifically, in step 43 A, computer 30 first activates the measurement components. In step 43 B, computer 30 determines whether the valve is in the proper (open) state. If not, computer 30 sends a signal to actuation assembly 42 to open valve 40 . In step 43 C, computer 30 directs measurement components 26 to measure the combined volume of the measurement chamber and calibration volume chamber. In step 43 D, computer 30 stores the values generated from the measurement in 43 C. In step 43 E, computer 30 sends an electrical signal to valve actuation assembly 42 to close valve 40 , thereby reducing the net chamber volume. In step 43 F, computer 30 directs measurement components 26 to measure the volume of measurement chamber 22 . In step 43 G, computer 30 stores the values generated by the measurement of step 43 F. In step 43 H, the measured volumes are then compared based on the known volume of calibration volume chamber 36 . Based on the above comparison, computer 30 finalizes calibration of measurement system 20 , and indicates to the technician that measurement of the test subject can begin.
The algorithms used to calibrate the plethysmographic measurement system based on the calibration processes of the present invention are known to those of skill in the art, and as such are not described herein.
In an alternative embodiment of the present invention, illustrated in the flow chart of FIG. 3, computer 30 can direct plethysmographic system 20 to first measure the volume of measurement chamber 22 when valve 40 is in the closed position.
Specifically, in step 45 A, computer 30 first activates the measurement components. In step 45 B, computer 30 determines whether the valve is in the proper (closed) state. If not, computer 30 sends a signal to actuation assembly 42 to close valve 40 . In step 45 C, computer 30 directs measurement components 26 to measure the volume of measurement chamber 22 . In step 45 D, computer 30 stores the values generated from the measurement in 45 C. In step 45 E, computer 30 sends an electrical signal to valve actuation assembly 42 to open valve 40 , thereby increasing the net chamber volume. In step 45 F, computer 30 directs measurement components 26 to measure the combined volume of the measurement chamber and calibration volume chamber. In step 45 G, computer 30 stores the values generated in step 45 F. In step 45 H, the measured volumes are then compared based on the known volume of calibration volume chamber 36 . Based on the above comparison, computer 30 finalizes calibration of measurement system 20 , and indicates to the technician that measurement of the test subject can begin. This calibration process results in calibration based on what is, in net effect, a negative volume measurement.
One of ordinary skill in the art would recognize that the are not limited to single measurements. Rather, multiple measurements of chamber volume with valve 40 open and closed can be used in accord with the present invention, with the system being calibrated based on the multiple data points generated by the measurements.
Further, one of ordinary skill in the art would recognize that the calibration methods disclosed herein could be conducted after plethysmographic measurement has been performed on the subject to be measured, because the methods of calibration disclosed herein are conducted by numerical calculations on measurement values. Thus, in such an embodiment, when the medical technician initiates the measurement sequence, measurements are first taken of the test subject in measurement chamber 22 . The data generated in conducting this plethysmographic measurement of the test subject is stored on computer 30 , after which the calibration methodology described above is conducted. Finally, the results of the calibration are applied to the measurements taken of the test subject to arrive at an accurate volume measurement for the subject.
Referring now to FIG. 4, a cross-sectional view of a first embodiment of the calibration volume chamber and valve actuation assembly of the present invention is described. Calibration volume chamber 36 is a roughly cylindrical chamber with a known, stable internal volume. Although any shape can be used for reference volume chamber 36 , it is preferred that the internal volume of reference volume chamber 36 be comparable to the volumes expected to be measured by the plethysmographic measurement system 20 in order to provide for more accurate calibration of the measurement system.
At one end of calibration chamber 36 is opening 38 that allows air to pass between calibration chamber 36 and plethysmographic chamber 22 .
Mounted about the circumference of opening 38 is valve mount collar 42 . Valve 40 is housed within valve mount collar 44 . Valve 40 is coupled to valve actuation assembly 42 , which opens and closes valve 40 in response to a signal from computer 30 . At the end of valve mount collar 44 distal from said opening 38 is valve opening 46 . When valve 40 is in the closed position, valve 40 creates a seal about valve opening 46 that completely seals off reference volume chamber 36 from plethysmographic chamber 22 .
Referring now to FIG. 5A, a detailed cross sectional view of the valve and valve actuation assembly of the present invention, in which valve 40 is in the open position, is described.
In this embodiment, valve actuation assembly 42 includes cam 50 , cam follower 52 , cam shaft 54 , stamping 56 (which is further comprised of follower stamping 62 and spring stamping 64 ), cam spring 58 , valve ball joint 60 , and valve assembly mounting plate 66 .
Valve 40 is coupled to a proximal end of cam shaft 52 by ball joint 60 . Cam shaft 52 is further coupled to stamping 56 at the end of cam shaft 52 distal from valve 40 .
Mounted around cam shaft 54 is cam spring 58 , which is coupled at one end to spring stamping 64 , and coupled at the opposite end to valve assembly mounting plate 66 . Cam spring 58 generates an extension force against stamping 56 .
Follower 52 is coupled to roller stamping 64 . The force generated by cam spring 58 pushes against follower 52 by means of its coupling to spring stamping 62 . This force ensures that follower 52 maintains solid contact with cam 50 .
To open valve 40 , cam motor 68 rotates cam 50 into an extended position, which exerts force on follower 52 , thereby pushing on stamping 56 and compressing spring 58 . This force applied to stamping 56 causes cam shaft 54 to move in the direction towards opening 38 , thereby opening valve 40 .
Referring now to FIG. 5B, a detailed cross sectional view of the valve and valve actuation assembly of the present invention, in which valve 40 is in the closed position, is described.
To close valve 40 , cam motor rotates cam 50 into a retracted position, which allows cam spring 58 to push on stamping 56 , and move cam shaft 54 until the edge of valve 40 makes contact with valve mount housing 44 , thereby sealing off reference chamber 36 from plethysmography chamber 22 .
In a preferred embodiment, a seal 70 is mounted about the circumference of valve 40 , such that when valve 40 is in the closed position, seal 70 is compressed by valve 40 against valve mount housing 40 , creating an air tight seal. Further, because ball joint 60 allows valve 40 to rotate with respect to cam shaft 54 , valve 40 forms a repeatable, air tight seal against valve mount 40 .
Referring now to FIG. 6, a representational view of an infant sized plethysmographic system in which embodiments of the present invention operate is described.
Plethysmographic system 80 comprises plethysmographic measurement chamber 82 , chamber door assembly 84 , plethysmographic measurement components 86 , manifold 88 and computer 90 . Calibration volume chamber 94 is coupled to measurement chamber 82 by manifold 88 (which also couples measurement components 86 to measurement chamber 82 ). Calibration chamber opening 96 allows air to pass from calibration volume chamber 94 , through manifold 88 , and into measurement chamber 82 .
Valve actuation assembly 100 is coupled to valve 101 , and seals and unseals opening 96 in response to commands from computer 90 .
As disclosed in connection with the previous embodiment, when the medical technician initiates a body composition measurement sequence for a test subject, computer 90 calibrates plethysmographic measurement system 80 prior to measuring the body composition of the test subject, without the necessity of technician intervention to conduct the calibration.
Specifically, as described above in connection with the flow chart illustrated in FIG. 2, computer 90 directs plethysmographic system 80 to first measure the volume of measurement chamber 82 when valve 101 is in the open position. Computer 90 then sends an electrical signal to valve actuation assembly 100 to close valve 101 , thereby reducing the net measurement chamber volume. The measured volumes are then compared to the expected volumes based on the known volume of calibration volume chamber 94 . Based on this comparison, computer 90 finalizes calibration of measurement system 80 , and indicates to the technician that measurement of the test subject can begin.
Similarly, the calibration system described above can calibrate measurement system 80 using the process illustrated in the flow chart of FIG. 3 .
Referring now to FIG. 7, a detailed cross-sectional view of the calibration volume and valve actuation assembly of the second embodiment of the present invention is described. As described above with respect to FIG. 4, measurement chamber 82 is coupled to calibration volume chamber 94 by manifold 88 , and calibration volume chamber opening 96 allows air to pass from calibration volume chamber 94 , through manifold 88 , and into measurement chamber 82 .
Valve actuation assembly 100 consists of solenoid 102 , solenoid mount 104 , inner manifold 106 , shaft 110 , and ball joint 112 coupled to valve 101 . Valve actuation assembly 100 is housed within inner manifold 106 , which is mounted across manifold 88 such that valve 101 can open and close calibration volume chamber opening 96 .
Solenoid 102 is coupled to inner manifold 106 by solenoid mount 104 . Solenoid 102 includes a plunger 116 , which is coupled to shaft 110 , such that the motion of shaft 110 tracks the motion of plunger 116 . Shaft 110 is further coupled to valve 101 by means of ball joint 112 at the end of shaft 110 that is distal to solenoid 102 . Valve 101 therefore opens and closes about calibration volume opening 96 in response to the motion of shaft 110 .
Particularly, when plunger 116 is extended, it exerts a force on shaft 110 , causing it to move in the direction of the force exerted by solenoid plunger 116 . Shaft 110 thereby pushes on valve 101 against calibration chamber opening 96 , sealing calibration volume chamber 94 from measurement chamber 82 . Further, because ball joint 112 allows valve 101 to rotate with respect to shaft 110 , valve 101 forms a repeatable, air tight seal against calibration volume chamber 94 . Alternatively, any other type of pivotal joint, such as a universal joint, can be used in place of ball joint 112 .
Similarly, when plunger 116 is retracted, it pulls shaft 110 away from the surface of calibration chamber opening 96 , thereby opening valve 101 and allowing air to pass from calibration volume chamber 94 to measurement chamber 82 .
One of ordinary skill in the art would recognize that the above disclosed embodiments for the valve actuator assemblies can be used interchangeably between infant and adult sized measurement chambers.
One of ordinary skill in the art would also recognize that alternative methods of controlling valves 40 and 101 can be used in accord with the present invention. For example, the use a pneumatic system that responds to a signal from a computer to open and close said valve is also contemplated by the present invention. Alternatively, a rotary motor coupled to ball screw, wherein the motor responds to a signal from a computer to open and close said valve, is also contemplated by the present invention.
Further, while preferred illustrative embodiments of the invention are described above, it will be apparent to one skilled in the art that various changes and modifications may be made therein without departing from the invention. The appended claims are intended to cover all such changes and modifications that fall within the true spirit and scope of the invention.
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Methods and apparatus for calibrating volume measurement in a plethysmographic chamber are described. The present invention involves the use of a calibration volume chamber of known volume coupled to a plethysmographic measurement chamber in a plethysmographic measurement system for determining body composition, wherein a computer system calibrates the measurement system prior to conducting a volume measurement of a test subject, by measuring the chamber volume before and after opening an electronically controlled valve that connects the controlled calibration volume to the plethysmographic chamber, and comparing the measured chamber volumes based on the known reference volume.
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FIELD OF THE INVENTION
The invention relates to a metering system for mixing an emulsion paint from two or more aqueous paint components in accordance with the preamble of claim 1 .
BACKGROUND OF THE INVENTION
A system of this kind is known from DE 196 54 829 A1. Containers used for the individual paint components are in that case steel tanks.
Aqueous paints which comprise fillers, pigments, polymers and the like are subject to microbial influences, such as bacterial or fungal infestation. Decomposition, discoloration, reduction in viscosity, and development of odor are the consequences. To protect paints against microbial infestation they are therefore admixed with a preservative in the tanks. Preservatives used are various biocides, examples being isothiazolines or formaldehyde donors.
In order to get as close as possible to meeting customer wishes for a particular paint composition, metering systems are set up in home improvement stores and similar points of sale for end customers. With such systems, certain paint components which are less popular may often reside in the storage tank for months. The tanks with the individual components for aqueous emulsion paints must therefore be admixed with unusually large amounts of biocides in order to allow the microbial infestation to be durably prevented. In certain countries, such as Germany, however, only relatively low maximum concentrations of biocides in paints are permitted. In these countries, therefore, metering systems for aqueous emulsion paints cannot be set up at such points of sale. In those countries, instead, a large range of emulsion paints, dispensed into buckets, must be held ready at the points of sale in order to allow at least part of the possible color range to be covered. This results in a correspondingly complex and costly stock-keeping.
It is an object of the invention to provide a metering system for mixing an emulsion paint from individual aqueous paint components in separate containers, with which there is no risk of microbial infestation of the paint components in the individual containers, even after months, without any biocide concentration or at any rate only with a very low biocide concentration.
This object is achieved in accordance with the metering system of the invention which provides for dispensing an aqueous emulsion paint in the desired composition, in buckets, to the end customers at the point of sale.
SUMMARY OF THE INVENTION
The metering system of the invention is characterized in that the containers for the individual paint components, from which the emulsion paint is mixed together for the customers, is formed by a watertight bag.
This allows microbial infestation of the aqueous paint components to be prevented. In storage tanks, indeed, the microbial infestation is primarily attributable to the gas space above the level of the liquid. This gas space leads, for example, to the drying of the paint on the inner wall. Beneath a dried-up paint layer of this kind, however, the development of the microorganisms is particularly rapid.
As a result of the containers of the invention, formed as watertight and gastight bags, for the aqueous paint components, however, it is ensured that the formation of such a gas space is prevented, since the internal volume of the container contracts on discharge in accordance with the volume of the container contents.
For this purpose the conveying line is preferably connected to the lower region of the bag. The bag may be composed of a polymeric film which shrinks as a result of the underpressure formed when the bag is discharged. It is also possible, however, to use a bag made from an elastomeric material. All that is important is that the baglike containers are watertight, gastight, and flexible.
The components dispensed in accordance with the invention into containers in the form of watertight bags are aqueous dispersions made up of the various components which can be used to form an aqueous emulsion paint. Thus it is possible, for example, for there to be one or more containers for one or more polymer dispersions, one or more containers for one or more pigment dispersions, and one or more containers for one or more filler dispersions. The number of aqueous dispersions and hence containers is selected such that the emulsion paint range can be largely covered thereby. Of course, in one container, there may also be a mixture of, for example, two components, in other words, for example, a mixture of a pigment dispersion and a filler dispersion. The mixing container is generally formed by the bucket that forms the selling can for the customer.
The amount of paint filled into the bucket is determined using a balance on which the bucket is disposed during dispensing. Beside the balance there may be a shaker provided for the homogeneous mixing of the dispensed paint. Between the balance and shaker there may be a transport apparatus located, a roller track for the bucket, for example.
In order to allow precise metering there is preferably a conveying pump provided in the conveying line between the respective container and the feed region to the bucket. The metering of the paint from the individual components is controlled by means of a control apparatus, a PC for example, the control apparatus being connected to the metering valves at the feed region to the bucket and preferably also to the conveying pumps in the conveying lines, and to the balance.
Connected to the PC is a keyboard or similar input device for controlling the metering valves and the conveying pumps for the individual paint components in accordance with the desired paint composition.
Provided on the control apparatus there may be a printer for a label to be applied to the bucket, this printer printing the data onto the label in a way which, if desired, is also machine-readable, e.g., as a barcode, for settlement at the till of the emulsion paint dispensed into the bucket, after the label has been adhered.
Computer-assisted advice and product selection give rise to a multiplicity of possible combinations. If, for example, a matt exterior paint of low hiding power is to be dispensed in the bucket, then, using the input device, a high proportion of polymer dispersions and fillers and a low proportion of pigment is set. The input device is also used to select the amount of paint to be dispensed into the bucket. Via the PC, in that case, the metering valves and conveying pumps for the individual paint components are controlled accordingly, with the metering valves being closed and the conveying pumps shut off when the amount of paint dispensed into the bucket reaches the predetermined level as measured by the balance.
In order that the baglike, flexible containers for the individual aqueous paint components can be held and fully discharged, they may be disposed in or on a frame and/or suspended by their top end. The frame in this case may be formed by a pallet having at the side a support on which the container is suspended. Moreover, the container does not need to be of fully flexible design. Instead it is conceivable for the container to be composed of a rigid material, in the form for example of a shell, in the region of the outlet opening, to which the conveying line is connected.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated below with reference to the attached drawing, whose single FIGURE shows in diagrammatic form a metering system according to one embodiment of the invention.
DETAILED DESCRIPTION
According to said FIGURE the metering system for mixing an aqueous emulsion paint has a bucket as mixing vessel 1 and two or more, five to eight for example, containers 2 , 3 each for one paint component, from which the emulsion paint is mixed, only two of these containers being depicted in the drawing. The containers 2 , 3 , which are filled with an aqueous dispersion of the respective paint component, in other words, for example, with a polymer dispersion, a pigment dispersion or a filler dispersion, are composed in each case of a watertight bag comprising a polymeric film. The bags 2 , 3 , which can have a capacity of 200 to 1500 liters, for example, stand in each case on a pallet 4 , 5 . Each pallet 4 , 5 is provided with a support 6 , 7 , from which the bag 2 or 3 is suspended. Each of the bags 2 or 3 is supported by a respective support pallet 4 , 5 having an upward facing pallet surface on which the bag 2 or 3 stands to support the contents in a lower bag end. The pallet includes one of the upstanding supports 6 or 7 from which the bag is suspended. As can be seen, the support 6 , 7 is engaged with a top bag end and maintains the bag in a vertically elongate condition during contraction of the bag and the internal bag volume during discharge of the contents. Each of the pallets 4 , 5 has the support 6 , 7 on one side of the support surface which extends vertically and overlies the top bag end which is suspended therefrom.
A plurality of the pallets 4 , 5 are provided which are independently transportable and positioned in a stationary position during mixing, wherein each of the pallets 4 , 5 supports a respective one of the bags 2 , 3 thereon in the vertically elongate condition.
Each container 2 , 3 has at the base an outlet opening 8 , 9 to which a conveying line 11 , 12 is connected, formed for example as a hose. The opening 8 , 9 is disposed above the pallet surface with the conveying line 11 , 12 and discharges to one side of the bag 2 , 3 and the pallet 4 , 5 through the conveying line 11 , 12 . The respective dispersion in the container 2 , 3 is supplied using a pump 13 , 14 in the conveying line 11 , 12 to a filling head 15 , which is located in the feed region above the bucket 1 .
Each conveying line 11 , 12 has a metering valve 16 , 17 connecting it to the filling head 15 . The bucket 1 is placed on a balance 18 . Beside the balance 18 there is a shaker 19 and, in between them, a roller track 21 .
The metering system is controlled by a PC 22 with monitor 23 and keyboard 24 or similar input device. From the PC 22 the pumps 13 , 14 and the metering valves 16 , 17 are driven. Furthermore, the balance 18 is connected to the PC 22 .
The keyboard 24 is used to input, in accordance with the predetermined formula, the nature and amount of the paint components in the containers 2 , 3 that are to be mixed together in the bucket 1 , and also the amount of emulsion paint to be filled into the bucket 1 . Using the PC 22 , the respective pump 13 or 14 in the respective conveying line 11 or 12 is actuated and the respective metering valve 16 or 17 is open in order to supply the relevant paint components from the individual containers 2 , 3 , in the desired amount, via the filling head 15 , to the bucket 1 . As soon as the predetermined amount of emulsion paint has been filled into the bucket 1 , the pumps 13 , 14 are switched off and the valves 16 , 17 are closed. The bucket 1 filled with the emulsion paint is then sealed with a lid and pushed on the roller track 21 to the shaker 19 , in order for the paint mixture in the bucket 1 to be homogenized.
Furthermore, a printer 25 with which a label for the bucket 1 is printed is connected to the PC 22 , and prints, for example, a barcode used for settlement of the purchased emulsion paint at the till of the point of sale.
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The invention relates to a dosing arrangement which is used to mix a dispersion paint. The dosing arrangement comprises a mixing vessel and one container for the aqueous paint components. Each container is connected to a dosing valve, which is arranged in the supply area of the mixing vessel, by way of a supply line. The containers for the aqueous paint components are formed by waterproof bags.
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CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority under 35 U.S.C. ยง119(e) to U.S. Provisional Patent Application No. 61/724,293, filed on Nov. 8, 2012, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to the polymerization and copolymerization of monomers in the presence of fluorinated propylene solvents. More particularly, the present invention relates to the use of polymerization mediums suitable to polymerize one or more monomers to form polymers and/or copolymers, with a tetrafluoropolypropylene being used as a solvent or diluent for the one or more monomers.
DESCRIPTION OF RELATED ART
Methyl chloride is commonly used as a solvent or diluent in the process of producing polyalpha-olefins such as polyisobutylene. For example, slurry polymerization processes in methyl chloride are used in the production of high molecular weight polyisobutylene and isobutylene-isoprene butyl rubber polymers. Likewise, polymerizations of isobutylene and para-methylstyrene are also conducted using methyl chloride. Similarly, star-branched butyl rubber is also produced using methyl chloride.
Typically, such polymerization processes use methyl chloride at low temperatures, generally at about โ90ยฐ C., as the diluent for the reaction mixture. Methyl chloride is employed for a variety of reasons, including that it dissolves the monomers and the catalyst, e.g., aluminum chloride, but not the polymer product.
However, there are a number of problems associated with the polymerization in methyl chloride, for example, the tendency of the polymer particles in the reactor to agglomerate with each other and to collect on the reactor wall, heat transfer surfaces, impeller(s), and the agitator(s)/pump(s). The rate of agglomeration increases rapidly as reaction temperature rises. Agglomerated particles tend to adhere to and grow and plate-out on all surfaces they contact, such as reactor discharge lines, as well as any heat transfer equipment being used to remove the exothermic heat of polymerization, which is critical since low temperature reaction conditions must be maintained.
SUMMARY OF THE INVENTION
The present invention relates to polymerization mediums suitable to polymerize one or more monomers to form polymers and copolymers thereof, a fluorinated polypropylene being used as a solvent or diluent for the one or more monomers. The polymerization mediums are especially suitable for slurry polymerization processes.
In one aspect, a polymerization medium is provided that includes, consists essentially of, or consists of, one or more catalysts, a tetrafluoropropylene, and one or more monomers including at least one alpha-olefin.
In another aspect, a polymerization process is provided which uses such a polymerization medium in a reactor to produce polymers and/or copolymers.
In yet another aspect, a polymerization medium and process is provided which uses trans-1-chloro-3,3,3-trifluoropropene in place of a tetrafluoropropene as set forth above.
DETAILED DESCRIPTION
There is concern for the environment in terms of global warming and ozone depletion. Use of tetrafluoropropylenes in the present invention addresses such issues. For example, trans-1,3,3,3-tetrafluoroprop-1-ene (or โtrans-HFO-1234zeโ) has zero ozone depletion potential (ODP), and a global warming potential (GWP) of 6, which is quite low.
The toxicity and flammability of hydrofluorocarbons and hydrofluoro-olefins is also of potential concern. Hydrofluoro-olefins, in particular, are often toxic and flammable; however, tetrafluoropropylenes of the present invention also address this issue as well. For example, trans-HFO-1234ze is bath non-toxic and is not highly flammable. Additionally, trans-HFO-1234ze, can reduce the flammability of some monomers (e.g., isobutylene) when used in combination with those monomers.
Monomers which may be used in accordance with the present invention include monomers which can be polymerized using a Lewis acid dispersed in a diluent. Alpha-olefins, such as isopropylene, are especially preferred; however, any monomer which may be cationically polymerized (e.g., olefins, benzenes, styrenes, vinyl ethers, etc.) may also be used in accordance with the present invention.
Particularly preferred tetrafluoropropylenes include: trans-1,3,3,3-tetrafluoroprop-1-ene; cis-1,3,3,3-tetrafluoroprop-1-ene; 2,3,3,3-tetrafluoropropene; and mixtures thereof. In the alternative, trans-1-chloro-3,3,3-trifluoropropene may be used instead of tetrafluoropropylene, and achieve many of the same benefits as tetrafluoropropylenes.
Some tetrafluoropropylenes in accordance with the present invention can also be useful in that they can form compositions which are azeotropic or azeotrope-like. As used herein, the term โazeotropic or azeotrope-likeโ is intended in its broad sense to include both compositions that are strictly azeotropic and compositions that behave like azeotropic mixtures. From fundamental principles, the thermodynamic state of a fluid is defined by pressure, temperature, liquid composition, and vapor composition. An azeotropic mixture is a system of two or more components in which the liquid composition and vapor composition are equal at the stated pressure and temperature. In practice, this means that the components of an azeotropic mixture are constant-boiling and cannot be separated during a phase change.
Azeotropic compositions are constant boiling compositions, and azeotrope-like compositions are constant boiling or essentially constant boiling. In other words, for azeotropic and azeotrope-like compositions, the composition of the vapor formed during boiling or evaporation is identical, or substantially identical, to the original liquid composition. Thus, with boiling or evaporation, the liquid composition changes, if at all, only to a minimal or negligible extent. This is to be contrasted with non-azeotrope-like compositions in which, during boiling or evaporation, the liquid composition changes to a substantial degree. All azeotropic or azeotrope-like compositions of the present invention within the indicated ranges, as well as, certain compositions outside these ranges, are azeotrope-like.
Azeotropic or azeotrope-like compositions in accordance with the invention may include additional components that do not form new azeotrope-like systems, or additional components that are not in the first distillation cut. The first distillation cut is the first cut taken after the distillation column displays steady state operation under total reflux conditions. One way to determine whether the addition of a component forms a new azeotrope-like system so as to be outside of this invention is to distill a sample of the composition with the component under conditions that would be expected to separate a non-azeotropic mixture into its separate components. If the mixture containing the additional component is non-azeotrope-like, the additional component will fractionate from the azeotrope-like components. If the mixture is azeotrope-like, some finite amount of a first distillation cut will be obtained that contains all of the mixture components that is constant boiling or behaves as a single substance.
It follows from this that another characteristic of azeotropic or azeotrope-like compositions is that there is a range of compositions containing the same components in varying proportions that are azeotrope-like or constant boiling. All such compositions are intended to be covered by the terms โazeotropic or azeotrope-likeโ and โconstant boiling.โ As an example, it is well known that at differing pressures, the composition of a given azeotrope will vary at least slightly, as does the boiling point of the composition. Thus, an azeotrope of A and B represents a unique type of relationship, but with a variable composition depending on temperature and/or pressure. It follows that, for azeotrope-like compositions, there is a range of compositions containing the same components in varying proportions that are azeotrope-like. All such compositions are intended to be covered by the term azeotrope-like as used herein.
It is well-recognized in the art that it is not possible to predict the formation of azeotropes, as indicated, for example, in (U.S. Pat. No. 5,648,017 (column 3, lines 64-65) and U.S. Pat. No. 5,182,040 (column 3, lines 62-63), both of which are incorporated herein by reference. Applicants have discovered unexpectedly that HFO-1234ze and isobutylene form azeotropic and azeotrope-like compositions.
According to certain preferred embodiments, the azeotropic or azeotrope-like compositions of the present invention comprise, and consist essentially of, or consist of, effective amounts of trans-HFO-1234ze and isobutylene. The term โeffective amountsโ as used herein refers to the amount of each component which, upon combination with the other component, results in the formation of an azeotropic or azeotrope-like composition. Any of a wide variety of methods known in the art for combining the components to form a composition can be adapted for use in the present methods to produce an azeotropic or azeotrope-like composition. For example, trans-HFO-1234ze and isobutylene can be mixed, blended, or otherwise contacted by hand and/or by machine, as part of a batch or continuous reaction and/or process, or via combinations of two or more such steps. In light of the disclosure herein, those of skill in the art will be readily able to prepare azeotropic or azeotrope-like compositions according to the present invention without undue experimentation.
In examples where azeotropic or azeotrope-like compositions of the present invention comprise, consist essentially of, or consist of, isobutylene and HFO-1234ze, the HFO-1234ze can be present in an amount from about 82% by weight of the composition to about 96% by weight of the composition, and more preferably, between about 85% by weight of the composition to about 91% by weight of the composition. As illustrated more fully in Example 1 below, the azeotrope has been found to occur when the trans-HFO-1234ze is present in an amount between about 85% by weight of the composition to about 91% by weight of the composition, i.e., at about a concentration of 88% by weight. The boiling point of the azeotrope was experimentally measured to be at about โ20.23ยฐ C. at a pressure of about 1 atmosphere.
As used herein, the term โaboutโ refers to an approximate amount that falls within an acceptable range of experimental error. For example, with respect to temperature, the term โaboutโ can mean the stated temperature plus or minus 0.05ยฐ C.
An azeotropic or azeotrope-like composition of the present invention can be used in polymerization mediums suitable to polymerize one or more monomers to form a polymer, or alternatively, some polymerization mediums in accordance with the present invention which are not azeotropic or azeotrope-like can be transformed into an azeotropic or azeotrope-like composition of the present invention through the simple addition of fluorinated propylene or monomer already present in the composition. For example, a polymerization medium in accordance with the present invention can comprise at least one catalyst, isobutylene and trans-HFO-1234ze. Preferably, the at least one catalyst comprises a Lewis acid, including but not limited to Lewis acids comprising aluminum, boron, gallium, or indium. For example, alkyl aluminum halides, boron halides, and organo-boron halides can be suitable catalysts. Some additional non-limiting examples of suitable Lewis acids are provided in U.S. Patent Application Publication No. 2005/0101751, the disclosure of which is hereby incorporated by reference.
Azeotropic or azeotrope-like compositions of isobutylene and trans-HFO-1234ze can be used in polymerization processes to produce polymers of one or more monomers. Such a polymerization process can include, for example, providing isobutylene by itself or in combination with other monomers, and contacting the isobutylene or the monomer mixture in a reactor with at least one catalyst in the presence of HFO-1234ze in an amount which forms an azeotropic or azeotrope-like composition of the present invention.
The compositions in accordance with the present invention improve the performance of the polymerization process, as well as the quality of a polymer product made therewith. As an initial matter, the compositions may be beneficially used to remove monomer from the reaction mixture. For example, at the end of a polymerization process, if an azeotropic or azeotrope-like composition is present, or is subsequently formed, the evaporation of solvent (e.g., trans-HFO-1234ze) facilitates the evaporation of monomer (e.g., isobutylene) from the mixture.
In addition, de compositions in accordance with the present invention may be used to address the problem with product agglomeration present in existing polymerization processes which use methyl chloride as a solvent. See, e.g., U.S. Pat. No. 7,423,100, column 42, paragraph 25. The compositions in accordance with the present invention could be used to improve product agglomeration properties during polymerization, i.e., by reducing, or possibly completely eliminating, the agglomeration of product.
Example 1
An ebulliometer composed of a vacuum jacketed tube with a condenser on top of which was further equipped with a quartz thermometer. 16.36 grams of HFO-1234ze was charged into the ebulliometer and the boiling point was observed. Isobutylene was then added in small increments, and the boiling point of each of the compositions was observed as the weight percentage of isobutylene was increased. A temperature depression was observed at about โ20.23ยฐ C., indicating a binary minimum boiling azeotrope. The results are shown in Table 1.
TABLE 1
Wt % trans-HFO-1234ze
Wt % isobutylene
T (ยฐ C.)
100.00
0.00
โ19.46
99.76
0.24
โ19.49
98.85
1.15
โ19.63
95.62
4.38
โ20.01
90.99
9.01
โ20.19
87.82
12.18
โ20.23
84.72
15.28
โ20.17
82.05
17.95
โ20.11
78.05
21.95
โ20.00
74.57
25.43
โ19.88
70.12
29.88
โ19.71
65.84
34.16
โ19.53
61.53
38.47
โ19.35
58.85
41.15
โ19.25
56.67
43.33
โ19.16
54.26
45.74
โ19.03
52.07
47.93
โ18.97
49.25
50.75
โ18.80
Example 2
An ebulliometer composed of a vacuum jacketed tube with a condenser on top of which was further equipped with a quartz thermometer. 8.06 grams of isobutylene was charged into the ebulliometer and the boiling point was observed. HFO-1234ze was then added in small increments, and the boiling point of each of the compositions was observed as the weight percentage of HFO-1234ze was increased. No temperature depression was observed over the range of compositions tested. The results are shown in Table 2.
TABLE 2
Wt % isobutylene
Wt % trans-HFO-1234ze
T (ยฐ C.)
100.00
0.00
โ7.40
97.34
2.66
โ8.71
86.48
13.52
โ13.61
75.61
24.39
โ16.84
66.12
33.88
โ17.84
53.41
46.59
โ18.63
47.89
52.11
โ18.91
44.12
55.88
โ19.12
From the foregoing, it will be appreciated that although specific examples have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit or scope of this disclosure. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to particularly point out and distinctly claim the claimed subject matter.
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The present invention relates to the polymerization and copolymerization of monomers in the presence of fluorinated propylene solvents. More particularly, the present invention relates to the use of polymerization mediums suitable to polymerize one or more monomers to form polymers and/or copolymers, with a tetrafluoropolypropylene being used as a solvent or diluent for the one or more monomers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a coating method and apparatus which is suited for forming magnetic coating on magnetic recording mediums.
2. Description of the Prior Art
In the conventional equipment for producing magnetic recording medium such as magnetic tape, a substrate or tape base 1, as shown in FIG. 1, is fed from a supply roll 10 and is applied with magnetic coating by the known coating applier of the extrusion type. The coated tape is then sent into a dryer 12 where it is dried by hot air 14 blown from nozzles 13. Next, the tape 1 coated with magnetic layer is calendered by known calender rolls 15 and, after coating it with a black coat if necessary, is wound on a take-up roll 16.
In this case the tape 1 is continuously made to run while being supported by a backup roll 18. A coating roll 17 is pressed against the backup roll 18. The coating liquid delivered from an extrusion type coating applier 11 onto the coating roll 17 is controlled to the desired thickness by a metering roll 19 and transferred onto the tape 1 running on the backup roll 18. This technique of magnetic coating is known as the reverse roll method disclosed in Japanese Patent Laid-Open Nos. 84242/1977 and 17661/1981.
FIG. 2 shows the detail of the magnetic liquid applying section using the reverse roll method. More coating liquid 2 than is needed is applied to the coating roll 17 from the liquid applier 11. The metering roll 19 is so located that it contacts the coating roll 17 at a point before the liquid on the coating roll reaches the backup roll 18. The metering roll 19 scrapes excess liquid off the coating roll 17 to control the amount of liquid to be transferred to the tape. The excess liquid 2 is collected in a container 3 from which it is circulated by a pump 4 to a reservoir 5 and further fed to the applier 11 by a pump 6. This liquid circulating system has disadvantages. For example, some foreign matter may get into the liquid while the liquid is staying in the container 3 causing abnormal liquid application; the composition and viscosity of the coating liquid may change while it is being circulated; also the particles may coagulate during circulation. These result in variation in the thickness and characteristic of the magnetic layer formed on the tape, deteriorating the quality and stability of the product.
Another known technique of magnetic coating is a gravure coating. This process is performed in a system which is exposed to the open air, so the coating liquid evaporates into the air changing the liquid composition and deteriorating the quality of the product. Moreover, the gravure pattern of the coating roll is subject to wear during operation, which results in a change in the coating thickness. This requires frequent replacement of the coating roll, reducing production efficiency.
In the extrusion coating method disclosed by the Japanese Patent Publicaton No. 10110/1981, the coating liquid 2 is supplied in volume several times more than necessary, as shown in FIG. 3, from the reservoir 22 to a chamber 23 of a liquid applier 31 by a pump 21. The liquid 2 fed into the chamber 23 is further supplied through a slot 25 to a nozzle 26 at the end of the slot where the liquid is controlled to the desired amount by a doctor edge 27 which is mounted immediately after the nozzle 26 with respect to the tape running direction. The regulated amount of coating liquid is applied onto the tape 1 running in the direction of the arrow. The thickness of the coating is about one-half of the gap between the doctor edge 27 and the tape 1. The excess liquid 2 flows down, as shown at 24, by gravity through a larger gap between the tape 1 and the edge 29 which is mounted on the tape-incoming side of the nozzle 26. The excess liquid 2 thus collected in the reservoir 28 is then supplied by a pump 30 to the reservoir 22. However, since the excess is recovered to a reservoir 28 and then to the tank 22, the system shown in FIG. 3 has similar drawbacks to those of FIG. 2 such as change in liquid composition, coagulation, and viscosity variation.
To remove these drawbacks, it has been proposed that in the extrusion coating system, only the exact amount of liquid necessary to form a specified thickness of coating on the tape is extruded (that is, in FIG. 3, the liquid amount is reduced to eliminate the excess). In this case, however, fine longitudinal streaks like the wood grain of lauan are formed on the surface of the coated layer, appearing from near the nozzle of the liquid applier.
The extrusion coating system published in the Japanese Patent Laid-Open No. 19060/1982 has been devised to remove the longitudinal streaks on the surface of the coated layer. According to this, as shown in FIG. 4, the coating liquid 2 is introduced from a supply nozzle 32 into the liquid chamber 23 in the liquid applier while at the same time a part of the liquid 2 is discharged from a discharge nozzle 33 at the other end of the applier. The amount of liquid supplied to the chamber 23 is greater than that coated on the tape and the excess liquid is discharged from the nozzle 33. So it is considered that the streaks will not result. Although there is no description as to the process of the liquid after being discharged from the nozzle 33, the excess liquid is considered to be circulated and recovered to the reservoir or discarded. If the liquid is circulated for reuse, the aforementioned drawback is not overcome at all. And if it is thrown out, the loss of liquid will inevitably increase cost.
SUMMARY OF THE INVENTION
The object of this invention is to provide a coating method and apparatus that can form a uniform coating on the tape at high efficiency while at the same time keeping the liquid composition and viscosity stable and preventing coagulation of particles.
In other words, this invention relates to a coating liquid application method in which the exact amount of liquid to be applied onto the tape is supplied from the liquid supply means and a part of the coating liquid is circulated in a closed system between the supply means to the liquid delivery nozzle of the liquid application section.
This invention further provides a coating apparatus which embodies the above coating method effectively and consists of: a coating liquid application section having a liquid delivery nozzle; a liquid supply means; a pipe introducing the liquid from the supply means into the application section; and a circulation path branched from the liquid passage of the application section and connected to the pipe.
Other objects and features of this invention will become apparent from the description and drawings that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 4 show examples of conventional coating apparatuses, of which;
FIG. 1 is a process flow diagram showing the magnetic coating process of the magnetic tape;
FIGS. 2 and 3 are simplified drawings showing two examples of coating apparatus; and
FIG. 4 is a cross section of a coating liquid applier;
FIGS. 5 through 11 show embodiments of this invention, of which;
FIG. 5 is a simplified drawing of the coating liquid applier;
FIG. 6 is an enlarged view of essential part of FIG. 5;
FIG. 7 is a perspective view of the applier partially cut away;
FIGS. 8 and 9 are simplified drawings of other two examples of coating liquid applier; and
FIGS. 10 and 11 are cross sections of the above two coating liquid appliers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be explained in detail by taking as examples the preferred embodiments.
The coating method and apparatus embodying this invention are suited for manufacturing the magnetic tape and can be applied basically in a way similar to that applied in the process of FIG. 1.
FIGS. 5 through 7 show the first embodiment of this invention.
In this embodiment, the coating liquid 2 is supplied from a reservoir 43 to a chamber 42 of an extrusion type liquid applier 41 by a pump 44. The liquid 2 is then fed through a slit 45 and a nozzle 46 onto the tape 1. The pump 44 delivers to the chamber 42 the exact amount of liquid that is to be coated on the tape 1.
The amount of liquid delivered to the chamber 42 is expressed as
R=VรhwรW
(where V is the speed at which the tape travels; hw is the thickness of coating layer when still wet; and W is the width of coating layer.)
What should be noted here is that a circulation slit 47 is formed in an intermediate position of the slit 45 (that is, between the chamber 42 and the nozzle 46) to communicate with the slit 45 and that a part of the coating liquid 2 is drawn out through the slit 47 in the tape transverse direction by a pump 48 and is circulated back to the chamber 42 through the supply port of the liquid applier 41. Reference number 50 in the figure denotes a pipe to supply liquid from the reservoir 43 to a supply port 49. 51 is a pipe for liquid circulation. The amount circulated by the pump 48 is 1.2 to 1.4 times that delivered by the pump 44 and this circulation increases the speed of the liquid flow rate.
With the above method and apparatus, since the part of the liquid that has been taken from the slit 45 is circulated in the totally closed system, it is not returned to the reservoir 43 as is the case with the conventional apparatus. This prevents any change in the liquid composition and viscosity due to evaporation. If as with the conventional apparatus the liquid is returned to the reservoir 43, the shearing force between particles will be weakened while the liquid stays in the reservoir, resulting in coagulation. In this embodiment, this undesired phenomenon will not occur. Further, as the return liquid is added from pipe 51 to the main stream of the pipe 50, the liquid is always moving in the applier 41 and the mixing of the two flows of liquid causes turbulence which in turn keeps constant the composition of the liquid to be coated to the tape. Since there is difference in speed among particles, no coagulation of liquid will occur. Particles are subjected to the action of shearing force when passing through narrow slit 45 and at the joint of slits 45 and 47. So no coagulation of particles will occur.
Moreover, since the coating liquid in the applier 41 is circulated inside, the apparent volume of liquid used for coating is VรhwรW and all of this liquid is coated onto the tape 1. This means that the thickness of the coating on the tape can be regulated only by the pump 44, which improves the coating thickness accuracy and facilitates the thickness control. Moreover, the internal circulation prevents the lauan grain-like streaks that occur when the coating liquid is supplied only in the volume of (VรhwรW), and also improves the electromagnetic characteristics of the magnetic recording medium, especially the chrominance S/N, RF output and frequency characteristic in the high frequency range. There is no particular limit to the amount of circulation flow by the pump 48, but it is desirable to set it at about 0.5 to 10 times the volume of (VรhwรW) (say 1.2 to 1.4 times that volume). Since any variation in the circulation flow is likely to result in a change in the coating thickness, it is desired that the pump 48 have very small flow variation, which is achieved by a pump such as the high accuracy external contact type gear pump with small delivery pulsation and good constant flow characteristic. This can also be said of the supply pump 44.
For further improvement of the coating thickness accuracy, a flow meter FM is provided on the delivery side of the supply pump 44 and the circulation pump 48 to control the rotating speed of the pumps, as shown in FIG. 8. In this example, the liquid is indirectly coated to the tape 1 through the applicator roll 17. The backup roll 18 or the applicator roll 17 is preferably an elastic roll.
FIGS. 9 and 10 show still another embodiment of this invention.
This example differs from the above example in that the excess liquid is drawn out from the chamber 42. The excess liquid is taken out from both ends of the chamber 42 and these two streams are combined and circulated by the pump 48 back to the chamber 42, as shown in FIG. 10. It is also possible, as shown in FIG. 11, to take a part of the liquid from the chamber 42 from different directions than those of FIG. 10.
Thus, the liquid applier 41 need not have a circulation slit 47. Also, the internal liquid circulation causes turbulence in the liquid flow (see FIGS. 10 and 11), generating shearing force in the liquid.
A more concrete explanation on the above embodiment is given in the following.
First, the coating liquid (magnetic coating liquid) with the following composition is prepared.
ฮณ-Fe 2 O 3 : 100 parts weight
Vinyl chloride-vinyl acetate copolymer (VAGH produced by Union Carbide Corp.): 6 parts weight
Nitrocellulose(Celluline L-200 produced by Daicel Ltd.): 6 parts weight
Polyurethane (Estan 5701, produced by Goodrich Co.): 12 parts weight
Lecithin: 5 parts weight
Toluene: 30 parts weight
Cyclohexanone: 180 parts weight
This coating liquid (about 2150 cp when measured by type B viscosity meter (60 rpm)) is applied continuously to the tape by the extrusion type liquid applier of FIG. 5 under the following condition.
Substrate: Polyethylene terephthalate
Width of the substrate: 360 mm
Thickness of the substrate: 14 ฮผm
Coating speed: 150 m/minute
Width of coating layer: 340 mm
Thickness of coating layer (when wet): 35 ฮผm
Volume of liquid supplied: 1785 cc/minute
During the coating process, the liquid is extracted from the circulation slit 47 of FIG. 5 in the following four kinds of volume and circulated back to the applier. The condition of the coating obtained and the magnetic tape characteristic are as follows.
__________________________________________________________________________ FrequencyAmount of circulated Condition of coating Luminance Chrominance RF output characteristicliquid (cc/min.) (fine longitudinal streaks) S/N (dB) S/N (dB) (dB) (10 kHz)__________________________________________________________________________ (dB)Test 1 0 Many streaks occurred 43.5 38.0 -27.3 0.8 (all over the coating surface)Test 2500 Few 44.0 39.5 -26.5 1.0Test 3 1000 Very few 44.0 40.8 -26.0 1.7Test 4 2000 None 44.7 42.0 -25.8 2.0__________________________________________________________________________
The above characteristics were measured under the following conditions.
Luminance S/N:
As a measurement signal, a 50% white signal was recorded and reproduced by video tape and was supplied to a color video noise meter 9250/1 (produced by Shibasoku Co.) to measure the noise level that remained after the signal was passed through the low range cut filter of 1 kHz and 10 kHz.
Chrominance S/N:
A 702 signal of 0.714 Vp-p was superimposed on a white signal of 0.36 Vp-p to produce a 100% color signal which was then recorded and reproduced. The bypass filter was set at 10 kHz and the low pass filter at 1 kHz, and AM noise and PM noise were measured.
RF output:
The FM output from the head was measured when a measurement was taken of luminance S/N.
Frequency characteristic:
The reproduce level was measured for the signal which had been recorded on the test tape with a specified vias current at a record level 10 dB lower than the specified voice level. This measurement was represented by the difference between the test tape and the standard tape.
These characteristics of magnetic tapes varied with elapse of time and this is shown below.
______________________________________ Viscosity of liquid Angular Luminance RF Output (cp) ratio S/N (dB) (db)______________________________________30 min. after 2200 0.83 44.5 -26.2liquid appli-cation60 min. later 2230 0.81 44.0 -25.7120 min. later 2200 0.82 44.7 -25.8______________________________________
From these results, it is seen that supplying liquid in volume of 1785 cc/min. (which is determined by VรhwรW) and circulating the liquid will produce uniform coating on the tape without any longitudinal streaks and with improved electromagnetic conversion characteristic. It is also seen that there is almost no deterioration of characteristics with elapse of time.
It should be noted here that various modifications may be made to the above embodiments according to the technological concept of this invention.
For example, the way in which the coating liquid is extracted from the liquid applier may be changed. It may be extracted from one end of the applier, instead of from the both ends. The point into which the extracted liquid is circulated back need only be somewhere between the supply port (at 49 in the above embodiment) of the liquid applier and the supply pump (at 44). The application of this invention is not limited to the coating of magnetic recording mediums such as magnetic tape, but it is also applicable to various kinds of coating liquid.
As mentioned above, since the liquid is circulated through the closed path branching from the main liquid passage of the liquid applier, the liquid quality is kept from deterioration as may be caused by evaporation and no coagulation will occur, forming uniform coating on the tape without any undesired streaks. Moreover, the liquid circulation can be regulated by controlling the liquid supply means to enable liquid coating of constant volume, which in turn assures high production efficiency.
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A coating method wherein a part of coating liquid supplied from a liquid supplying device is circulated through a closed passage running somewhere between the liquid supply device and a liquid delivery nozzle of a liquid applying section from the liquid applying section to the liquid supply device while the coating process is in operation. The amount of liquid circulated in the closed passage is 0.5 to 10 times the amount of liquid supplied by the liquid supply device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an active matrix type liquid crystal display apparatus. More particularly, the present invention relates to a liquid crystal display apparatus in which a noise is not displayed as a regular pattern, if an interlaced scanning is performed for jumping over a horizontal display line every other line to write an image data, when an enlarged display is performed on an image display unit, and a display method.
2. Description of the Related Art
In an active matrix type liquid crystal display apparatus, characteristic errors of signal processors are averaged to improve the quality of display.
FIG. 1 is a configuration diagram showing an example of a liquid crystal display apparatus using this averaging operation.
An input image signal Sin is provided with analog R, G and B signals, and is inputted to a time base converter 101 . The input image signal Sin may be any of an interlace signal and a progressive signal. The time base converter 101 samples the successively supplied input image signal Sin through a sampling and holding circuit, and then divides the data into n sections in parallel to drop the frequency.
As the input image signal Sin becomes high accurate, an operation frequency of a sampling and holding circuit in an image display driver 104 becomes higher associated with the higher accuracy. Thus, it is difficult to attain a function of the image display driver 104 . As shown in FIG. 1, inner operations of the image display driver 104 can be performed in parallel by providing n input terminals for the image display driver 104 , in order to drop the operation frequency. The time base converter 101 performs a 2n-paralleling process on the input image signal Sin. So, the signals obtained by the 2n-paralleling process are processed in parallel to each other by 2n signal processors 1 to 2n to drop the operational frequency.
Here, a position at which the time base converter 101 starts sampling the input image signal Sin can be arbitrarily determined in accordance with an SP control signal Ssp 2 inputted to the time base converter 101 from a switching controller 106 . In short, a data processed by the sampling and holding circuit different for each frame is supplied to a particular pixel. This is an averaging principle.
In the switching controller 106 , its averaging period is set at a 2n vertical period and a 2n horizontal period. The vertical period corresponds to the 2n of the number of signal processors 1 to 2n. The horizontal period corresponds to the 2n of the number of signal processors 1 to 2n. The 2n vertical period and the 2n horizontal period will be described later.
The time base converter 101 performs a parallel time base conversion on the input image signal Sin to generate conversion image signals SC 1 to SC2n. The number of conversion image signals SC 1 to SC2n is equal to two times the division ratio n. The time base converter 101 is connected to 2n signal processors 1 to 2n which are connected parallel to each other. The time base converter 101 outputs the conversion image signals SC 1 to SC2n to the signal processors 1 to 2n, respectively.
The signal processors 1 to 2n perform a signal process, such as a ฮณ conversion, a data inversion and the like, on the conversion image signals SC 1 to SC2n, respectively, to thereby generate processed image signals SP 1 to SP2n.
The signal processors 1 to 2n are connected to a switching selector 103 . The switching selector 103 , in response to a selector signal Ssel 2 outputted from the switching controller 106 , selects half n signals from the image signals (the processed image signals SP 1 to SP2n) corresponding to 2n dots stored in the signal processors 1 to 2n. This is because the switching selector 103 samples the processed image signals corresponding to the latter n dots while the switching selector 103 outputs the processed image signals corresponding to the former n dots as image signals S 1 to Sn.
The switching selector 103 outputs the image signals S 1 to Sn divided into the n sections, from n output sections SO 1 to SOn. The image signal S 1 is outputted from the first output section SO 1 of the switching selector 103 , the image signal S 2 is outputted from the second output section SO 2 , and the image signal Sn is outputted from the n-th output section SOn.
The processed image signal processed by which number of signal processor among the signal processors 1 to 2n to be outputted as the image signal S 1 from the first output section SO 1 can be selected as desired. At this time, the processed image signals outputted as the image signals S 2 , S 3 to Sn from the second, third to n-th output sections SO 2 , SO 3 to SOn following the first output section SO 1 are selected such that they are arranged in order with respect to the processed image signal outputted as the image signal S 1 from the first output section SO 1 .
For example, the number of signal processors 1 to 2n is defined as 8 (n=4). Here, it is assumed that the processed image signal SP 3 outputted from the third signal processor 3 is outputted as the image signal S 1 from the first output section SO 1 of the switching selector 103 . In this case, the processed image signals SP 3 , SP 4 , SP 5 and SP 6 outputted from the signal processors 3 , 4 , 5 and 6 in the former period are outputted as the image signals S 1 to S 4 , from the first to fourth output sections SO 1 to SO 4 . Also in the latter period, the processed image signals SP 7 , SP 8 , SP 1 and SP 2 outputted from the signal processors 7 , 8 , 1 and 2 are outputted as the image signals S 1 to S 4 , from the first to fourth output sections SO 1 to SO 4 .
The image signals S 1 to Sn outputted from the output sections SO 1 to SOn of the switching selector 103 are supplied to the image display driver 104 . The image display driver 104 is provided with a plurality of blocks arrayed along an image display unit 105 composed of a liquid crystal panel and the like. The image display driver 104 outputs the image signals to the image display unit 105 , each time it samples the image signals S 1 to Sn divided into the n sections by the switching selector 103 by using an n-division clock signal, or after it completes sampling the image signals in one horizontal period.
The image signals S 1 to Sn outputted from the switching selector 103 are inputted to one terminal of the plurality of blocks of the image display driver 104 , and sequentially shifted to another block. Then, the image display driver 104 samples a pixel data of each block at a predetermined frequency.
The operation of the liquid crystal display apparatus shown in FIG. 1 will be described below with reference to FIGS. 2A to 6 .
FIGS. 2A to 2 H show averaging patterns generated by the switching controller 106 if the number of signal processors 1 to 2n is 8 (n=4), namely, formats 1 to 8 . One table described in each of FIGS. 2A to 2 H shows an averaging pattern in one frame. A horizontal axis indicates an order in a horizontal direction, and a vertical axis indicates an order in a vertical direction.
Numerals in the respective tables denote the numbers corresponding to the processed image signals SP 1 to SP 8 outputted from the selected signal processors 1 to 8 . A slant line portion indicates that the processed image signal SP 1 outputted from the first signal processor 1 is selected.
FIGS. 3A to 3 H show display images when the averaging patterns of FIGS. 2A to 2 H are used, respectively. Numerals in respective tables indicate that the image data (processed image signals) SP 1 to SP 8 processed by the signal processors 1 to 8 corresponding to its number are displayed. A slant line portion indicates a position on the display screen of the image display unit 105 of the processed image signal SP 1 processed by the first signal processor 1 . A horizontal axis indicates a pixel which is a set of respective dots of R, G and B of the image display unit 105 , and a vertical axis indicates a horizontal line.
A first frame (a format 1 ) of FIG. 3A is exemplified and described. In the first pixel on the first horizontal line, the processed image signal SP 1 processed by the first signal processor 1 is indicated as a number [1]. Hereafter, in order from the second pixel to the eighth pixel, the processed image signals SP 2 to SP 8 processed by the second to eighth signal processors 2 to 8 are indicated as respective numbers [2, 3, 4, 5, 6, 7 and 8].
Similarly, in the first pixel on the second horizontal line, the processed image signal SP 3 processed by the third signal processor 3 is indicated as a number [3]. After the first pixel on the second horizontal line, the processed image signals SP 4 , SP 5 , SP 6 , SP 7 , SP 8 , SP 1 and SP 2 are sequentially indicated as numbers [4, 5, 6, 7, 8, 1 and 2]. This case implies that the processed image signal SP 1 processed by the first signal processor 1 is indicated in the seventh pixel on the second horizontal line. The procedure after that is same. Thus, its description is omitted.
Here, in the successive eight horizontal lines, it is selected such that the same image data (for example, the processed image signal SP 1 ) is not displayed in a particular pixel (for example, the first pixel). This selecting method is performed on one frame (the successive eight horizontal lines). Thus, in order to uniformly locate the image signals (the processed image signals SP 1 to SP 8 ) processed by the 8 signal processors 1 to 8 in all eight pixels on all the eight horizontal lines, 8 frames are needed as shown in FIGS. 3A to 3 H.
FIGS. 4A to 4 H show a display images when a 1.6-times enlarged displaying is performed on each of the averaging patterns of FIGS. 2A to 2 H. The 1.6-times enlarged displaying is attained by using the following method. From image data of five lines, each of image data of three lines is displayed as two lines. In each of FIGS. 4A to 4 H, from five lines A to E in each of FIGS. 3A to 3 H, each of the lines A, B and D is displayed with two lines to thereby carry out the enlarged displaying.
If such enlarged displaying is done, data of one line is enlarged as the two lines. Thus, in the enlarged portion, the averaging pattern is similarly enlarged. Also, in this case, the data is written to the image display unit 105 , two times in one horizontal period. Thus, a write time is equal to half the normal time. So, in order to reserve the write time corresponding to the one horizontal period similarly to the normal case, an interlaced scanning is performed on the enlarged result of each of FIGS. 4A to 4 H, as shown in each of FIGS. 5A to 5 H. A half-tone dot meshing portion indicates a line jumped over in each frame. Even-numbered lines are jumped over in each of the odd-numbered frames, and odd-numbered lines are jumped over in each of even-numbered frames.
As mentioned above, when the 1.6-times enlarged displaying is done in the image display unit 105 , the interlaced scanning is carried out for making the write time equal to the normal case that the 1.6-times enlarged displaying is not done.
Next, FIG. 6 is explained. The processed image signal SP 1 ([1]) processed by the first signal processor S 1 is extracted from the remaining portion that is not jumped over in each of 8 formats in FIGS. 5A to 5 H. FIG. 6 shows the state that in this case, the portions [1] included in the 8 formats are overwritten. As shown in FIG. 6, blank portions BK are generated. As a result, the noise in the form of lattice is displayed.
As mentioned above, when the number of signal processors is 2n, the averaging period is as follows. That is, if a certain pixel in the image display unit 105 is noted, the averaging is attained in a vertically temporal time axis at the 2n vertical periods. Similarly, the averaging is attained in the horizontally time base axis at the 2n horizontal periods. That is, the perfectly averaging operation are possible in the vertical period and the horizontal period corresponding to the number of signal processors.
However, when the enlarged displaying is done, if the interlaced scanning is carried out, the jumped over one horizontal (line) data is not drawn on the image display unit 105 . This causes the averaging operation to be imperfect. The image signal finally outputted from the certain particular signal processor is displayed on the image display unit 105 , as shown in FIG. 6 . Its certain determined pattern is displayed on the image display unit 105 as the noise in the form of lattice.
In addition, in order to improve the quality of the display after the averaging operation, Japanese Laid Open Patent Application (JP-A-Heisei, 4-355788) discloses a technique that a switching circuit can switch between one of terminals of a driving circuit and one of signal processors at a vertical period or a horizontal period freely. However, although the switching circuit can be arbitrarily switched between them at the vertical or horizontal period, its period is always predetermined to be fixed. Therefore, when the interlaced scanning is done based on the fixed period, averaging patterns obtained by the fixed period are inadequate. Thus, it is difficult to surely guard against the noise in the form of lattice, as mentioned above.
SUMMARY OF THE INVENTION
The present invention has been made to solve the above-described problems of the conventional method of driving a display apparatus. An object of the present invention is to provide a method of driving a display apparatus which can obtain a high quality display without any noise in a form of lattice, in which an averaging operation can be perfectly done even if a interlaced scanning is done. In this case, the display apparatus can be an active matrix type liquid crystal display apparatus.
In order to achieve an aspect of the present invention, a method of driving a display apparatus, includes: (a) providing a plurality of processors outputting a plurality of output signals, respectively; (b) providing a plurality of frames, wherein each of the plurality of frames has an averaging pattern for averaging characteristic errors of the plurality of processors and has a plurality of lines; (c) performing a first scanning on a predetermined frame of the plurality of frames such that a predetermined line of the plurality of lines of the predetermined frame is not scanned; and (d) performing a second scanning on a specific frame of the plurality of frames such that a line corresponding to the predetermined line of the specific frame is scanned, the specific frame having a same averaging pattern as the averaging pattern of the predetermined frame.
In order to achieve another aspect of the present invention, a method of driving a display apparatus, further includes: (e) performing a third scanning on the predetermined frame such that all lines of the predetermined frame are scanned; and (f) performing a forth scanning on the specific frame such that all lines of the specific frame are scanned, and wherein one of first and second groups is performed selectively, the first group including the (c) and (d) steps and the second group including the (e) and (f) steps
In this case, the first group is performed when each of the plurality of frames is displayed to be enlarged such that a single line of the plurality of lines is displayed as the lines of two, and the second group is performed when each of the plurality of frames is displayed not to be enlarged.
In order to achieve still another aspect of the present invention, a method of driving a display apparatus, includes: (aa) providing a plurality of processors of M (M is a positive integer) outputting a plurality of output signals of the M, respectively; (ab) providing a plurality of frames, wherein each of the plurality of frames is formed to be a matrix with a plurality of lines of the M rows and a plurality of pixels of the M columns, and wherein the plurality of output signals of the M are inputted to the plurality of pixels of the M columns on a specific line of the plurality of lines of the M rows, respectively, and are inputted to the plurality of pixels of the M of a specific column of the M columns on the plurality of lines of the M rows, respectively, to generate an averaging pattern in the each frame; and (ac) performing a scanning on a predetermined frame of the plurality of frames such that a predetermined line of the plurality of lines of the predetermined frame is not scanned, and (ad) performing a scanning on a specific frame of the plurality of frames such that a line corresponding to the predetermined line of the specific frame is scanned, the specific frame having a same averaging pattern as the averaging pattern of the predetermined frame.
In this case, the plurality of output signals of the M are obtained by a result that an image signal is time-base converted to generate a plurality of converted signals of the M and the plurality of converted signals of the M are inputted to the plurality of processors of the M, respectively.
Also in this case, each of the plurality of frames is displayed to be enlarged such that a single line of the plurality of lines of the M rows is displayed as the lines of two.
Further in this case, the (ab) step includes providing the plurality of frames of double the M which have a plurality of the averaging patterns of the M type.
In this case, when the (c) step is performed, an even-numbered line as the predetermined line of the predetermined frame is not scanned and an odd-numbered line of the predetermined frame is scanned, and when the (d) step is performed, an odd-numbered line of the specific frame is not scanned and an even-numbered line as the line of the specific frame is scanned.
Also in this case, when the pixel of P-th (P is a positive integer) of the plurality of the pixels of the M columns on a predetermined line of the plurality of lines of the M rows inputs the output signal outputted from the processor of Q-th (Q is a positive integer) of the plurality of processors of the M, the pixel of (the P+1)-th of the plurality of the pixels of the M columns on the predetermined line inputs the output signal outputted from the processor of (the Q+1)-th of the plurality of processors of the M.
Further in this case, a single cycle of averaging characteristic errors of the plurality of processors of the M consists of the plurality of frames of double the M which have a plurality of the averaging patterns of the M.
In order to achieve yet still another aspect of the present invention, a display apparatus, includes: a display unit displaying an image based on a plurality of frames; a time base converter dividing an image signal on a time base in response to a first control signal to generate a plurality of converted signals of M (M is a positive integer); a plurality of processors of the M outputting a plurality of output signals of the M based on the plurality of converted signals of the M, respectively; a frame generating unit generating the plurality of frames based on the plurality of output signals in response to a second control signal such that each of the plurality of frames has an averaging pattern for averaging characteristic errors of the plurality of processors of the M; and a control circuit generating the first and second control signals such that the time base converter generates the plurality of converted signals of double the M in a single period of the averaging in response to the first control signal, and the frame generating unit generates the plurality of frames of double the M in the single period in response to the second control signal.
In this case, the display unit is a liquid crystal display of active matrix type.
Also in this case, the control circuit generates the first control signal such that the time base converter generates the plurality of converted signals of double the M in a vertical period corresponding to (the Mร2) and a horizontal period corresponding to the M in response to the first control signal.
Further in this case, the control circuit generates the second control signal such that the frame generating unit generates the plurality of frames of double the M in a vertical period corresponding to (the Mร2) and a horizontal period corresponding to the M in response to the second control signal.
In this case, a division ratio when the time base converter divides the image signal corresponds to (the M divided by 2).
In order to achieve another aspect of the present invention, a display apparatus, includes: a plurality of processors outputting a plurality of output signals, respectively; a plurality of frames, wherein each of the plurality of frames has an averaging pattern for averaging characteristic errors of the plurality of processors and has a plurality of lines; a scanning unit performing a first scanning on a predetermined frame of the plurality of frames such that a predetermined line of the plurality of lines of the predetermined frame is not scanned, and performing a second scanning on a specific frame of the plurality of frames such that a line corresponding to the predetermined line of the specific frame is scanned, the specific frame having a same averaging pattern as the averaging pattern of the predetermined frame.
In this case, the scanning unit performs a third scanning on the predetermined frame such that all lines of the predetermined frame are scanned, and performs a forth scanning on the specific frame such that all lines of the specific frame are scanned, and performs one of first and second groups selectively, the first group including the first and second scannings and the second group including the third and fourth scannings.
Also in this case, the scanning unit performs the first group when each of the plurality of frames is displayed to be enlarged such that a single line of the plurality of lines is displayed as the lines of two, and performs the second group when each of the plurality of frames is displayed not to be enlarged.
Further in this case, when the scanning unit performs the first scanning, the scanning unit scans an odd-numbered line of the predetermined frame without scanning an even-numbered line as the predetermined line of the predetermined frame and when the scanning unit performs the second scanning, the scanning unit scans an even-numbered line as the line of the specific frame without scanning an odd-numbered line of the specific frame.
In order to achieve still another aspect of the present invention, a display apparatus, includes: a plurality of processors of M (M is a positive integer) outputting a plurality of output signals of the M, respectively; a frame generating unit generating a plurality of frames, wherein each of the plurality of frames is formed to be a matrix with a plurality of lines of the M rows and a plurality of pixels of the M columns, and wherein the plurality of output signals of the M are inputted to the plurality of pixels of the M columns on a specific line of the plurality of lines of the M rows, respectively, and are inputted to the plurality of pixels of the M of a specific column of the M columns on the plurality of lines of the M rows, respectively, to generate an averaging pattern in the each frame; and a scanning unit performing a scanning on a predetermined frame of the plurality of frames such that a predetermined line of the plurality of lines of the predetermined frame is not scanned, and performing a scanning on a specific frame of the plurality of frames such that a line corresponding to the predetermined line of the specific frame is scanned, the specific frame having a same averaging pattern as the averaging pattern of the predetermined frame.
In this case, a display apparatus further includes: a time base converter time-converting an image signal to generate a plurality of converted signals of the M, and wherein the plurality of processors of the M input the plurality of converted signals of the M to output the plurality of output signals of the M, respectively.
Also in this case, each of the plurality of frames is displayed to be enlarged such that a single line of the plurality of lines of the M rows is displayed as the lines of two.
Further in this case, the frame generating unit generates the plurality of frames of double the M which have a plurality of the averaging patterns of the M type.
In this case, when the pixel of P-th (P is a positive integer) of the plurality of the pixels of the M columns on a predetermined line of the plurality of lines of the M rows inputs the output signal outputted from the processor of Q-th (Q is a positive integer) of the plurality of processors of the M, the pixel of (the P+1)-th of the plurality of the pixels of the M columns on the predetermined line inputs the output signal outputted from the processor of (the Q+1)-th of the plurality of processors of the M.
Also in this case, a single cycle of averaging characteristic errors of the plurality of processors of the M consists of the plurality of frames of double the M which have a plurality of the averaging patterns of the M.
In order to achieve yet still another aspect of the present invention, a computer readable recording medium for recording a program for a process, includes: (g) providing a plurality of processors outputting a plurality of output signals, respectively; (h) providing a plurality of frames, wherein each of the plurality of frames has an averaging pattern for averaging characteristic errors of the plurality of processors and has a plurality of lines; (i) performing a first scanning on a predetermined frame of the plurality of frames such that a predetermined line of the plurality of lines of the predetermined frame is not scanned; and (j) performing a second scanning on a specific frame of the plurality of frames such that a line corresponding to the predetermined line of the specific frame is scanned, the specific frame having a same averaging pattern as the averaging pattern of the predetermined frame.
In a liquid crystal display apparatus of the present invention, an input image signal is divided on a time base and then an active matrix type displaying is performed on an image display unit while rearranging the divided image signals in accordance with an averaging format. In the liquid crystal display apparatus, the same averaging format is used in a frame interlaced (jumped over) of an even-numbered line and another frame interlaced (jumped over) of an odd-numbered line, when an interlaced scanning is performed on the image display unit.
That is, as one embodiment to attain the present invention, a liquid crystal display includes: a time base converter for dividing an input image signal on a time base; a plurality of signal processors for respectively performing a signal process on the divided image signal; a switching selector for selecting outputs of the respective signal processors; an image display unit for sequentially receiving the outputs selected by the switching selector and carrying out a display of an active matrix type; and a first switching controller for outputting a control signal to control a selection order of the outputs of the respective signal processors in the switching selector in accordance with a set averaging format, wherein the first switching controller is designed so as to use the same averaging format in a frame jumping over an even-numbered line and a frame jumping over an odd-numbered line, at a time of a interlaced scanning in the image display unit.
Also, the present invention may be designed so as to include: a second switching controller for using he averaging formats which are respectively different between the frame jumping over the even-numbered line and the frame jumping over the odd-numbered line, as the averaging format; and a selecting circuit for selecting the respective control signals from the first switching controller and the second switching controller, wherein it may be designed so as to select the control signal from the second switching controller if the interlaced scanning is not done in the image display unit.
Moreover, in the present invention, a displaying method is provided that in a liquid crystal display, which divides an input image signal on a time base and then carries out a display of an active matrix type on an image display unit while rearranging the divided image signals in accordance with an averaging format, uses the same averaging format in a frame jumping over an even-numbered line and a frame jumping over an odd-numbered line, at a time of a interlaced scanning in the image display unit.
According to the present invention, in an active matrix type liquid crystal display, when a interlaced scanning is done to display an image signal by jumping over a horizontal display line every other line, such as an enlarged display and the like, the same averaging format is used in a frame jumping over an even-numbered line and a frame jumping over an odd-numbered line.
Thus, an averaging pattern when a data on a horizontal line is jumped over is used when a different horizontal line is jumped over in another frame, which enables the perfectly averaging operation. Hence, even if the interlaced scanning is done, the noise in the form of lattice can be surely protected.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the teachings of the present invention may be acquired by referring to the accompanying figures, in which like reference numbers indicate like features and wherein:
FIG. 1 is a block diagram showing an example of conventional liquid crystal display apparatus;
FIG. 2A is a view showing an averaging pattern obtained by a conventional switching controller;
FIG. 2B is a view showing another averaging pattern obtained by the conventional switching controller;
FIG. 2C is a view showing still another averaging pattern obtained by the conventional switching controller;
FIG. 2D is a view showing still another averaging pattern obtained by the conventional switching controller;
FIG. 2E is a view showing still another averaging pattern obtained by the conventional switching controller;
FIG. 2F is a view showing still another averaging pattern obtained by the conventional switching controller;
FIG. 2G is a view showing still another averaging pattern obtained by the conventional switching controller;
FIG. 2H is a view showing still another averaging pattern obtained by the conventional switching controller;
FIG. 3A is a view showing a display image using the averaging pattern of FIG. 2A;
FIG. 3B is a view showing a display image using the averaging pattern of FIG. 2B;
FIG. 3C is a view showing a display image using the averaging pattern of FIG. 2C;
FIG. 3D is a view showing a display image using the averaging pattern of FIG. 2D;
FIG. 3E is a view showing a display image using the averaging pattern of FIG. 2E;
FIG. 3F is a view showing a display image using the averaging pattern of FIG. 2F;
FIG. 3G is a view showing a display image using the averaging pattern of FIG. 2G;
FIG. 3H is a view showing a display image using the averaging pattern of FIG. 2H;
FIG. 4A is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3A;
FIG. 4B is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3B;
FIG. 4C is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3C;
FIG. 4D is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3D;
FIG. 4E is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3E;
FIG. 4F is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3F;
FIG. 4G is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3G;
FIG. 4H is a view showing a display image when a 1.6-times enlarged displaying is performed on FIG. 3H;
FIG. 5A is a view showing display image when a interlaced scanning is performed on FIG. 4A;
FIG. 5B is a view showing display image when a interlaced scanning is performed on FIG. 4B;
FIG. 5C is a view showing display image when a interlaced scanning is performed on FIG. 4C;
FIG. 5D is a view showing display image when a interlaced scanning is performed on FIG. 4D;
FIG. 5E is a view showing display image when a interlaced scanning is performed on FIG. 4E;
FIG. 5F is a view showing display image when a interlaced scanning is performed on FIG. 4F;
FIG. 5G is a view showing display image when a interlaced scanning is performed on FIG. 4G;
FIG. 5H is a view showing display image when a interlaced scanning is performed on FIG. 4H;
FIG. 6 is a view showing a state that a particular image signal is displayed on an image display unit, in the conventional technique;
FIG. 7 is a block diagram showing a first embodiment of the present invention;
FIG. 8A is a view showing an averaging pattern obtained by the switching controller of the present invention;
FIG. 8B is a view showing another averaging pattern obtained by the switching controller of the present invention;
FIG. 8C is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8D is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8E is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8F is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8G is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8H is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8I is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8J is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8K is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8L is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8M is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8N is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8O is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 8P is a view showing still another averaging pattern obtained by the switching controller of the present invention;
FIG. 9A is a view showing a display image using the averaging pattern of FIG. 8A;
FIG. 9B is a view showing a display image using the averaging pattern of FIG. 8B;
FIG. 9C is a view showing a display image using the averaging pattern of FIG. 8C;
FIG. 9D is a view showing a display image using the averaging pattern of FIG. 8D;
FIG. 9E is a view showing a display image using the averaging pattern of FIG. 8E;
FIG. 9F is a view showing a display image using the averaging pattern of FIG. 8F;
FIG. 9G is a view showing a display image using the averaging pattern of FIG. 8G;
FIG. 9H is a view showing a display image using the averaging pattern of FIG. 8H;
FIG. 9I is a view showing a display image using the averaging pattern of FIG. 8I;
FIG. 9J is a view showing a display image using the averaging pattern of FIG. 8J;
FIG. 9K is a view showing a display image using the averaging pattern of FIG. 8K;
FIG. 9L is a view showing a display image using the averaging pattern of FIG. 8L;
FIG. 9M is a view showing a display image using the averaging pattern of FIG. 8M;
FIG. 9N is a view showing a display image using the averaging pattern of FIG. 8N;
FIG. 9O is a view showing a display image using the averaging pattern of FIG. 8O;
FIG. 9P is a view showing a display image using the averaging pattern of FIG. 8P;
FIG. 10A is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9A;
FIG. 10B is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9B;
FIG. 10C is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9C;
FIG. 10D is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9D;
FIG. 10E is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9E;
FIG. 10F is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9F;
FIG. 10G is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9G;
FIG. 10H is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9H;
FIG. 10I is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9I;
FIG. 10J is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9J;
FIG. 10K is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9K;
FIG. 10L is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9L;
FIG. 10M is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9M;
FIG. 10N is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9N;
FIG. 10O is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9O;
FIG. 10P is a view showing display image when the 1.6-times enlarged displaying is performed on FIG. 9P;
FIG. 11A is a view showing display image when the interlaced scanning is performed on FIG. 10A;
FIG. 11B is a view showing display image when the interlaced scanning is performed on FIG. 10B;
FIG. 11C is a view showing display image when the interlaced scanning is performed on FIG. 10C;
FIG. 11D is a view showing display image when the interlaced scanning is performed on FIG. 10D;
FIG. 11E is a view showing display image when the interlaced scanning is performed on FIG. 10E;
FIG. 11F is a view showing display image when the interlaced scanning is performed on FIG. 10F;
FIG. 11G is a view showing display image when the interlaced scanning is performed on FIG. 10G;
FIG. 11H is a view showing display image when the interlaced scanning is performed on FIG. 10H;
FIG. 11I is a view showing display image when the interlaced scanning is performed on FIG. 10I;
FIG. 11J is a view showing display image when the interlaced scanning is performed on FIG. 10J;
FIG. 11K is a view showing display image when the interlaced scanning is performed on FIG. 10K;
FIG. 11L is a view showing display image when the interlaced scanning is performed on FIG. 10L;
FIG. 11M is a view showing display image when the interlaced scanning is performed on FIG. 10M;
FIG. 11N is a view showing display image when the interlaced scanning is performed on FIG. 10N;
FIG. 11O is a view showing display image when the interlaced scanning is performed on FIG. 10O;
FIG. 11P is a view showing display image when the interlaced scanning is performed on FIG. 10P;
FIG. 12 is a view showing a state that a particular image signal is displayed on an image display unit in the present invention; and
FIG. 13 is a block diagram showing a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below with reference to the attached drawings.
FIG. 7 is a block diagram showing a first embodiment of an active matrix type liquid crystal display apparatus of the present invention. Here, it is shown as a liquid crystal display apparatus used as an image display unit of a personal computer and the like. In addition, the same symbols are given to those equivalent to the conventional configuration shown in FIG. 1 .
An input image signal Sin is provided with analog R, G and B signals, and is inputted to a time base converter 101 . The input image signal Sin may be any of an interlace signal and a progressive signal. The time base converter 101 samples the successively supplied input image signal Sin through a sampling and holding circuit, and then divides the data into n sections in parallel to drop the frequency.
As the input image signal Sin becomes high accurate, an operation frequency of a sampling and holding circuit in an image display driver 104 becomes higher associated with the higher accuracy. Thus, it is difficult to attain a function of the image display driver 104 . As shown in FIG. 7, inner operations of the image display driver 104 can be performed in parallel by providing n input terminals for the image display driver 104 , in order to drop the operation frequency. The time base converter 101 performs a 2n paralleling process on the input image signal Sin. So, the signals obtained by the 2n-paralleling process are processed in parallel to each other by 2n signal processors 1 to 2n to drop the operational frequency.
Here, a position at which the time base converter 101 starts sampling the input image signal Sin can be arbitrarily determined in accordance with an SP control signal Ssp 2 inputted to the time base converter 101 from a switching controller 102 . In short, a data processed by the sampling and holding circuit different for each frame is supplied to a particular pixel. This is an averaging principle.
Here, in the switching controller 102 , its averaging period is not different from the 2n vertical period and the 2n horizontal period of the conventional switching controller 106 . Then, its vertical period is set at a 2nร2 vertical period equal to two times the conventional vertical period, and its horizontal period is set at the 2n horizontal period. The vertical period corresponds to two times the 2n of the number of signal processors 1 to 2n. The horizontal period corresponds to the 2n of the number of signal processors 1 to 2n.
The time base converter 101 performs a parallel time base conversion on the input image signal Sin to generate conversion image signals SC 1 to SC2n. The number of conversion image signals SC 1 to SC2n is equal to two times the division ratio n. The time base converter 101 is connected to 2n signal processors 1 to 2n which are connected parallel to each other. The time base converter 101 outputs the conversion image signals SC 1 to SC2n to the signal processors 1 to 2n, respectively.
The signal processors 1 to 2n perform a signal process, such as a ฮณ conversion, a data inversion and the like, on the conversion image signals SC 1 to SC2n, respectively, to thereby generate processed image signals SP 1 to SP2n. The signal processors 1 to 2n are connected to a switching selector 103 .
The switching selector 103 , in response to a selector signal Ssell outputted from the switching controller 102 , selects half n signals from the image signals (the processed image signals SP 1 to SP2n ) corresponding to 2n dots stored in the signal processors 1 to 2n. This is because the switching selector 103 samples the processed image signals corresponding to the latter n dots while the switching selector 103 outputs the processed image signals corresponding to the former n dots as image signals S 1 to Sn.
The switching selector 103 outputs the image signals S 1 to Sn divided into the n sections, from n output sections SO 1 to SOn. The image signal S 1 is outputted from the first output section SO 1 of the switching selector 103 , the image signal S 2 is outputted from the second output section SO 2 , and the image signal Sn is outputted from the n-th output section SOn.
The processed image signal processed by which number of signal processor among the signal processors 1 to 2n to be outputted as the image signal S 1 from the first output section SO 1 can be selected as desired. At this time, the processed image signals outputted as the image signals S 2 , S 3 to Sn from the second, third to n-th output sections SO 2 , SO 3 to SOn following the first output section SO 1 are selected such that they are arranged in order with respect to the processed image signal outputted as the image signal S 1 from the first output section SO 1 .
For example, the number of signal processors 1 to 2n is defined as 8 (n=4). Here, it is assumed that the processed image signal SP 3 outputted from the third signal processor 3 is outputted as the image signal S 1 from the first output section SO 1 of the switching selector 103 . In this case, the processed image signals SP 3 , SP 4 , SP 5 and SP 6 outputted from the signal processors 3 , 4 , 5 and 6 in the former period are outputted as the image signals S 1 to S 4 , from the first to fourth output sections SO 1 to SO 4 . Also in the latter period, the processed image signals SP 7 , SP 8 , SP 1 and SP 2 outputted from the signal processors 7 , 8 , 1 and 2 are outputted as the image signals S 1 to S 4 , from the first to fourth output sections SO 1 to SO 4 .
The image signals S 1 to Sn outputted from the output sections SO 1 to SOn of the switching selector 103 are supplied to the image display driver 104 . The image display driver 104 is provided with a plurality of blocks arrayed along an image display unit 105 composed of a liquid crystal panel and the like. The image display driver 104 outputs the image signals to the image display unit 105 , each time it samples the image signals S 1 to Sn divided into the n sections by the switching selector 103 by using an n-division clock signal, or after it completes sampling the image signals in one horizontal period.
The image signals S 1 to Sn outputted from the switching selector 103 are inputted to one terminal of the plurality of blocks of the image display driver 104 , and sequentially shifted to another block. Then, the image display driver 104 samples a pixel data of each block at a predetermined frequency.
The operation of the liquid crystal display apparatus shown in FIG. 7 will be described below with reference to FIGS. 8A to 12 .
FIGS. 8A to 8 P show averaging patterns generated by the switching controller 102 if the number of signal processors 1 to 2n is 8 (n=4), namely, formats 1 to 8 . One table described in each of FIGS. 8A to 8 P shows an averaging pattern in one frame. The each of formats 1 to 8 in FIGS. 8A to 8 P corresponds to the formats 1 to 8 in FIGS. 2A to 2 H, respectively. A horizontal axis indicates an order in a horizontal direction, and a vertical axis indicates an order in a vertical direction. Numerals in the respective tables denote the numbers corresponding to the processed image signals SP 1 to SP 8 outputted from the selected signal processors 1 to 8 . A slant line portion indicates that the processed image signal SP 1 outputted from the first signal processor 1 is selected.
Each of FIGS. 9A to 9 P shows a display image when the averaging pattern of each of FIGS. 8A to 8 P is used. Numerals in respective tables indicate that the image data (processed image signals) SP 1 to SP 8 processed by the signal processors 1 to 8 corresponding to its number are displayed. A slant line portion indicates a position on the display screen of the image display unit 105 of the processed image signal SP 1 processed by the first signal processor 1 . A horizontal axis indicates a pixel which is a set of respective dots of R, G and B of the image display unit 105 , and a vertical axis indicates a horizontal line.
A first frame (a format 1 ) of FIG. 9A is exemplified and described. In the first pixel on the first horizontal line, the processed image signal SP 1 processed by the first signal processor 1 is indicated as a number [1]. Hereafter, in order from the second pixel to the eighth pixel, the processed image signals SP 2 to SP 8 processed by the second to eighth signal processors 2 to 8 are indicated as respective numbers [2, 3, 4, 5, 6, 7 and 8].
Similarly, in the first pixel on the second horizontal line, the processed image signal SP 3 processed by the third signal processor 3 is indicated as a number [3]. After the first pixel on the second horizontal line, the processed image signals SP 4 , SP 5 , SP 6 , SP 7 , SP 8 , SP 1 and SP 2 are sequentially indicated as numbers [4, 5, 6, 7, 8, 1 and 2]. This case implies that the processed image signal SP 1 processed by the first signal processor 1 is indicated in the seventh pixel on the second horizontal line. The procedure after that is same. Thus, its description is omitted.
Here, in the successive eight horizontal lines, it is selected such that the same image data (for example, the processed image signal SP 1 ) is not displayed in a particular pixel (for example, the first pixel). This selecting method is performed on one frame (the successive eight horizontal lines). Thus, in order to uniformly locate the image signals (the processed image signals SP 1 to SP 8 ) processed by the 8 signal processors 1 to 8 in all eight pixels on all the eight horizontal lines, 8 frames are needed.
In this embodiment, the switching controller 102 is set at the 2nร2 vertical period and the 2n horizontal period. Thus, as shown in FIGS. 8A to 9 P, it is designed such that the same averaging pattern is used in an odd-numbered frame and an even-numbered frame which are adjacent to each other. As shown in FIGS. 8 and 9, one round or cycle of the averaging operation is completed in 16 frames.
Each of FIGS. 10A to 10 P shows a display image when a 1.6-times enlarged displaying is performed in the averaging pattern of each of FIGS. 9A to 9 P. The 1.6-times enlarged displaying is attained by using the following method. From image data of five lines, each of image data of three lines is displayed as two lines. In each of FIGS. 10A to 10 P, from five lines A to E in each of FIGS. 8A to 8 P, each of the lines A, B and D is displayed with two lines to thereby carry out the enlarged displaying.
If such enlarged displaying is done, data of one line is enlarged as the two lines. Thus, in the enlarged portion, the averaging pattern is similarly enlarged. Also, in this case, the data is written to the image display unit 105 , two times in one horizontal period. Thus, a write time is equal to half the normal time. So, in order to reserve the write time corresponding to the one horizontal period similarly to the normal case, an interlaced scanning is performed on the enlarged result of each of FIGS. 10A to 10 P, as shown in each of FIGS. 11A to 11 P. A half-tone dot meshing portion indicates a line jumped over in each frame. Even-numbered lines are jumped over in each of the odd-numbered frames, and odd-numbered lines are jumped over in each of even-numbered frames.
As mentioned above, when the 1.6-times enlarged displaying is done in the image display unit 105 , the interlaced scanning is carried out for making the write time equal to the normal case that the 1.6-times enlarged displaying is not done.
Next, FIG. 12 is explained. The processed image signal SP 1 ([1]) processed by the first signal processor S 1 is extracted from the remaining portion that is not jumped over in each of 8 formats in FIGS. 11 A to 11 P. The FIG. 12 shows the state that in this case, the portions [1] included in the 8 formats are overwritten. As shown in FIG. 12, it is understood that the processed image signal Sp 1 processed by the first signal processor 1 is embedded in all pixels in the image display unit 105 . This is similar even in a case of taking notice of the other signal processors 2 to 8 .
In this way, when the interlaced scanning is performed, a certain line jumped over in a frame having an averaging pattern is not jumped over in another frame having the same averaging pattern. Accordingly, it is possible to perfectly average the characteristic errors of the signal processors in all pixels on one screen. Also, it is possible to obtain the display quality in which a mark pattern having a particular regularity is not displayed.
It will be described below with reference to the first frame in FIG. 11 A and the second frame in FIG. 11 B. In the first frame in FIG. 11 A and the second frame in FIG. 11B, the same averaging pattern described as format 1 is used. The image signal SP 1 processed by the first signal processor 1 and inputted to the portions of the first pixel on the second line, the seventh pixel on the fourth line, the sixth pixel on the sixth line, the second pixel on the eighth line, the eighth pixel on the tenth line, and the third pixel on the twelfth line, of the first frame is jumped over not to be displayed on the screen as the result of the interlaced scanning. The above-mentioned portions jumped over in the first frame are displayed by using the second frame having the same averaging pattern as the first frame. The portions jumped over in the second frame are already displayed in the first frame. This is also similar in the third and fourth frames, the fifth and sixth frames, . . . , and the fifteenth and sixteenth frames.
FIG. 13 is a block diagram showing a second embodiment of the present invention. In this embodiment, its basic configuration is similar to that of the first embodiment. However, its switching control system is further thought out.
As shown in FIG. 13, the second embodiment includes a first switching controller 102 , a second switching controller 106 , a display mode judging circuit 107 and a switching control signal selecting circuit 108 .
In the first switching controller 102 , it is set at the 2n horizontal period in the 2nร2 vertical period. The first switching controller 102 is used when the interlaced scanning is done. The second switching controller 106 generates a control signal when the interlaced scanning is not carried out. It is set at the 2n horizontal period in the 2n vertical period.
The display mode judging circuit 107 outputs a judgment output signal Sm indicative of a display mode to the switching control signal selecting circuit 108 . The switching control signal selecting circuit 108 selects one of selector signals Ssel 1 , Ssel 2 and one of SP control signals Ssp 1 , Ssp 2 respectively outputted from the first and second switching controllers 102 , 106 , in accordance with the judgment output signal Sm. The selected SP control signal is inputted to the time base converter 101 as the SP control signal Ssp. The selected selector signal is inputted to the switching selector 103 as the selector signal Ssel to select the its switching period. Since the configurations and the operations of the other sections are similar, their explanations are omitted here.
In the second embodiment, the control signal Ssp 1 and the selector signal Ssel 1 of the 2n horizontal period in the 2nร2 vertical period of the first switching controller 102 are selected by the display mode judging circuit 107 and the switching control signal selecting circuit 108 , if the interlaced scanning is done, for example, when the enlarged displaying is performed. This selection can attain the display quality similar to that of the first embodiment.
If the interlaced scanning is not done, the control signal Ssp 2 and the selector signal Ssel 2 of the 2n horizontal period in the 2n vertical period of the second switching controller 106 are selected by the display mode judging circuit 107 and the switching control signal selecting circuit 108 , if the interlaced scanning is not done. This selection can maintain the display quality similar to that of FIG. 1 .
In the explanation of the operation in this embodiment, the case of the eight signal processors is described, namely, the case of n=4 is described. However, of course, n is not limited to this value. Also, of course, the enlargement magnification is not limited to the 1.6-times. Moreover, the input image signal in the present invention may be any of the interlace signal and the progressive signal. So, it may be applied to any signal.
As mentioned above, according to the present invention, in the active matrix type liquid crystal display apparatus, when the interlaced scanning is done to display the image signal by jumping over the horizontal display line every other line, for the enlarged displaying and the like, the same averaging format is used as each of the frame in which the even-numbered lines are jumped over and the frame in which the odd-numbered lines are jumped over. In short, the averaging pattern in which the horizontal lines are jumped over is used for another frame when the different horizontal lines are jumped over, which enables the perfectly averaging operation. Hence, even if the interlaced scanning is done, it is possible to obtain the display quality in which the pattern having the particular regularity, such as the noise in the form of lattice is not displayed.
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A method of driving a display apparatus, includes (a) providing a plurality of processors outputting a plurality of output signals, respectively; (b) providing a plurality of frames, wherein each of the plurality of frames has an averaging pattern for averaging characteristic errors of the plurality of processors and has a plurality of lines; (c) performing a first scanning on a predetermined frame of the plurality of frames such that a predetermined line of the plurality of lines of the predetermined frame is not scanned; and (d) performing a second scanning on a specific frame of the plurality of frames such that a line corresponding to the predetermined line of the specific frame is scanned, the specific frame having a same averaging pattern as the averaging pattern of the predetermined frame.
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BACKGROUND
The present invention relates to spiral coils that can be interlaced to create fabrics or seams for use in the papermaking industry. It further relates to a method for extruding and cutting tubes to produce the coils.
It has been recognized in the prior art that spiral coils can be used to create all or part of a papermaking fabric. The most common spiral coils are made from extruded monofilaments that are thermally treated and wrapped about a mandrel for shaping into a helical form. The resultant coils and fabrics are sensitive to fluctuations in ambient temperature and moisture which leads to their destabilization in use. This tendency to destabilize is believed to be attributable to orientation of the polymer molecules in the monofilament along the longitudinal axis established during the monofilament extrusion process. Conventional prior art methods generally require a coiling process that limits them to certain materials. In addition, the coiled materials generally require further heat setting to achieve a flat or planer coil array. These conditions generally limit the coiling method to round or oval monofilaments which have lower surface contact areas.
SUMMARY
The invention is directed to an apparatus or the creation of a spiral coil by extruding a hollow tube and cutting the tube in a fixed plane relative to the tube. Additionally, the invention is directed to a fabric made from such spiral coils.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an apparatus for converting an extruded hollow tube into a spiral coil.
FIG. 2 is a cross-section taken along line 2 โ 2 in FIG. 1 .
FIG. 3 is a perspective view of the apparatus of FIG. 1 with a portion of the cutter housing being partially broken away.
FIG. 4 is a cross-section taken along line 4 โ 4 in FIG. 3 .
FIG. 5 illustrates a cutting tool used in the apparatus of FIG. 1 .
FIG. 6 illustrates a cutting edge profile for the cutting tool of FIG. 5 .
FIG. 7 illustrates a cutting edge with coil smoothing means.
FIG. 8 is a top plan view of a fabric fragment having intermeshed spiral coils.
FIG. 9 is a cross-section taken along line 9 - 9 in FIG. 8 .
FIG. 10 is a cross-section similar to FIG. 2 of a second embodiment of an apparatus for converting an extruded hollow tube into a hollow coil.
FIG. 11 is an elevational view, partially broken away, of a third embodiment of an apparatus for converting an extruded hollow tube into a hollow coil.
FIG. 12 is a cross-section taken along line 12 - 12 in FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described with reference to the drawing figures wherein like numerals indicate like elements throughout.
In FIG. 1, a hollow tube 2 is shown having a wall 3 of a desired thickness that surrounds and defines a tube interior 5 . The tube interior 5 is dimensioned to provide an approximately desired space between end curves 9 of a desired coil 10 . Preferably, the tube 2 is extruded from an extruder 4 and is moved at a constant speed through the path of a cutting device 6 , located in an opening 11 in a housing 7 . Mounted within the housing 7 is a cutting tool 8 with a cutting edge 14 . The tool 8 moves in a fixed plane that is perpendicular to the direction of travel of the tube 2 . The tool 8 repeatedly navigates a path normal to the tube wall 3 . The movement of the tube 2 through the perpendicular fixed plane and the movement of the cutting edge 14 in the plane are coordinated so that a uniform spiral coil 10 is cut from the tube 2 .
FIGS. 1 and 2 illustrate a first preferred embodiment of the cutting device 6 . The housing 7 supports the cutting tool 8 that creates the coil 10 from tube 2 . A groove 16 is located in housing 7 and receives a drive belt 17 , as shown in FIG. 2 . As shown in FIG. 3, a chamber 19 is located adjacent the groove 16 , and receives a means for driving the belt 17 , such as a drive gear which engages and advances the belt. The cutting tool 8 preferably passes through a slot 18 that extends inwardly from the groove 16 and is advanced by the drive belt 17 as it moves within the groove 16 . The slot 18 is dimensioned to allow passage of the tool 8 through the groove 16 while stabilizing the cutting edge 14 against vibration and other mechanical deflections. This is illustrated in FIG. 4 . The belt 17 may be driven by an electric motor or pneumatic or fluid means, not shown, such as will be known to those skilled in the art.
Referring now to FIG. 5, a preferred cutting edge 14 on the tool 8 is shown in detail. The cutting edge 14 on the tool 8 is preferably formed by a notch 20 , having an angled base 22 with a sharp edge 24 . Preferably, the notch 20 is sized to receive the wall 3 of the tube 2 , with the thickness of the wall 3 being approximately equal to or less than the opening of the notch 20 . In a preferred embodiment, the opening of the notch 20 is chamfered to provide a lead-in surface for receiving the wall 3 of the tube 2 .
Referring now to FIGS. 6 and 7, an alternate embodiment of the tool 8 โฒ is shown. The alternate embodiment of the tool 8 โฒ includes smoothing bars 26 and 28 located generally behind the cutting edge 14 in the cutting direction. The smoothing bars 26 , 28 hold the cut portion of the coil 10 , parallel to the tube 2 in the area directly after the cut is formed to smooth the cut edges and to prevent tearing and/or uneven cutting as the cutting edge 14 is carried through the wall 3 of the tube 2 to form the coil 10 . This provides for a more uniform and consistent cut. Preferably the opening D is equal to the all thickness of the coil 10 and is in the range of about 0.3 to 0.7 mm.
Referring now to FIGS. 8 and 9, there is shown a small portion of a fabric 32 that is comprised of a plurality of intermeshed spiral coils 10 in accordance with the present invention which are retained in the intermeshed condition by a plurality of pintles 40 , 42 . As shown in FIG. 9, the major axis M represents the length and the minor axis N represents the caliper or height of the coil 10 . The major axis M is preferably in the range of 5 to 10 mms and the minor axis N is preferably in the range of 2 to 4 mm. The wall thickness D of the coil 10 is preferably in the range of 0.3 to 0.7 mm, and is approximately equal to the opening height D of the notch 20 used to form the cutting edge 14 in the tool 8 . Filler strands may be inserted in the open channels 52 if it is desired to further reduce the permeability of the fabric 32 .
Those skilled in the art will recognize from the present disclosure that the coils 10 can be utilized to form an entire fabric 32 or may be used to form only a portion thereof, such as a seam to connect two ends of a woven fabric together to form an endless belt.
The hollow tube 2 can be made of any extrudable polymer, and in any number of shapes or sizes. Currently, preferred coil shapes are oval with flat top and bottom surfaces. Currently preferred polymers are PET; PA; PPS/PEEK. However, those skilled in the art will recognize from the present disclosure that other suitable materials may be utilized to form the tube 2 , if desired.
Preferably, the material is processed through a single screw extruder at the required melt temperature and extruded through a die head having the desired tube profile. The extrudate is then fed directly to the cutting device 6 to form the coil 10 . Preferably, the extrusion process results in either random orientation of molecules in the extruded tube 2 , or, to the extent that the molecule strands are oriented, they are oriented generally in the direction of flow 0 , as shown in FIG. 1 . Because of the cutting and assembling process, the molecules in the final coils 10 and fabric 32 are either randomly oriented or generally oriented perpendicular or transverse to the direction of travel of coil 10 or fabric 32 on a paper making machine. This is similar to what may be found in an injection molded coil.
As shown in FIG. 8, the longitudinal portions of the coil 10 , as indicated by coil portions 36 , are oriented in the machine direction and running generally perpendicular to the extruded molecules flow direction, as indicated by arrow 34 . Similarly, the interconnecting portions, as indicated by 38 , are generally oblique to the extruded molecules' flow. The head curves 9 will have intermediate portions of each. No portion of the coil 10 in the fabric 32 has an extended orientation parallel to the orientation of the original tube 2 .
Since the extruded tubes are not subjected to a post extrusion draw, the coil 10 will not be oriented in the manner of a conventional monofilament. The lower level of orientation results in a generally tougher coil that is more closely likened to an injection molded product. The absence or reduction of directional orientation reduces the thermal and moisture reactivity in the same direction, and to the extent that any orientation of molecules would generally be in the extrusion direction O (shown in FIG. 1 ), this is transverse to the machine direction in the finished fabric or portion of fabric in which the coil 10 is used.
Referring now to FIG. 10, a second embodiment 60 of the cutting device is shown. In the second embodiment of the cutting device 60 , a cutting tool 62 is mounted on a centrally located shaft 64 . Preferably, the cutting tool 62 includes an elongated cutting edge 66 . The cutting tool 62 is rotated by the central shaft 64 to cut the coil 10 from the tube 2 . Preferably, the free end 68 of the cutting tool 62 is constrained to travel within a slot 70 , formed in the housing 72 of the cutting device 60 . The slot 70 is sized to stabilize the cutting tool 62 to prevent vibration or mechanical deflection as the cutting edge 66 cuts the tube 2 to form the coil 10 . Preferably, the feed rate of the tube 2 through the cutting device 60 is coordinated with the rotation speed of the cutting tool 62 in order to form a uniform coil 10 in the same manner as described above in connection with the cutting device 6 in accordance with the first embodiment. The central shaft 64 is preferably rotated via a controllable pneumatic or electric motor.
Referring now to FIGS. 11 and 12, a third embodiment of the cutting device 80 , in accordance with the present invention is shown. The cutting device 80 includes a cutting tool 82 having a cutting edge 83 . The cutting tool 82 is mounted on a ring gear 84 for rotary movement about the tube 2 . The ring gear 84 is supported by a roller bearing 88 mounted on a support 90 . The ring gear 84 is driven via a drive motor 92 , having a drive gear 94 which engages the gear teeth 86 of the ring gear 84 . The speed of the motor 92 is coordinated with the extrusion rate of the tube 2 in order to cut the uniform coil 10 . Preferably, the cutting device 80 is located adjacent to the extruder dye face 96 and the cutting tool 82 is moved along the dye face 96 as the tube 2 is being extruded to form the coil 10 .
Due to the oval shape of the tube 2 , the cutting edges 66 , 83 on the cutting tools 62 , 82 must be elongated since the area of the cutting edge 83 on the cutting tool 82 contacting the tube 2 will vary, depending upon the location of the cutting tool 82 .
Preferably, the motor 92 is a controllable electric or pneumatic motor, such that the speed of the motor can be controlled to a desired rate.
It will be appreciated by those skilled in the art that changes can be made to the preferred embodiments of the cutting device described above, as well as to the shape and size of the coil formed by the cutting tools, without departing from the broad inventive concept of the present invention. The size of the coils and fabrics made therewith can also be altered, as desired. It is understood, therefore, that the invention is not limited to the particular embodiments disclosed, and is intended to cover modifications within the spirit and scope of the present invention.
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An apparatus for the creation of a spiral coil by extruding a hollow tube and cutting the tube in a fixed plane relative to the tube is provided. A fabric made from such spiral coils is also provided.
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This application is a continuation-in-part of pending application Ser. No. 450,493, filed Dec. 16, 1982, now abandoned, which is in turn a continuation of application Ser. No. 192,806, filed Oct. 1, 1980, now abandoned, which is in turn a divisional of application Ser. No. 093,594, filed Nov. 13, 1979, now U.S. Pat. No. 4,287,205, which is in turn a continuation of Ser. No. 917,327, filed June 20, 1978, now abandoned.
RELATED CASES
This application is related to pending application Ser. No. 192,815, of Szent-Gyorgyi and Fodor, filed Oct. 1, 1980, now abandoned, which is in turn a divisional of application Ser. No. 093,594, filed Nov. 13, 1979, now U.S. Pat. No. 4,287,205, which is in turn a continuation of application Ser. No. 917,327, filed June 20, 1978, now abandoned.
This application is also related to application Ser. No. 536,993 of Fodor, filed concurrently herewith, now abandoned, which is in turn a continuation-in-part of application Ser. No. 478,331, filed Mar. 24, 1983, now abandoned, and to application Ser. No. 536,995 of Veltri, filed concurrently herewith, now U.S. Pat. No. 4,518,611, which is in turn a continuation-in-part of application Ser. No. 481,998, filed Apr. 4, 1983, now abandoned, which is in turn a continuation-in-part of application Ser. No. 449,584, filed Dec. 14, 1982, now abandoned.
U.S. Pat. No. 4,287,205 discloses subject matter related to the present invention, particularly in that starting reactants are overlapping. The reaction mechanism and the structure of the resulting compounds are, however, substantially different. The utility of the related, prior invention is closely related to that of the present invention.
It is believed that the present invention is much narrower in scope than the prior invention, and where the prior invention is applicable to a broad variety of enediol reactants, the present invention is limited to reactants where the enediol structure is a part of a 2,3-dihydroxybutenolide. While aldehyde or ketone reactants are defined in the prior patent, the present application is limited to 2,5-dialkoxy-2,5-dihydrofurans, which are the product of a ring closure of certain types of aldehydes and ketones of the prior cases.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 2,927,054 discloses the condensation of certain sugars, e.g., glucose, mannose, fructose, etc., with an aldehyde or ketone to form cyclic acetals of the sugar. The mechanism apparently involves the elimination of water by union of the oxygen of the carbonyl group of the aldehyde or ketone and the hydrogen from each of two hydroxyl groups of the sugar. This condensation reaction proceeds upon heating the mixture to the boiling point of the aldehyde in the presence of an acid acetalization catalyst, conditions favoring the open chain form of the sugar. The two adjacent carbon atoms of the cyclic acetal ring are adjacent carbons of the aliphatic chain of the sugar molecule. Several of such cyclic acetal rings may be formed on the same sugar molecule, forming poly-cyclic acetals.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a process for preparing the novel compounds discussed herein.
Another object of this invention is to perform the reaction of the 2,3-dihydroxybutenolides and 2,5-dialkoxy-2,5-dihydrofurans of the invention in aqueous media.
Still another object of this invention is to provide novel compounds having immunomodulatory activity.
A still further object of the present invention is to provide novel compositions effective in the treatment of immune disorders, and methods for the application of such compositions.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed discussion.
The description of the novel invention described herein includes reference to the following figures:
FIG. 1 presents the X-ray crystal structure of the product of Example 1.
DESCRIPTION OF THE INVENTION
The novel compounds of the instant invention are produced by reacting approximately equal amounts of compound of the general formula ##STR1## wherein: R 1 and R 2 are selected from the group consisting of hydrogen and lower alkyl, provided that at least one is hydrogen;
R 3 and R 4 may be the same or different and are selected from the group consisting of lower alkyl and aryl;
R 5 and R 6 are selected from the group consisting of hydrogen and lower alkyl and may be the same or different
and a compound of the general formula ##STR2## wherein: X is selected from the group consisting of O, S, and NH;
R 7 and R 8 are selected from the group consisting of hydrogen and lower alkyl and may be the same or different;
R 7 may be ##STR3## R 9 is selected from the group consisting of ##STR4## R 10 and R 11 are selected from the group consisting of hydrogen, lower alkyl, phenyl and hydroxyl substituted lower alkyl and may be the same or different,
obtaining the product of the reaction, treating the product with acid anhydride or acid imide, refluxing and crystallizing the novel compounds. Recovery of the pure product may be facilitated by treatment or purification of the intermediate by any of the several techniques known to one of ordinary skill in the art such as, for example, charcoal filtration, ion exchange or gel chromatography.
The novel compounds produced by the above described process include ##STR5## wherein: R 2 is selected from the group consisting of hydrogen and lower alkyl;
R 5 and R 6 are selected from the group consisting of hydrogen and lower alkyl and may be the same or different;
R 7 and R 8 are selected from the group consisting of hydrogen and lower alkyl and may be the same or different;
R 7 may be ##STR6## R 9 is selected from the group consisting of ##STR7## R 10 and R 11 are selected from the group consisting of hydrogen, lower alkyl, phenyl and hydroxyl substituted lower alkyl and may be the same or different;
when R 7 contains a hydroxyl group in the ฮฑ, ฮฒ, or ฮณ position, R 7 may form the hemiketal ring closure at carbon 3 of the butyrolactone with protonation of the carbonyl group on the same carbon atom;
n is selected from the group consisting of 1, 2, and 3; and
X is selected from the group consisting of O, S, and NH.
Lactone ring formation, ##STR8## wherein R 2 , R 5 , R 6 , R 10 , X, and n are as described above can occur. These rings will ordinarily partially rearrange, in aqueous or highly polar media to give tautomeric equilibrium products ##STR9## wherein R 2 , R 5 , R 6 , R 7 , R 8 , R 10 , R 11 , and n are as described above.
The novel compounds can be formulated with generally known pharmaceutical carriers into compositions which can be administered to animals and humans. These compositions show immunomodulatory and cytotoxic activity at very low acute toxicity values.
It is believed that the cytotoxic activity of these compositions may be attributable to stimulation of the immune system by the compounds or to the cytoxicity of the compounds per se or to a combination of both effects.
The compositions may be used in immune therapy of depressed immune systems, as in the case of AIDS (Acquired Immune Disorder Syndrome).
The compositions, when administered to mammalian lymphocytes, have a profound effect on thier ability to reproduce as measured by their ability to synthesize DNA. This effect is bimodal. In higher concentrations, the compositions act as immunosuppressants while in lower concentrations they act as immunostimulants.
This immunomodulatory effect is seen in vitro in human blood lymphocytes and in vivo and in vitro in mouse spleen lymphocytes.
Various immunomodulatory studies have been conducted using these compositions. In these studies, T- and B-lymphocytes are isolated from human blood and mice spleens. Five strains of mice are used as lymphocyte donors, BALB/C, C57BL/6 BDF 1 , SJL/J and DBA/2. The lymphocytes are then treated with plant proteins called lectins which act as mitogens.
Mitogens are substances which stimulate DNA synthesis and mitosis. The mitogens used in these studies were phytohemagglutinin (PHA) which is isolated from the red kidney bean and concanavalin-A (Con-A) which is isolated from the jack bean. Con-A binds to specific receptors (glycoproteins) containing -mannosyl or -glucosyl moieties and stimulates all murine T-cells to synthesize DNA, divide, and release lymphokines. Con-A in a soluble form allows distinction between T- and B-cells in the mouse, because although both T- and B-cells can bind 10 6 molecules of Con-A per cell, only T-cells are stimulated when this lectin is presented in a soluble form. PHA stimulates only subpopulations (T 2 cells) of T- or B-cells. In the mouse, PHA activates a subpopulation of T-cells and does not stimulate B-cells. In humans, both T- and B-cells are probably stimulated. The activation of B-cells may be indirect and mediated by the release of soluble mediators from PHA-activated T-cells.
At doses ranging from 0.001 ฮผg to 100 ฮผg, the compounds of this invention have profound effects on lymphocyte mitogenesis when tested directly in vitro versus human lymphocytes. At lower doses, 0.001 to 1 ฮผg, there is stimulation, above control levels, of PHA or Con-A mediated mitogenesis. At high doses, 10 to 100 ฮผg, there is a profound suppression of the mitogenetic activity of lymphocytes treated with mitogens PHA and Con-A.
In vivo treatment of C57BL/6 mice comprising intraperitoneal (i.p.) administration of varying doses of the compounds for 4-12 days and subsequent testing of spleen lymphocytes with PHA and Con-A reveal a similar pattern to that of the in vitro system at doses of the compounds of 400 and 800 mg/kg versus 50 to 200 mg/kg. The observed suppression, at high doses, or stimulation, at low doses, showed statistically significant differences, with P<0.05.
Other experiments have been done to test the effect of the compounds on the antibody response to specific antigens, bovine serum albumin and keyhole limpet hemocyanin. It is found that high doses of the compounds do not inhibit the secondary immune response to the antigen but instead significantly enhance this response. Such doses, which routinely suppressed the in vivo and in vitro cell mediated response to mitogens did not significantly suppress humoral immunity. These data demonstrate the possibility of regulation of specific antibody production through immunostimulation.
In the experiments described below, the trends observed with high doses or low doses of the compound follow the general pattern noted above. However, differences can be noted in the actual response to the compounds of PHA versus Con-A stimulated lymphocytes. This may be due to the fact that Con-A and PHA do not stimulate the same kinds of lymphocytes. Differences can also be noted in the responses of the various strains of mice. These could reflect genetic variation with respect to response of lymphocytes to mitogens. Differences observed in the in vivo versus in vitro response can be due to differences in in vivo and in vitro metabolism and to the difference between the human and murine lymphocytes.
In all these experiments, it should be noted that control cultures not stimulated with mitogens or specific antigens, and which, therefore, could be considered resting cells, are not affected by the compounds. The dramatic stimulatory or inhibitory effects are only demonstrated in cells with active DNA synthesis, that is those cells undergoing cell division.
Tests were also done to determine the immunomodulatory effects of the compounds on the cytotoxic lymphocyte activity of sensitized lymphocytes obtained from tumor dormant DBA/2 mice. The experimental model involved establishment of the dormant state in DBA/2 mice and then conducting studies to assess the effect of the compounds disclosed in this invention on the tumor dormant state. The animal model described above, mimics a suspected tumor dormant state that is suggested by clinical observations of human recurrent breast tumors and melanomas many years after apparent cure of the primary tumors.
A. LYMPHOCYTE STIMULATION ASSAY PROTOCOLS
The purpose of this assay is to challenge lymphocytes in microcultures with one or more polyclonal mitogens at concentrations that will induce mitogenesis within 72 hours of stimulation.
In the mouse model, spleens are removed from different strains of mice and the spleen cells are teased free and suspended in RPMI-1640 tissue culture medium at a concentration of usually 1ร10 7 ml. These cells are dispensed at a concentration of 5.0ร10 5 cells per microculture well in a 96 well flat bottom 96 well tissue culture plate. All testing of the compounds of this invention or mitogens are done in replicates of 10. The cells are then treated with PHA, Con-A, specific antigens, or buffer only. If in vitro testing is done, varying concentrations of the compounds of this invention or buffer only are added to the cells as well. After treatment with the mitogens and/or compounds of this invention, the cells are incubated for 72 hours. The response of these cells to mitogens and/or the compounds of this invention is assessed using 14 C-thymidine labeling on the fourth day at a concentration of 0.01 ฮผCi/well. The labeled cells are harvested using a lymphocyte harvestor and placed onto fibrous paper discs. A scintillation cocktail is added to vials contaning the discs and the results are obtained using a LKB-liquid scintillation counter (Model 1216/Rackbeta II). The data is expressed as a ratio of the cpm of the mitogen stimulated group to the control (non-mitogen) treated group=lymphocyte stimulation index (LSI).
The lymphocyte stimulation assay may be performed directly on spleen cells obtained from various strains of mice not treated with the compounds of this invention or on lymphocytes obtained from human plasma. In such experiments, the compounds of this invention are added directly to the spleen lymphocytes in vitro and the assay is completed and results interpreted. Alternatively, the mice may be treated in vivo with the compounds of this invention by intraperitoneal multi-dose schedules, followed by sacrifice and harvesting spleen lymphocytes. These cells are then tested for their response to polyclonal mitogens or specific antigens used to immunize the mice. In this sytem however, no additional compound is added to the in vitro lymphocyte stimulation assay system.
B. THE SECONDARY RESPONSE STUDIES
The effect of the compounds of this invention on the immune response to specific antigens involves immunization of mice with specific anitgens such as bovine serum albumin (BSA) or keyhole limpet hemocyanin (KLH). Following immunization, it is possible to assess the cell-mediated or humoral (antibody) immune response to these antigens by various methods:
(1) Lymphocyte stimulation assays can be performed using varying concentrations of the specific antigens as mitogens in the lymphocyte stimulation microculture system described above. The only difference is that the incubation period is extended to five days instead of three as for the polyclonal mitogens.
(2) Antibody response to soluble antigens such as BSA or KLH can be quantitated using a micro-ELISA solid phase heterogeneous immunoassay. The assay can be designed to quantitate class specific immunoglobulins (i.e., IgG or IgM).
Results of the humoral (antibody) response to BSA are obtained using a solid phase heterogeneous sandwich ELISA micromethod in 96 well Immulon microtiter plates. The cut-off for the titer was the highest dilution of mouse serum yielding an O.D.โฆ0.1 when read on the MR-600 Dynatech micro-ELISA reader.
C. MEASUREMENT OF CYTOTOXIC LYMPHOCYTE ACTIVITY--METHOD
A mixed lymphocyte tumor culture (MLTC) immunoassay, used to determine the cytotoxic lymphocyte (CTL) activity employs lymphocytes from either immunized (sensitized) mice or DBA/2 tumor dormant state animals in various stages of the tumor dormant state (TDS). The assay employs L5178Y target cells labeled with 51 Chromium and effector cells (sensitized lymphocytes) from the above-mentioned sources. Effector-target cell ratios will vary with different experimental conditions and may or may not include irradiated stimulator L5178Y cells. Results are expressed as % lysis of target cells based on ratio of cpm of test group over cpm of total release (maximum) both of which are corrected for spontaneous release of 51 Cr. The assay can be performed as an 8 or 18 hour release assay.
In order to induce the tumor dormant state (TDS), a large group of DBA/2 mice is injected subcutaneously with 1ร10 6 viable L5178Y leukemia cells subcutaneously on the midventral side of the abdomen. Ten days later the resultant tumor nodule, about 1 cm in size, is surgically excised. If the excision was successful, no subcutaneous tumors develop at the site of implantation. Seven days postexcision, the mice are challenged with 50,000 viable L5178Y leukemia cells, a dose that routinely produces death due to ascitic tumors in 100% of normal DBA/2 mice within 14 days. Immune mice resisted rapid outgrowth of the challenge L5178Y dose and remained clinically normal for many weeks thereafter. These mice are considered to be in the tumor dormant state.
ANTI-CANCER STUDIES--METHOD
Mice of the BDF 1 strain are given an i.p. inoculation of 10 6 L-1210 leukemia cells on day 0. Twenty-four hours later, groups of 7 mice each are started on a nine day treatment regimen of various doses of the compounds of this invention. The experiment is continued according to the guidelines provided under the National Cancer Institute protocol for screening new anti-cancer agents and T/C ratios (median or mean survival time of treated groups over median or mean survival time of controls) are calculated. A T/C value โง1.25 (or 125%) is considered significant anticancer activity.
EXAMPLE 1
93 g 2-methyl-2,5-dimethoxy-dihydrofuran (N. Clauson-Kaas and F. Lindborg (1947) Acta Chem. Scand. 1: 619. was added under vigorous mechanical stirring to a solution of 75 g L-ascorbic acid in 750 ml water at room temperature. The furan was used in 50% excess. The solution became homogenous within 15-20 minutes. The reaction was monitored by a high pressure liquid chromograph equipped with a UV detector. The original peak of Rf 1.6 of L-ascorbic acid at 254 nm in 20% aqueous methanol disappeared while a new peak appeared at Rf 5.9 to 6.0, under 64 atmospheres. It was simultaneously observed that the solution did not consume any more iodine which is indicative of the total disappearance of L-ascorbic acid.
After standing overnight at 20ยฐ C. the aqueous solution was freeze-dried to give a pale yellow foam. The latter showed well defined IR, 13 C NMR and 1 H NMR spectra.
Next, 64.0 g (0.25M) of the crude product (melting point 55ยฐ C.) and 25.0 g (0.25M) of succinic anhydride were placed into a 1 liter round-bottomed flask equipped with a reflux condenser and a nitrogen inlet tube. After adding 200 ml of HPLC-grade ethyl acetate, the reaction mixture was refluxed for 4 hours. The homogeneous solution was cooled to room temperature and then placed in an ice-water bath. A white precipitate formed which was filtered by suction and washed with a few ml of cold ethyl acetate to give 29.9 g of the crude product (yield 46.6%). The filtrate was concentrated to half volume and cooled in an ice-water bath. The second crop of precipitate was again filtered to give 13.5 g of solid which contained some unreacted succinic anhydride.
The product was recrystallized from a solvent mixture (ethyl acetate/chloroform : 20/80) to give a total yield of 22.5 g (yield 35.2%) of pure product (long white needles--melting point 134ยฐ-134.5ยฐ C.).
Analysis: Calculated for C 26 H 28 O 17 : C, 50.99; H, 4.61; O, 44.41.
Found: C, 50.67; H, 4.52; O, 44.58.
X-ray crystallography, FIG. 1, confirmed the structure of the compound and showed the presence of a 2:1, 2-furylbutyrolactone:succinic anhydride, molecular complex in a unit cell. ##STR10##
EXAMPLE 2
186 g 2-methyl-2,5-dimethoxy-dihydrofuran (N. Clauson-Kaas and F. Lindborg (1947) Acta Chem. Scand. 1: 619. was added under vigorous mechanical stirring to a solution of 150 g L-ascorbic acid in 1.5 L water at room temperature. The furan was used in 50% excess. The solution became homogenous within 15-20 minutes. The reaction was monitored by a high pressure liquid chromograph equipped with a UV detector. The original peak of Rf 1.6 of L-ascorbic acid at 254 nm in 20% aqueous methanol disappeared while a new peak appeared at Rf 5.9 to 6.0, under 64 atmospheres. It was simultaneously observed that the solution did not consume any more iodine which is indicative of the total disappearance of L-ascorbic acid.
After standing overnight at 20ยฐ C. the aqueous solution was freeze-dried to give a pale yellow foam. The latter showed well defined IR, 13 C NMR and 1 H NMR spectra.
Next, 119.65 g (0.467 mole--assuming 100% purity) of the crude product (melting point 55ยฐ C.) were dissolved in 216 ml of HPLC grade ethylacetate. 23.3 g succinimide (0.235 mole) were added and the mixture was stirred under positive nitrogen pressure. After a few minutes of stirring, a white solid precipitated. The reaction mixture was then heated for 30 min. in an oil bath until the solid redissolved. Heating was stopped and the solution was allowed to cool to room temperature while stirring and then in an ice water bath for 2 hours. A precipitate formed which was filtered by suction, washed with 150 ml of cold chloroform and dried under vacuum to give 67.4 g of crude product (56.3% yield).
The product was recrystallized from a solvent mixture (ethyl acetate/chloroform : 60/40) to give a total yield of 52.2 g (yield 43.6%) of pure product (long white needles--melting point 132ยฐ-133ยฐ C.).
Analysis: Calculated for C 26 H 29 NO 16 : C, 51.07; H, 4.78; O, 41.86; N, 2.29.
Found: C, 51.17; H, 4,93; O, 41.81; N, 2.21.
X-ray crystallography, confirmed the structure of the compound and showed the presence of a 2:1, 2-furylbutyrolactone:succinimide molecular complex in a unit cell. ##STR11##
EXAMPLE 3
93 g 2-methyl-2,5-dimethoxy-dihydrofuran (N. Clauson-Kaas and F. Lindborg (1947) Acta Chem. Scand. 1: 619. was added under vigorous mechanical stirring to a solution of 75 g L-ascorbic acid in 750 ml water at room temperature. The furan was used in 50% excess. The solution became homogenous within 15-20 minutes. The reaction was monitored by a high pressure liquid chromograph equipped with a UV detector. The original peak of Rf 1.6 of L-ascorbic acid at 254 nm in 20% aqueous methanol disappeared while a new peak appeared at Rf 5.9 to 6.0, under 64 atmospheres. It was simultaneously observed that the solution did not consume any more iodine which is indicative of the total disappearance of L-ascorbic acid.
After standing overnight at 20ยฐ C. the aqueous solution was freeze-dried to give a pale yellow foam. The latter showed well defined IR, 13 C NMR and 1 H NMR spectra.
Next, 10.24 g (0.04M) of the crude product (melting point 55ยฐ C.) and 2.5 g (0.022M) of N-methylsuccinimide were placed into a 1 liter round-bottomed flask equipped with a reflux condenser and a nitrogen inlet tube. After adding 20 ml of HPLC-grade ethyl acetate, the reaction mixture was refluxed for 4 hours. The homogeneous solution was cooled to room temperature and then placed in an ice-water bath. A white precipitated formed which was filtered by suction and washed with a few ml of cold ethyl acetate to give 5.20 g of the crude point (yield 50.8%). The filtrate was concentrated to half volume and cooled in an ice-water bath.
The product was recrystallized from a solvent mixture (ethyl acetate/chloroform : 1/1) to give a total yield of 3.21 g (yield 31.3%) of pure product (long white needles--melting point 105ยฐ-106.5ยฐ C.).
Analysis: Calculated for C 27 H 31 NO 16 : C, 51.84; H, 5.00; N, 2.24; O, 40.92.
Found: C, 51.98; H, 5.12; N, 2.08; O 40.63.
X-ray crystallography, FIG. 1, confirmed the structure of the compound and showed the presence of a 2:1, 2-furylbutyrolactone:N-methylsuccinimide molecular complex in a unit cell. ##STR12##
EXAMPLE 4
The compound of Example 1 dissolves completely in 0.238 molar bicarbonate buffered saline (0.85%) to form ##STR13## and succinic anhydride.
EXAMPLE 5
The compound of Example 2 dissolves completely in 2.38 mm bicarbonate buffered saline (0.89%) to form ##STR14## and succinimide.
EXAMPLE 6
The compound of Example 3 dissolves completely in 2.38 mm bicarbonate buffered saline (0.85%) to form ##STR15## and N-methylsuccinimide.
EXAMPLE 7
Single dose LD 50 in C57BL/6 mice for Cpd. 1 is determined following the method of Spearman and Karber described in Basic Exercises in Immunochemistry, 1979. Briefly, 0.5 ml of each dose is given to each of ten mice. The survivors are counted after 3 days and the LD 50 is calculated using the following formula: ##EQU1## where D=fold diferences between doses, R=total number dead, and N=total number of animals tested.
TABLE 1______________________________________Results of Cpd. 1 Single I.P. Dose LD.sub.50 DeterminationUsing C57BL/6 Strain of MiceDose of Cpd. 1 Number Dead on Day 3______________________________________272 mg/17 g mouse (16,000 mg/kg) 10136 mg/17 g mouse (8,000 mg/kg) 10 68 mg/17 g mouse (4,000 mg/kg) 7 34 mg/17 g mouse (2,000 mg/kg) 0 17 mg/17 g mouse (1,000 mg/kg) 0______________________________________
Cpd. 1 LD 50 =59.2 mg/17 g mouse=3,480 mg/kg.
Purified Cpd. 1 is tested in C57BL/6 mice by single i.p. injection and gives an LD 50 in excess of 3 g/kg.
EXAMPLE 8
Single oral dose LD 50 in CD-1 mice and CD rats, obtained from Charles River U.K. Ltd., for Cpd. 1 is determined. Briefly, the compound, 5 g/kg, is dissolved in 0.0238M bicarbonate buffer containing 0.85% sodium chloride, pH 6.8, and administered orally using a constant dose volume of 10 ml/kg. Cpd. 1, dissolved in buffer, or just buffer is administered orally and the mice and rats are observed for 14 days after dosing. After 14 days, the animals are sacrified and necropsy is performed to check for gross evidence of toxicity.
No deaths or signs of toxicity are observed during this study, indicating a single oral dose LD 50 for Cpd. 1 in excess of 5 g/kg.
EXAMPLE 9
Two strains of mice, C57BL/6 and BDF 1 are treated for seven days with i.p. administration of either 25, 50, 100, 200, or 400 mg/kg of Cpd. 1 or just buffer. This is followed on the eighth day by a lymphocyte stimulation assay.
TABLE 2-A______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, on C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________400 mg/kg 3.2 20.7 1.0200 mg/kg 21.3 34.0 1.0100 mg/kg 17.7 40.0 1.3 50 mg/kg * 26.0 1.0 0 mg/kg 17.3 16.7 --______________________________________ *No results reported
TABLE 2-B______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, on BDF.sub.1 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Con. PHA Con-A Control*______________________________________400 mg/kg 1.1 0.9 0.9200 mg/kg 7.8 2.9 0.8100 mg/kg 48.7 17.9 0.7 50 mg/kg 52.1 21.6 0.9 25 mg/kg 13.8 4.3 0.8 0 mg/kg 5.5 1.6 --______________________________________ *Buffer, pH 8.05
The high dose of 400 mg/kg shows strong suppression of the PHA response in the C57BL/6 mice as well as BDF 1 mice, a slight suppression of the Con-A response in the BDF 1 mice, and a suppression of the Con-A response in C57BL/6 mice when compared to the 200 mg/kg dose. However, the stimulation of T-lymphocyte proliferation is evident for PHA at doses of 50 and 100 mg/kg in BDF 1 mice and at a dose of 200 mg/kg in C57BL/6 mice. The Con-A response in the BDF 1 strain is significantly increased at doses between 50 and 100 mg/kg of Cpd. 1 and in the C57BL/6 strain, it is increased at doses of 50, 100 and 200 mg/kg.
EXAMPLE 10
A comparison is made of the lymphocyte response to C57BL/6 mice treated 4 days with i.p. administration of either 50, 100, 200, 400 or 800 mg/kg of Cpd. 1, 50, 100, 200, 400 or 800 mg/kg of ascorbic acid (AA), or just buffer. This is followed on the fifth day by a lymphocyte stimulation assay.
TABLE 3-A______________________________________Effect of AA In Vivo, as measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexAA Conc. PHA Con-A Control______________________________________800 mg/kg 12.1 23.9 .50400 mg/kg 14.3 17.8 1.3200 mg/kg 10.0 21.1 1.3100 mg/kg 17.1 19.8 1.8 50 mg/kg 17.1 25.5 .56 0 mg/kg 14.2 17.1 --______________________________________
TABLE 3-B______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________800 mg/kg .408 .612 .31400 mg/kg 4.8 40.0 1.0200 mg/kg 42.8 67.4 1.6100 mg/kg 34.8 80.0 1.6 50 mg/kg * 52.8 1.2 0 mg/kg 33.0 32.6 --______________________________________ *No results reported.
No statistically significant measurable effect of AA was demonstrable with PHA but a single stimulation of proliferation did occur at 50 mg/kg in the Con-A stimulated group.
In spleen cells treated with PHA, doses of 100 and 200 mg/kg of Cpd. 1 tend to stimulate lymphocyte DNA synthesis. Doses ranging from 400 to 800 suppress DNA synthesis of spleen lymphocytes. In spleen cells treated with Con-A, doses ranging from 50 to 200 mg/kg have a significant stimulatory effect and doses ranging from 400 to 800 mg/kg have a significant anti-proliferative effect, particularly the 800 mg/kg dose. These data suggest an immunostimulatory effect of Cpd. 1 at low to median concentrations and an immunosuppressive effect of Cpd. 1 at higher concentrations. Also, the likelihood that ascorbic acid by itself can exert a similar effect to Cpd. 1 is unsupported by these experiments.
EXAMPLE 11
Two strains of mice, C57BL/6 and BALB/c, are treated 4 days with i.p. administration of either 50, 100, 200, or 400 mg/kg of Cpd. 1, or just buffer. This is followed on the fifth day by a lymphocyte stimulation assay.
TABLE 4-A______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________400 mg/kg 14.8 30.9 .61200 mg/kg 25.2 41.1 .93100 mg/kg 17.0 22.3 1.3 50 mg/kg 13.6 20.6 .87 0 mg/kg 7.85 11.4 --______________________________________
TABLE 4-B______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, in BALB/C Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________400 mg/kg 6.71 18.7 .90200 mg/kg 7.65 20.5 .76100 mg/kg 5.24 21.8 1.0 50 mg/kg 6.44 20.5 1.4 0 mg/kg 1.76 9.87 --______________________________________
In spleens treated with PHA and Con-A, doses of 50, 100 and 200 mg/kg tend to stimulate lymphocyte DNA synthesis in both strains of mice. Doses of 400 mg/kg suppress DNA synthesis of spleen cell lymphocytes when compared to the activity at a dose of 200 mg/kg.
EXAMPLE 12
An in vitro lymphocyte stimulation assay is performed directly on normal spleen lymphocytes removed from five normal C57BL/6 mice, using concentrations of Cpd. 1 of 0.001, 0.01, 0.1, 1.0, or 10 ฮผg test well (5ร10 5 cells/well) or just buffer. Following three days of incubation the assay is completed.
TABLE 5-A______________________________________Effect of Cpd. 1 In Vitro, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________10 ฮผg/well .920 2.15 1.91 ฮผg/well 53.8 178 2.6.1 ฮผg/well 83.1 198 3.2.01 ฮผg/well 87.5 198 3.2.001 ฮผg/well 80.4 198 3.80 ฮผg/well 21.9 126 --______________________________________
The results indicate significant stimulation of mitogenesis across a range of doses from 0.001-1.0 ฮผg/well and significant suppression at a dose of 10 ฮผg/well for both PHA and Con-A mitogens. The range of concentration effectiveness in vitro may be the result of exclusion of the influence of the host's metabolic system on drug metabolism.
EXAMPLE 13
Lymphocytes isolated from 5 human volunteers are treated in vitro with PHA and Con-A and either 0.1, 1, 10, 50, or 100 ฮผg/well of Cpd. 1, 0.1, 1, 10, 50, or 100 ฮผg/well of AA, or buffer.
TABLE 6-A______________________________________Effect of AA on the In Vitro LymphocyteStimulation Assay in Humans Lymphocyte Stimulation IndexAA Concentration PHA Con-A______________________________________100 ฮผg/well 34.23 25.1850 ฮผg/well 35.93 23.3110 ฮผg/well 35.10 27.351.0 ฮผg/well 34.69 24.760.1 ฮผg/well 38.29 24.370 ฮผg/well 31.25 25.86______________________________________
TABLE 6-B______________________________________Effect of Cpd. 1 on the In Vitro LymphocyteStimulation Assay in Humans Lymphocyte Stimulation IndexCpd. 1 Concentration PHA Con-A______________________________________100 ฮผg/well 0.544 0.4450 ฮผg/well 0.40 1.3310 ฮผg/well 34.37 23.821.0 ฮผg/well 48.60 32.630.1 ฮผg/well 56.67 38.060 ฮผg/well 39.82 26.62______________________________________
There is no significant proliferative or anti-proliferative effect demonstrated for AA alone. Whereas for Cpd. 1, a high dose anti-proliferative effect, at doses of 100 and 50 ฮผg/ml, is followed by a markedly increased lymphocyte response at very low doses of 1 and 0.1 ฮผg/ml. The same profile of results are exhibited for both PHA and Con-A mitogens.
EXAMPLE 14
C57BL/6 mice were treated with four daily i.p. doses of either 50, 100, 200, or 400 mg/kg of Cpd. 1 or just buffer. On the fifth day a lymphocyte stimulation assay was performed.
TABLE 7______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________400 mg/kg 18.7 26.4 .31200 mg/kg 23.2 26.3 .22100 mg/kg 23.8 25.4 .40 50 mg/kg 17.0 23.0 1.1 0 mg/kg 14.9 19.9 --______________________________________
Stimulation of the response to polyclonal mitogens at doses of Cpd. 1 from 50-400 mg/kg with a maximum response achieved between doses of 100-200 mg/kg for both PHA and Con-A test mitogens was observed. It can also be seen that there was a decrease in the response to PHA at the 400 mg/kg dose when compared to the response at the 200 mg/kg dose. This appears to follow the trend of immunosuppression at high doses.
EXAMPLE 15
The in vivo immunomodulatory effect of Cpd. 1 on C57BL/6 mice was studied.
Mice of the C57BL/6 strain were tested with i.p. administration of either 100, 200, 400 or 600 mg/kg of Cpd. 1 or just buffer. This was followed by removal of spleens and treatment of lymphocytes therein with mitogens PHA and Con-A.
TABLE 8______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, on C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________600 mg/kg 17.6 26.5 1.7400 mg/kg 44.9 42.4 .49200 mg/kg 48.2 36.6 .62100 mg/kg 51.1 43.9 .80 0 mg/kg 13.1 26.7 --______________________________________
Doses ranging from 100 to 400 mg/kg of Cpd. 1 caused significant stimulation of both the Con-A and PHA treated lymphocytes. The high dose, 600 mg/kg, caused less stimulation than the 100 to 400 mg/kg doses and gave levels comparable to controls. There was no evidence of toxicity in the 600 mg/kg treated animals given the five day administration of Cpd. 1.
EXAMPLE 16
An in vitro lymphocyte stimulation assay was performed using spleen lymphocytes from normal C57BL/6 mice. The lymphocytes were treated with either 1, 5, 10, 50, or 100 ฮผg/well of Cpd. 1 or buffer.
TABLE 9______________________________________Effect of Cpd. 1 In Vitro, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________100 ฮผg/well .292 .308 .2050 ฮผg/well .261 3.78 .2010 ฮผg/well 126 194 .665 ฮผg/well 157 162 1.81 ฮผg/well 80.4 123 1.20 ฮผg/well 59.5 122 --______________________________________
Doses of 5 and 10 ฮผg/well caused significant increases in the response to PHA and Con-A while doses of 50 and 100 ฮผg/well caused significant decreases in the lymphocyte response to the mitogens.
EXAMPLE 17
The compound of Example 2, Cpd. 2, was tested in vivo by using C57BL/6 mice and treating them with Cpd. 3 or just buffer for four consecutive days by the i.p. route. On the fifth day a lymphocyte stimulation assay was performed.
TABLE 3-B______________________________________Effect of Cpd. 2 In Vivo, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 2 Conc. PHA Con-A Control______________________________________600 mg/kg 15.8 94.0 1.5400 mg/kg 12.9 109 1.3200 mg/kg 11.3 99.3 .69100 mg/kg 15.4 105 1.5 50 mg/kg 15.5 96.1 .88 0 mg/kg 11.0 75.1 --______________________________________
Cpd. 2 produced only marginal stimulation of Con-A mitogenesis and had no effect on PHA mitogenesis.
EXAMPLE 18
Cpd. 2 was tested using normal spleen lymphocytes from C57BL/6 mice. A lymphocyte stimulation assay was conducted using either 1, 5, 10, 50, or 100 ฮผg/well Cpd. 3 or just buffer.
TABLE 11______________________________________Effect of Cpd. 2 In Vitro, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 2 Conc. PHA Con-A Control______________________________________100 ฮผg/well 3.83 144 .4950 ฮผg/well 45.8 218 .8010 ฮผg/well 38.8 164 1.15 ฮผg/well 29.8 148 1.21 ฮผg/well 25.4 147 .920 ฮผg/well 23.5 175 --______________________________________
In spleen cells treated with PHA, doses of 50 and 100 ฮผg/well of Cpd. 2 tended to stimulate lymphocyte DNA synthesis. The 100 ฮผg/well dose suppressed DNA synthesis of spleen lymphocytes. In spleen cells treated with Con-A, the 200 ฮผg/well dose had a stimulatory effect and the 400 ฮผg/well doses had an anti-proliferative effect.
EXAMPLE 19
Spleen cells from C57BL/6 mice were treated, in vitro, with the crystallizing reagents, succinic acid and succinimide. Since these compounds are spontaneously released from the molecular complex in solution at a molar ratio of 2 moles of Cpds. 1, 2, or 3 per mole of the crystalline reagent, these reagents were treated in the lymphocyte stimulation assay at proper molar concentrations.
TABLE 12-A______________________________________Effect of Succinic Acid In Vitro, as Measuredby the Lymphocyte Stimulation Assay, inC57BL/6 Strain of Mice Lymphocyte Stimulation IndexSuccinic Acid Conc. PHA Con-A Control______________________________________16.6 ฮผg/well 11.5 38.5 1.18.3 ฮผg/well 12.4 35.6 .914.15 ฮผg/well 14.0 42.3 .912.08 ฮผg/well 15.3 51.1 1.01.04 ฮผg/well 15.7 64.6 .940 ฮผg/well 15.9 83.5 --______________________________________
TABLE 12-B______________________________________Effect of Succinimide In Vitro, as Measuredby the Lymphocyte Stimulation Assay,in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexSuccinimide Acid Conc. PHA Con-A Control______________________________________13.92 ฮผg/well 17.1 92.9 1.46.96 ฮผg/well 17.2 71.9 1.13.48 ฮผg/well 18.1 85.1 .981.74 ฮผg/well 17.5 83.4 1.10.87 ฮผg/well 19.5 76.0 .910 ฮผg/well 19.1 100 --______________________________________
The lymphocytes treated with succinic acid showed a decrease in PHA and Con-A mitogenesis with increased succinic acid dosage. The succinimide demonstrated no significant suppressive or enhancing effect on the response of the lymphocytes to either mitogen.
EXAMPLE 20
The compound of example 3, Cpd. 3, was used to treat C57BL/6 spleen lymphocytes in vitro. The lymphocytes were treated with either 1, 5, 10, 50, or 100 ฮผg/well of Cpd. 3 or just buffer and then a lymphocyte stimulation assay was performed.
TABLE 13______________________________________Effect of Cpd. 3 In Vitro, as Measured by the LymphocyteStimulation Assay, in C57BL/6 Strain of Mice Lymphocyte Stimulation IndexCpd. 3 Conc. PHA Con-A Control______________________________________100 ฮผg/well 0.263 2.88 .2550 ฮผg/well 4.08 97.2 .2710 ฮผg/well 24.0 89.6 .475 ฮผg/well 18.5 80.9 .641 ฮผg/well 12.5 73.2 .600 ฮผg/well 12.2 94.6 --______________________________________
The 10 ฮผg/well dose of Cpd. 3 significantly stimulated the response to PHA while the 50 and 100 ฮผg/well doses suppressed the response. The 50 ฮผg/well dose slightly stimulated the response to Con-A and the 100 ฮผg/well dose suppressed the response.
EXAMPLE 21
Three month old mice of the SJL/J strain, which are T-cell deficient, are treated with i.p. administration of 100, 200, or 400 mg/kg of Cpd. 1 or just buffer for four days. This is followed by a lymphocyte stimulation assay.
TABLE 14______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, in SJL/J Strain of Mice Lymphocyte Stimulation IndexCpd. 1 Conc. PHA Con-A Control______________________________________400 mg/kg 2.31 3.30 0.693200 mg/kg 1.79 4.57 0.732100 mg/kg 1.85 5.01 0.573 0 mg/kg 1.11 2.4 --______________________________________
EXAMPLE 22
The SJL/J mice apparently shift to a loss of immune regulation function as they age and the latter is evidenced by a hyperresponsiveness to alloantigens and production of circulating antibodies to nuclear material as well as synthetic double stranded RNA and poly I/C. The continuous erosion of immune competence in the SJL/J mice has been observed to extend from birth to death indicating defects in regulatory T-cell subpopulations (possibly suppressor and/or amplifier cells). Because the dynamics of the T-lymphocyte population changes with age, it must be assumed that age plays a role in affecting the results obtained when treating SJL/J mice with Cpd. 1.
An in vivo lymphocyte stimulation assay was performed on SJL/J mice of different ages, either 2, 5, or 10 months. The mice received i.p. injections of either 100 mg/kg of Cpd. 1 or just buffer.
TABLE 15______________________________________Effect of Cpd. 1 In Vivo, as Measured by the LymphocyteStimulation Assay, in SJL/J Strain of Mice Lymphocyte Stimulation IndexAge of Mice (Months) PHA Con-A Control______________________________________2 0 mg/kg 40.8 103 --100 mg/kg 32.6 167 2.35 0 mg/kg 2.09 19.5 --100 mg/kg 1.16 12.9 1.910 0 mg/kg 3.97 21.9 --100 mg/kg 9.18 14.5 2.1______________________________________
The results obtained from the untreated controls demonstrated the age dependent variation of the PHA and Con-A lymphocyte proliferation responses.
Also, at 2 months of age Cpd. 1 administered at a dose of 100 mg/kg caused a decreased PHA versus increased Con-A response. In contrast, at 5 months of age the SJL/J mice given the dose of Cpd. 1 showed a depressed mitogenesis response to both PHA and Con-A. The ten month old SJL/J mice showed a complete reversal and demonstrated significant stimulation of both the PHA and Con-A mitogenic response upon treatment of mice at the same dose.
EXAMPLE 23
Mice of the C57BL/6 strain are given i.p. injections of either 50, 100, 200 or 400 mg/kg of Cpd. 1 or buffer for twelve days (days 1-12). An antigen, bovine serum albumin (BSA), is administered intraperitoneally with Freund's Complete Adjuvant (FCA) on days 1, 7 and 14. Blood samples are taken for assay of the antibody response on days 0, 5, 13, and 19. Also, on days 13 and 10 a lymphocyte proliferation assay is performed on spleen lymphocytes from these same mice using either the BSA antigen as the specific recall antigen (mitogen) at concentrations of 0.01, 0.1, 0.5 or 1.0 ฮผg/well or just buffer.
TABLE 16-A______________________________________Enhancement of the Secondary Immune Response toBSA by Cpd. 1, as Measured by Micro-ELISA titer Micro-ELISA TiterCpd. 1 Conc. Prebleed Day 5 Day 13 Day 19______________________________________400 mg/kg N/R* N/R 1:80 1:320200 mg/kg N/R N/R 1:80 1:1280100 mg/kg N/R N/R 1:40 1:1280 50 mg/kg N/R N/R 1:40 1:640 0 mg/kg N/R N/R 1:20 1:320______________________________________ *N/R = no response.
TABLE 16-B______________________________________Effect of Cpd. 1 In Vivo on the Secondary Immune Responseto BSA, as Measured by Lymphocyte StimulationAssay, in C57BL/6 Strain of Mice, Day 13 Lymphocyte Stimulation Index BSA (ฮผg/well)Cpd. 1 Conc. 0 0.01 0.1 0.5 1______________________________________400 mg/kg 10.9 13.7 12.8 12.3 13.8200 mg/kg 10.6 14.1 15.8 13.8 14.0100 mg/kg 3.22 9.8 11.9 12.3 10.2 50 mg/kg 16.5 19.9 23.1 22.9 18.2 0 mg/kg -- 14.0 14.6 12.8 13.0______________________________________
TABLE 16-C______________________________________Effect of Cpd. 1 In Vivo on the Secondary Immune Responseto BSA, as Measured by Lymphocyte StimulationAssay, in C57BL/6 Strain of Mice, Day 19 Lymphocyte Stimulation Index BSA (ฮผg/well)Cpd. 1 Conc. 0 0.01 0.1 0.5 1.0______________________________________400 mg/kg 5.0 3.26 2.89 1.94 1.04200 mg/kg 0.42 2.94 2.82 2.56 2.12100 mg/kg 4.1 3.79 2.68 2.03 .26 50 mg/kg .26 2.33 2.27 2.37 2.63 0 mg/kg -- 1.58 1.56 2.07 1.02______________________________________
No antibody response is observed until day 13. On that day, a significant (four-fold) stimulation is observed at Cpd. 1 doses of 200 and 400 mg/kg and only a slight amount of stimulation is observed at doses of 50 and 100 mg/kg of Cpd. 1. A much more dramatic response is observed on day 19. At that time, the antibody responses to BSA are equal at the 0 mg/kg and 400 mg/kg dose of Cpd. 1, and higher than observed on day 13. A slight increase of antibody titer over the control is observed at 50 mg/kg of Cpd. 1 while 100 and 200 mg/kg doses of Cpd. 1 are extremely stimulatory, demonstrating a 16-fold increase over controls.
The second component of Example 23 illustrates the effects of Cpd. 1 on the lymphocyte proliferation of spleen cells to the immunizing antigen (BSA). Only the 50 mg/kg dose shows significant stimulation of DNA synthesis on day 13 compared to controls. This effect has waned by day 19, indicating the importance of sustaining treatment to stimulate the cell-mediated (T-cell) component of the immune response. The above mentioned antibody response is likely to be sustained after cessation of therapy since the half life of IgG (the antibody) in vivo is approximately 5-7 days.
EXAMPLE 24
Mice of the C57BL/6 strain are given i.p. injections of either 50, 100, 200 or 400 mg/kg of Cpd. 1 or buffer for ten days (days 1-10). An antigen, keyhole limpet hemocyanin (KLH), is administered intraperitoneally with Freund's Complete Adjuvant (FCA) on days 1, 7, and 13. Blood samples are taken for assay of the antibody response on days 0, 5, 12, and 17. Spleens are removed, lymphocytes isolated and a lymphocyte stimulation assay with PHA, Con-A or KLH antigen as the mitogens is performed on day 17 of the experiment.
TABLE 17-A______________________________________Enhancement of the Secondary Immune Response to KLHby Cpd. 1, as Measured by Micro-ELISA Titer Micro-ELISA TiterCpd. 1 Conc. Prebleed Day 5 Day 12 Day 17______________________________________400 mg/kg N/R* N/R 1:5120 1:10,240200 mg/kg N/R N/R 1:5120 1:10,240100 mg/kg N/R N/R 1:2560 1:5120 50 mg/kg N/R N/R 1:2560 1:5120 0 mg/kg N/R N/R 1:2560 1:1280______________________________________ *N/R -- no response.
TABLE 17-B______________________________________Effect of Cpd. 1 In Vivo on the Response to KLH, PHA andCon-A as Measured by Lymphocyte Stimulation Assay,in C57BL/6 Strain of Mice, Day 17 Lymphocyte Stimulation IndexCpd. 1 KLH (ฮผg/well)Conc. 1.0 0.5 0.5 0.025 PHA Con-A Control______________________________________400 0.589 0.232 0.667 1.03 2.32 35.5 0.840mg/kg200 7.45 4.26 1.02 3.91 12.4 51.7 1.73mg/kg100 0.898 0.734 0.526 0.401 9.12 15.6 0.961mg/kg 50 0.536 0.415 0.357 0.0386 7.65 19.0 0.976mg/kg 0 0.715 0.614 0.739 1.06 11.0 34.1 --mg/kg______________________________________
No antibody response is observed until day 12, when the 200 and 400 mg/kg treatment groups show significant stimulation (four-fold increases) over the control treatment groups. A similar pattern of difference between the controls and treated groups holds on day 17, seven days after cessation of Cpd. 1 treatment, with the 200 and 400 mg/kg doses showing an eight-fold increase over the untreated antigen-sensitized controls.
The lymphocyte proliferation assay is only performed on day 17, some five days subsequent to completion of the Cpd. 1 treatment protocol. A statistically significant increase in lymphocyte DNA synthesis is seen in the 200 mg/kg treated mice stimulated by Con-A or KLH mitogens. The lymphocyte mitogen response to Con-A (T-cell mitogen) correlated well with a positive response to KLH of the KLH sensitized spleen lymphocytes.
EXAMPLE 25
The effect of Cpd. 1 on cytotoxic lymphocyte (CTL) activity is measured using five DBA/2 mice in the early stage of the TDS, 10 days after challenge with viable L5178Y tumor cells. Six doses of Cpd. 1, 0.001, 0.01, 0.1, 1.0, 10, or 100 ฮผg/ml or just buffer are added in 100 ฮผl volumes to MLTC microculture wells containing washed spleen lymphocytes from the DBA/2 mice, effector, and L5178Y target cells at varying E/T ratios. The MLTC reaction is performed in the presence or absence of irradiated L5178Y stimulator cells.
TABLE 18-A______________________________________Effect of Cpd. 1 on CTL Activity of TDS Spleen Lymphocytesfrom DBA/2 Mice, as Measured by MLTC Assay UsingEffector Cells Co-cultured with Stimulator Cells % Lysis E/T RatioCpd. 1 Conc. 100:1 30:1 10:1______________________________________100 ฮผg/ml 87.3 54.2 21.210 ฮผg/ml 74.3 42.0 15.91.0 ฮผg/ml 71.5 46.0 15.60.1 ฮผg/ml 79.0 51.0 20.20.01 ฮผg/ml 77.1 55.8 20.60.001 ฮผg/ml 71.1 40.2 16.70 ฮผg/ml 55.2 23.0 8.2______________________________________
TABLE 18-B______________________________________Effect of Cpd. 1 on CTL Activity of TDS Spleen Lymphocytesfrom DBA/2 Strain of Mice, as Measured by MLTC AssayUsing Effector Cells Without Stimulator Cells % Lysis E/T RatioCpd. 1 Conc. 100:1 30:1 10:1______________________________________100 ฮผg/ml 42.0 18.7 8.610 ฮผg/ml 36.3 16.8 4.61.0 ฮผg/ml 40.1 20.0 4.60.1 ฮผg/ml 31.6 14.8 3.50.01 ฮผg/ml 26.0 15.7 3.50.001 ฮผg/ml 23.4 12.2 3.90 ฮผg/ml 22.7 11.0 -2.2______________________________________
Cpd. 1 causes a significant increase in CTL activity expressed as % lysis at several concentrations irrespective of the E/T ratio employed or whether or not stimulator cells are present.
This data therefore supports amplification of the specific CTL response of TDS mouse spleen cells sensitized to L5178Y tumor cells in a drug dose dependent manner.
EXAMPLE 26
Five DBA/2 mice in the early stage of the TDS, 10 days after challenge with viable L5178Y tumor cells were used to measure the effect of Cpd. 1 on CTL activity. Two doses of Cpd. 1, 10, or 100 ฮผg/ml, or just buffer were added in 100 ฮผl volumes to the MLTC microculture wells containing washed spleen lymphocytes from the DBA/2 mice, effector and L5178Y target cells at varying E/T ratios. The MLTC reaction was performed in the presence or absence of irradiated L5178Y stimulator cells.
TABLE 19-A______________________________________Effect of Cpd. 1 on CTL Activity of TDS Spleen Lymphocytesfrom DBA/2 Mice, as Measured by MLTC Assay UsingEffector Cells Co-cultured with Stimulator Cells % Lysis E/T RatioCpd. 1 Conc. 50:1 25:1 12.5:1 6.25:1______________________________________100 ฮผg/ml 71.6 79.8 75.7 56.3 10 ฮผg/ml 75.7 72.0 67.1 60.5 0 ฮผg/ml 63.9 61.9 45.0 35.5______________________________________
TABLE 19-B______________________________________Effect of Cpd. 1 on CTL Activity of TDS Spleen Lymphocytesfrom DBA/2 Strain of Mice, as Measured by MLTC AssayUsing Effector Cells Without Stimulator Cells % Lysis E/T RatioCpd. 1 Conc. 50:1 25:1 12.5:1 6.25:1______________________________________100 ฮผg/ml 21.8 16.6 11.1 6.1 10 ฮผg/ml 12.8 8.1 6.9 .7 0 ฮผg/ml -7.5 -3.0 -3.5 -1.3______________________________________
Cpd. 1 caused a significant increase in CTL activity expressed as % lysis, at several concentrations irrespective of the E/T ratio employed or whether or not stimulator cells were present.
EXAMPLE 27
DBA/2 mice in the early stage of TDS, prior to challenge with viable L5178Y tumor cells, were used to measure the effect of Cpd. 2 on CTL activity. Cpd. 2, 0.1, 1.0, 10 or 100 ฮผg/ml, or just buffer was added in 100 ฮผl volumes to MLTC microculture wells containing washed spleen lymphocytes from DBA/2 mice, effector, and L5178Y target cells at varying E/T ratios. The MLTC reaction was performed in the presence or absence of irradiated L5178Y stimulator cells.
TABLE 20-A______________________________________Effect of Cpd. 2 on CTL Activity of Pre-Challenge TDSSpleen Lymphocytes from DBA/2 Mice, as Measuredby MLTC Assay Using Effector CellsCo-cultured with Stimulator Cells % Lysis E/T RatioCpd. 2 Conc. 100:1 50:1 25:1 12.5:1______________________________________100 ฮผg/ml 78.5 73.5 65.0 47.010 ฮผg/ml 73.5 72.5 72.5 58.51 ฮผg/ml 75.5 72.5 69.5 58.00.1 ฮผg/ml 74.5 69.5 64.0 47.50 ฮผg/ml 68.5 67.0 57.0 37.5______________________________________
TABLE 20-B______________________________________Effect of Cpd. 2 on CTL Activity of Pre-ChallengeTDS Spleen Lymphocytes from DBA/2 Mice,as Measured by MLTC Assay Using Effector CellsWithout Stimulator Cells % Lysis E/T RatioCpd. 2 Conc. 100:1 50:1 25:1 12.5:1______________________________________10 ฮผg/ml 61.5 56.5 40.0 26.50.1 ฮผg/ml 48.0 43.5 29.5 16.50 ฮผg/ml 58.5 49.0 32.5 19.5______________________________________
Cpd. 2 caused an increase in CTL activity, expressed as % lysis, at several concentrations irrespective of the E/T ratio employed or whether or not stimulator cells were present. The one exception was the 0.1 ฮผg/ml dose when no stimulator cells were present.
EXAMPLE 28
An MLTC assay is performed to assess the CTL activity and tumor target cell specificity of Cpd. 1. Tumor dormant spleen cells and normal spleen cells of DBA/2 mice are used as effector cells. Irradiated L5178Y cells are used as stimulator cells. 51 Cr-labeled L5178Y cells and FLC-745 cells are used as target cells. The effector/target ratios studied are 100:1, 30:1 and 10:1.
TABLE 21______________________________________Effect of Cpd. 1 In Vitro, as Measured byMLTC Assay, on TDS and Normal SpleenCells from the DBA/2 Strain of Mice % Lysis E/T Ratio 100:1 30:1 10:1______________________________________Target cell - L5178YE + S + D 82.3 69.2 34.9E + S 55.5 39.3 11.4E + D 52.8 29.8 9.0E 50.9 29.2 7.2N + S + D -9.5 -9.7 -10.9N + S -14.2 -10.5 -11.2N + D -12.4 -11.4 -10.3N -11.2 -11.0 -10.9Target cell - FLC-745E + S + D 13.4 3.6 0.5E + S 6.9 1.4 -4.0E + D 6.6 4.6 0.7E 11.8 6.6 -1.3N + S + D 5.8 -0.8 -1.1N + S 5.8 1.1 -2.6N + D 13.9 0.9 -3.5N 1.7 -1.8 -2.9______________________________________
E=Effector, Tumor dormant spleen cells; S=Stimulator, Irradiated L5178Y cells; D=Cpd. 1; N=Normal effector cells, Normal spleen cells.
A significant specific enhancement of CTL activity of effector cells in the presence of stimulator cells was noted in the L5178Y target control system when Cpd. 1 is present. This effect is not observed in the FLC-745 target control system nor did effector cells alone yield an enhancement effect. These results demonstrate the enhancement of the activity of stimulated effector cells by Cpd. 1, the activity of the T-cell memory of the system, and the specificity of the stimulated effector cells.
EXAMPLE 29
The effect of Cpd. 1 on the emergence from the L5178Y tumor dormant state is studied by treating forty DBA/2 mice with Cpd. 1 after the mice have undergone the TDS inducing procedure. Two days after the mice have been challenged with i.p. administration of 50,000 viable L5178Y tumor cells, twenty of these mice receive seven consecutive days of i.p. treatment with Cpd. 1 at 100 mg/kg and the remaining twenty mice receive buffer only. A partial peritoneal lavage is performed twenty-five days after the last dose of Cpd. 1 and the peritoneal exudate fluid is plated out for determination of tumor cell numbers (tumor cell quantitative assay). Survival time is recorded out to 90 days after challenge with the viable L5178Y tumor cells. The percent mortality is calculated for each group.
TABLE 22-A______________________________________Range Distribution of Tumor Cells in TDS DBA/2 Mice,as Measured by Tumor Cell Quantitative Assay Treated Group Control Group % ofNo. Tumor Cells Frequency % of Total Frequency Total______________________________________0 1 6 4 22<1,000 6 35 6 331,000 to 100,000 8 47 7 39>100,000 2 12 1 6______________________________________
TABLE 22-B______________________________________Mortality Statistics for TDS DBA/2 Miceat 90 Days Post-ChallengeCpd. 1 Concentration No. Survivors % Survival______________________________________100 mg/kg 10 55.6 0 mg/kg 3 17.6______________________________________
There is significant reduction in the numbers of tumor cells recovered from Cpd. 1 treated animals versus the controls. The treated group shows more mice demonstrating lower tumor cell numbers in peritoneal washes. There is a significantly greater survival of these mice treated with Cpd. 1 over untreated controls.
EXAMPLE 30
The effect of Cpd. 1 on the emergence from the L5178Y tumor dormant state was studied by treating forty DBA/2 mice with Cpd. 1 after the mice had undergone the TDS inducing procedure. Two days after the mice were challenged with i.p. administration of 50,000 viable L5178Y tumor cells, twenty of these mice received seven consecutive days of i.p. treatment with Cpd. 1 at 100 mg/kg and the remaining twenty mice received buffer only. A partial peritoneal lavage was performed twenty-five days after the last dose of Cpd. 1 and the peritoneal exudate fluid was plated out for determination of tumor cell numbers (tumor cell quantitative assay). Survival time was recorded out to 114 days after challenge with the viable L5178Y tumor cells. The percent mortality was calculated for each group.
TABLE 23-A______________________________________Range Distribution of Tumor Cells in TDS DBA/2 Mice,as Measured by Tumor Cell Quantitative Assay Treated Group Control Group % ofNo. Tumor Cells Frequency % of Total Frequency Total______________________________________0 3 13.0 16 69.6<1,000 8 34.8 2 8.71,000 to 100,000 10 43.5 4 17.4>100,000 2 8.7 1 4.3______________________________________
TABLE 23-B______________________________________Mortality Statistics for TDS DBA/2 Miceat 114 Days Post-ChallengeCpd. 1 Concentration No. Survivors % Survival______________________________________100 mg/kg 19 82.6 0 mg/kg 11 47.8______________________________________
There was significant reduction in the numbers of tumor cells recovered from Cpd. 1 treated animals versus the controls. The treated group showed more mice demonstrating lower tumor cells numbers in peritoneal washes. There was a significantly greater survival of mice treated with Cpd. 1 over untreated controls.
EXAMPLE 31
Mice of the BDF 1 strain, inoculated with L-1210 leukemia cells, are treated for seven days with either 25, 50, 100, 200 or 400 mg/kg of Cpd. 1 or just buffer. The National Cancer Institute protocol for screening new anti-cancer agents is followed and T/C ratios are calculated.
TABLE 24______________________________________Effect of Cpd. 1 on the Treatment of L-1210 Leukemia,as Measured by T/C Ratios, in BDF.sub.1 Strain of MiceCpd. 1 Conc. Median Survival Time (Days) T/C______________________________________400 mg/kg 25 1.25200 mg/kg 30 1.50100 mg/kg 30 1.50 50 mg/kg 21 1.05 25 mg/kg 20 1.00 0 mg/kg 20 --______________________________________
The doses of 400, 200 and 100 mg/kg yield T/C values of 1.25, 1.50 and 1.50 respectively, which are considered significant by National Cancer Institute standards of evaluation.
EXAMPLE 32
Mice of the BDF 1 strain, inoculated with L-1210 leukemia cells, are treated for seven days with either 100 mg/kg of Cpd. 1, 20 mg/kg of 5-fluorouracil (5-FU), a known anti-cancer agent, or just buffer. The National Cancer Institute protocol for screening new anti-cancer agents is followed and T/C ratios are calculated.
TABLE 25______________________________________Effect of Cpd. 1 and 5-FU on the Treatment of L-1210Leukemia, as Measured by T/C Ratios, in BDF.sub.1 Strain of MiceDrug Conc. Median Survival Time T/C______________________________________Cpd. 1 100 mg/kg 28 1.405-FU 20 mg/kg 30 1.50Buffer -- 20 --______________________________________
The 100 mg/kg Cpd. 1 treatment dose yields a T/C value of 1.40 compared to 1.50 for the 5-FU positive control. This data substantiated the positive findings of Example 31 and also compares the anti cancer results observed after use of Cpd. 1 to the results observed after use of an accepted positive control drug, 5-FU.
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Novel 2-furylbutyrolactones are directly formed by reaction of 2,5-dialkoxy-2,5-dihydrofurans and 2,3-dihydroxybutenolides in aqueous media and recovering crystalline product from an anhydrous medium. These novel compounds and compositions containing same may be used for lymophocyte stimulation.
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This is a division of application Ser. No. 07/765,605 filed Sept. 25, 1991, now U.S. Pat. No. 5,210,300.
FIELD OF THE INVENTION
The present invention relates the use of continuous deionization as an alternative or substitute method for purification of a crude contrast agent, and more particularly, to an improved method of purifying Ioversol by removing acids and other impurities present in the crude form thereof.
BACKGROUND OF THE INVENTION
Ioversol is disclosed as a useful nonionic X-ray contrast agent in U.S. Pat. No. 4,396,598, incorporated herein by reference. N,N'-bis(2,3-dihydroxypropyl)-5-[N(2-hydroxyethyl) glycolamido]-2,4,6-triiodoisophthalamide, more commonly called Ioversol has the following structure: ##STR1## In the production of Ioversol, purification columns are used to remove impurities from the crude Ioversol product following completion of the synthetic steps as described in U.S. Pat. No. 4,396,598. Approximately 11 per cent of the crude Ioversol produced is lost from the time it enters the purification plant to the final purification of the product. Besides this large loss of Ioversol during purification, the cost and time involved in the purification operations, such as regenerating and replacing the purification columns is significant. Large amounts of costly resins and large volumes of solutions are also necessary to regenerate the purification columns between uses. These costs are significant in the production of Ioversol.
An improved procedure which eliminates the need for costly purification columns to remove impurities from the crude Ioversol product following synthesis thereof is desired as an alternate and/or a more cost efficient method of producing Ioversol. It is, therefore, an object of the present invention to meet these needs.
Additional objects and features of the present invention will appear from the following description in which the preferred methods are set forth in detail in conjunction with the accompanying drawing.
FIG. 1 is a schematic cross-sectional view of a continuous deionization system.
SUMMARY OF THE INVENTION
The present invention is a method of purifying crude Ioversol, without the costly use of purification columns, by using continuous deionization to remove a variety of impurities therefrom. Continuous deionization works like a mixed-bed resin deionizer to purify nonionic process streams while greatly reducing the amount of product customarily lost through absorption by the resin portion of the chromatography columns. This method of purifying Ioversol significantly reduces operating costs since no resin regeneration is required. Additionally, no waste streams are produced as with the regeneration of purification columns. Continuous deionization can be extended beyond currently known uses and used to remove organic and inorganic acids and/or bases and iodinated impurities from a nonionic radio-opaque process stream such as in the production of Ioversol. Impurities which may be so removed include weakly acidic and weakly basic impurities in addition to organic and inorganic acids from neutrally charged magnetic resonance imaging (MRI) agent process streams. Continuous deionization can be used to remove strong acids such as sulfuric acid, weak acids such as acetic acid in addition to the removing organic acid died impurities of 5-acetamido-N,N'-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide and N,N'-bis(2,3-dihydroxypropyl)-5-glycolamido-2,4,6-triiodoisoPhthalamide from the crude Ioversol product process stream. Continuous deionization can also be used to remove intermediate impurities including the tri-iodinated, half-acid, half-amide 5-amino-N,(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamic acid from the 5-amino-N,N'-bis (2,3-dihydroxpropyl)-2,4,6-triiodoisophthalamide process stream. 5-amino-N,N'-bis(2,3-dihydroxypropyl)-2,4,6-triiodisophthalamide is a valuable intermediate used to make Ioversol. Some of the 5-amino-N, N'-bis(2,3-dihydroxypropyl)-2,4,6-triiodophthalamide remains in the iodination liquor because of the presence of manufacturing impurities such as 5-amino-N(2,3-dihydroxypropyl)2,4,6-triiodoisophthalamic acid, 3-amino-1,2-propanediol, HCl, H 2 SO 4 , Na 2 SO 4 , Na 3 PO 4 , NaCl, Na 2 SO 3 and NaHSO 3 . Continuous deionization likewise removes organic and inorganic impurities, including acid, from crude MRI agents such as for example {[N,N"-bis[(2-methoxyethyl)amino)carbamoylmethyl]diethylenetriamine-N,N', N"-triaceto) gadolinium (III) process streams.
An alternate method of purification for crude agents such as those just described is greatly needed to reduce the cost of producing such agents. Continuous deionization fulfills that need by reducing the amount of product lost during purification and reducing operational costs through the elimination of the need for resin regeneration.
DETAILED DESCRIPTION OF THE INVENTION
Crude Ioversol once produced must be purified prior to its use as a X-ray contrast agent. Currently, purification columns are used for this purpose. However, continuous deionization may be used as a separation technology to remove, acids and other impurities from the crude Ioversol through the use of resins similar to those used in common purification columns. Continuous deionization has the removal efficiency of mixed-resin bed deionization without the need for chemical regeneration between cycles. This means continuous deionization can purify product streams while lowering overall operating costs by eliminating the costly regeneration of chemicals. Continuous deionization removes acids and other impurities from crude Ioversol in accordance with the method illustrated in FIG. 1.
The continuous deionization system 10 illustrated in FIG. 1 is known to those skilled in the art for removing salt ions from water and other aqueous solutions. Continuous dionization system 10 is also capable of removing varied impurities from the crude Ioversol process stream without the need for chemical regeneration cycles which is the subject of the present invention. The crude Ioversol stream is drawn into the diluting compartment 18 which contains a mixed resin 20 and 22 designed to trap undesirable impurities. The impurities are then pumped out of the mixed resin 20 and 22, and across ion exchange membranes 24 and 26 by dc voltage.
Ion exchange membrane 24 is a cation permeable membrane which allows the passage of cations but not anions into the concentrating compartment 14. Opposite ion exchange membrane 24 is anion permeable membrane 12. The anion permeable membrane 12 allows anions but not cations to pass into the concentrating compartment 14. Likewise, ion exchange membrane 26 is an anion permeable membrane which allows passage of anions but notifications into the concentrating compartment 28 from the diluting compartment 18. Cation permeable membrane 30 opposite membrane 26 allows the passage of cations but not anions into the concentrating compartment 28. The anode 32 and the cathode 16 located at opposed sides of the system together create the dc voltage which powers the ion transport across the described selectively permeable membranes. Through this process of pulling anion and cation impurities from the crude Ioversol trapped in the mixed-resin bed 20 and 22, Ioversol is purified. Purified Ioversol emerges by gravity or forced flow from the diluting compartment 18.
Each of the ion exchange membranes described act as check valves to prevent acid and other impurities from reentering the purified Ioversol. The same method holds true for the purification of a crude magnetic resonance imaging (MRI) agent. The use of mixed resins in the diluting compartment is key to the present process for two reasons. First, the mixed resin makes for impurity transfer across the membrane possible even in solutions with less than one part per million concentration of impurities. Secondly, the use of mixed resins prevents H+ and OH- ions from producing localized pH shifts even at low solution conductivities. The benefits of the present method to purify nonionic X-ray contrast agents and MRI agents through continuous deionization is that the method is extremely efficient, resulting in low operating and production costs. Additionally, electrical power consumption is minimal and continuous operation of the system reduces labor costs. The present invention for the improved method of removing impurities from nonionic X-ray contrast agents such as Ioversol or neutrally charged MRI agents through the continuous deionization process is further illustrated by the following examples, but is not intended to be limited thereby.
EXAMPLE 1
Purification of Crude Ioversol Using Continuous Deionization
A crude solution of Ioversol containing 1 to 25% weight per volume Ioversol, small amounts of N,N'-bis(2,3-dihydroxypropyl)-5-glycolamido-2,4,6-triiodoisophthalamide, 5-acetamid-N,N'-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide, 5-amino-N,N'-bis(2,3-dihydroxpropyl)-2,4,6-triiodoisophthalamide, and N,N'-bis(2,3-dihydroxypropyl)-5-[N(2-hydroxyethyl) acetamido]-2,4,6-triiodoisophthalamide, a very small amount of N,N'-bis(2,3-dihydroxypropyl)-5-[[N-(2-hydroxyethyl)-carbamoyl]methoxy]-2,4,6-triiodoisophthalamide, about 0.07 milliequivalents/milliliter of H 2 SO 4 , and about 0.03 milliequivalents/milliliter of acetic acid is pumped through the cells of the continuous deionization system at a rate of 1 to 10 gallons per minute. The pH of the crude Ioversol solution is initially ranging between a pH 1.0 to 2.0, but the pH will rise as it passes through the compartments or cells of the continuous deionization system. The continuous deionization system is operated at 2 to 7 dc volts per cell. The sulfuric acid, acetic acid, N,N'-bis(2,3-dihydroxypropyl)-5-glycolamido-2,4,6-triiodoisophthalamide, and 5-amino-N,N'-bis(2,3-dihydroxpropyl)-2,4,6-triiodoisophthalamide are nearly completely removed and some N,N'-bis (2,3-dihydroxypropyl)-5-[[N-(2-hydroxyethyl)-carbamoyl]methoxy]-2,4,6-triiodoisophthalamide and 5-acetamido-N,N'-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide triiodoisophthalamide is likewise removed.
EXAMPLE 2
Purification of crude {[N,N''-bis}(2-methoxyethyl)amino) carbamoyl-methyl]diethylenetriamine-N,N'N''-triaceto) gadolinium (III) Using Continuous Deionization
A crude solution of the neutral MRI agent ([N,N''-bis[(2-methoxyethyl)amino) carbamoyl-methyl]diethylenetriamine-N,N'N ''-triaceto) gadolinium (III) hereinafter called MEAGdDTPA, containing 2 to 30% weight per volume MEAGdDTPA, small amounts of gadolinium diethylenetriamine pentaacetic acid (GdDTPA), monomethoxyethylamide, and similar acidic gadolinium complexes which are impurities arising from the MEAGdDTPA manufacture is pumped through the compartments or cells of the continuous deionization system at a rate 1 to 20 gallons per minute. The pH of the crude MEAGdDTPA solution will rise as it passes through the cell of the continuous deionization system. The continuous deionization system is operated at 2 to 7 dc volts per cell. All impurity components are nearly completely removed.
EXAMPLE 3
Removal of Salts and Acids From 5-amino-N,N'-bis-(2.3 dihydroxypropyl)-2,4,6-triiodoisophthalamide production Waste Stream Using Continuous Deionization
This example process of the present invention, as with the previous examples given, is less expensive, easier to perform and results in fewer impurities than currently used processes.
The waste stream from 5-amino--N,N'-bis-(2,3 dihydroxypropyl)-2,4,6-triiodoisophthalamide manufacture containing 1 to 20 percent weight per volume 5-amino--N,N'-bis-(2,3 dihydroxypropyl)-2,4,6-triiodoisophthalamide is filtered to remove salts and is then pumped through the cells of the continuous deionization system at a rate of 1 to 20 gallons per minute. The pH of the solution is initially about 1 to 5 but rises as it passes through the cell of the continuous deionization system. The continuous deionization system is operated at 2 to 7 volts dc per cell. Nearly all the HC1, H 2 SO 4 , NaHSO 3 , Na 2 SO 4 , Na 3 PO 4 , NaC1, Na 2 SO 4 , 5-amino-N(2,3-dihydroxypropyl) 2,4,6-triiodoisophthalamic acid and 3-amino-1,2-propanediol are removed. The waste stream that has been purified by the continuous deionization system is concentrated to cause the crystallization of 5-amino-N,N'-bis-(2,3 dihydroxypropyl)-2,4,6-triiodoisophthalamide. The 5-amino-N,N'-bis--(2,3 dihydroxypropyl)-2,4,6-triiodoisophthalamide is then collected, dried and used in the manufacture of Ioversol.
The improved method of purification for nonionic X-ray contrast and FLRI agents of the present invention is less expensive, easier to perform and results in significantly fewer impurities than currently used processes.
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The use of continuous deionization as an alternative or substitute method for the purification of a crude magnetic resonate.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2011/058965 filed May 31, 2011 and claims the benefit thereof. The International Application claims the benefits of European application No. 10005771.0 filed Jun. 2, 2010, both of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to an alloy, to a protective layer for protecting a component against corrosion and/or oxidation, in particular at high temperatures, to a component.
BACKGROUND OF THE INVENTION
[0003] Large numbers of protective layers for metal components, which are intended to increase their corrosion resistance and/or oxidation resistance, are known in the prior art. Most of these protective layers are known by the generic name MCrAlY, where M stands for at least one of the elements from the group comprising iron, cobalt and nickel and other essential constituents are chromium, aluminum and yttrium.
[0004] Typical coatings of this type are known from U.S. Pat. Nos. 4,005,989 and 4,034,142.
[0005] The endeavor to increase the intake temperatures both in static gas turbines and in aircraft engines is of great importance in the specialist field of gas turbines, since the intake temperatures are important determining quantities for the thermodynamic efficiencies achievable with gas turbines. Intake temperatures significantly higher than 1000 ยฐ C. are possible when using specially developed alloys as base materials for components to be heavily loaded thermally, such as guide vanes and rotor blades, in particular by using single-crystal superalloys. To date, the prior art permits intake temperatures of 950ยฐ C. or more for static gas turbines and 1100ยฐ C. or more in gas turbines of aircraft engines.
[0006] Examples of the structure of a turbine blade with a single-crystal substrate, which in turn may be complexly constructed, are disclosed by WO 91/01433 A1.
[0007] While the physical loading capacity of the base materials so far developed for the components to be heavily loaded is substantially unproblematic in respect of possible further increases in the intake temperatures, it is necessary to resort to protective layers in order to achieve sufficient resistance against oxidation and corrosion. Besides sufficient chemical stability of a protective layer under the aggressions which are to be expected from exhaust gases at temperatures of the order of 1000ยฐ C., a protective layer must also have sufficiently good mechanical properties, not least in respect of the mechanical interaction between the protective layer and the base material. In particular, the protective layer must be ductile enough to be able to accommodate possible deformations of the base material and not crack, since points of attack would thereby be provided for oxidation and corrosion.. In this case, the typical problem that occurs is that an increase in the properties of elements such as aluminum and chromium, which can improve the resistance of a protective layer against oxidation and corrosion, leads to a deterioration in the ductility of the protective layer, such that mechanical failure, in particular the formation of cracks, is to be expected in the case of mechanical loading conventionally occurring in a gas turbine.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the invention to provide an alloy and a protective layer, having good high-temperature resistance to corrosion and oxidation, has good longterm stability and which is furthermore adapted particularly well to a mechanical load which is to be expected particularly in a gas turbine at a high temperature.
[0009] The object is achieved by an alloy and a protective layer.
[0010] It is another object of the invention to provide a component which has increased protection against corrosion and oxidation.
[0011] The object is likewise achieved by a component, in particular a component of a gas turbine or steam turbine, which comprises a protective layer of the type described above for protection against corrosion and oxidation at high temperatures.
[0012] Further advantageous measures, which may advantageously be combined with one another in any desired way, are listed in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be explained in more detail below.
[0014] FIG. 1 shows a layer system with a protective layer,
[0015] FIG. 2 shows compositions of superalloys,
[0016] FIG. 3 shows a gas turbine,
[0017] FIG. 4 shows a turbine blade and
[0018] FIG. 5 shows a combustion chamber.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The figures and the description merely represent exemplary embodiments of the invention.
[0020] According to the invention, a protective layer 7 ( FIG. 1 ) for protecting a component against corrosion and oxidation at a high temperature essentially consists of the following elements (proportions indicated in wt %):
[0021] Nickel,
[0022] Co: 24%-26%
[0023] Cr: 12%-15%
[0024] Al: 10.5%-11.5%
[0025] 0.1%-0.7% rare earth element (yttrium, etc.) and/or scandium (SC):
[0026] optionally
[0027] Si: 0.05%-0.4%,
[0028] Ta: 0.1%-3%.
[0029] The list of the alloying elements Ni, Co, Cr, Al, Y, Si, Ta is not conclusive.
[0030] Nickel preferably forms the matrix.
[0031] The list of Ni, Co, Cr, Al, Y, Si, Ta is preferably conclusive.
[0032] The contents of the alloying elements have the following advantages:
[0033] Moderately high Co content:
[0034] Extension of the beta/gamma field, avoidance of brittle phases such as, for example, the alpha phases.
[0035] Moderate Cr content:
[0036] Sufficiently high for increasing the activity of Al for the Al 2 O 3 formation; low enough to avoid brittle phases (alpha chromium or sigma phase).
[0037] Moderately high Al content:
[0038] Sufficiently high for Al activity for the formation of a stable Al 2 O 3 layer;
[0039] low enough to avoid embrittlement effects.
[0040] Low Y content:
[0041] Sufficiently high to still form sufficient Y aluminate for the formation of Y-containing โpegsโ with low oxygen contamination;
[0042] low enough to negatively accelerate the oxide layer growth of the Al 2 O 3 layer.
[0043] Low Si content:
[0044] High enough to slightly improve the oxide layer adhesion;
[0045] low enough not to impair the ductility of the layer.
[0046] It is to be noted that the proportions of the individual elements are specially adapted with a view to their effects, which are to be seen particularly in connection with the element silicon. If the proportions are dimensioned in such a way that no silicon precipitates are formed, then advantageously no brittle phases are created during use of the protective layer so that the operating time performance is improved and extended.
[0047] This arises not only through a low chromium content, but also, when considering the influence of aluminum on the phase formation, by exact dimensioning of the content of aluminum.
[0048] In conjunction with the reduction of the brittle phases, which have a detrimental effect particularly with high mechanical properties, the reduction of the mechanical stresses due to the selected nickel content improves the mechanical properties.
[0049] With good corrosion resistance, the protective layer has particularly good resistance against oxidation and is also distinguished by particularly good ductility properties, so that it is particularly qualified for use in a gas turbine 100 ( FIG. 3 ) with a further increase in the intake temperature. During operation, embrittlement scarcely takes place since the layer comprises hardly any chromium-silicon precipitates, which become embrittled in the course of use.
[0050] An equally important role is played by the trace elements in the powder to be sprayed, which form precipitates and hence represent embrittlements.
[0051] The powders are for example applied by plasma spraying (APS, LPPS, VPS, etc.) in order to form a protective layer. Other methods may likewise be envisaged (PVD, CVD, SPPS, etc.).
[0052] The described protective layer 7 also acts as a layer which improves adhesion to the superalloy.
[0053] Further layers, in particular ceramic thermal barrier layers 10 , may be applied onto this protective layer 7 .
[0054] In a component 1 , the protective layer 7 is advantageously applied onto a substrate 4 made of a nickel-based or cobalt-based superalloy ( FIG. 2 ).
[0055] The following composition in particular may be suitable as substrate (data in wt %):
[0056] from 0.1% to 0.15% carbon
[0057] from 18% to 22% chromium
[0058] from 18% to 19% cobalt
[0059] from 0% to 2% tungsten
[0060] from 0% to 4% molybdenum
[0061] from 0% to 1.5% tantalum
[0062] from 0% to 1% niobium
[0063] from 1% to 3% aluminum
[0064] from 2% to 4% titanium
[0065] from 0% to 0.75% hafnium,
[0000] optionally small proportions of boron and/or zirconium, remainder nickel.
[0066] Compositions of this type are known as casting alloys under the references GDT222, IN939, IN6203 and Udimet 500.
[0067] Other alternatives for the substrate 4 ( FIG. 2 ) of the component 1 , 120 , 130 , 155 are listed in FIG. 2 .
[0068] The thickness of the protective layer 7 on the component 1 is preferably dimensioned with a value of between about 100 ฮผm and 300 ฮผm.
[0069] The protective layer 7 is particularly suitable for protecting the component 1 , 120 , 130 , 155 against corrosion and oxidation while the component is being exposed to an exhaust gas at a material temperature of about 950ยฐ C., or even about 1100ยฐ C. in aircraft turbines.
[0070] The protective layer 7 according to the invention is therefore particularly qualified for protecting a component of a gas turbine 100 , in particular a guide vane 120 , rotor blade 130 or a heat shield element 155 , which is exposed to hot gas before or in the turbine of the gas turbine 100 or of the steam turbine.
[0071] The protective layer 7 may be used as an overlay (the protective layer is the outermost layer) or as a bondcoat (the protective layer is an interlayer).
[0072] FIG. 1 shows a layer system 1 as a component. The layer system 1 has a substrate 4 . The substrate 4 may be metallic and/or ceramic. Particularly in the case of turbine components, for example turbine rotor blades 120 ( FIG. 4 ) or guide vanes 130 ( FIGS. 3 , 4 ), heat shield elements 155 ( FIG. 5 ) or other housing parts of a steam or gas turbine 100 ( FIG. 3 ), the substrate 4 has a nickel-, cobalt- or iron-based superalloy, in particular it consists thereof.
[0073] Nickel-based superalloys ( FIG. 2 ) are preferably used.
[0074] The protective layer 7 according to the invention is provided on the substrate 4 . This protective layer 7 is preferably applied by plasma spraying (VPS, LPPS, APS, etc.). It may be used as an outer layer (not shown) or interlayer ( FIG. 1 ). Preferably, there will be a ceramic thermal barrier layer 10 on the protective layer 7 .
[0075] Preferably, the layer system consists of substrate 4 , protective layer 7 and ceramic thermal barrier layer 10 , optionally a TGO underneath the thermal barrier layer 10 .
[0076] The protective layer 7 may be applied onto newly produced components and refurbished components. Refurbishment means that components 1 are separated if need be from layers (thermal barrier layer) after their use and corrosion and oxidation products are removed, for example by an acid treatment (acid stripping). It may sometimes also be necessary to repair cracks. Such a component may subsequently be recoated, since the substrate 4 is very expensive.
[0077] FIG. 3 shows a gas turbine 100 by way of example in a partial longitudinal section. The gas turbine 100 internally comprises a rotor 103 , which will also be referred to as the turbine rotor, mounted so as to rotate about a rotation axis 102 and having a shaft 101 . Successively along the rotor 103 , there are an intake manifold 104 , a compressor 105 , an e.g. toroidal combustion chamber 110 , in particular a ring combustion chamber, having a plurality of burners 107 arranged coaxially, a turbine 108 and the exhaust manifold 109 . The ring combustion chamber 110 communicates with an e.g. annular hot gas channel 111 . There, for example, four successively connected turbine stages 112 form the turbine 108 . Each turbine stage 112 is formed for example by two blade rings. As seen in the flow direction of a working medium 113 , a guide vane row 115 is followed in the hot gas channel 111 by a row 125 formed by rotor blades 120 .
[0078] The guide vanes 130 are fastened on an inner housing 138 of a stator 143 while the rotor blades 120 of a row 125 are fitted on the rotor 103 , for example by means of a turbine disk 133 . Coupled to the rotor 103 , there is a generator or a work engine (not shown).
[0079] During operation of the gas turbine 100 , air 135 is taken in and compressed by the compressor 105 through the intake manifold 104 . The compressed air provided at the turbine-side end of the compressor 105 is delivered to the burners 107 and mixed there with a fuel. The mixture is then burnt to form the working medium 113 in the combustion chamber 110 . From there, the working medium 113 flows along the hot gas channel 111 past the guide vanes 130 and the rotor blades 120 . At the rotor blades 120 , the working medium 113 expands by imparting momentum, so that the rotor blades 120 drive the rotor 103 and the work engine coupled to it.
[0080] The components exposed to the hot working medium 113 experience thermal loads during operation of the gas turbine 100 . Apart from the heat shield elements lining the ring combustion chamber 110 , the guide vanes 130 and rotor blades 120 of the first turbine stage 112 , as seen in the flow direction of the working medium 113 , are heated the most.
[0081] In order to withstand the temperatures prevailing there, they may be cooled by means of a coolant. The substrates may likewise comprise a directional structure, i.e. they are single-crystal (SX structure) or comprise only longitudinally directed grains (DS structure). Iron-, nickel- or cobalt-based superalloys are for example used as the material for the components, in particular for the turbine blades 120 , 130 and components of the combustion chamber 110 . Such superalloys are known for example from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949.
[0082] The guide vanes 130 comprise a guide vane root (not shown here) facing the inner housing 138 of the turbine 108 , and a guide vane head lying opposite the guide vane root. The guide vane head faces the rotor 103 and is fixed on a fastening ring 140 of the stator 143 .
[0083] FIG. 4 shows a perspective view of a rotor blade 120 or guide vane 130 of a turbomachine, which extends along a longitudinal axis 121 . The turbomachine may be a gas turbine of an aircraft or of a power plant for electricity generation, a steam turbine or a compressor.
[0084] The blade 120 , 130 comprises, successively along the longitudinal axis 121 , a fastening zone 400 , a blade platform 403 adjacent thereto as well as a blade surface 406 and a blade tip 415 . As a guide vane 130 , the vane 130 may have a further platform (not shown) at its vane tip 415 .
[0085] A blade root 183 which is used to fasten the rotor blades 120 , 130 on a shaft or a disk (not shown) is formed in the fastening zone 400 . The blade root 183 is configured, for example, as a hammerhead. Other configurations as a firtree or dovetail root are possible. The blade 120 , 130 comprises a leading edge 409 and a trailing edge 412 for a medium which flows past the blade surface 406 .
[0086] In conventional blades 120 , 130 , for example solid metallic materials, in particular superalloys, are used in all regions 400 , 403 , 406 of the blade 120 , 130 . Such superalloys are known for example from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949.
[0087] The blade 120 , 130 may in this case be manufactured by a casting method, also by means of directional solidification, by a forging method, by a machining method or combinations thereof.
[0088] Workpieces with a single-crystal structure or single-crystal structures are used as components for machines which are exposed to heavy mechanical, thermal and/or chemical loads during operation. Such single-crystal workpieces are manufactured, for example, by directional solidification from the melts. These are casting methods in which the liquid metal alloy is solidified to form a single-crystal structure, i.e. to form the single-crystal workpiece, or is directionally solidified.
[0089] Dendritic crystals are in this case aligned along the heat flux and form either a rod crystalline grain structure (columnar, i.e. grains which extend over the entire length of the workpiece and in this case, according to general terminology usage, are referred to as directionally solidified) or a single-crystal structure, i.e. the entire workpiece consists of a single crystal. It is necessary to avoid the transition to globulitic (polycrystalline) solidification in these methods, since nondirectional growth will necessarily form transverse and longitudinal grain boundaries which negate the beneficial properties of the directionally solidified or single-crystal component.
[0090] When directionally solidified structures are referred to in general, this is intended to mean both single crystals which have no grain boundaries or at most small-angle grain boundaries, and also rod crystal structures which, although they do have grain boundaries extending in the longitudinal direction, do not have any transverse grain boundaries. These latter crystalline structures are also referred to as directionally solidified structures. Such methods are known from U.S. Pat. No. 6,024,792 and EP 0 892 090 A1.
[0091] The blades 120 , 130 may also have layers 7 according to the invention protecting against corrosion or oxidation. The density is preferably 95% of the theoretical density. A protective aluminum oxide layer (TGO=thermally grown oxide layer) is formed on the MCrAlX layer (as an interlayer or as the outermost layer).
[0092] On the MCrAlX, there may furthermore be a thermal barrier layer, which is preferably the outermost layer and consists for example of ZrO 2 , Y 2 O 3 -ZrO 2 , i.e. it is not stabilized or is partially or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide. The thermal barrier layer covers the entire MCrAlX layer. Rod-shaped grains are produced in the thermal barrier layer by suitable coating methods, for example electron beam deposition (EB-PVD). Other coating methods may be envisaged, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier layer may comprise porous, micro- or macro-cracked grains for better thermal shock resistance. The thermal barrier layer is thus preferably more porous than the MCrAlX layer.
[0093] The blade 120 , 130 may be designed to be hollow or solid. If the blade 120 , 130 is intended to be cooled, it will be hollow and optionally also comprise film cooling holes 418 (indicated by dashes).
[0094] FIG. 5 shows a combustion chamber 110 of the gas turbine 100 . The combustion chamber 110 is designed for example as a so-called ring combustion chamber in which a multiplicity of burners 107 , which produce flames 156 and are arranged in the circumferential direction around a rotation axis 102 , open into a common combustion chamber space 154 . To this end, the combustion chamber 110 as a whole is designed as an annular structure which is positioned around the rotation axis 102 .
[0095] In order to achieve a comparatively high efficiency, the combustion chamber 110 is designed for a relatively high temperature of the working medium M, of about 1000ยฐ C. to 1600ยฐ C. In order to permit a comparatively long operating time even under these operating parameters which are unfavorable for the materials, the combustion chamber wall 153 is provided with an inner lining formed by heat shield elements 155 on its side facing the working medium M.
[0096] Owing to the high temperatures inside the combustion chamber 110 , a cooling system may also be provided for the heat shield elements 155 or for their retaining elements. The heat shield elements 155 are then hollow, for example, and optionally also have cooling holes (not shown) opening into the combustion chamber space 154 .
[0097] Each heat shield element 155 made of an alloy is equipped with a particularly heat-resistant protective layer (MCrAlX layer and/or ceramic coating) on the working medium side, or is made of refractory material (solid ceramic blocks). These protective layers 7 may be similar to the turbine blades. On the MCrAlX, there may furthermore be an e.g. ceramic thermal barrier layer which consists for example of ZrO 2 , Y 2 O 3 -ZrO 2 , i.e. it is not stabilized or is partially or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide. Rod-shaped grains are produced in the thermal barrier layer by suitable coating methods, for example electron beam deposition (EB-PVD).
[0098] Other coating methods may be envisaged, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier layer may comprise porous, micro- or macro-cracked grains for better thermal shock resistance.
[0099] Refurbishment means that turbine blades 120 , 130 or heat shield elements 155 may need to be stripped of protective layers (for example by sandblasting) after their use. The corrosion and/or oxidation layers or products are then removed. Optionally, cracks in the turbine blade 120 , 130 or heat shield element 155 are also repaired. The turbine blades 120 , 130 or heat shield elements 155 are then recoated and the turbine blades 120 , 130 or heat shield elements 155 are used again.
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A known protective layer has a high Cr content and additionally containing a silicon, forms brittle phases, which become additionally embrittled under the influence of carbon during use. A proposed protective layer has the following composition: 24% to 26% cobalt, 10.5% to 11.5% aluminum, 0.1% to 0.7% yttrium and/or at least one equivalent metal from the group of scandium and the rare earth elements, 12% to 15% chromium, optionally 0.1% to 3% tantalum, optionally 0.05% to 0.5% silicon, with the remainder being nickel.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/331,045 filed May 4, 2010.
FIELD OF THE INVENTION
[0002] This invention concerns a synergistic herbicidal composition containing (a) a dicamba derivative and (b) a glyphosate derivative.
BACKGROUND OF THE INVENTION
[0003] The protection of crops from weeds and other vegetation which inhibit crop growth is a constantly recurring problem in agriculture. To help combat this problem, researchers in the field of synthetic chemistry have produced an extensive variety of chemicals and chemical formulations effective in the control of such unwanted growth. Chemical herbicides of many types have been disclosed in the literature and a large number are in commercial use.
[0004] In some cases, herbicidal active ingredients have been shown to be more effective in combination than when applied individually and this is referred to as โsynergism.โ As described in the Herbicide Handbook of the Weed Science Society of America, Ninth Edition, 2007, p. 429, โโsynergismโ[is] an interaction of two or more factors such that the effect when combined is greater than the predicted effect based on the response of each factor applied separately.โ The present invention is based on the discovery that substituted phenoxy alkanoic acid derivatives and glyphosate derivatives, already known individually for their herbicidal efficacy, display a synergistic effect when applied in combination.
[0005] For example, dicamba, 3,6-dichloro-2-methoxybenzoic acid, is a selective systemic herbicide used to control annual and perennial broad-leaved weeds in various crops as well as in non-crop land. It is commercially available, for example, as a dimethylammonium salt such as Banvelโข herbicide from Arysta LifeScience and as a diglycolamine salt such as Clarityโข herbicide from BASF.
[0006] Glyphosate, N-(phosphonomethyl)glycine, is a non-selective systemic herbicide used to control annual and perennial grasses and broad-leaved weeds, particularly in crops that have been genetically modified to be tolerant of glyphosate. It is commercially available, for example, as an isopropylammonium salt such as Glyphomax P1usโข herbicide from Dow AgroSciences, as a potassium salt such as Roundup PowerMaxโข herbicide from Monsanto, as a diammonium salt such as Touchdownโข herbicide from Syngenta, or as a dimethylammonium salt such as Durangoโข herbicide from Dow AgroSciences.
SUMMARY OF THE INVENTION
[0007] The present invention concerns a synergistic herbicidal mixture comprising an herbicidally effective amount of (a) a dicamba derivative and (b) a glyphosate derivative. The compositions may also contain an agriculturally acceptable adjuvant or carrier.
[0008] The present invention also concerns a method of controlling the growth of undesirable vegetation, particularly in crops that are tolerant, either naturally or through genetic modification, to the active herbicides of the synergistic mixture, and the use of this synergistic composition.
[0009] The species spectra of the compounds of the synergistic mixture, i.e., the weed species which the respective compounds control, are broad and highly complementary. While glyphosate is a non-selective herbicide, resistance to glyphosate by several weed species, for example, horseweed ( Conyza Canadensis , ERICA), giant and common ragweeds ( Ambrosia trifida , AMBTR and Ambrosia artemisiifolia ), and various amaranths ( Amaranthus spp., AMASS) have been well documented. Additionally, certain common lambsquarters ( Chenopodium album L ., CHEAL) biotypes are difficult to control (resistant) with glyphosate. Recent reports of dicamba-resistant CHEAL have been reported. The synergistic mixture of dicamba and glyphosate is particularly effective at controlling these glyphosate- and dicamba-resistant weeds and maintaining the utility of these herbicides. Other weeds which the mixture of dicamba and glyphosate synergistically control include spiderwort ( Commelina benghalensis ; COMBE).
DETAILED DESCRIPTION OF THE INVENTION
[0010] The term herbicide is used herein to mean an active ingredient that kills, controls or otherwise adversely modifies the growth of plants. An herbicidally effective or vegetation controlling amount is an amount of active ingredient which causes an adversely modifying effect and includes deviations from natural development, killing, regulation, desiccation, retardation, and the like. The terms plants and vegetation include germinating seeds, emerging seedlings and established vegetation.
[0011] Herbicidal activity is exhibited by the compounds of the synergistic mixture when they are applied directly to the plant or to the locus of the plant at any stage of growth or before planting or emergence. The effect observed depends upon the plant species to be controlled, the stage of growth of the plant, the application parameters of dilution and spray drop size, the particle size of solid components, the environmental conditions at the time of use, the specific compound employed, the specific adjuvants and carriers employed, the soil type, and the like, as well as the amount of chemical applied. These and other factors can be adjusted as is known in the art to promote non-selective or selective herbicidal action.
[0012] Generally, it is preferred to apply the composition of the present invention postemergence to relatively immature undesirable vegetation to achieve the maximum control of weeds.
[0013] Dicamba derivatives and glyphosate derivatives mean the acids themselves and their agriculturally acceptable esters and salts.
[0014] Suitable salts include those derived from alkali or alkaline earth metals and those derived from ammonia and amines. Preferred cations include sodium, potassium, magnesium, and aminium cations of the formula:
[0000] R 1 R 2 R 3 R 4 N +
[0000] wherein R 1 , R 2 , R 3 and R 4 each, independently represents hydrogen or C 1 -C 12 alkyl, C 3 -C 12 alkenyl or C 3 -C 12 alkynyl, each of which is optionally substituted by one or more hydroxy, C 1 -C 4 alkoxy, C 1 -C 4 alkylthio or phenyl groups, provided that R 1 , R 2 , R 3 and R 4 are sterically compatible. Preferred amine salts are those derived from ammonia, methylamine, dimethylamine, trimethylamine, isopropylamine, monoethanolamine, diethanolamine, triethanolamine, diglyclolamine, triisopropanolamine, choline, 2-methylthiopropylamine, bisallylamine, 2-butoxyethylamine, morpholine, cyclododecylamine, or benzylamine. Amine salts are often preferred because they are water-soluble and lend themselves to the preparation of desirable aqueous based herbicidal compositions.
[0015] Suitable esters include those derived from C 1 -C 12 alkyl, C 3 -C 12 alkenyl or C 3 -C 12 alkynyl alcohols, such as methanol, isopropanol, butanol, 2-ethylhexanol, butoxyethanol, methoxypropanol, allyl alcohol, propargyl alcohol or cyclohexanol.
[0016] In the composition of this invention, the weight ratio on an acid equivalent basis of the dicamba component to glyphosate component at which the herbicidal effect is synergistic lies within the range of between about 8:1 and about 1:8. Preferably the weight ratio of the dicamba component to the glyphosate component lies within the range of between about 4:1 and about 1:4 with a weight ratio of between about 2:1 and 1:2 being preferred and a weight ratio of about 1:1 being especially preferred.
[0017] The rate at which the synergistic composition is applied will depend upon the particular type of weed to be controlled, the degree of control required, and the timing and method of application. In general, the composition of the invention can be applied at an application rate of between about 100 grams of acid equivalents per hectare (g ae/ha) and about 2000 g ae/ha based on the total amount of active ingredients in the composition. An application rate of between about 200 g ae/ha and about 1000 g ae/ha is preferred. In an especially preferred embodiment of the invention, the dicamba component is applied at a rate of between about 35 g ae/ha and about 560 g ae/ha and the glyphosate component is applied at a rate of between about 35 g ae/ha and about 1120 g ae/ha.
[0018] The components of the synergistic mixture of the present invention can be applied either separately or as part of a multipart herbicidal system.
[0019] The synergistic mixture of the present invention can be applied in conjunction with one or more other herbicides to control a wider variety of undesirable vegetation. When used in conjunction with other herbicides, the composition can be formulated with the other herbicide or herbicides, tank mixed with the other herbicide or herbicides or applied sequentially with the other herbicide or herbicides. Some of the herbicides that can be employed in conjunction with the synergistic composition of the present invention include: 4-CPA; 4-CPB; 4-CPP; 2,4-D; 3,4-DA; 2,4-DB; 3,4-DB; 2,4-DEB; 2,4-DEP; 3,4-DP; 2,3,6-TBA; 2,4,5-T; 2,4,5-TB; acetochlor, acifluorfen, aclonifen, acrolein, alachlor, allidochlor, alloxydim, allyl alcohol, alorac, ametridione, ametryn, amibuzin, amicarbazone, amidosulfuron, aminocyclopyrachlor, aminopyralid, amiprofos-methyl, amitrole, ammonium sulfamate, anilofos, anisuron, asulam, atraton, atrazine, azafenidin, azimsulfuron, aziprotryne, barban, BCPC, beflubutamid, benazolin, bencarbazone, benfluralin, benfuresate, bensulfuron, bensulide, bentazone, benzadox, benzfendizone, benzipram, benzobicyclon, benzofenap, benzofluor, benzoylprop, benzthiazuron, bicyclopyrone, bifenox, bilanafos, bispyribac, borax, bromacil, bromobonil, bromobutide, bromofenoxim, bromoxynil, brompyrazon, butachlor, butafenacil, butamifos, butenachlor, buthidazole, buthiuron, butralin, butroxydim, buturon, butylate, cacodylic acid, cafenstrole, calcium chlorate, calcium cyanamide, cambendichlor, carbasulam, carbetamide, carboxazole chlorprocarb, carfentrazone, CDEA,
[0020] CEPC, chlomethoxyfen, chloramben, chloranocryl, chlorazifop, chlorazine, chlorbromuron, chlorbufam, chloreturon, chlorfenac, chlorfenprop, chlorflurazole, chlorflurenol, chloridazon, chlorimuron, chlornitrofen, chloropon, chlorotoluron, chloroxuron, chloroxynil, chlorpropham, chlorsulfuron, chlorthal, chlorthiamid, cinidon-ethyl, cinmethylin, cinosulfuron, cisanilide, clethodim, cliodinate, clodinafop, clofop, clomazone, clomeprop, cloprop, cloproxydim, clopyralid, cloransulam, CMA, copper sulfate, CPMF, CPPC, credazine, cresol, cumyluron, cyanatryn, cyanazine, cycloate, cyclosulfamuron, cycloxydim, cycluron, cyhalofop, cyperquat, cyprazine, cyprazole, cypromid, daimuron, dalapon, dazomet, delachlor, desmedipham, desmetryn, di-allate, dichlobenil, dichloralurea, dichlormate, dichlorprop, dichlorprop-P, diclofop, diclosulam, diethamquat, diethatyl, difenopenten, difenoxuron, difenzoquat, diflufenican, diflufenzopyr, dimefuron, dimepiperate, dimethachlor, dimethametryn, dimethenamid, dimethenamid-P, dimexano, dimidazon, dinitramine, dinofenate, dinoprop, dinosam, dinoseb, dinoterb, diphenamid, dipropetryn, diquat, disul, dithiopyr, diuron, DMPA, DNOC, DSMA, EBEP, eglinazine, endothal, epronaz, EPTC, erbon, esprocarb, ethalfluralin, ethametsulfuron, ethidimuron, ethiolate, ethofumesate, ethoxyfen, ethoxysulfuron, etinofen, etnipromid, etobenzanid, EXD, fenasulam, fenoprop, fenoxaprop, fenoxaprop-P, fenoxasulfone, fenteracol, fenthiaprop, fentrazamide, fenuron, ferrous sulfate, flamprop, flamprop-M, flazasulfuron, florasulam, fluazifop, fluazifop-P, fluazolate, flucarbazone, flucetosulfuron, fluchloralin, flufenacet, flufenican, flufenpyr, flumetsulam, flumezin, flumiclorac, flumioxazin, flumipropyn, fluometuron, fluorodifen, fluoroglycofen, fluoromidine, fluoronitrofen, fluothiuron, flupoxam, flupropacil, flupropanate, flupyrsulfuron, fluridone, flurochloridone, fluroxypyr, flurtamone, fluthiacet, fomesafen, foramsulfuron, fosamine, furyloxyfen, glufosinate, glufosinate-P, halosafen, halosulfuron, haloxydine, haloxyfop, haloxyfop-P, hexachloroacetone, hexaflurate, hexazinone, imazamethabenz, imazamox, imazapic, imazapyr, imazaquin, imazethapyr, imazosulfuron, indanofan, indaziflam, iodobonil, iodomethane, iodosulfuron, ioxynil, ipazine, ipfencarbazone, iprymidam, isocarbamid, isocil, isomethiozin, isonoruron, isopolinate, isopropalin, isoproturon, isouron, isoxaben, isoxachlortole, isoxaflutole, isoxapyrifop, karbutilate, ketospiradox, lactofen, lenacil, linuron,
[0021] MAA, MAMA, MCPA, MCPA-thioethyl, MCPB, mecoprop, mecoprop-P, medinoterb, mefenacet, mefluidide, mesoprazine, mesosulfuron, mesotrione, metam, metamifop, metamitron, metazachlor, metazosulfuron, metflurazon, methabenzthiazuron, methalpropalin, methazole, methiobencarb, methiozolin, methiuron, methometon, methoprotryne, methyl bromide, methyl isothiocyanate, methyldymron, metobenzuron, metobromuron, metolachlor, metosulam, metoxuron, metribuzin, metsulfuron, molinate, monalide, monisouron, monochloroacetic acid, monolinuron, monuron, morfamquat, MSMA, naproanilide, napropamide, naptalam, neburon, nicosulfuron, nipyraclofen, nitralin, nitrofen, nitrofluorfen, norflurazon, noruron, OCH, orbencarb, ortho-dichlorobenzene, orthosulfamuron, oryzalin, oxadiargyl, oxadiazon, oxapyrazon, oxasulfuron, oxaziclomefone, oxyfluorfen, parafluron, paraquat, pebulate, pelargonic acid, pendimethalin, penoxsulam, pentachlorophenol, pentanochlor, pentoxazone, perfluidone, pethoxamid, phenisopham, phenmedipham, phenmedipham-ethyl, phenobenzuron, phenylmercury acetate, picloram, picolinafen, pinoxaden, piperophos, potassium arsenite, potassium azide, potassium cyanate, pretilachlor, primisulfuron, procyazine, prodiamine, profluazol, profluralin, profoxydim, proglinazine, prometon, prometryn, propachlor, propanil, propaquizafop, propazine, propham, propisochlor, propoxycarbazone, propyrisulfuron, propyzamide, prosulfalin, prosulfocarb, prosulfuron, proxan, prynachlor, pydanon, pyraclonil, pyraflufen, pyrasulfotole, pyrazolynate, pyrazosulfuron, pyrazoxyfen, pyribenzoxim, pyributicarb, pyriclor, pyridafol, pyridate, pyriftalid, pyriminobac, pyrimisulfan, pyrithiobac, pyroxasulfone, pyroxsulam, quinclorac, quinmerac, quinoclamine, quinonamid, quizalofop, quizalofop-P, rhodethanil, rimsulfuron, saflufenacil, S-metolachlor, sebuthylazine, secbumeton, sethoxydim, siduron, simazine, simeton, simetryn, SMA, sodium arsenite, sodium azide, sodium chlorate, sulcotrione, sulfallate, sulfentrazone, sulfometuron, sulfosulfuron, sulfuric acid, sulglycapin, swep, TCA, tebutam, tebuthiuron, tefuryltrione, tembotrione, tepraloxydim, terbacil, terbucarb, terbuchlor, terbumeton, terbuthylazine, terbutryn, tetrafluron, thenylchlor, thiazafluron, thiazopyr, thidiazimin, thidiazuron, thiencarbazone-methyl, thifensulfuron, thiobencarb, tiocarbazil, tioclorim, topramezone, tralkoxydim, tri-allate, triasulfuron, triaziflam, tribenuron, tricamba, triclopyr, tridiphane, trietazine, trifloxysulfuron, trifluralin, triflusulfuron, trifop, trifopsime, trihydroxytriazine, trimeturon, tripropindan, tritac tritosulfuron, vernolate and xylachlor.
[0022] The synergistic composition of the present invention is particularly useful when used on glyphosate-tolerant, glufosinate-tolerant, 2,4-D-tolerant, dicamba-tolerant or imiazolinone-tolerant crops. It is generally preferred to use the synergistic composition of the present invention in combination with herbicides that are selective for the crop being treated and which complement the spectrum of weeds controlled by these compounds at the application rate employed. It is further generally preferred to apply the synergistic composition of the present invention and other complementary herbicides at the same time, either as a combination formulation or as a tank mix.
[0023] The synergistic composition of the present invention can generally be employed in combination with known herbicide safeners, such as benoxacor, benthiocarb, brassinolide, cloquintocet (mexyl), cyometrinil, daimuron, dichlormid, dicyclonon, dimepiperate, disulfoton, fenchlorazole-ethyl, fenclorim, flurazole, fluxofenim, furilazole, isoxadifen-ethyl, mefenpyr-diethyl, MG 191, MON 4660, naphthalic anhydride (NA), oxabetrinil, 829148 and N-phenylsulfonylbenzoic acid amides, to enhance their selectivity.
[0024] In practice, it is preferable to use the synergistic composition of the present invention in mixtures containing an herbicidally effective amount of the herbicidal components along with at least one agriculturally acceptable adjuvant or carrier. Suitable adjuvants or carriers should not be phytotoxic to valuable crops, particularly at the concentrations employed in applying the compositions for selective weed control in the presence of crops, and should not react chemically with herbicidal components or other composition ingredients. Such mixtures can be designed for application directly to weeds or their locus or can be concentrates or formulations that are normally diluted with additional carriers and adjuvants before application. They can be solids, such as, for example, dusts, granules, water dispersible granules, or wettable powders, or liquids, such as, for example, emulsifiable concentrates, solutions, emulsions or suspensions.
[0025] Suitable agricultural adjuvants and carriers that are useful in preparing the herbicidal mixtures of the invention are well known to those skilled in the art.
[0026] Liquid carriers that can be employed include water, toluene, xylene, petroleum naphtha, crop oil, acetone, methyl ethyl ketone, cyclohexanone, trichloroethylene, perchloroethylene, ethyl acetate, amyl acetate, butyl acetate, propylene glycol monomethyl ether and diethylene glycol monomethyl ether, methanol, ethanol, isopropanol, amyl alcohol, ethylene glycol, propylene glycol, glycerine, N-methylpyrrolidinone, N-N-dimethylalkylamides, dimethyl sulfoxide and the like. Water is generally the carrier of choice for the dilution of concentrates.
[0027] Suitable solid carriers include talc, pyrophyllite clay, silica, attapulgus clay, kaolin clay, kieselguhr, chalk, diatomaceous earth, lime, calcium carbonate, bentonite clay, Fuller's earth, cotton seed hulls, wheat flour, soybean flour, pumice, wood flour, walnut shell flour, lignin, and the like.
[0028] It is usually desirable to incorporate one or more surface-active agents into the compositions of the present invention. Such surface-active agents are advantageously employed in both solid and liquid compositions, especially those designed to be diluted with carrier before application. The surface-active agents can be anionic, cationic or nonionic in character and can be employed as emulsifying agents, wetting agents, suspending agents, or for other purposes. Typical surface-active agents include salts of alkyl sulfates, such as diethanolammonium lauryl sulfate; alkylarylsulfonate salts, such as calcium dodecyl-benzenesulfonate; alkylphenol-alkylene oxide addition products, such as nonylphenol-C 18 ethoxylate; alcohol-alkylene oxide addition products, such as tridecyl alcohol-C 16 ethoxylate; soaps, such as sodium stearate; alkylnaphthalene-sulfonate salts, such as sodium dibutylnaphthalenesulfonate; dialkyl esters of sulfosuccinate salts, such as sodium di(2-ethylhexyl) sulfosuccinate; sorbitol esters, such as sorbitol oleate; quaternary amines, such as lauryl trimethylammonium chloride; polyethylene glycol esters of fatty acids, such as polyethylene glycol stearate; block copolymers of ethylene oxide and propylene oxide; and salts of mono and dialkyl phosphate esters.
[0029] Other adjuvants commonly used in agricultural compositions include compatibilizing agents, antifoam agents, sequestering agents, neutralizing agents and buffers, corrosion inhibitors, dyes, odorants, spreading agents, penetration aids, sticking agents, dispersing agents, thickening agents, freezing point depressants, antimicrobial agents, and the like. The compositions may also contain other compatible components, for example, other herbicides, plant growth regulants, fungicides, insecticides, and the like and can be formulated with liquid fertilizers or solid, particulate fertilizer carriers such as ammonium nitrate, urea and the like.
[0030] The concentration of the active ingredients in the synergistic composition of the present invention is generally from 0.001 to 98 percent by weight. Concentrations from 0.01 to 90 percent by weight are often employed. In compositions designed to be employed as concentrates, the active ingredients are generally present in a concentration from 5 to 98 weight percent, preferably 10 to 90 weight percent. Such compositions are typically diluted with an inert carrier, such as water, before application. The diluted compositions usually applied to weeds or the locus of weeds generally contain 0.0001 to 1 weight percent active ingredient and preferably contain 0.001 to 0.05 weight percent.
[0031] The present compositions can be applied to weeds or their locus by the use of conventional ground or aerial dusters, sprayers, and granule applicators, by addition to irrigation water, and by other conventional means known to those skilled in the art.
[0032] The following example illustrate the present invention.
EXAMPLE
[0033] Seeds of the desired test plant species were planted in Sun Gro MetroMix 306 planting mixture, which typically has a pH of 6.0 to 6.8 and an organic matter content of about 30 percent, in plastic pots with a surface area of 103.2 square centimeters (cm 2 ). When required to ensure good germination and healthy plants, a fungicide treatment and/or other chemical or physical treatment was applied. The plants were grown for 7-36 days (d) in a greenhouse with an approximate 16 hour (h) photoperiod which was maintained at about 28ยฐ C. during the day and 26ยฐ C. during the night. Nutrients and water were added on a regular basis and supplemental lighting was provided with overhead metal halide 1000-Watt lamps as necessary. The plants were employed for testing when they reached the second or third true leaf stage.
[0034] Treatments consisted of Banvelโข (dicamba dimethylamine salt) and Durangoโข herbicide (glyphosate dimethylamine salt) alone and in combinations. An aliquot of
[0035] Banvel TM (dicamba dimethylamine salt) was placed in 25 milliliter (mL) glass vials and diluted in a volume of water to obtain 1.5 milligrams (mg) active ingredient (ai)/mL concentrated solutions. Subsequent concentrations of Banvelโข (dicamba dimethylamine salt) were obtained by dilution with an equal volume of water. Spray solutions of Durangoโข herbicide (glyphosate dimethylamine salt) were prepared following the aforementioned procedure. An aliquot of Durangoโข herbicide (glyphosate dimethylamine salt) was placed in 25 milliter (mL) glass vials and mixed in a volume of 100:2 w/w water/ammonium sulfate (AMS) dilution solution to obtain 1.5 milligrams (mg) active ingredient (ai)/mL concentrated solutions.
[0036] Compound requirements are based upon a 12 mL application volume at a rate of 187 liters per hectare (L/ha). Spray solutions of the Banvel TM (dicamba dimethylamine salt) and Durangoโข herbicide (glyphosate dimethylamine salt) were prepared by adding the concentrated solutions to the appropriate amount of dilution solution to form 12 mL spray solution with active ingredients in combination. Banvelโข (dicamba dimethylamine salt) and Durangoโข herbicide (glyphosate dimethylamine salt) alone and in combinations were applied to the foliage of plant material with an overhead Mandel track sprayer equipped with 8002E nozzles calibrated to deliver 187 L/ha over an application area of 0.503 square meters (m 2 ) at a spray height of 18 inches (43 cm) above average plant canopy. Control plants were sprayed in the same manner with the solvent blank.
[0037] The treated plants and control plants were placed in a greenhouse as described above and watered by sub-irrigation to prevent wash-off of the test compounds. After 14-21 d, the condition of the test plants as compared with that of the control plants was determined visually and scored on a scale of 0 to 100 percent where 0 corresponds to no injury and 100 corresponds to complete kill.
[0038] Colby's equation was used to determine the herbicidal effects expected from the mixtures (Colby, S. R. 1967. Calculation of the synergistic and antagonistic response of herbicide combinations. Weeds 15:20-22.).
[0039] The following equation was used to calculate the expected activity of mixtures containing two active ingredients, A and B:
[0000] Expected= A+B โ( AรB/ 100)
[0040] A=observed efficacy of active ingredient A at the same concentration as used in the mixture;
[0041] B=observed efficacy of active ingredient B at the same concentration as used in the mixture.
[0042] Table I contains the data for expected and actual herbicidal growth reduction caused by relevant individual herbicides and combinations of these herbicides on agronomically important weeds.
[0000]
TABLE I
Herbicidal effects of Dicamba and Glyphosate and combinations
of the two herbicides on select broadleaf weeds.
Application
Rate (g/ha)
Di-
Glypho-
CHEAL
ERICA
cam-
sate +
CHEAL
GLY-RES
COMBE
ERICA
GLY-RES
ba
AMS
Ob
Ex
Ob
Ex
Ob
Ex
Ob
Ex
Ob
Ex
35
0
34
โ
33
โ
18
โ
62
โ
62
โ
70
0
40
โ
48
โ
25
โ
81
โ
83
โ
140
0
52
โ
64
โ
43
โ
93
โ
95
โ
280
0
61
โ
83
โ
42
โ
97
โ
97
โ
0
35
8
โ
9
โ
7
โ
47
โ
0
โ
0
70
12
โ
9
โ
27
โ
55
โ
0
โ
0
140
57
โ
41
โ
49
โ
72
โ
3
โ
0
280
66
โ
51
โ
58
โ
78
โ
7
โ
35
35
48
39
60
39
62
24
83
80
64
62
70
70
60
47
72
53
71
45
96
91
81
83
140
140
87
79
88
79
83
71
98
98
91
95
280
280
95
87
96
92
84
76
100
99
100
97
CHEAL = Chenopodium album (Common lambsquarters/fat hen)
COMBE = Commelina benghalensis (Dayflower)
ERICA = Conyza canadensis (horseweed/marestail)
GLY-RES = Glyphosate-resistant
Ob = observed
Ex = expected
[0043] Although the invention has been described with reference to preferred embodiments and examples thereof, the scope of the present invention is not limited only to those described embodiments. As will be apparent to persons skilled in the art, modifications and adaptations to the above-described invention can be made without departing from the spirit and scope of the invention, which is defined and circumscribed by the appended claims.
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An herbicidal composition containing (a) an herbicidal dicamba derivative component and (b) an herbicidal glyphosate derivative component provides synergistic control of selected weeds.
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BACKGROUND OF THE INVENTION
This invention relates generally to the isomerization of hydrocarbons. This invention relates more specifically to the processing of benzene-containing hydrocarbon feeds and the isomerization of light paraffins.
DESCRIPTION OF THE PRIOR ART
High octane gasoline is required for modern gasoline engines. Formerly it was common practice to accomplish octane number improvement by the use of various lead-containing additives. As lead is phased out of gasoline for environmental reasons, it is necessary to rearrange the structure of the hydrocarbons used in gasoline blending in order to achieve high octane ratings. Catalytic reforming and catalytic isomerization are two widely used processes for this upgrading.
A gasoline blending pool is usually derived from naphtha feedstocks and includes C 4 and heavier hydrocarbons having boiling points of less than 205ยฐ C. (400ยฐ F.) at atmospheric pressure. This range of hydrocarbon includes C 4 -C 9 paraffins, cycloparaffins and aromatics. Of particular interest have been the C 5 and C 6 normal paraffins which have relatively low octane numbers. The C 4 -C 6 hydrocarbons have the greatest susceptibility to octane improvement by lead addition and were formerly upgraded in this manner. Octane improvement can. also be obtained by catalytically isomerizing the paraffinic hydrocarbons to rearrange the structure of the paraffinic hydrocarbons into branch-chained paraffins or reforming to convert the C 6 and heavier hydrocarbons to aromatic compounds. Normal C 5 hydrocarbons are not readily converted into aromatics, therefore, the common practice has been to isomerize these lighter hydrocarbons into corresponding branch-chained isoparaffins. Although the non-cyclic C 6 and heavier hydrocarbons can be upgraded into aromatics through dehydrocyclization, the conversion of C 6 's to aromatics creates higher density species and increases gas yields with both effects leading to a reduction in liquid volume yields. Therefore, it is preferable to charge the non-cyclic C 6 paraffins to an isomerization unit to obtain C 6 isoparaffin hydrocarbons. Consequently, octane upgrading commonly uses isomerization to convert normal C 6 and lighter boiling hydrocarbons and reforming to convert C 6 cycloparaffins and higher boiling hydrocarbons.
In the reforming process, C 6 cycloparaffins and other higher boiling cyclic hydrocarbons are converted to benzene and benzene derivatives. Since benzene and these derivatives have a relatively high octane value, the aromatization of these naphthenic hydrocarbons has been the preferred processing route. However, many countries are contemplating or have enacted legislation to restrict the benzene concentration of motor fuels. Therefore, processes are needed for reducing the benzene content of the gasoline pool while maintaining sufficient conversion to satisfy the octane requirements of modern engines.
Combination processes using isomerization and reforming to convert naphtha range feedstocks are well known. U.S. Pat. No. 4,457,832 uses reforming and isomerization in combination to upgrade a naphtha feedstock by first reforming the feedstock, separating a C 5 -C 6 paraffin fraction from the reformate product, isomerizing the C 5 -C 6 fraction to upgrade the octane number of these components and recovering a C 5 -C 6 isomerate liquid which may be blended with the reformate product. U.S. Pat. Nos. 4,181,599 and 3,761,392 show a combination isomerization-reforming process where a full range naphtha boiling feedstock enters a first distillation zone which splits the feedstock into a lighter fraction that enters an isomerization zone and a heavier fraction that is charged as feed to a reforming zone. In both the '392 and '599 patents, reformate from one or more reforming zones undergoes additional separation and conversion, the separation including possible aromatics recovery, which results in additional C 5 -C 6 hydrocarbons being charged to the isomerization zone.
The benzene contribution from the reformate portion of the gasoline pool can be decreased or eliminated by altering the operation of the reforming section. There are a variety of ways in which the operation of the refining section may be altered to reduce the reformate benzene concentration. Changing the cut point of the naphtha feed split between the reforming and isomerization zones from 180ยฐ to 200ยฐ F. will remove benzene, cyclohexane and methylcyclopentane from the reformer feed. Benzene can alternately also be removed from the reformate product by splitting the reformate into a heavy fraction and a light fraction that contains the majority of the benzene. Practicing either method will put a large quantity of benzene into the feed to the isomerization zone.
The isomerization of paraffins is a reversible reaction which is limited by thermodynamic equilibrium. The basic types of catalyst systems that are used in effecting the reaction are a hydrochloric acid promoted aluminum chloride system and a supported aluminum chloride catalyst. Either catalyst is very reactive and can generate undesirable side reactions such as disproportionation and cracking. These side reactions not only decrease the product yield but can form olefinic fragments that combine with the catalyst and shorten its life. One commonly practiced method of controlling these undesired reactions has been to carry out the reaction in the presence of hydrogen. With the hydrogen that is normally present and the high reactivity of the catalyst, any benzene entering the isomerization zone is quickly hydrogenated. The hydrogenation of benzene in the isomerization zone increases the concentration of naphthenic hydrocarbons in the isomerization zone.
A large percentage of the C 4 -C 6 paraffin fractions that are available as feedstocks for C 4 -C 6 isomerization processes include cyclic hydrocarbons. Cyclic hydrocarbons present in the reaction zone or formed in the reaction zone tend to be absorbed on the isomerization catalysts. Absorption of the cyclic compounds blocks active sites on the catalyst and thereby inhibits the isomerizable paraffins from the catalyst. This exclusion diminishes the overall conversion of the process. As a result, removal of cyclic hydrocarbons from an isomerization process has been generally practiced to increase conversion of the paraffins to more highly branched paraffins. Complete removal of cyclic hydrocarbons by ordinary separation cannot be achieved due to the boiling points of the C 6 paraffins and many of the cyclic hydrocarbons, in particular, normal hexane and methylcyclopentane.
It is also known to eliminate cyclic hydrocarbons by opening rings. U.S. Pat. No. 2,915,571 teaches the reduction of naphthenes in an isomerization feed fraction by contact with a ring opening catalyst containing an iron group metal in a first reaction zone, and subsequent isomerization of the feed fraction by contact with a different catalyst in an isomerization zone. Opening of the cyclic hydrocarbons has the two fold advantage of eliminating the cyclic hydrocarbons that can cause catalyst fouling and increasing the volume of lower density isomerizable hydrocarbons that in turn increases product yields. The use of different catalysts for ring opening and isomerization imposes a major drawback on the process of U.S. Pat. No. 2,915,571 since it requires at least one additional reaction zone. U.S. Pat. No. 3,631,117 describes a process for the hydro-isomerization of cyclic hydrocarbons that uses a zeolite supported Group VIII metal as a ring opening catalyst at high severity conditions and as an isomerization catalyst at low severity conditions to obtain cyclic isomers having at least one less carbon atom per ring than the unconverted cyclic hydrocarbons. It is also known from U.S. Pat. No. 4,834,866 that rings can be opened in an isomerization zone using a chlorided platinum alumina catalyst at moderate isomerization conditions. When high severity operating conditions are used to open rings, substantial cracking of C 4 -C 6 hydrocarbons to light ends will also occur. Therefore, high severity conditions to open rings in C 4 -C 6 hydrocarbon feedstocks are usually avoided.
Apart from any problems posed by the saturation of the benzene and the resulting increase in the concentration of cyclic hydrocarbons, the saturation of benzene has the disadvantage of raising the temperature in the isomerization zone. In order to achieve a desired conversion, the feed to the isomerization zone is heated to a temperature that will promote the isomerization reaction. The additional heat resulting from benzene saturation can raise the temperature of the isomerization zone above that which will provide the highest conversion of less highly branched C 5 and C 6 hydrocarbons to more highly branched C 5 and C 6 hydrocarbons. It has therefore been difficult to process high concentrations of benzene in feeds to C 5 and C 6 isomerization zones. The heat associated with benzene saturation has either posed limitations on the amount of benzene that can be processed in an isomerization zone or have reduced yields of desired isomers.
It is, therefore, an object of this invention to provide a process that will facilitate the removal of benzene from the gasoline pool.
It is a further object of this invention to advantageously increase the benzene saturation capacity of a light paraffin isomerization process.
A yet further object of this invention is to reduce the loss of light paraffin conversion from the saturation of benzene in an isomerization process.
BRIEF DESCRIPTION OF THE INVENTION
This invention is a process for isomerizing a feedstock comprising C 4 -C 6 paraffins and benzene by splitting the benzene containing feedstream between at least two reaction zones and combining the feed fractions with the effluent streams of the reaction zones to saturate benzene with isomerization catalyst while maintaining favorable isomerization temperatures in the reaction zones. The benzene content in the gasoline pool is reduced by its saturation in the isomerization process. The splitting of the feed stream distributes the heat of reaction over two reactors and lowers the maximum exotherm selective to that developed in any individual reactor. The lower exotherm permits the saturation of higher benzene content feeds in a multi-reactor isomerization zone without reducing product quality or the reduction of the maximum temperature of any of the reaction zones for a given level of benzene saturation.
The feed splitting aspects of this invention require at least two reaction zones. These reaction zones are operated to accomplish some degree of isomerization along with saturation of benzene. The reaction zones can provide partial or essentially full saturation of benzene. Full saturation of benzene refers to an outlet benzene concentration of less than 0.1 mol % in the effluent stream. The at least two reaction zones are needed to split feed entering the process and to perform benzene saturation in each reaction zone. The process is not limited to the use of only two reaction zones for benzene saturation and the benzene containing feed may be split between any number of reaction zones. Additional reaction zones dedicated principally to isomerization may also be provided. In most arrangements, the process will use two reaction zones between which the entering feed is split and a final reaction zone that receives the effluent from the upstream reaction zones for additional isomerization conversion.
Accordingly in one embodiment this invention is a process for the isomerization of C 4 -C 6 paraffinic feedstock that contains at least 1 wt. % benzene. The process separates the feedstock into at least two portions to provide a first and a second feedstream and contacts the first feedstream, a recycle stream and a hydrogen containing gas stream with an isomerization catalyst at isomerization conditions in a first isomerization reactor and recovers a first isomerization zone effluent. The second feedstream and at least a portion of the first isomerization zone effluent contacts an isomerization catalyst at isomerization conditions in a second isomerization reactor to recover a second isomerization zone effluent. At least a portion of the second effluent stream is recovered as the recycle stream.
In a more specific embodiment this invention is a process for the isomerization of C 5 -C 6 paraffinic feedstocks that contain at least 5 wt. % benzene. The process comprises: separating the feedstock into two aliquot portions comprising a first and a second feedstream; combining a hydrogen-rich gas stream and a recycle stream with the first feedstream to provide a combined feedstream; contacting the combined feedstream with an isomerization catalyst at isomerization conditions in a first isomerization reactor and recovering a first isomerization zone effluent; contacting the second feedstream and the first isomerization zone effluent with an isomerization catalyst at isomerization conditions in a second isomerization zone and recovering a second isomerization zone effluent; contacting the second isomerization zone effluent with an isomerization catalyst at isomerization conditions in a third isomerization reactor and recovering a third isomerization zone effluent; and, separating at least a portion of the third isomerization zone effluent into the recycle stream and a product stream.
Other embodiments, aspects and details of this invention are disclosed in the following detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE shows a preferred arrangement for the process of this invention.
DETAILED DESCRIPTION OF THE INVENTION
A basic arrangement for the processing equipment used in this invention can be readily understood by a review of the flow scheme presented in the FIGURE. The FIGURE and this description make no mention of pumps, compressors, receivers, condensers, reboilers, instruments and other well-known items of processing equipment in order to simplify the explanation of the invention. Looking then at the FIGURE, a feedstream comprising C 5 and C 6 paraffins along with at least 1 wt. % benzene enter the process through line 10 and pass through a drier 12 that removes water and any other catalyst poisons from the feedstream. Lines 11 and 13 split the dried feedstock into two feedstreams. Make-up hydrogen enters the process through line 14 and a drier 16 for removal of water and, if provided, combines with a hydrogen recycle stream 15. The feedstream of line 13 and the dried hydrogen from a line 17 are combined in a line 21 to form a combined feed. The combined feed receives an additional input of isomerization product recycle from a line 23 which provides the feed to isomerization zone 20 via a line 18. The contents of line 18 are heat exchanged in an exchanger 24 against the contents of line 20' which carries the effluent from a third isomerization reactor 22. The contents of line 18 are further heat exchanged in an exchanger 26 against the contents of a line 28 which carries the effluent from a second isomerization reactor 30. The contents of line 18 may be further heat exchanged against the effluent 27 of the first reaction zone in an exchanger 37. After heating in another exchanger 19 the contents of line 18 enter reactor 20. When using a chloride promoted catalyst, a line 25 injects a chloride-containing compound into line 18. The isomerization reactor 20 performs the first stage of isomerization and saturates benzene in the combined feed. Line 27 carries an effluent, at an elevated temperature relative to the contents of line 23, into admixture with the other feed portion, carried by line 11 to provide a second combined feed taken by line 31. Where necessary, the feed portion of line 11 may be heated in an exchanger 29. Line 31 carries a saturated effluent and the additional feed portion into a second isomerization reactor 30. A second stage of isomerization takes place in reactor 30. Following the second stage of isomerization, line 28 carries the partially cooled isomerization effluent from reactor 30 to reactor 22. After further isomerization in reactor 22, an isomerate product is taken by line 20. In those operations that operate with recycle hydrogen a separator 33 receives the isomerization zone effluent and recovers recycle hydrogen overhead through a line 35 which feeds a compressor 36 for the return of hydrogen to the isomerization reactors via line 15. Bottoms from separator 33 pass to a fractionation column 40 via lines 37 and 38. If desired line 39 may divert a portion of the separated isomerization fraction for supplying recycle to the isomerization zones. Fractionation column 40 removes light gases from the isomerate product which are taken overhead by line 42 and withdrawn from the process through the top of a receiver 44 via line 46. Line 45 provides reflux from receiver 44 back to column 40. The stabilized isomerate product is withdrawn from the bottom of fractionator 40 by line 48. A portion of the stabilized product is taken by a line 41. Line 41 and/or the separated fraction diverted by line 39 supply the recycle that enters the isomerization reactors via lines 23 and 18.
Suitable feedstocks for this invention will include C 4 plus hydrocarbons up to an end boiling point of about 250ยฐ C. (482ยฐ F.). The feedstocks that are used in this invention will typically include hydrocarbon fractions rich in C 4 -C 6 normal paraffins. The term "rich" is defined to mean a stream having more than 50% of the mentioned component. In addition, the feedstock will include significant amounts of benzene. In order to realize the advantages of this invention, the concentration of benzene in the feedstock will at least equal 1 wt. % and will normally be at least 2 wt. %. Preferably, the concentration of benzene will equal at least 5 wt. % and will more preferably be in a range of from 10 to 25 wt. %. The upper limit on the concentration of benzene is dictated by the need to have sufficient paraffinic hydrocarbons present for isomerization and to limit the concentration of benzene. The other feed components will usually comprise C 5 -C 6 cyclic and paraffinic hydrocarbons with normal and isohexane providing most of the paraffinic components.
As hereinafter described in more detail, some of the possible isomerization zone catalysts suitable for use in this invention are highly sensitive to water and other contaminants. In order to keep water content within acceptable levels for such catalysts, all of the isomerization zone feed passes first through a drying zone. The drying zone for this purpose may be of any design that will reduce water content to 0.1 ppm or less. Suitable adsorption processes for this purpose are well known in the art. The isomerization zone catalyst is often sulfur sensitive. Suitable guard beds or adsorptive separation processes may be used to reduce the sulfur concentration of the feedstock. The FIGURE shows the treatment of the feedstock upstream of the hydrogen addition point; however, the feedstock may be treated for any necessary water and contaminant removal at any point upstream of the isomerization catalyst.
A hydrogen stream is combined with the feedstock to provide hydrogen for the hydrogenation and isomerization zones. When the hydrogen is added downstream of the feedstock treating section, the hydrogen stream also undergoes drying or other treatment necessary for the sustained operation of the isomerization zone. The saturation of benzene results in a net consumption of hydrogen. Although hydrogen is not consumed by the isomerization reaction, the isomerization of the light paraffins is usually carried out in the presence of hydrogen. Therefore, the amount of hydrogen added to the feedstock should be sufficient for both the requirements of the hydrogenation zone and the isomerization zone.
The amount of hydrogen admixed with the feedstock varies widely. For the isomerization zones, the amount of hydrogen can vary to produce anywhere from a 0.01 to a 10 hydrogen to hydrocarbon mol ratio in the last isomerization zone effluent. Consumption of hydrogen by saturation increases the required amount of hydrogen admixed with the feedstock. Therefore, hydrogen will usually be mixed with the feedstock in an amount sufficient to create a combined feed having a hydrogen to hydrocarbon ratio of from 0.1 to 5. Lower hydrogen to hydrocarbon ratios in the combined feed are preferred to simplify the system and equipment associated with the addition of hydrogen. At minimum, the hydrogen to hydrocarbon ratio must supply the stoichiometric requirements for the saturation reaction. In order for the saturation to take place at the mild conditions of this invention, it is preferable that an excess of hydrogen be provided with the combined feed. Although no net hydrogen is consumed in the isomerization reaction, the isomerization zone will have a net consumption of hydrogen often referred to as the stoichiometric hydrogen requirement which is associated with the saturation reaction and a number of side reactions that occur. These side reactions include saturation of olefins and aromatics, cracking and disproportionation. Hydrogen in excess of the stoichiometric amounts for the side reactions is maintained in the isomerization zone to provide good stability and conversion by compensating for variations in feedstream compositions that alter the stoichiometric hydrogen requirements and to prolong catalyst life by suppressing side reactions such as cracking and disproportionation. Side reactions left unchecked reduce conversion and lead to the formation of carbonaceous compounds, i.e., coke, that foul the catalyst.
It has been found to be advantageous in some cases to minimize the amount of hydrogen added to the feedstock. When the hydrogen to hydrocarbon ratio at the effluent of the isomerization zone exceeds about 0.1, it is not economically desirable to operate the isomerization process without the recovery and recycle of hydrogen to supply a portion of the hydrogen requirements. Facilities for the recovery of hydrogen from the effluent are needed to prevent the loss of product and feed components that can escape with the flashing of hydrogen from the isomerization zone effluent. These facilities add to the cost of the process and complicate the operation of the process. It is possible to operate the isomerization zone with the effluent hydrogen to hydrocarbon ratio as low as 0.05 without adversely affecting conversion or catalyst stability. Accordingly where possible, the addition of hydrogen to the feedstock will be kept to below an amount that will produce a hydrogen to hydrocarbon ratio in excess of 0.1 and more preferably 0.05 in the effluent from the isomerization zone.
In this invention, split feed and hydrogen enters at least two isomerization zones for the rearrangement of the paraffins contained therein from less highly branched hydrocarbons to more highly branched hydrocarbons. Furthermore, at least two of the isomerization zones saturate the benzene contained in the feed. The isomerization zones use a solid isomerization catalyst to promote the isomerization reaction. The catalyst used in the process can be distributed equally or in varying proportions between the reactors. There are a number of different isomerization catalysts that can be used for this purpose. The two general classes of isomerization catalysts use a noble metal as a catalytic component. This noble metal, usually platinum, is utilized on a chlorided alumina support when incorporated into one general type of catalyst and for the other general type of catalyst the platinum is present on a crystalline alumina silicate support that is typically diluted with an inorganic binder. Preferably, the crystalline alumina type support of the latter catalyst type is a zeolitic support and more preferably a mordenite type zeolite. The zeolitic type isomerization catalysts are well known and are described in detail in U.S. Pat. Nos. 3,442,794 and 3,836,597.
Although either type of catalyst may be used in this invention, the preferred catalyst is a high chloride catalyst on an alumina base that contains platinum. The alumina is preferably an anhydrous gamma-alumina with a high degree of purity. The catalyst may also contain other platinum group metals. The term platinum group metals refers to noble metals excluding silver and gold which are selected from the group consisting of platinum, palladium, germanium, ruthenium, rhodium, osmium, and iridium. These metals demonstrate differences in activity and selectivity such that platinum has now been found to be the most suitable for this process. The catalyst will contain from about 0.1 to 0.25 wt. % of the platinum. Other platinum group metals may be present in a concentration of from 0.1 to 0.25 wt. %. The platinum component may exist within the final catalytic composite as an oxide or halide or as an elemental metal. The presence of the platinum component in its reduced state has been found most suitable for this process.
The catalyst also contains a chloride component. The chloride component termed in the art "a combined chloride" is present in an amount from about 2 to about 10 wt. % based upon the dry support material. The use of chloride in amounts greater than 5 wt. % have been found to be the most beneficial for this process.
There are a variety of ways for preparing the catalytic composite and incorporating the platinum metal and the chloride therein. The method that has shown the best results in this invention prepares the catalyst by impregnating the carrier material through contact with an aqueous solution of a water-soluble decomposable compound of the platinum group metal. For best results, the impregnation is carried out by dipping the carrier material in a solution of chloroplatinic acid. Additional solutions that may be used include ammonium chloroplatinate, bromoplatinic acid or platinum dichloride. Use of the platinum chloride compound serves the dual function of incorporating the platinum component and at least a minor quantity of the chloride into the catalyst. Additional amounts of the chloride must be incorporated into the catalyst by the addition or formation of aluminum chloride to or on the platinum-alumina catalyst base. An alternate method of increasing the chloride concentration in the final catalyst composite is to use an aluminum hydrosol to form the alumina carrier material such that the carrier material also contains at least a portion of the chloride. Halogen may also be added to the carrier material by contacting the calcined carrier material with an aqueous solution of the halogen acid such as hydrogen chloride.
It is generally known that high chlorided platinum-alumina catalysts of this type are highly sensitive to sulfur and oxygen-containing compounds. Therefore, the feedstock must be relatively free of such compounds. A sulfur concentration no greater than 0.5 ppm is generally required. The presence of sulfur in the feedstock serves to temporarily deactivate the catalyst by platinum poisoning. Activity of the catalyst may be restored by hot hydrogen stripping of sulfur from the catalyst composite or by lowering the sulfur concentration in the incoming feed to below 0.5 ppm so that the hydrocarbon will desorb the sulfur that has been adsorbed on the catalyst. Water can act to permanently deactivate the catalyst by removing high activity chloride from the catalyst and replacing it with inactive aluminum hydroxide. Therefore, water, as well as oxygenates, in particular C 1 -C 5 oxygenates, that can decompose to form water, can only be tolerated in very low concentrations. In general, this requires a limitation of oxygenates in the feed to about 0.1 ppm or less. As previously mentioned, the feedstock may be treated by any method that will remove water and sulfur compounds. Sulfur may be removed from the feedstock by hydrotreating. Adsorption processes for the removal of sulfur and water from hydrocarbon streams are also well known to those skilled in the art.
Operation of the reaction zone with a chloride promoted catalyst also requires the presence of a small amount of an organic chloride promoter. The organic chloride promoter serves to maintain a high level of active chloride on the catalyst as small amounts of chloride are continuously stripped off the catalyst by the hydrocarbon feed. The concentration of promoter in the reaction zone is usually maintained at from 30 to 300 ppm. The preferred promoter compound is carbon tetrachloride. Other suitable promoter compounds include oxygen-free decomposable organic chlorides such as perchloroethylene, propyldichloride, butylchloride, and chloroform to name only a few of such compounds. The need to keep the reactants dry is reinforced by the presence of the organic chloride compound which may convert, in part, to hydrogen chloride. As long as the process streams are kept dry, there will be no adverse effect from the presence of small amounts of hydrogen chloride.
Operating conditions within the isomerization zone are selected to maximize the production of isoalkane product from the feed components. Temperatures within the reaction zone will usually range from about 40ยฐ-260ยฐ C. (105ยฐ-500ยฐ F.). Lower reaction temperatures are preferred for purposes of isomerization conversion since they favor isoalkanes over normal alkanes in equilibrium mixtures. The isoalkane product recovery can be increased by opening some of the cyclohexane rings produced by the saturation of the benzene. However, if it is desired, maximizing ring opening usually requires temperatures in excess of those that are most favorable from an equilibrium standpoint. For example, when the feed mixture is primarily C 5 and C 6 alkanes, temperatures in the range of 60ยฐ-160ยฐ C. are desired from a normal-isoalkane equilibrium standpoint but, in order to achieve significant opening of C 5 and C 6 cyclic hydrocarbon ring, the preferred temperature range for this invention lies between 100ยฐ-200ยฐ C. When it is desired to also isomerize significant amounts of C 4 hydrocarbons, higher reaction temperatures are required to maintain catalyst activity. Thus, when the feed mixture contains significant portions of C 4 -C 6 alkanes the most suitable operating temperatures for ring opening and isoalkane equilibrium coincide and are in the range from 145ยฐ-225ยฐ C. The reaction zone may be maintained over a wide range of pressures. Pressure conditions in the isomerization of C 4 -C 6 paraffins range from 7 barsg to 70 barsg. Higher pressures favor ring opening, therefore, the preferred pressures for this process are in the range of from 25 barsg to 60 barsg when ring opening is desired. The feed rate to the reaction zone can also vary over a wide range. These conditions include liquid hourly space velocities ranging from 0.5 to 12 hr. -1 , however, space velocities between 0.5 and 3 hr. -1 are preferred.
The combined feed enters a first isomerization zone for the isomerization of hydrocarbons and the saturation of benzene that operates at isomerization and benzene saturation conditions. In some cases the saturation of benzene will be the primary reaction occurring in the isomerization zone. It is not necessary to operate the first reaction zone to obtain a complete elimination of benzene. In most cases, the process lowers the benzene concentration in the outlet from the first reaction zone to less than 0.1 wt %. The isomerization and saturation reactor will usually operate at a pressure of from 100 to 1000 psig and more typically in a pressure range of from 300 to 500 psig. The initial reactor and any additional reactors usually operate with a liquid hourly space velocity (LHSV) range of from 1 to 8. The amount of benzene saturation performed in the reaction zones is ordinarily maintained at a level that restricts the temperature rise to the reaction zone to less than about 100ยฐ F. In order to initiate benzene saturation, the isomerization zone will typically operate at a temperature of at least 180ยฐ F. although lower temperatures are also known to provide some benzene saturation. Preferrably the first reaction zone will have a maximum outlet temperature of 280ยฐ F. In most cases, the reaction zone will operate at inlet temperatures of between 200ยฐ-220ยฐ F. Such operating temperatures are somewhat lower than typical isomerization temperatures which lie in a range of 260ยฐ-340ยฐ F. The lower temperatures for the saturation reaction are preferred to avoid unwanted side reactions and to provide a two-phase flow out of the isomerization reactor. The two-phase flow provides additional temperature control to compensate for changes in the benzene feed concentration to the reaction zone. Preferred outlet conditions will limit the vapor fraction to 0.9 or less and usually corresponds to operate with an outlet temperature above 15ยฐ-25ยฐ F. below the dew point of the effluent.
The amount of benzene saturation and the temperature rise that takes place in the first reactor is a direct result of the initial feed benzene concentration, the split of feed between the reaction zones receiving the initial feed, and the temperature rise in each reaction zone where benzene saturation occurs. The proportion of feed split between the two reaction zones will be determined by the overall benzene concentration and the temperature rise through the reaction zones. The feed split between the reaction zone and the amount of recycle sent back to the reaction zones is generally set to maintain a concentration of 5 wt % benzene when admixed with the recycle liquid.
Typically, a greater proportion of feed is transferred to the second reaction zone. The first reaction zone will usually receive from 25 to 45% of the feedstock. For a feed containing about 15 mol % benzene, from 30-40% of the feed will usually enter the first reaction zone with the remainder sent to a second reaction zone. The amount of recycled effluent entering the first reaction zone can also undergo adjustment to control the temperature rise. The amount of feed recycled to the first and second or any additional reaction zones receiving a split of the initial benzene feed will fall in a range of recycled to combined feed of about 0.5 to 4. Preferably, the ratio of recycle to feed will be in a range of from 1 to 2.5.
The feed to the second reaction zone is a mixture of an aliquot portion of the entering feed and the effluent from the first reaction zone. Operating conditions in the second reaction zone are similar to those for the first reaction zone. However, the operation of the second reaction zone may have slightly elevated temperatures which at the inlet are typically 10ยฐ-20ยฐ higher than those in the first reaction zone. Preferrably the second reaction zone will also have a maximum outlet temperature of 280ยฐ F. It is also desirable that the second reaction zone operate in a mixed phase to provide a liquid buffer that controls the temperature rise in the effluent from the reaction zone.
The feed to the first reaction zone undergoes several stages of heat exchange to raise it to operating temperature. The incoming feed may be exchanged against the effluent from each reaction zone, or only heat exchanged against the effluent from the latter reactors which usually tend to operate hotter. A charge heater will typically be provided to the first reaction zone to supply any additional heat required by the first reactor. In processing low benzene concentrations feed with the split feed arrangement, an additional charge heater may be provided for the portion of the split feed that enters subsequent reaction zones. Therefore, the figure shows the optional arrangement of an additional charge heater 29 to heat the split feed portion entering the second reactor.
Operation of the second reaction zone can again achieve either full or partial saturation of the benzene in the combined feed passing therethrough. Whether fully converted or containing benzene, the effluent from the second reaction zone can optionally pass on to a third isomerization zone. In many arrangements, a third and any subsequent isomerization reactors will accomplish a greater portion of the isomerization than either the first or second reaction zone individually and often collectively. The third reaction zone will operate at temperatures in the range of from 200ยฐ to 450ยฐ F. and preferably in a range of from 260ยฐ-400ยฐ F. The third reaction zone and any subsequent reaction zones in most instances complete the saturation of benzene. The effluent from the final reaction zone will preferably have a benzene concentration of less than 0.1 wt. %. Additional coolers or exchangers can be provided downstream of the primary benzene separation reactors to cool the subsequent reactors and provide temperatures more favorable for particular isomerization conversions.
Whether operated with two, three or more reaction zones, the effluent of the process will enter separation facilities for the recovery of an isoalkane product. At minimum, the separation facilities divide the reaction zone effluent into a product stream comprising C 5 and heavier hydrocarbons and a gas stream which is made up of C 3 lighter hydrocarbons and hydrogen. To the extent that C 4 hydrocarbons are present, the acceptability of these hydrocarbons in the product stream will depend on the blending characteristics of the desired product, in particular vapor pressure considerations. Consequently, C 4 hydrocarbons may be recovered with the heavier isomerization products or withdrawn as part of the overhead or in an independent product stream. Suitable designs for rectification columns and separator vessels to separate the isomerization zone effluent are well known to those skilled in the art.
When hydrogen is received for recycle from the isomerization zone effluent, the separation facilities, in simplified form, can consist of a product separator and a stabilizer. The product separator operates as a simple flash separator that produces a vapor stream rich in hydrogen with the remainder of its volume principally comprising C 1 and C 2 hydrocarbons. The vapor stream serves primarily as a source of recycle hydrogen which is usually returned directly to the first isomerization reactor. The separator may contain packing or other liquid vapor separation devices to limit the carryover of hydrocarbons. The presence of C 1 and C 2 hydrocarbons in the vapor stream does not interfere with the isomerization process, therefore, some additional mass flow for these components is accepted in exchange for a simplified column design. The remainder of the isomerization effluent leaves the separator as a liquid which is passed on to a stabilizer, typically a trayed column containing approximately 30 trays. The column will ordinarily contain condensing and reboiler loops for the withdrawal of a light gas stream comprising at least a majority of the remaining C 3 hydrocarbons from the feed stream and a liquid bottoms stream comprising C 5 and heavier hydrocarbons. Normally when the isomerization zone contains only a small quantity of C 4 hydrocarbons, the C 4 's are withdrawn with the light gas stream. After caustic treatment for the removal of chloride compounds, the light gas stream will ordinarily serve as a fuel gas. The stabilizer overhead liquid, which represents the remainder of the isomerization zone effluent passes back to the fractionation zone as recycle input.
The FIGURE show a flow scheme that uses recycle hydrogen. A simplified flow scheme for use without a hydrogen recycle stream would most often take all of the excess hydrogen from the isomerization zone with the overhead stream from the stabilizer drum or receiver. Since, as a precondition for the use of the non hydrogen recycle arrangement, the amount of hydrogen entering the stabilizer is low, the rejection of hydrogen with the fuel gas stream does not significantly increase the loss of product hydrocarbons.
An essential part of this invention is the recycle of a portion of the isomerization zone effluent in combination with the feed to the first reaction zone. The effluent may be taken directly from any of the reaction zones after any desired heat exchange. The bottoms stream from a stabilizer, where provided, may supply the isomerization zone effluent for recycle. As an additional or separate source, the bottoms stream from the separator can supply all or a portion of the isomerization zone effluent recycled to the first reactor. Those skilled in the art will be aware of the most advantageous locations to withdraw the recycle for the first reaction zone to maximize conversion and heat integration aspects of any particular process.
In order to more fully illustrate the process, the following example is presented to demonstrate the operation of the process utilizing the flow scheme of the FIGURE. This example is based in part on a computer simulation of the process and experience with other isomerization and fractionation systems. All of the numbers identifying vessels and lines correspond to those given in the FIGURE.
A C 5 plus naphtha feed having the composition given in the Table enters through line 10 and after drying is split to send approximately 37% of the feed to reactor 20 and approximately 63% of the feed to reactor 30. The feed is combined with dry make-up and recycle hydrogen to produce a hydrogen to hydrocarbon ratio of about 2.0 in the feed passing to the first reactor via line 18. Recycle isomerization zone effluent from line 23 combines with the incoming feed at a combined feed ratio of about 1.5 in a pressure of about 500 psig. Exchanger 24 heats the incoming feed and the recycle from a temperature of about 100ยฐ F. to a temperature of about 160ยฐ F. In the arrangement of this example, the combined feed by-passes exchanger 22 and is heated in exchanger 37 from a temperature of about 160ยฐ to a temperature of about 185ยฐ. Charge heater 19 raises the temperature of the incoming feed to a temperature of about 190ยฐ F. Carbon tetrachloride is added as a chloride promoter at a rate to provide the feedstream entering the first reaction zone with 100 wt. ppm chloride in the incoming feed. After addition of the chloride promoter, the feed contacts a chlorided platinum aluminum catalyst in the first reactor at a liquid hourly space velocity (LHSV) of about 2.0. The effluent from reactor 20 has a temperature of about 250ยฐ F. and mixes with the remainder of the reactor charge. Auxiliary charge heater 29 operates without additional heat input and the combined feed enters the second isomerization zone 30 at a combined feed ratio of 1.5 and a temperature of about 205ยฐ F. Passage of the second combined feed through the second isomerization zone at a pressure of about 500 psig produces an effluent stream that exits the reactor at a temperature of about 280ยฐ and passes to reactor 22 without further heat exchange for additional isomerization. The converted isomerization zone feed leaves reactor 22 at a temperature of about 285ยฐ F. which, after heat exchange, is reduced to a temperature of about 260ยฐ F. Separator 33 recovers a hydrogen recycle stream that supplies hydrogen to the inlet of reactor 1. In this example, the bottoms from separator 33 provides all of the recycle to the first isomerization zone and the remainder of the separator bottoms enters stabilizer section 40. Stabilizer 40 provides a bottoms product stream having an octane of from 83 to 79 RONC and a mass volume increase of about 3% over the entering feed.
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The benzene content in a gasoline pool is reduced by an isomerization process that splits a benzene-containing C 4 -C 6 feedstream between at least two reaction zones and combines the feed fractions with effluent streams. The splitting of the feed stream distributes the heat of reaction over two reactors and lowers the relative exotherm. The lower exotherm for benzene saturation permits higher benzene feeds to be processed without reducing product quality.
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[0001] This application claims priority under 35 U.S.C. 119(e) to U.S. provisional application 60/962,690, filed Jul. 31, 2007, the contents of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of refining and/or producing hydrocarbons such as biofuels by the method of vacuum distillation.
BACKGROUND
[0003] In an effort to partially replace dependence on petroleum-based diesel, vegetable oils have been directly added to diesel fuel. These vegetable oils are composed mainly of triglycerides, and often contain small amounts (typically between 1 and 10% by weight) of free fatty acids. Some vegetable oils may also contain small amounts (typically less than a few percent by weight) of mono- and di-glycerides.
[0004] Triglycerides are esters of glycerol, CH 2 (OH)CH(OH)CH 2 (OH), and three fatty acids. Fatty acids are, in turn, aliphatic compounds containing 4 to 24 carbon atoms and having a terminal carboxyl group. Diglycerides are esters of glycerol and two fatty acids, and monoglycerides are esters of glycerol and one fatty acid. Naturally occurring fatty acids, with only minor exceptions, have an even number of carbon atoms and, if any unsaturation is present, the first double bond is generally located between the ninth and tenth carbon atoms. The characteristics of the triglyceride are influenced by the nature of their fatty acid residues.
[0005] The production of alkyl esters of glycerides by transesterification is a known process. However, transesterification suffers in that the reaction generally requires the addition of an acid or base catalyst which must be neutralized after the reaction thereby generating salts and soaps. In addition, while transesterification results in the separation of fatty acid esters from triglycerides, it also results in the production of glycerin, which must then be separated from the fatty acid esters, glycerin, excess alcohol, salts, and soaps.
[0006] The production of alkyl esters of fatty acids by acid catalyzed esterification is also known. However, the use a strong acid, such as sulfuric acid, typically leads to higher sulfur content in the resulting ester as the acid reacts with the double bonds in the fatty acid chains. In addition, conversion of the esterification reaction is limited by equilibrium constraints such that either excessive time and equipment size are required or less conversion needs to be accepted. In an effort to overcome some of the problems associated with transesterification, several attempts have been made to employ esterification between fatty acids and alcohols. In these processes, fatty acids are prepared from triglycerides by hydrolysis, followed by catalyzed esterification of the fatty acids with an alcohol, preferably methanol. While this practice is practiced in the production of fatty alcohols and fatty acid esters, as described in U.S. Pat. No. 5,536,856 (Harrison et al), it has not been practiced in the production of Renewable Diesel.
[0007] Vacuum distillation of hydrocarbons is a refining process that can be utilized to minimize thermal cracking of heavier fractions of hydrocarbons and obtain lighter desired products. Distilling these materials under vacuum, i.e., lower pressure, decreases the boiling temperature of the various hydrocarbon fractions in the feed and therefore minimizes thermal cracking of these fractions.
[0008] In conventional vacuum distillation systems, distillation is carried out in a vacuum column under pressures typically in the range of 25 to 100 millimeters of mercury (mmHg). It is important in such systems to reduce pressure as much as possible to improve vaporization. Vaporization is enhanced by various methods such as the addition of steam at the furnace inlet and at the bottom of the vacuum distillation column. Vacuum is created and maintained using cooling water condensers and steam driven ejectors. The size and number of ejectors and condensers used is determined by the vacuum needed and the quantity and quality of vapors handled. While vacuum distillation is practiced in the production of petroleum-based products, it has not been practiced in the production of Renewable Diesel in a continuous process combined with esterification in a reactive distillation process.
[0009] Accordingly, one object of the present invention is to utilize vacuum distillation in combination with reactive distillation during esterification to produce a product that meets either ASTM D396 or ASTMD975 specifications or both.
SUMMARY
[0010] The present invention provides a vacuum distillation system and method utilizing high free fatty acid feedstock. Operation of the distillation system enables production of esters including biodiesel and other biofuels in an economically advantageous manner. The vacuum distillation system is optionally located upstream of an esterification unit or other biodiesel production facility for improvement in production economy.
[0011] In one embodiment, the invention is a process for preparing Renewable Diesel comprising the step of vacuum distillation of oil of vegetable and/or animal origin followed by the step of esterification to yield diesel fuel according to either ASTM D396 or ASTM D975 or both. In a preferred embodiment, the feedstock for the process is an oil of vegetable and/or animal origin which is selected from Palm Fatty Acid Distillate (PFAD), Palm Acid Oil (PAO), Acid Oil (Acidulated Soap Stock), and mixtures thereof. In one embodiment, the feedstock oil further comprises up to about 20% pre-split tallow and/or up to about 5% tall oil fatty acid. Alternatively, in one embodiment, the feedstock oil is essentially free of tallow or poultry fat.
[0012] In one embodiment, esterification is carried out by reactive distillation using a solid catalyst. Preferably, the solid catalyst is an ion exchange resin catalyst comprising โSO3H or โCO2H functional groups. Preferably, the step of esterification is performed with an alcohol selected from methanol, t-butanol, isobutanol, or a mixture thereof.
[0013] In one embodiment, a fat splitter may be integrated into the process, optionally between the vacuum distillation unit and the esterification unit.
[0014] In one embodiment, the Renewable Diesel is high value and low acidity. In a preferred embodiment, the process is carried out on an industrial scale. Preferably, the process is continuous.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 shows one embodiment of the present reaction for the preparation of low acidity Renewable Diesel by vacuum distillation followed by reactive distillation esterification.
[0016] FIG. 2 shows another embodiment of the present reaction for the preparation of low acidity Renewable Diesel by vacuum distillation followed by reactive distillation esterification.
[0017] FIG. 3 shows a process flow diagram model according to the invention, providing details of various embodiments.
DETAILED DESCRIPTION
[0018] The present invention provides a process for the production of Renewable Diesel fuels having low acidity, low glycerin, and low sulfur content, from oils of animal and vegetable origin. Renewable Diesel is a material derived from animal or vegetable origin which meets ASTM D396 and/or ASTM D975 specifications. The process of the present invention employs a combination of vacuum distillation and, if desired, reactive distillation esterification to produce fuels that meet either or both of these standards and therefore qualify as Renewable Diesel.
[0019] The animal or vegetable oil feedstocks for use according to the invention include, but are not limited to, fatty acids such as decanoic acid, dodecanoic acid, tetradecanoic acid, hexadecanoic, acid, octadecanoic acid, octadecenoic acid, linoleic acid, eicosanoic acid, isostearic acid and the like, as well as mixtures of two or more thereof as well as oils described as coconut oil, rape seed oil, and palm oils, tall oils, lard, bacon grease, yellow grease, tallow and fish oils. Additional oils may be sourced from whale oil and poultry fat, as well as corn, palm kernel, soybean, olive, sesame, and any other oils of animal or vegetal origin not explicitly identified herein. If desired, such mixtures of acids can be subjected to distillation to remove lower boiling acids having a lower boiling point than a chosen temperature (e.g. C 8 to C 10 acids) and thus produce a โtoppedโ mixture of acids. Optionally, the mixtures can be distilled to remove higher boiling acids having a boiling point higher than a second chosen temperature (e.g. C 22 + acids) and thus produce a โtailedโ mixture of acids. Additionally, both lower and higher boiling acids may be removed and thus produce a โtopped and tailedโ mixture of acids. Such fatty acid mixtures may also contain ethylenically unsaturated acids such as oleic acid. Such mixtures may also contain fatty acid esters. In a preferred embodiment, the feedstock for the process is an oil of vegetable and/or animal origin which is selected from Palm Fatty Acid Distillate (PFAD), Palm Acid Oil (PAO), Acid Oil (Acidulated Soap Stock), and mixtures thereof. In one embodiment, the feedstock oil further comprises up to about 20% pre-split tallow and/or up to about 5% tall oil fatty acid. For example, in one embodiment, about 115 MMlb/yr of pre-split tallow may be used. Use of tall oil fatty acid is envisioned as a cold flow improving blendstock. Alternatively, in one embodiment, the feedstock oil is essentially free of tallow or poultry fat. By essentially free is meant that tallow or poultry fat are not introduced into the feedstock, or in the event of residual contamination from processing of various batches, are not introduced in quantities that affect the processing parameters of the feedstock.
[0020] In one embodiment, the purpose of vacuum distillation is to distill all or nearly all fatty acids and those triglycerides not needed for steam generation while leaving a pitch that contains high-boiling material. In one embodiment, additional beneficial effects may be obtained at higher pressures and temperatures, such as additional fat splitting. In a preferred embodiment, four cuts are made during distillation: 1) water, glycerin, fatty acids, and low boiling material; 2) fatty acids and monoglycerides; 3) tri- and di-glycerides; and 4) pitch. In one embodiment, five cuts are made during distillation: 1) water and low boiling material; 2) glycerin and fatty acids; 3) fatty acids and monoglycerides; 4) tri- and di-glycerides; and 5) pitch.
[0021] In a preferred embodiment, steam from a pre-existing natural gas turbine or coal power plant is used to reduce costs of construction. In a preferred embodiment, pitch or waste organics generated during vacuum distillation are sold to a third-party to improve the overall economic equation for the process.
[0022] Reactive Distillation Esterification refers to a process taking place in a column so designed such that the vapor stream of the more volatile of the two components, (i.e. the more volatile of the vacuum distillation product component and the alcohol component), flows countercurrent to the less volatile component such that the vapor stream carries away water produced in the esterification reaction, while advantageously not carrying away a significant quantity of the less volatile component. For this reason it is essential that the boiling point of the vapor mixture exiting the esterification reactor, or of the highest boiling compound present in that vapor mixture, be significantly lower, at the pressure prevailing in the uppermost stage of the esterification reactor, than the boiling point at that pressure of either of the less volatile one of the two components. By the phrase โsignificantly lowerโ is meant that the boiling point difference shall be at least about 20ยฐ C., and preferably at least about 25ยฐ C., at the relevant operating pressure of the column. In practice, the more volatile component of the two will frequently be the alcohol component. For example, methanol will be the more volatile component in the production from fatty acid mixtures obtained by the hydrolysis of triglycerides of methyl fatty acid ester mixtures for subsequent processing, for example for production of detergent alcohols by ester hydrogenation.
[0023] In one aspect of the present invention, Renewable Diesel fuels prepared according to the present invention are provided. Sulfur content of the Renewable Diesel fuel is one of many parameters of interest for commercial use. Sulfur is typically present as a result of the use of sulfuric acid catalysts, and can result in increased engine wear and deposits. Additionally, environmental concerns dictate a desired low sulfur content in the Renewable Diesel fuel. Preferably, Renewable Diesels prepared according the methods provided herein have a sulfur content (as measured by ASTM test method D5453) of less than 500 ppm, more preferably less than 200 ppm, less than 100 ppm, less than 50 ppm, less than 25 ppm, less than 10 ppm, and most preferably less than 5 ppm.
[0024] The cetane number (i.e., the measure of the ignition quality of the fuel, as measured by ASTM test methods D976 or D4737) is preferably greater than 47, more preferably greater than 50, and most preferably greater than 55.
[0025] Cloud points are defined as the temperature at which a cloud or haze of crystals appears in the fuel. Cloud points determine the climate and season in which the Renewable Diesel fuel may be used. Preferably the cloud point of the Renewable Diesel is less than 0ยฐ C., more preferably less than โ5ยฐ C., less than โ10ยฐ C., less than โ15ยฐ C., less than โ20ยฐ C., less than โ25ยฐ C., less than โ30ยฐ C., less than โ35ยฐ C., less than โ40ยฐ C., and most preferably, less than โ45ยฐ C.
[0026] Total free glycerin in the Renewable Diesel is preferably less than 0.03% by weight, more preferably less than 0.20% by weight, less than 0.018% by weight, less than 0.016% by weight, and most preferably, less than 0.015% by weight. Total glycerin present in the Renewable Diesel fuel is preferably less than 0.25% by weight, more preferably less than 0.24% by weight, less than 0.23% by weight, less than 0.22% by weight, 0.21% by weight, and most preferably, less than 0.20% by weight.
[0027] Residual methanol in the Renewable Diesel is desired to be minimized, and is preferably less than 0.2% by weight, more preferably less than 0.18% by weight, and most preferably less than 0.15% by weight.
[0028] Water content in the Renewable Diesel fuel produced according the present invention is preferably less than 500 ppm, preferably less than 450 ppm, more preferably less than 400 ppm and most preferably less than 300 ppm.
[0029] It can be important to define a minimum viscosity of the Renewable Diesel fuel because of power loss due to injection pump and injector leakage. Preferably, the viscosity of the Renewable Diesel fuel is between 1.0 and 50 mm 2 /s, more preferably between 1.3 and 15.0 mm 2 /s, even more preferably between 1.3 and 2.1 mm 2 /s.
[0030] In one embodiment, the Renewable Diesel is produced on an industrial scale. Global biodiesel production is estimated at several million tons per year. In a preferred embodiment, production occurs from 500 kg or more of feedstock per day. Alternatively, production may occur on batches or continuous feeds of 1,000 kg, 5,000 kg, 10,000 kg or more feedstock per day. Alternatively, vacuum distillation may occur on a scale of about 200 tons per day, while esterification may occur on a scale of about 300 tons per day. In one embodiment, a fat splitter with capacity of, for example, about 100 tons per day or about 150 tons per day, may be integrated into the process, optionally between the vacuum distillation unit and the esterification unit. Additionally, a properly scaled glycerin concentration unit assuming feedstock with about 30% free fatty acid may be incorporated into the process. Glycerin recovery is envisioned to account for glycerin carryover from the vacuum distillation process, if present.
[0031] Referring now to FIG. 1 , there is provided an embodiment of a process for the preparation of Renewable Diesel from animal and vegetable oils. Feed Stream 1 contains liquids derived from animal and vegetable sources. Such liquids may contain fatty acids, glycerides of fatty acids, esters, alcohols, and other hydrocarbons. Feed stream 1 could also contain petroleum derived hydrocarbons. Feed stream 1 is fed to a vacuum distillation unit 2 .
[0032] Vacuum distillation unit 2 may or may not be equipped to contain a thermal oxidizer for management of tank vapors as well as an emergency MeOH scrubber able to operate without plant power. Preferably, vacuum distillation unit 2 can operate without any fired heaters, but a steam heating and/or hot oil system may optionally be included to allow for distillation at higher temperatures. Vacuum distillation unit 2 , and any coupled separation device such as a glycerin condensing unit or a fatty acid splitter, is operated in order to, at a minimum, provide free fatty acids to the reactive distillation esterification unit. Vacuum distillation unit 2 and any coupled device therewith incorporated may produce a product 3 consisting of lower boiling hydrocarbons, CO, CO 2 , hydrogen, and water and liquid product 4 . Liquid product 4 of vacuum distillation unit 2 may or may not meet all specifications of ASTM D396 and/or D975 at this point, but liquid product 4 may meet the distillation and flash point ranges are near as possible.
[0033] In one embodiment, liquid product 4 is fed to Reactive Distillation Esterification Unit 6 . Reactive Distillation Esterification Unit 6 is also fed with an alcohol stream 5 . Within the Reactive Distillation Esterification Unit 6 , acidic components in the liquid product 4 are reacted with the alcohol from stream 5 and converted to esters product 7 . Water of reaction and alcohol are also separated so that excess alcohol used in the reaction can be recycled.
[0034] Referring to FIG. 2 , the same process is contemplated with the difference being the feeding of stream 8 along with the feedstock in stream 1 . Stream 8 contains water or steam. Feeding steam or water as stream 8 along with feed stream 1 is intended to help maximize the output of liquid product 4 . In one embodiment, FIG. 2 corresponds in all other regards to FIG. 1 .
[0035] Referring to FIG. 3 , one possible embodiment according to the invention is provided, including a vacuum distillation unit and an esterification unit.
[0036] It will be understood by those skilled in the art that the drawings are diagrammatic and that further items of equipment such as reflux drums, pumps, vacuum pumps, temperature sensors, pressure sensors, pressure relief valves, control valves, flow controllers, level controllers, holding tanks, storage tanks, and the like may be required in a commercial plant. The provision of such ancillary items of equipment forms no part of the present invention and is in accordance with conventional chemical engineering practice.
[0037] Modifications and variations of the present invention relating to the selection of reactors, feedstocks, alcohols and catalysts will be obvious to those skilled in the art from the foregoing detailed description of the invention. Such modifications and variations are intended to come within the scope of the appended claims. All numerical values are understood to be prefaced by the term โaboutโ where appropriate. All references cited herein are hereby incorporated by reference in their entirety.
[0038] The process and apparatus of the invention can be used in biodiesel refining, and in petrochemical and other industries where vacuum processing of liquid products is required. It is possible to economically integrate the invention process into conventional vacuum distillation systems. It should be noted that various changes and amendments can be made in the details within the scope of the claims set forth below without departing from the spirit of the claimed invention. It should therefore be understood that the claimed invention should not be limited to the specific details shown and described.
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The present invention relates to a process and apparatus for the production of diesel fuel from feedstocks containing fatty acids, glycerated fatty acids, and glycerin by vacuum distillation followed by esterification. Specifically, the present invention relates to the production of Renewable Diesel having low glycerin, water, and sulfur content. Operation of the distillation system enables production of esters including biodiesel and other biofuels in an economically advantageous manner. The vacuum distillation system is optionally located upstream of an esterification unit or other biodiesel production facility for improvement in production economy.
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[0001] This application is a continuation of Patent Application No. PCT/KR2004/003052 filed Nov. 24, 2004 which designates the United States and claims priority of Korean Patent Application No. 2004-0067290 filed on Aug. 25, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to a MADS-box promoter directing high level expression in a plant storage root, an expression vector using the same and a transient assay method in a plant storage root using the same vector. More specifically, the present invention relates to a sweet potato MADS-box gene promoter sequence directing a high level expression in a plant storage root, a plasmid vector using the same and a transient assay method in a plant storage root using the same vector.
BACKGROUND ART
[0003] The molecular breeding technology of crops makes it possible to use the genes of all species as breeding materials and to regulate the effects of breeding minutely at the gene level instead of at the genome level as in the past. Therefore it is one of the core technologies leading into the next generation of agriculture.
[0004] In order to maximize the effects of such molecular breeding technologies of crops, the essential prerequisites are as follows:
1) the accumulation of a database of genes to represent various plants; 2) the establishment of transformation systems for various crops; and 3) the development of promoters that regulate the expression of foreign genes inserted into plants.
[0008] In foreign countries promoters regulating the expression of plant genes have been studied since the early 1980's. It was suggested that a promoter of cauliflower mosaic virus could induce high levels of gene expression in all kinds of plant tissues (Hohn et al., 1982 , Curr. Topics Microbiol. Immunol. 96:193-236).
[0009] Subsequently, the sequence of the promoter was identified (Odell et al., 1985 , Nature 313:810-812). It was proved that the promoter could induce high levels of gene expression in plants (Sanders et al., 1987 , Nucleic Acids Res. 15: 1543-58). Since then, CaMV 35S promoter (Patent NO.: JP1993192172-A1) has become the most universal promoter used in plants.
[0010] Since the identification of CaMV 35S, promoters expressing genes in specific plant tissues have been actively studied. The specific studies relating to the promoters expressing genes in specific plant tissues are as follows.
The Studies Relating to Seed Specific Promoters
[0011] Since seed specific promoters are expected to be highly useful in molecular breeding technologies for crops, the field of study relating to them is one of the fields that have been most actively studied concerning tissues specific promoters. Beta-phaseolin is the seed storage protein of French bean. The promoter of its gene has been cloned (Bustos et al., 1989 , Plant Cell 1: 839-853). Then it was found that the UAS1 (โ295หโ109) part of the promoter is a necessary cis-element for seed specific expression (Bustos et al., 1991 , EMBO J. 10: 1469-1479). After that it was reported that 68 bp (โ64ห+6) in UAS1 acts as a seed specific enhancer (van der Geest and Hall, 1996 , Plant Mol. Biol. 32: 579-588).
[0012] In addition, it was found that B-box ABA-complex and RY/G complex are necessary for napin gene promoter (napA) to express a gene in seed tissue (Ezcurra et al., 1999 , Plant Mol. Biol. 40: 699-709). Various seed specific promoters have been found, such as the promoter of storage protein glutelin gene (Glu-B1) in a rice plant (Washida et al., 1999 , Plant Mol. Biol. 40: 1-12) and the promoter of trypsin/chymotrypsin inhibitor gene (TI) in a pea (Welham and Domoney, 2000 , Plant Sci. 159: 289-299).
The Studies Relating to Flower Tissue Specific Promoters
[0013] It was found that 67 bp of chsA (chalcone synthase) gene promoter in Petunia is necessary to express a gene in the flower tissue (van der Meer et al., 1990 , Plant Mol. Biol. 15: 95-109). It was also reported that the promoter of the tomato LAP (leucine aminopeptidase) gene is a flower tissue specific promoter and the region from bp โ317 to โ3 of the gene is a decisive factor in order to express a gene in the flower tissue (Ruiz-Rivero and Prat, 1998 , Plant Mol. Biol. 36: 639-648).
The Studies Relating to Root Tissue Specific Promoters
[0014] The peroxidase gene promoter (prxEa) of Arabidopsis thaliana is the root tissue specific promoter and the regulating factor for tissue specific expression is in between bp โ172 and โ1 of the gene (Wanapu and Shinmyo, 1996 , Ann N.Y. Acad. Sci. 782: 107-114). Recently another root specific promoter (Pyk10) of Arabidopsis thaliana has been reported and the regulating factor of the promoter has also been reported (Nitz et al., 2001 , Plant Sci. 161: 337-346).
The Studies Relating to Potato Tuber Specific Promoters
[0015] A patatin gene is glycoprotein expressed in the potato tuber in large quantities and is related to the activity of lipid acyl hydrolase. A patatin gene promoter can regulate the potato tuber specific expression (Patent No. EP0375092, B1; Jefferson et al., 1990 , Plant Mol. Biol. 14: 995-1006). The regulating factor located in bp โ183 to โ143 of the gene acts as a decisive factor for tuber specific expression induced by sugar (Liu et al., 1990 , Mol. Genl Genet. 223: 401-406). Further, a nucleus protein has been reported as a trans-acting factor that regulates the tuber specific expression of the patatin promoter (Kim et al., 1994 , Plant Mol. Biol. 26: 603-615).
[0016] Meanwhile, sporamin accounts for 60-80% of the total soluble proteins in the storage roots of a sweet potato. Therefore, various studies have been conducted in order to use the above gene promoter as a storage root specific promoter in sweet potato.
[0017] However, it has not been identified whether the promoter can induce expression of a gene in storage root yet. A high level of expression was found in the stalks, leaves and sieve tube tissues of a transgenic tobacco plant using the same promoter (Hattori et al., Plant Mol. Biol. 14: 595-604. 1990, Ohta et al., Mol. Gen. Genet. 1991, 225:369-378).
[0018] Therefore, despite the wide scope of studies relating to tissue specific promoters, a storage root specific promoter that is selectively functional in plant storage root has not been reported yet.
DISCLOSURE OF THE INVENTION
Technical Problem
[0019] In order to solve the above problems and needs, an object of the present invention is to provide the promoter DNA sequences directing high levels of expression of a gene in plant storage root.
[0020] Another object of the present invention is to provide a vector comprising the promoter DNA sequence directing high levels of expression of a gene in plant storage roots.
[0021] A still further object of the present invention is to provide the transient assay method for the expression of foreign genes in plant storage root using the same vector.
Technical Solution
[0022] In order to accomplish the above objects, the present inventors have cloned root- and storage root-specific promoter region of sweet potato MADS-box gene and developed promoter inducing high levels of expression of a gene in storage roots with the 5โฒ-non translated region of the same gene. These inventors have subsequently induced transient expression in the storage roots of carrots and small radishes ( Raphanus Sativus L.) and observed the high levels of activity of the promoter to perfect the present invention.
[0023] Therefore, the present invention provides the isolated DNA sequence of the root- and storage root-specific promoter region and the 5โฒ-non translated region of sweet potato MADS-box gene comprising the sequences of SEQ ID NO: 1.
[0024] The above DNA sequence of the promoter is derived from the region of bp โ1 to โ2801 relative to the transcription initiation site of the sweet potato MADS-box gene in SEQ ID NO: 1( FIG. 5 ). The promoter according to the present invention can induce high levels of expression of target genes in plant storage roots.
[0025] The above non translated region comprises the non translated region of bp+1 to +209 relative to the transcription initiation site of the sweet potato MADS-box gene in SEQ ID NO: 1 ( FIG. 5 ). The non translated region can enhance the translation efficacy of a target gene introduced into the plant to induce high levels of expression of the target gene like the other reported 5โฒ-non translated regions of plant.
[0026] In order to accomplish another object, the present invention provides an expression vector comprising the storage root-specific promoter and 5โฒ-non translated region of the sweet potato MADS-box gene directing high levels of expression in plant storage roots.
[0027] The above storage root specific expression vector may be a transient expression vector that can transiently express foreign genes in plants. However, it may preferably be a binary vector that can permanently express foreign genes in transgenic plants. In the present invention, for example, a transformation using the transient expression vector was performed.
[0028] The binary vector can be any binary vector comprising the RB and LB of T-DNA that can transform the plant in the presence of the Ti plasmid of Agrobacterium tumefaciens . Preferably, it may be a binary vector frequently used in the related field such as the pBI101 (cat#: 6018-1, Clonetech, USA), pBIN (Genbank accession NO. U09365), pBI121, pBIN20 or BIBAC vector.
[0029] If the above expression vector for storage roots is a binary vector, plants can be transformed using the method of Agrobacterium tumefaciens (An, G. 1987, Plant Physiology) or particle bombardment (Lacorte et al., 1997, Plant Cell Reports).
[0030] The present invention provides a transient expression vector that can transiently express foreign genes in a plant.
[0031] Concerning the expression vector of the present invention for plant storage roots, the promoter and 5โฒ-non translated region of MADS-box gene according to the present invention are located in front of the foreign gene in the pBI221 vector. The present invention provides the pSPmasds-3.0 and pSPmads-1.5( FIG. 6 ) prepared by inserting the promoter and 5โฒ-non translated region of MADS-box gene according to the present invention into the vector (pBI221) including the GUS reporter gene. However, the GUS reporter gene is a foreign gene and may be replaced with other foreign genes as is deemed useful.
[0032] Further the present invention provides the storage root transformed transiently using the transient expression vector according to the present invention.
[0033] Plant storage root can be transiently transformed using expression vectors according to the present invention using the particle bombardment method (Lacorte et al., 1997, Plant Cell Reports). Expression vectors of the present invention for plant storage roots can transform the storage root regardless of the kind of crop. Examples of the crop may be carrot, small radish, etc.
[0034] In order to accomplish another object, the present invention provides a transient assay method that may induce high levels of expression of foreign genes transiently in plant storage roots using the expression vector of the present invention for plant storage root.
[0035] The above foreign gene may any gene that is intended to be expressed in large quantities in plant storage root. Furthermore, they are located next to the promoter and 5โฒ-non translated region of the sweet potato MADS-box gene in the expression vector for plant storage root according to the present invention and may be expressed fused with the reporter genes if necessary.
[0036] The present invention provides PCR primers represented as SEQ ID NO: 2 and SEQ ID NO: 4 in order to clone the sweet potato MADS-box promoter.
[0037] The present invention provides PCR primers represented as SEQ ID NO: 6หSEQ ID NO: 9 in order to amplify the DNA fragment of the promoter comprising the sequence represented as SEQ ID NO: 1.
Advantageous Effects
[0038] The present invention relates to the promoter and 5โฒ-non translated region of the MADS-box gene derived from sweet potato ( Ipomoea batatas ). The promoter and 5โฒ-non translated region of the sweet potato MADS-box gene according to the present invention can induce plant root and storage root specific expression and particularly can induce high levels of expression in plant storage roots. Therefore the present invention may be useful for the development of transgenic plants to produce valuable materials in large quantities in plant storage roots.
BRIEF DESCRIPTION OF DRAWINGS
[0039] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0040] FIG. 1 shows tissues of sweet potato used in Northern blot analysis to analyze expression patterns of Ipomoea batatas MADS-box gene (ibMADS) in the present invention;
[0041] FIG. 2 shows the result of Northern blot analysis of ibMADS using sweet potato tissues shown in FIG. 1 ;
[0042] FIG. 3 shows a PCR process for cloning of the promoter according to the present invention;
[0043] FIG. 4 shows the identification of promoter according to the present invention using restriction enzymes;
[0044] FIG. 5 shows sequences of promoter and 5โฒ-non translated region of the sweet potato MADS-box gene according to the present invention;
[0045] FIG. 6 shows a transient expression vector (hereinafter referred to pSPmads-1.5 or pSPmads-3.0) comprising promoter and 5โฒ-non translated regions of the sweet potato MADS-box gene according to the present invention;
[0046] FIG. 7 shows the result of a transient assay using pSPmads-1.5 or pSPmads-3.0 according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0047] The following examples will enable those skilled in the art to more clearly understand how to practice the present invention. It is to be understood that, while the invention has been described in conjunction with the preferred specific embodiments thereof, that which follows is intended to illustrate, not to limit the scope of the invention. Other aspects of the invention will be apparent to those skilled in the art to which the invention pertains.
EXAMPLE 1
Identification of a Gene Expressed Particularly in Plant Root and Storage Root
[0048] In order to find a gene expressed particularly in plant root and storage root, the present inventors performed Northern blot analysis with various sweet potato tissues. More specifically, ESTs of sweet potato ( Ipomoea batatas cv. Jinhongmi) storage roots expressed at the early stage of development were analyzed (You et al., 2003, FEBS Letters, 536; 101-105).
[0049] Total RNA was isolated from leaf (Leaf-FRN), stem (Stem-FRN), petiole (Petiole-FRN) and root (FRN) of sweet potato at a non-storage root stage, leaf (Leaf-SR), stem (Stem-SR), petiole (Petiole-SR), root (FRES) and storage root (SR) of sweet potato at an early storage root stage, and root (FRLS) of sweet potato at a late storage root stage.
[0050] FRN means fibrous root of non-storage root stage and FRES means fibrous root of early storage root stage. Furthermore SR means Storage root (<1.5 cm in diameter) and FRLS means fibrous root of late storage root stage ( FIG. 1 ).
[0051] Using sweet potato ESTs as a probe, the extracted total RNA were analyzed by Northern blot analysis. As a result, sweet potato MADS-box gene was found to be expressed in root tissues at a non storage root stage and an early storage root stage of development. Furthermore, it was identified that the MADS-box gene was highly expressed in storage root tissues at a mature storage root stage ( FIG. 2 ). However, it was not expressed in the other tissues of sweet potato. Therefore, the MADS-box gene is found to be expressed particularly in plant root and storage root tissues.
EXAMPLE 2
Cloning for the Promoter of the Sweet Potato MADS-Box Gene
[0052] In order to clone the promoter of the sweet potato MADS-box gene, sweet potato ( Ipomoea batatas cv White Star) Genome Walker library was screened by PCR.
[0053] For the first PCR, Mads (124)R primer(SEQ ID NO: 2 in the Table 1) generated on the basis of the sweet potato ( Ipomoea batatas cv. Jinhongmi) MADS-box cDNA sequence and adapter primer 1(SEQ ID NO: 3 in the Table 1) were used.
[0054] In the second PCR, Mads (94)R primer (SEQ ID NO: 4 in the Table 1) generated on the basis of the sweet potato ( Ipomoea batatas cv. Jinhongmi) MADS-box cDNA sequence and nested adapter primer 2 (SEQ ID NO: 5 in the Table 1) were used. PCR was carried out according to the guide book of Universal Genome Walker Kit (Clonetech).
TABLE 1 Primers for 5โฒ-ATCCTCCTAATTTCAACCTTGC SEQ ID NO:2 the first CCCTC-3โฒ PCR 5โฒ-GTAATACGACTCACTATAGGGC SEQ ID NO:3 -3โฒ Primers for 5โฒ-ATCCTTCTCCTCCCTATTTCTG SEQ ID NO:4 the second GGATG-3โฒ PCR 5โฒ-ACTATAGGGCACGCGTGGT-3โฒ SEQ ID NO:5
[0055] The result is presented in FIG. 3 and FIG. 4 that show electrophoresis of the first and second PCR products in the agarose gel. The No.2 product (3-6 kb) of the second PCR products was eluted from the agarose gel and inserted into pCR-XL-TOPO vector using the TOPO XL PCR Cloning Kit (Invitrogen). Then, plasmids were extracted from 20 colonies of E. coli and identified by restriction enzymes ( FIG. 4 ). Through sequencing of plasmids, it was identified that one of plasmids had homology with the 5โฒ sequence of sweet potato ( Ipomoea batatas cv. Jinhongmi) MADS-box cDNA (NO. 10 in FIG. 4 ). The total sequence of the cloned region (about 3 kb) was registered in NCBI GenBank (Accession no. AY655162).
[0056] FIG. 5 shows sequences of promoter and 5โฒ-non translated region of sweet potato MADS-box gene according to the present invention. The start codon โATGโ of protein synthesis is underlined and base โAโ of transcription initiation site is indicated โ+1โ. Though there is a putative intron (indicated with an italic letter) in the 5โฒ-non translated region, the sequence of the intron region is different from the sequence of cDNA of sweet potato ( Ipomoea batatas cv. Jinhongmi).
EXAMPLE 3
Construction of Vectors for Transient Expression of Plant Storage Root Specific Promoter
[0057] The sweet potato MADS-box promoter and 5โฒ-non translated region cloned in example 2 were inserted in a pBI221 vector. In this case, two lengths of promoter regions were used. One promoter was 3,010 bp (bp โ1 to โ2801) and the other promoter was 1,437 bp (bp โ1 to โ1228). Both of them included the 209 bp of the 5โฒ-non translated region.
[0058] The above 3,010 bp promoter and 1,437 bp promoter were amplified by PCR and restricted by SphI and BamHI. Then they were inserted into SphI and BamHI sites of pBI221. The vectors were named pSPmads-3.0 and pSPmads-1.5 respectively ( FIG. 6 ). The primers used in the above PCR are shown in Table 2 in detail.
[0059] In the PCR, after the process was conducted for 4 min at 94ยฐ C., the following cycling parameters were used; 5 cycles [94ยฐ C., 1 min; 60ยฐ C., 1 min; 72ยฐ C., 2 min and 30 s], 5 cycles [94ยฐ C., 1 min; 63ยฐ C., 1 min; 72ยฐ C., 2 min and 30 s], 20 cycles [94ยฐ C., 1 min; 66ยฐ C., 1 min; 72ยฐ C., 2 min and 30 s]. After that the process was carried out for 5 min at 72ยฐ C.
TABLE 2 PCR Primers 5โฒโprimer SEQ ID NO:6 for 3,010 bp 5โฒ-CATGTCGACGGCTGGTTTCTAAG promoter ACAT-3โฒ 3โฒโprimer SEQ ID NO:7 5โฒ-GCTAGATCTCCTTCTCCTCCCTG AAGAAATC-3โฒ PCR Primers 5โฒโprimer SEQ ID NO:8 for 1,437 bp 5โฒ-CATGCATGCCCGCGGGTGTGACT promoter ATT-3โฒ 3โฒโprimer SEQ ID NO:9 5โฒ-GCTAGATCTCCTTCTCCTCCCTG AAGAAATC-3โฒ
EXAMPLE 4
Identification of the Activity of the Storage Root Specific Promoter by the Transient Assay Method
[0060] In order to identify the activity of pSPmads-3.0 and pSPmads-1.5 vector, the transient assay method was carried out. More specifically, the storage roots of carrots and small radishes ( Raphanus Sativus L.) in growth and enlargement stages were picked and washed. Then the storage roots were cut 5 mm thick crosswise and placed fully wet in Petri dishes for 4-5 hours at 4ยฐ C.
[0061] According to the method of Sanford et al. (1993 , Meth Enzymol 217:485-509), DNA was mixed and coated with gold particles 1.0 ฮผm in diameter. In this case, the following bombarding conditions were used; [1.0 ฮผg DNA in density, 1,350 PSi helium gas in pressure and 6 cm from carrots or small radishes ( Raphanus Sativus L.) in distance].
[0062] After bombarding, they were placed in the darkness for 24 hours at 25ยฐ C. and histochemical staining was carried out to identify the activity of GUS. In order to stain the cut storage root tissues of carrots or small radishes, they were soaked in the solution comprising 1 mM X-glu (5-bromo-4-chloro-3-indoly-ฮฒ-glucuronide) dissolved in DMSO (dimethyl sulfoxide), 100 mM sodium phosphate (pH 7.0), 10 mM EDTA, 0.5 mM potassium ferricyanide, 0.5 mM potassium ferrocyanide and 0.1% Triton X-10, and reacted for 24 hours at 37ยฐ C.
[0063] After the solution was removed, cut storage root tissues were rinsed with 70% ethanol for 24 hours and then were placed in regularly changed 100% ethanol for a few days to remove the chlorophyll contained in the tissues.
[0064] As shown in FIG. 7 , it was identified that pSPmads-3.0 was active in all carrot tissues with the exception of the secondary xylem tissue. And pSPmads-1.5 showed high levels of activity in all carrot tissues. Furthermore both the promoters showed high levels of activity in vascular cambium of carrot.
[0065] Meanwhile both pSPmads-3.0 and pSPmads-1.5 were highly active in all small radish tissues. However, when leaves of carrot or small radish were transformed with the above promoters, those promoters didn't show any activity ( FIG. 7 ).
[0066] If the above results and the Northern blot assay result are considered together, it can be said that the activity of promoters according to the present invention is specific to plant storage roots and roots.
INDUSTRIAL APPLICABILITY
[0067] As described above, the present invention provides storage root specific promoters comprising promoter and 5โฒ-non translated regions of sweet potato MADS-box genes. For a transient expression assay, the present invention provides the transient expression vector prepared by inserting the promoter into the pBI221. The transient assay shows that the promoter has a high level of activity particularly in the storage roots of carrots and small radishes. Therefore, it is identified that the promoter according to the present invention has activity specific to plant roots and storage roots.
[0068] The promoter according to the present invention is very useful for producing valuable proteins in the transformed storage root tissue, or for metabolic regulation of storage root tissue and for producing functional materials using transgenic plants.
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The present invention relates to a promoter directing high levels of expression of a gene in plant storage roots, derived from the sweet potato MADS-box gene, a vector directing high levels of expression of a gene in plant storage roots comprising the same and a transient assay method expressing a foreign gene transiently in plant storage roots using the same vector. The promoter according to the present invention can induce high levels of expression particularly in plant storage roots. Therefore the present invention is very useful for the development of transgenic plants to produce valuable materials in large quantities in plant storage roots.
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TECHNICAL FIELD
[0001] The invention relates generally to the controlling dispensing of material from a roll, and more specifically, dispensing packaging material from a roll.
BACKGROUND
[0002] Various sheet-type materials are provided in roll form for easy storage, shipping, and dispensing for use. In the packing material industry, for example, Kraft paper is crumpled and used to fill empty portions of shipped containers. In various applications, it is advantageous to have the material be unrolled and crumpled in a continuous and easy manner to facilitate quick and efficient packing of objections for shipping.
[0003] Devices exist that facilitates fast crumpling of the packing material as it is dispensed from the roll by passing the material through a relatively small passage. The engagement of the material with the passage crumples the paper for the user to then quickly apply to the shipped load. Rolls of packing material such as Kraft paper, however, are generally not uniform in their form. For example, typical Kraft paper rolls are wound around a cylindrical core. This core, however, may not have perfectly near circular circumference, either through manufacturing or through the handling of the roll before it is disposed for dispensing the material. Then, when that core is disposed on a support around which the roll will rotate during dispensing of the packing material, the roll will have an uneven rotation rate. For instance, the roll may rotate at a first rate until a flat portion of the core engages the roll's support, at which time the roll may slip and rotate quickly and then stop suddenly. Such motion can cause a tear in the packing material, which can render that portion of the material unsuitable for the packing task at hand.
SUMMARY
[0004] Generally speaking and pursuant to these various embodiments, a rolled material dispenser includes a brake mechanism designed to govern the rolling of a roll of packing material during dispensing of the packing material to reduce unintended tearing of the packing material or improve the user experience of handling such material dispensing. In one example, the brake mechanism includes a first portion configured to engage the roll during normal unloading of material from the roll and a second portion configured to engage the roll to impede rotation of the roll when unloading of material is uneven.
[0005] In one example, the brake mechanism is biased to engage the roll with a brake structure to impede roll rotation. When the packing material is tensioned such as when paper is pulled from the roll, the tensioned paper effects removal of the brake mechanism from engagement with the roll. If during the dispensing of paper the roll rotates unevenly or for another reason the paper tension reduces, the reduced tension allows the brake mechanism to re-engage the roll to slow and/or stop its rotation. So configured, uneven rolling of the packing material is restrained to reduce the amount of unwanted tearing of the material and to improve the user experience. These and other benefits may become clearer upon making a thorough review and study of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The above needs are at least partially met through provision of the brake to facilitate dispensing of material from a roll described in the following detailed description, particularly when studied in conjunction with the drawings, wherein:
[0007] FIG. 1 comprises a perspective view of an example packaging material dispenser in accordance with various embodiments;
[0008] FIG. 2 comprises a perspective view of the idler roller and corresponding support for the example packaging material dispenser of FIG. 1 ;
[0009] FIG. 3 comprises a side view of the brake arm with a brake edge engaging the roll of the example packaging material dispenser of FIG. 1 ;
[0010] FIG. 4 comprises a perspective view of the engagement of the brake arm to a corresponding support post of the example packaging material dispenser of FIG. 1 ;
[0011] FIG. 5 comprises a side view of the brake arm with a brake roller engaging the roll of the example packaging material dispenser of FIG. 1 ;
[0012] FIG. 6 comprises a perspective view of the brake arm with a brake roller engaging the roll of the example packaging material dispenser of FIG. 1 ;
[0013] FIG. 7 comprises a flow diagram for an example method of operation of a packaging material dispenser in accordance with various embodiments.
[0014] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.
DETAILED DESCRIPTION
[0015] Referring now to the drawings and, in particular to FIGS. 1-6 , an example apparatus 100 for dispensing packing material 105 will be described. In the illustrated example, the apparatus 100 includes a support arm 110 configured to support a roll 120 of packing material 105 . Typically, the packing material 105 will be craft paper or a similar paper used for packing in the shipping industry. Other packing material is possible such as sheets of foam and the like. The support arm 110 may include a rotatable component 115 configured to engage the inside of the roll 120 to rotate as the roll 120 rotates with dispensing of the packaging material 105 .
[0016] The packaging material dispensing apparatus 100 also includes an idler roller 125 configured to engage and roll with the packing material 105 dispensed from the roll 120 . The idler roller 125 may include a surface portion 128 on all or part of its outer cylindrical surface. This surface portion 128 has a relatively high tackiness or outer surface friction such that the surface portion 128 engages the packing material 105 when the packing material is being pulled from the packaging material dispenser. As the packaging material is pulled from the dispenser, it separates from the roll 120 and passes over and around the idler roller 125 . The surface portion 128 of the idler roller 125 engages the packaging material 105 such that the idler roller 125 rolls together with and at generally the same speed as the packaging material 105 as it is dispensed from the roll 120 .
[0017] The idler roller 125 is supported on a rod 130 . The rod 130 is optionally spring supported such that the forces of tension on the packaging material 105 in the direction around the idler roller 125 is somewhat absorbed by the support to avoid unnecessary tearing of the packaging material 105 when being pulled around the idler roller 125 . In the illustrated example, the support includes a post 133 around which a spring 135 extends. The spring 135 engages a washer 136 , which washer 136 supports the weight of the rod 130 thereby supporting also the weight of the idler roller 125 . Accordingly, the spring 135 absorbs at least some of the downward forces applied to it during the dispensing of packaging material 105 around the idler roller 125 . The tension on the spring 135 can be adjusted by rotation of the nut 137 disposed opposite of the spring 135 relative to the support rod 130 . The absorption of forces on the idler roller 125 takes some of the forces off of the packaging material 105 such that the packaging material 105 is less likely to tear on application of certain forces.
[0018] In the illustrated example, a brake arm 140 is disposed to extend along the length of the roll 120 to engage the roll 120 with at least one brake arm roller 142 during dispensing of packaging material 105 from the roll 120 . In the illustrated example, the brake arm 140 includes a first edge 144 that supports the at least one brake arm roller 142 . Three rollers 142 are illustrated in this example, although any number of rollers can be used based upon the length of the roll of packaging material and/or the type of packaging material. The brake arm 140 also includes a second edge 146 of the brake arm 140 disposed opposite of the first edge 144 . This second edge 146 with the brake arm 140 comprises a brake edge 146 , wherein the brake arm 140 is configured to engage the roll 120 with the brake edge 146 in response to uneven rolling of the roll 120 on the support arm 110 .
[0019] In the illustrated example, the brake arm 140 is supported to rotate to selectively engage the roll 120 with either the at least one brake arm roller 142 of the first edge 144 or the second edge 146 . The brake arm 140 is biased to engage the roll 120 on a side of the roll 120 toward the idler roller 145 with the second edge 146 to restrict rotation of the roll 120 . For instance, FIG. 3 shows the second or braking edge 146 of the brake arm 140 engaging the roll 120 when the packaging material 105 is not being pulled or dispensed from the roll 120 . Turning to FIG. 5 , the packaging material 105 is being pulled from the packaging material dispenser 100 thereby producing tension on the packaging material 105 between the roll 120 and the idler roller 125 . The tension results in a force where the packaging material 105 pushes the brake arm second edge 146 away from the roll 120 , such that the second or brake edge 146 slides over the paper or packaging material 105 as it moves around the idler roller 125 . By pushing the brake edge 146 away from the roll 120 , the brake arm rotates such that its roller(s) 142 engages the roll 120 to help control the separation of the packaging material 105 from the roll 120 . Should the tension in the packaging material 105 be lost, for example, during an uneven rotation of the roll 120 or by an uneven pulling tension being applied to the packaging material 105 during dispensing, the brake arm will rotate in a manner such that the brake edge 146 reengages with the roll 120 to slow and/or stop its rotation. The slowing or stopping of the roll's rotation reduces the amount of packaging material that may dispense from the roll during rotation. This brake mechanism stops the flow of paper almost immediately so that a user does not unroll more material than desired. The brake mechanism is activated by pulling the material forward, which immediately releases the brake so that the material pulls freely from the roll. This is particularly advantageous when the inner core of the roll is uneven, but this approach generally works to quickly and easily dispense the packaging material from the device in an even and controlled process.
[0020] In the illustrated example, the brake arm 140 includes a metal body although other materials can be used that provide the friction used to slide over the dispensed packaging material and yet impede or stop the roll's rotation when so engaged. The illustrated brake arm 140 also includes an indented middle portion 148 such that a cross-section of the brake arm 140 resembles the number โ3.โ The brake arm is supported by two posts 150 and 152 configured to engage and support the brake arm 140 and bias the brake arm 140 to engage the roll 120 . For example, as illustrated in FIG. 6 , the posts 150 and 152 may be biased by a spring 154 configured to attach to an end surface 153 and the post 150 (with similar unillustrated structure operating with the second post 152 ) to pull the posts 150 and 152 , which in turn pull the brake arm 140 towards the roll 120 .
[0021] In this case, the brake arm 140 defines two apertures 155 and 157 configured to individually engage the individual ones of the two posts 150 and 152 . The two posts 150 and 152 individually define tapered portions 160 to engage the brake arm 140 at the two apertures 155 and 157 . The tapered portions 160 begin with a wider portion 162 disposed at a post end 165 that taper down to a smaller width at a tapered portion 166 further down the post 150 . The contour of the aperture 155 defined by its location at the middle portion 148 of the brake arm 140 creates several surfaces available to engage different tapered portions 160 of the post 150 as well as possibly an non-tapered portion of the post 150 itself, as illustrated in FIG. 4 . For example, when there is reduced tension in the packaging material 105 , the aperture 155 portion extending into a first flange 172 of the brake arm 140 , which flange 172 terminates in the first edge 144 that supports the rollers 142 , allows the aperture 155 to engage the thick portion 162 of the tapered post. The aperture 155 portion that extends into a second flange 174 of the brake arm 140 , which second flange 174 terminates in the brake edge 146 , allows the aperture 155 part in the second flange 174 to engage further down the post 150 even beyond the tapered portion 160 .
[0022] Turning to FIG. 5 , which illustrates an example where there is tension on the packaging material 105 sufficient to rotate the brake arm 140 brake edge 146 away from the roll 120 , the aperture 155 portion extending into the second flange 174 now engages a thick portion 162 of the tapered port while the aperture 155 portion extending into the first flange 172 in turn moves along and may or may not engage the narrowly tapered portion 166 or the non-tapered portion of the post 150 .
[0023] So configured, through the arrangement of the aperture within the shape of the brake arm and the respective engagement with the tapered nature of the post, the brake arm is biased to engage the roll 120 with the brake edge 146 of the brake arm 140 . Whereas, when tension is applied to the packing material 105 to overcome that biasing, the brake arm 140 is rotated to engage the roll 120 with the brake arm rollers 142 . Such a configuration can mediate or modulate the occasional uneven forces created during the unrolling and dispensing of packaging materials 105 such as craft paper from its roll 120 , which forces may cause unwanted tearing and user dissatisfaction.
[0024] Referring now to FIG. 7 , an example method for dispensing packing material from a roll according to these teachings will now be described. In the example, tension in a web of packaging material dispensed from a roll is sensed 705 . The method further includes engaging 710 the roll with a brake arm to restrict rotation of the roll in response to sensing that the tension in the packing material is below a threshold. With reference to the above example implementation, the tension is sensed by the brake edge 146 and the threshold is the force needed to overcome the bias force pushing the brake edge 146 to engage the roll. Thus, if the sensed force drops below that threshold, the brake edge 146 will move back into engagement with the roll. On the other hand, the method also includes removing 715 the brake arm from the roll to facilitate rotation of the roll in response to sensing that the tension in the packing material is above the threshold. Optionally, the roll of packing material is engaged 720 with a brake arm roller supported by the brake arm in response to sensing that the tension in the packing material is above the threshold. In the example illustrated above, the device may implement the method by engaging the brake edge 146 with tension in the packaging material 105 , which tension overcomes or not the bias force on the brake edge 146 . In other embodiments, force sensors can be used for the feedback to control the engagement of the brake edge and/or the rollers.
[0025] In another aspect, the method may further include engaging 725 the packing material with an idler roller during dispensing of the packing material from the roll. Further, the idler roller may be resiliently supported 730 to absorb forces imposed on the idler roller by the packaging material during dispensing of the packaging material. The resilient support thereby can absorb some of the excess forces on the packaging material that could cause an undesired tear.
[0026] So configured, packaging material can be dispensed from a roll with modulated uneven rotation and other features to decrease undesired tearing of the material. Such an approach can improve efficiency whereby less material is thrown out because of having unwanted tearing. Further, user satisfaction with the device is then improved.
[0027] Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention. For instance, the profile of the brake arm and tapered portions of the support posts for the brake arm could be modified. Also, brake arm need not extend the length of the paper roll; instead, one or brake portions could be stationed along the roll as long as the feedback regarding paper tension is provided to selectively engage the roll with the brake to ameliorate paper tearing and user frustration with uneven roll rotation. Similarly, the spring based biasing described herein can be accomplished using any number of known biasing structures. Such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.
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A rolled material dispenser includes a brake mechanism designed to govern the rolling of a roll of packing material during dispensing of the packing material to reduce unintended tearing of the packing material and improve the user experience of handling such material dispensing. In one example, the brake mechanism includes a first portion configured to engage the roll during normal unloading of material from the roll and a second portion configured to engage the roll to impede rotation of the roll when unloading of material is uneven. An idler roller engages the material being dispensed, which idler roller may be resiliently supported to absorb forces on the material.
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BACKGROUND
1. Technical Field
The present invention relates generally to speech coding; and, more particularly, it relates to hybrid extraction of linear prediction coefficients as a function of frequency within speech data.
2. Related Art
Conventional speech coding systems that employ linear prediction speech coding, such as code-excited linear prediction speech coding, uses methods based on minimizing the prediction error energy associated with the linear prediction coefficients (LPC s ) generated during the encoding of a speech signal, such as the auto-correlation method. This conventional method is inherently an energy driven system. For typical broad band signals that are frequently present within speech coding systems, the linear prediction coefficients (LPC s ) are very representative of the speech signal, but for speech signals having a widely dispersed power spectral density, the spectral information in one portion of the speech signal is commonly under-represented by the linear prediction coefficients (LPC s ) and its associated parameters. This under-representation provides an undesirably poor speech quality when the speech signal is later reproduced in the speech coding system.
Specifically, one concern for conventional speech coding systems is that when there is a large disparity between the energy levels across the frequency spectrum of the speech signal, the conventional methods of speech coding that generate a single set of linear prediction coefficients (LPC s ) for the speech signal fail to provide a high perceptual quality upon subsequent reproduction of the speech signal.
Further limitations and disadvantages of conventional and traditional systems will become apparent to one of skill in the art through comparison of such systems with the present invention as set forth in the remainder of the present application with reference to the drawings.
SUMMARY OF THE INVENTION
Various aspects of the present invention can be found in a speech codec that performs linear prediction speech coding on a speech signal. The speech codec includes, among other things, an encoder circuitry and a decoder circuitry that are communicatively coupled via a communication link. The encoder circuitry receives the speech signal that is provided to the speech codec. In addition, the speech codec contains a linear prediction coefficient parameter extraction circuitry that extracts two sets of linear prediction coefficients during the coding of the speech signal and a linear prediction coefficient combination circuitry that combines the two sets of linear prediction coefficients to generate a hybrid set of linear prediction coefficients.
The linear prediction coefficient parameter extraction circuitry itself contains a high frequency speech signal processing circuitry and a low frequency speech signal processing circuitry. The high frequency speech signal processing circuitry extracts a set of linear prediction coefficients representing better a high frequency component of the speech signal, and the low frequency speech signal processing circuitry extracts a set of linear prediction coefficients representing better a low frequency component of the speech signal.
The linear prediction coefficient combination circuitry takes as input the two sets of linear prediction coefficients and performs appropriate hybrid combination in order to generate a new set of linear prediction coefficients (LPCs) to be used by the speech codec. In certain embodiments of the invention, the two sets of linear prediction coefficients are first converted to the line spectral frequency (LSF) domain, then a hybrid combination in line spectral frequency (LSF) domain takes place to obtain a combined set of line spectral frequencies (LSFs), which is converted back to the linear prediction coefficient (LPC) domain to obtain the hybrid combined set of linear prediction coefficients (LPCs). In other embodiments of the invention, the hybrid combination might take place in other parameter domains, such as reflection coefficients, auto-correlation coefficients, or even in the original speech signal domain. It is understood that proper parameter conversions back and forth and appropriate weighting function for the combination are necessary and essential.
In certain embodiments of the invention, the speech codec further calculates a set of line spectral frequencies (LSF) from the calculated linear prediction coefficients (LPCs). The line spectral frequencies are used by the linear prediction coefficient combination circuitry to perform the hybrid combination of the two sets of linear prediction coefficients. The final set of linear prediction coefficients corresponds to a hybrid combination of the sets of linear prediction coefficients. In other embodiments of the invention, the speech codec further determines speech signal spectral information from the speech signal, and wherein the speech signal spectral information from the speech signal is used by the linear prediction coefficient parameter extraction circuitry to perform the combination of the two sets of linear prediction coefficients.
The linear prediction coefficient combination circuitry combines the two sets of linear prediction coefficients to generate a hybrid set of linear prediction coefficients by employing a weighted averaging to combine the two sets of linear prediction coefficients. The linear prediction coefficient parameter extraction circuitry extracts at least one additional set of linear prediction coefficients during the coding of the speech signal in certain embodiments of the invention. The linear prediction coefficient combination circuitry that combines the two sets of linear prediction coefficients to generate a hybrid set of linear prediction coefficients employs a weighted averaging to combine the two sets of linear prediction coefficients and to produce the at least one additional set of linear prediction coefficients. If desired, the entirety of the speech codec is contained within a speech signal processor.
Other aspects of the present invention can be found in a speech coding system that performs hybrid extraction of linear prediction coefficients (LPCs) during coding of a speech signal. The speech coding system itself contains, among other things, a linear prediction coefficient parameter extraction circuitry and a linear prediction coefficient combination circuitry. The linear prediction coefficient parameter extraction circuitry extracts at least two sets of linear prediction coefficients during the coding of the speech signal, and the linear prediction coefficient combination circuitry combines the at least two sets of linear prediction coefficients to generate a hybrid set of linear prediction coefficients.
In certain embodiments of the invention, the speech coding system further determines the spectral content of the speech signal after first having generated the linear prediction coefficients (LPCs), and the spectral content of the speech signal is used by the linear prediction coefficient parameter extraction circuitry to perform the combination of the sets of linear prediction coefficients (LPCs). The speech codec calculates a set of line spectral frequencies using the linear prediction coefficients (LPCs), and the line spectral frequencies are used by the linear prediction coefficient combination circuitry to perform the hybrid combination of the sets of linear prediction coefficients (LPCs). One of the at least two sets of linear prediction coefficients corresponds to a pre-emphasized component of the speech signal. If desired, the entirety of the speech coding system is contained within a speech signal processor.
In other embodiments of the invention within the speech coding system, one of the at least two sets of linear prediction coefficients corresponds to a high frequency component of the speech signal extracted using a high pass tilted filter, the other of the at least two sets of linear prediction coefficients corresponds to a low frequency component of the speech signal extracted using a low pass tilted filter. When the speech coding system is contained within a speech codec having an encoder circuitry and a decoder circuitry, the linear prediction coefficient parameter extraction circuitry and the linear prediction coefficient combination circuitry are contained in the encoder circuitry of the speech codec.
Other aspects of the present invention can be found in a method that performs hybrid extraction of linear prediction coefficients from a speech signal. The method involves calculating a first and a second set of linear prediction coefficients from the speech signal, and combining the first set of linear prediction coefficients and the second set of linear prediction coefficients to generate a hybrid set of linear prediction coefficients.
In certain embodiments of the invention, the method further includes calculating an additional set of linear prediction coefficients from the speech signal, and combining the first set of linear prediction coefficients and the second set of linear prediction coefficients with the at least one additional set of linear prediction coefficients to generate a hybrid set of linear prediction coefficients. In addition, the method includes calculating a first set and a second set of line spectral frequencies using the linear prediction coefficients (LPCs) that are generated from the speech signal. For example, the first set of line spectral frequencies are calculated using the first set of linear prediction coefficients (LPCs), and the second set of line spectral frequencies are calculated using the second set of linear prediction coefficients (LPCs). Also, when combining the first set of linear prediction coefficients (LPCs) and the second set of linear prediction coefficients to generate a hybrid set of linear prediction coefficients (LPCs), a weighted filter is applied to the first set of linear prediction coefficients and the second set of linear prediction coefficients (LPCs).
Other aspects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system diagram illustrating one embodiment of a speech coding system built in accordance with the present invention.
FIG. 2 is a system diagram illustrating another embodiment of a speech coding system built in accordance with the present invention.
FIG. 3 is a system diagram illustrating an embodiment of a speech signal processing system built in accordance with the present invention.
FIG. 4 is a system diagram illustrating an embodiment of a speech codec built in accordance with the present invention that communicates using a communication link.
FIG. 5 is a functional block diagram illustrating an embodiment of a speech coding method performed in accordance with the present invention that calculates and combines two sets of linear prediction coefficients.
FIG. 6 is a functional block diagram illustrating an embodiment of a speech coding method performed in accordance with the present invention that calculates and combines an indefinite number of sets of linear prediction coefficients corresponding to an input speech signal.
FIG. 7 is a functional block diagram illustrating an embodiment of a speech coding method that calculates line spectral frequencies corresponding to two sets of linear prediction coefficients and uses the line spectral frequencies to generate a hybrid set of linear prediction coefficients corresponding to an input speech signal.
FIG. 8 is a functional block diagram illustrating an embodiment of a speech coding method that calculates line spectral frequencies corresponding to an indefinite number of sets of linear prediction coefficients and uses the line spectral frequencies to generate a hybrid set of linear prediction coefficients corresponding to an input speech signal.
DETAILED DESCRIPTION OF THE INVENTION
The speech coding that is performed in accordance with the present invention is adaptable with the ITU-Recommendation speech coding standards known in the art of speech coding and speech signal processing.
FIG. 1 is a system diagram illustrating one embodiment of a speech coding system 100 built in accordance with the present invention. The speech coding system 100 converts an input speech signal 120 into an output speech signal 130 . The speech coding system 100 performs a modified version of linear prediction speech coding on the input speech signal 120 in accordance with the present invention. Conventional linear prediction speech coding is known in the art is speech coding and speech signal processing. One example of linear prediction speech coding is code-excited linear prediction speech coding.
To perform this conversion of the input speech signal 120 to the output speech signal 130 , the speech coding system 100 employs a speech codec 110 . The speech codec 110 itself contains, among other things, a linear prediction coefficient (LPC) parameter extraction circuitry 114 , and a linear prediction coefficient (LPC) combination circuitry 116 . In one embodiment of the invention, the linear prediction coefficient (LPC) parameter extraction circuitry 114 derives two sets of linear prediction coefficient (LPC) parameters from the input speech signal by employing the well known auto-correlation method: two sets of auto-correlation coefficients are generated from the speech signal that has been preprocessed in two different ways (e.g. pre-emphasized filtering with gain in high frequency and original speech signal processing such as high-pass filtering or band pass filtering), then two sets of reflection coefficients (K i ) are generated using the auto-correlation coefficients, then two sets of linear prediction coefficients (LPCs) (a i ) are generated using the corresponding reflection coefficients (K i ). The linear prediction coefficient (LPC) combination circuitry 116 combines the two sets of linear prediction coefficient (LPC) parameters into one hybrid linear prediction coefficient (LPC) parameter set by converting first the two set of linear prediction coefficients (LPCs) (a i ) into the line spectral frequencies (LSFs), then by performing a hybrid linear combination in line spectral frequency (LSF) domain to generate a single set of line spectral frequency (LSF) parameters, and finally by converting the line spectral frequency (LSF) parameters back to the linear prediction coefficients (LPCs) (a i ).
In this way, the speech signal spectral information for a predetermined or selected low frequency region (e.g. from 60 Hz to 2 kHz) is represented in the linear prediction coefficient (LPC) set derived from the speech signal having been passed through the original speech signal processing circuitry, while the speech signal spectral information for a predetermined or selected high frequency region (e.g., from 2 kHz to 3.5 kHz) is better represented in the linear prediction coefficient (LPC) set derived from the speech signal having been passed through a pre-emphasize filtering circuitry which is a pre-emphasized speech signal processing circuitry 114 a in one embodiment of the invention. The line spectral frequencies (LSFs) are used to perform linear combination as combination using line spectral frequencies (LSFs) can be more stable than performing a straightforward linear combination of the linear prediction coefficients (LPCs) in certain embodiments of the invention. Alternatively, the linear prediction coefficients (LPCs) can be linearly combined directly, but the intervening use of the line spectral frequencies (LSFs) to perform the linear combination of the linear prediction coefficients (LPCs) is operable without departing from the scope and spirit of the invention.
Other information corresponding to the input speech signal 120 is used by the linear prediction coefficient (LPC) parameter extraction circuitry 114 to generate the linear prediction coefficients (LPCs) in other embodiments of the invention. Within the linear prediction coefficient (LPC) parameter extraction circuitry 114 , the pre-emphasized speech signal processing circuitry 114 a and original speech signal processing circuitry 114 b operate on the information that is generated or extracted from the input speech signal 120 to perform various speech coding operations on the input speech signal 120 .
One example of speech coding performed on the input speech signal 120 within the linear prediction coefficient (LPC) parameter extraction circuitry 114 is the extraction of linear prediction coefficients (LPCs) themselves using linear prediction speech coding methods known in the art of speech coding and speech signal processing. Alternatively, multiple sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 120 in certain embodiments of the invention. If desired, only two sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 120 , yet any number of sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 120 in other embodiments of the invention.
The number of sets of linear prediction coefficients (LPCs) that is extracted from the input speech signal 120 is dependent upon any number of parameters or elements. For example, in the situation where only two sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 120 , the decision of what amount of pre-emphasize filtering (or modification) should be applied to the speech signal before extracting the linear prediction coefficients (LPCs) from the pre-emphasized speech signal is determined using the power spectral density of the input speech signal 120 . Additional parameters are employed to direct the decision of how to modify the input speech signal 120 before extracting any sets of linear prediction coefficients (LPCs) including, but not limited to, other parameters known within the art of speech coding such as pitch, intensity, line spectral frequencies, and other parameters and characteristics extracted from and pertaining to the input speech signal 120 .
For those embodiments of the invention where two sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 120 , the linear prediction coefficient (LPC) combination circuitry 116 combines the two sets of linear prediction coefficients (LPCs) into a single set of linear prediction coefficients (LPCs) corresponding to the input speech signal 120 . Alternatively, for those embodiments of the invention where multiple sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 120 , the linear prediction coefficient (LPC) combination circuitry 116 combines the multiple sets of linear prediction coefficients (LPCs) into a single set of linear prediction coefficients (LPCs) corresponding to the input speech signal 120 . From certain perspectives, the combination of the multiple sets of linear prediction coefficients (LPCs) into a single set of linear prediction coefficients (LPCs) constitutes generating a hybrid set of linear prediction coefficients (LPC hybrid ) for the input speech signal 120 .
If desired, the linear prediction coefficient (LPC) combination circuitry 116 combines the multiple sets of linear prediction coefficients (LPCs) into a number of sets of linear prediction coefficients (LPCs) wherein the number of sets of linear prediction coefficients (LPCs) is less than the multiple sets of linear prediction coefficients (LPCs), i.e., the linear prediction coefficient (LPC) combination circuitry 116 decreases the number of sets of linear prediction coefficients (LPCs) without reducing strictly to a single set of linear prediction coefficients (LPCs), but merely decreases the number of sets of linear prediction coefficients (LPCs) by a predetermined amount.
FIG. 2 is a system diagram illustrating another embodiment of a speech coding system 200 built in accordance with the present invention. The speech coding system 200 converts an input speech signal 220 into an output speech signal 230 . To perform this conversion of the input speech signal 220 to the output speech signal 230 , the speech coding system 200 employs a speech codec 210 . The speech codec 210 itself contains, among other things, a linear prediction coefficient (LPC) parameter extraction circuitry 214 , and a linear prediction coefficient (LPC) combination circuitry 216 .
The linear prediction coefficient (LPC) parameter extraction circuitry 214 receives line spectral frequency (LSF) information that is generated from the input speech signal 220 . Within the linear prediction coefficient (LPC) parameter extraction circuitry 214 , a high frequency speech signal processing circuitry 214 a and a low frequency speech signal processing circuitry 214 b operate on the speech signal 220 to generate line spectral frequency information to perform various speech coding operations on the input speech signal 220 . Line spectral frequency (LSF) extraction is known to those skilled in the art is speech coding, yet the manner of combination performed in accordance with the present invention presents a novel way to generate a single set of linear prediction coefficients (LPCs) more representative of the entire speech signal 220 .
Similar the embodiment of the invention illustrated in the FIG. 1 that employs the linear prediction coefficient (LPC) parameter extraction circuitry 114 , the linear prediction coefficient (LPC) parameter extraction circuitry 214 of the FIG. 2 is operable to derive two sets of linear prediction coefficient (LPC) parameters from the input speech signal by employing the well known autocorrelation method: two sets of auto-correlation coefficients are generated from the speech signal that has been preprocessed in two different ways (e.g. pre-emphasized filtering with gain in high frequency and original speech signal processing such as high-pass filtering or band pass filtering), then two sets of reflection coefficients (K i ) are generated using the auto-correlation coefficients, then two sets of linear prediction coefficients (LPCs) (a i ) are generated using the corresponding reflection coefficients (K i ). The linear prediction coefficient (LPC) combination circuitry 216 combines the two sets of linear prediction coefficient (LPC) parameters into one hybrid linear prediction coefficient (LPC) parameter set by converting first the two set of linear prediction coefficients (LPCs) (a i ) into the line spectral frequencies (LSFs), then by performing a hybrid linear combination in line spectral frequency (LSF) domain to generate a single set of line spectral frequency (LSF) parameters, and finally by converting the line spectral frequency (LSF) parameters back to the linear prediction coefficients (LPCs) (a i ) to generate the one hybrid linear prediction coefficient (LPC) parameter set.
In this way, the speech signal spectral information for a predetermined or selected low frequency region (e.g. from 60 Hz to 2 kHz) is represented in the linear prediction coefficient (LPC) set that is derived from the speech signal using the low frequency speech signal processing circuitry 214 b , while the speech signal spectral information for a predetermined or selected high frequency region (e.g., from 2 kHz to 3.5 kHz) is better represented in the linear prediction coefficient (LPC) set that is derived from the speech signal using the high frequency speech signal processing circuitry 214 a . The line spectral frequencies (LSFs) are used to perform linear combination as combination using line spectral frequencies (LSFs) can be more stable than performing a straightforward linear combination of the linear prediction coefficients (LPCs) in certain embodiments of the invention. Alternatively, the linear prediction coefficients (LPCs) can be linearly combined directly, but the intervening use of the line spectral frequencies (LSFs) to perform the linear combination of the linear prediction coefficients (LPCs) is operable without departing from the scope and spirit of the invention.
In the specific embodiment shown by the speech coding system 200 in the FIG. 2, the input speech signal 220 is partitioned, from certain perspectives, into a high frequency component and a low frequency component. This partition is achieved using the high frequency speech signal processing circuitry 214 a and the low frequency speech signal processing circuitry 214 b . To perform the partition of the input speech signal 220 into a high frequency component and a low frequency component, a low pass tilted filter and a high pass tilted filter are used to perform filtering on the input speech signal 220 . That is to say, the low pass tilted filter and the high pass tilted filter are not per se a low pass filter of a high pass filter, but a modified low pass filter and a modified high pass filter where the rejection band spectrum is not entirely cut off, but rather attenuated by a predetermined amount which itself may be a function of frequency. For example, a low pass tilted filter may have a predetermined attenuation of a certain dB value below its โcutoffโ frequency, but the frequencies below that traditional โcutoffโ frequency are only attenuated, and not cut off completely. This way of partitioning the input speech signal 220 into a high frequency component and a low frequency component is amenable within the present invention.
Each of the high frequency component and a low frequency component of the input speech signal 220 is treated independently during speech coding of the input speech signal 220 and then a final combination is performed to perform speech coding on the speech signal 220 . If desired, the high frequency component of the input speech signal 220 is further partitioned into a number of components, and the low frequency component of the speech signal segment 220 is further partitioned into a number of components. In this embodiment, the high frequency speech signal processing circuitry 214 a operates on the high frequency component of the input speech signal 220 , and the low frequency speech signal processing circuitry 214 b operates on the low frequency component of the input speech signal 220 .
One example of speech coding performed on the input speech signal 220 within the linear prediction coefficient (LPC) parameter extraction circuitry 214 are the extraction of linear prediction coefficients (LPCs) themselves using linear prediction speech coding methods known in the art. Alternatively, multiple sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 220 in certain embodiments of the invention. If desired, only two sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 220 , yet any number of sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 220 in other embodiments of the invention. Also, the number of sets of linear prediction coefficients (LPCs) that are extracted from the input speech signal 220 is a function of components into which the input speech signal 220 is partitioned using the high frequency speech signal processing circuitry 214 a and the low frequency speech signal processing circuitry 214 b in accordance with the present invention as described above. For example, one set of linear prediction coefficients (LPCs) is generated for each of the low frequency component of the input speech signal 220 and the high frequency component of the input speech signal 220 . In addition, for those cases where each of the low frequency component of the input speech signal 220 and the high frequency component of the input speech signal 220 is further partitioned into a number of components, an individual set of linear prediction coefficients (LPCs) is calculated for each of the number of components within each of the low frequency component of the input speech signal 220 and the high frequency component of the input speech signal 220 .
The number of sets of linear prediction coefficients (LPCs) that are extracted from the input speech signal 220 is dependent upon any number of parameters or elements. For example, in the situation where only two sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 220 , the decision of what amount of pre-emphasize filtering (or modification) should be applied to the speech signal before extracting the linear prediction coefficients (LPCs) from the pre-emphasized speech signal is determined using the power spectral density of the input speech signal 220 . Additional parameters are employed to direct the decision of how to modify the input speech signal 220 before extracting any sets of linear prediction coefficients (LPCs) including, but not limited to, other parameters known within the art of speech coding such as pitch, intensity, line spectral frequencies, and other parameters and characteristics extracted from and pertaining to the input speech signal 220 .
For those embodiments of the invention where two sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 220 , the linear prediction coefficient (LPC) combination circuitry 216 combines the two sets of linear prediction coefficients (LPCs) into a single set of linear prediction coefficients (LPCs) corresponding to the input speech signal 220 . If desired, the intervening use of line spectral frequencies, derived from each of the two sets of linear prediction coefficients (LPCs), are used to perform the linear combination of the two sets of the linear prediction coefficients (LPCs) into a single set of linear prediction coefficients (LPCs). For example, the generation of line spectral frequencies (LSFs) is performed using the two sets of linear prediction coefficients (LPCs) as described above in various embodiments of the invention. However, the linear combination of the two sets of linear prediction coefficients (LPCs) could nevertheless performed in a straightforward manner in certain embodiments of the invention.
In addition, for those embodiments of the invention where multiple sets of linear prediction coefficients (LPCs) are extracted from the input speech signal 220 , the linear prediction coefficient (LPC) combination circuitry 216 combines the multiple sets of linear prediction coefficients (LPCs) into a single set of linear prediction coefficients (LPCs) corresponding to the input speech signal 220 . From certain perspectives, the combination of the multiple sets of linear prediction coefficients (LPCs) into a single set of linear prediction coefficients (LPCs) constitutes generating a hybrid set of linear prediction coefficients (LPCs) for the input speech signal 220 .
If desired, the linear prediction coefficient (LPC) combination circuitry 216 combines the multiple sets of linear prediction coefficients (LPCs) into a number of sets of linear prediction coefficients (LPCs) wherein the number of sets of linear prediction coefficients (LPCs) is less than the multiple sets of linear prediction coefficients (LPCs), i.e., the linear prediction coefficient (LPC) combination circuitry 216 decreases the number of sets of linear prediction coefficients (LPCs) without reducing strictly to a single set of linear prediction coefficients (LPCs), but merely decreases the number of sets of linear prediction coefficients (LPCs) by a predetermined amount.
FIG. 3 is a system diagram illustrating an embodiment of a speech signal processing system 300 built in accordance with the present invention. The speech signal processor 310 receives an unprocessed speech signal 320 and produces a processed speech signal 330 .
In certain embodiments of the invention, the speech signal processor 310 is processing circuitry that performs the loading of the unprocessed speech signal 320 into a memory from which selected portions of the unprocessed speech signal 320 are processed in various manners including a sequential manner. The processing circuitry possesses insufficient processing capability to handle the entirety of the unprocessed speech signal 320 at a single, given time. The processing circuitry may employ any method known in the art that transfers data from a memory for processing and returns the processed speech signal 330 to the memory. In other embodiments of the invention, the speech signal processor 310 is a system that converts a speech signal into encoded speech data. The encoded speech data is then used to generate a reproduced speech signal that is substantially perceptually indistinguishable from the speech signal using speech reproduction circuitry. In other embodiments of the invention, the speech signal processor 310 is a system that converts encoded speech data, represented as the unprocessed speech signal 320 , into decoded and reproduced speech data, represented as the processed speech signal 330 . In other embodiments of the invention, the speech signal processor 310 converts encoded speech data that is already in a form suitable for generating a reproduced speech signal that is substantially perceptually indistinguishable from the speech signal, yet additional processing is performed to improve the perceptual quality of the encoded speech data for reproduction.
The speech signal processing system 300 is, in some embodiments, the speech codec 100 , or, alternatively, the speech codec 200 as described in the FIGS. 1 and 2, respectively. The speech signal processor 310 operates to convert the unprocessed speech signal 320 into the processed speech signal 330 . The conversion performed by the speech signal processor 310 is viewed, in various embodiments of the invention, as taking place at any interface wherein data must be converted from one form to another, i.e. from speech data to coded speech data, from coded data to a reproduced speech signal, etc. The speech coding performed in accordance with the present invention is performed, in various embodiments of the invention, within the speech signal processor 310 . From certain perspectives, the conversion of the unprocessed speech signal 320 into the processed speech signal 330 is the extraction of the linear prediction coefficients (LPCs) and the combination of the linear prediction coefficients (LPCs), as described above in the various embodiments of the invention.
FIG. 4 is a system diagram illustrating an embodiment of a speech codec 400 built in accordance with the present invention that communicates across a communication link 410 . A speech signal 420 is input into an encoder circuitry 440 in which it is coded for data transmission via the communication link . 410 to a decoder circuitry 450 . The decoder processing circuit 450 converts the coded data to generate a reproduced speech signal 430 that is substantially perceptually indistinguishable from the speech signal 420 .
The speech coding performed in accordance with the present invention is performed, in various embodiments of the invention, in the encoder circuitry 440 or alternatively, in the decoder circuitry 450 . If desired, a portion of the speech coding is performed in the encoder circuitry 440 , and another portion of the speech coding of the speech signal is performed in the decoder circuitry 450 of the speech codec 400 . That is to say, for example, the extraction of the linear prediction coefficients (LPCs), in accordance with the various embodiments of the invention described above, is performed exclusively in the encoder circuitry 440 , or alternatively, exclusively in the decoder circuitry 450 of the speech codec 400 . Moreover, the extraction of the linear prediction coefficients (LPCs) is performed partially in the encoder circuitry 440 and partially in the decoder circuitry 450 in other embodiments of the invention. Similarly, the combination of sets of linear prediction coefficients (LPCs) is performed, in certain embodiments of the invention, is performed exclusively in the encoder circuitry 440 , or alternatively, exclusively in the decoder circuitry 450 of the speech codec 400 . Moreover, the combination of sets of linear prediction coefficients (LPCs) is performed partially in the encoder circuitry 440 and partially in the decoder circuitry 450 in other embodiments of the invention.
In certain embodiments of the invention, the decoder circuitry 450 includes speech reproduction circuitry. Similarly, the encoder circuitry 440 includes selection circuitry that is operable to select from a plurality of coding modes. The communication link 410 is either a wireless or a wireline communication link without departing from the scope and spirit of the invention. In addition, the communication link 410 is a network capable of handling the transmission of speech signals in other embodiments of the invention. Examples of such networks include, but are not limited to, Internet and intra-net networks capable of handling such transmission. If desired, the encoder circuitry 440 identifies at least one perceptual characteristic of the speech signal and selects an appropriate speech signal coding scheme depending on the at least one perceptual characteristic. The speech codec 400 is, in one embodiment, a multi-rate speech codec that performs speech coding on the speech signal 420 using the encoder circuitry 440 and the decoder circuitry 450 . The speech codec 400 is operable to perform hybrid extraction of linear prediction coefficients as a function of frequency within speech data in accordance with the present invention.
FIG. 5 is a functional block diagram illustrating an embodiment of a speech coding method 500 performed in accordance with the present invention that calculates and combines two sets of linear prediction coefficients. In a block 510 , a first set of linear prediction coefficients (LPC 1 ) is calculated that corresponds to a speech signal. The first set of linear prediction coefficients (LPC 1 ) of the block 510 represents the low frequency spectrum of the speech signal. This representation is achieved, among other ways, by employing a low pass tilted filter to the speech signal. As described above in various embodiments of the invention, the low pass tilted filter need not be a per se low pass filter, but a modified low pass filter that attenuates the frequencies above the โcutoffโ frequency by a predetermined amount, which may itself be a function of frequency, yet those frequencies are not completely rejected. For example, the attenuation above the โcutoffโ frequency is a predetermined amount of dB in certain embodiments of the invention, whereas the frequencies below the โcutoffโ frequency are passed. This is in contrast to a traditional low pass filter where frequencies below the โcutoffโ frequency are passed, and the frequencies above the โcutoffโ frequency are rejected.
Subsequently, in a block 520 , a second set of linear prediction coefficients (LPC 2 ) is calculated. The second set of linear prediction coefficients (LPC 2 ) of the block 520 represents the high frequency spectrum of the speech signal. This representation is achieved, among other ways, by employing a high pass tilted filter to the speech signal. As described above in various embodiments of the invention, the high pass tilted filter need not be a per se high pass filter, but a modified high pass filter that attenuates the frequencies below the โcutoffโ frequency by a predetermined amount, which may itself be a function of frequency yet those frequencies are not completely rejected. For example, the attenuation below the โcutoffโ frequency is a predetermined amount of dB in certain embodiments of the invention, whereas the frequencies above the โcutoffโ frequency are passed. This is in contrast to a traditional high pass filter where frequencies above the โcutoffโ frequency are passed, and the frequencies below the โcutoffโ frequency are rejected.
After each of the first set of linear prediction coefficients (LPC 1 ) and the second set of linear prediction coefficients (LPC 2 ) are calculated in each of the blocks 510 and 520 , respectively, the first set of linear prediction coefficients (LPC 1 ) and the second set of linear prediction coefficients (LPC 2 ) are combined in a block 530 . If desired, the first set of linear prediction coefficients (LPC 1 ) and the second set of linear prediction coefficients (LPC 2 ) are combined into a single set of linear prediction coefficients (LPCs). From certain perspectives, the single set of linear prediction coefficients (LPCs) is a hybrid set of linear prediction coefficients (LPC hybrid ).
From certain perspectives, the combination of the first set of linear prediction coefficients (LPC 1 ) and the second set of linear prediction coefficients (LPC 2 ) are combined into a single set of linear prediction coefficients (LPCs) that provides for a greater perceptually quality of a reproduced speech signal than if a single set of linear prediction coefficients (LPCs) is generated immediately from an input speech signal, without having first generated each of the first set of linear prediction coefficients (LPC 1 ) and the second set of linear prediction coefficients (LPC 2 ) from the input speech signal. That is to say, the decision of how to partition an input speech signal is appropriately chosen such that the first set of linear prediction coefficients (LPC 1 ) is directed substantially to maximize a perceptual quality of a first portion of the input speech signal, and the second set of linear prediction coefficients (LPC 2 ) is directed substantially to maximize a perceptual quality of a second portion of the input speech signal. In certain embodiments of the invention, the first portion of the input speech signal and the second portion of the input speech signal correspond to a high frequency component of the input speech signal and a low frequency component of the input speech signal, each of which is best represented by the first set of linear prediction coefficients (LPC 1 ) and the second set of linear prediction coefficients (LPC 2 ), respectively. In other embodiments of the invention, the first portion of the input speech signal and the second portion of the input speech signal correspond to a high energy component of the input speech signal and a low energy component of the input speech signal.
FIG. 6 is a functional block diagram illustrating an embodiment of a speech coding method 600 performed in accordance with the present invention that calculates and combines an indefinite number of sets of linear prediction coefficients corresponding to an input speech signal.
In a block 610 , a first set of linear prediction coefficients (LPC 1 ) is calculated. Subsequently, in a block 620 , a second set of linear prediction coefficients (LPC 2 ) is calculated, and in a block 625 , an n th set of linear prediction coefficients (LPC n ) is calculated. If desired, each of the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ) and the n th set of linear prediction coefficients (LPC n ) of the blocks 610 , 620 , and 625 , are derived using a predetermined filtering method. Specific examples of filtering include applying a low pass tilted filter or a high pass tilted filter to the various portions of a speech signal. As shown in the embodiment of the speech coding method 500 in FIG. 5, various types of filtering are applied to various portions of the speech signal in order to maximize certain perceptual qualities of those portions of the speech signal. Similarly, as desired in the specific application, the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ) and the n th set of linear prediction coefficients (LPC n ) of the blocks 610 , 620 , and 625 are tailored to maximize certain perceptual characteristics of certain portions of the speech signal in various embodiments of the invention.
After each of the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ), and the n th set of linear prediction coefficients (LPC n ) are calculated in each of the blocks 610 , 620 , and 625 , respectively, the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ), and the n th set of linear prediction coefficients (LPC n ), are combined in a block 630 . If desired, the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ), and the n th set of linear prediction coefficients (LPC n ), are combined into a single set of linear prediction coefficients (LPCs). From certain perspectives, the single set of linear prediction coefficients (LPCs) is a hybrid set of linear prediction coefficients (LPC hybrid ).
From certain perspectives, the combination of the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ), and the n th set of linear prediction coefficients (LPC n ) are combined into a single set of linear prediction coefficients (LPCs) that provides for a greater perceptually quality of a reproduced speech signal than if a single set of linear prediction coefficients (LPCs) is generated immediately from an input speech signal, without having first generated each of the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ), and the n th set of linear prediction coefficients (LPC n ) from the input speech signal. That is to say, the decision of how to partition an input speech signal is appropriately chosen such that the first set of linear prediction coefficients (LPC 1 ) is directed substantially to maximize a perceptual quality of a first portion of the input speech signal; the second set of linear prediction coefficients (LPC 2 ) is directed substantially to maximize a perceptual quality of a second portion of the input speech signal; and the n th set of linear prediction coefficients (LPC n ) is directed substantially to maximize a perceptual quality of an n th portion of the input speech signal.
In certain embodiments of the invention, the first portion of the input speech signal corresponds to a first frequency component of the input speech signal. The second portion of the input speech signal corresponds to a second frequency component of the input speech signal, and the n th portion of the input speech signal corresponds to an n th frequency component of the input speech signal. In other embodiments of the invention, the first portion of the input speech signal corresponds to a first energy component of the input speech signal. The second portion of the input speech signal corresponds to a second energy component of the input speech signal, and the n th portion of the input speech signal corresponds to an n th energy component of the input speech signal.
FIG. 7 is a functional block diagram illustrating an embodiment of a speech coding method 700 that calculates line spectral frequencies corresponding to two sets of linear prediction coefficients and uses the line spectral frequencies to generate a hybrid set of linear prediction coefficients corresponding to an input speech signal.
In a block 705 , a first set of linear prediction coefficients (LPC 1 ) is calculated using more weighting on the low frequency components of the speech signal. If desired, a low pass tilted filter is used to perform the weighting on the low frequency components of the speech signal in certain embodiments of the invention as similarly shown in certain aspects of the speech coding method 500 illustrated in FIG. 5 dealing with applying a low pass tilted filter to the speech signal. For the first set of linear prediction coefficients (LPC 1 ) that is calculated in the block 705 , a first set of line spectral frequencies (LSF 1 ) is calculated is calculated in a block 710 . Extracting line spectral frequencies from a speech signal is known in the art of speech signal processing.
The first set of line spectral frequencies (LSF 1 ) is calculated using the first set of linear prediction coefficients (LPC 1 ). In one embodiment of the invention, a number of auto-correlation coefficients are generated from the speech signal, then a number of reflection coefficients (K i ) are generated using the auto-correlation coefficients, then first set of linear prediction coefficients (LPC 1 ) are generated using the number of reflection coefficients (K i ), and finally the first set of line spectral frequencies (LSF 1 ) is generated using the first set of linear prediction coefficients (LPC 1 ). In this way, the generation of the first set of line spectral frequencies (LSF 1 ) is derivative from the first set of linear prediction coefficients (LPC 1 ).
Subsequently, in a block 715 , a second set of linear prediction coefficients (LPC 2 ) is calculated using more weighting on the high frequency components of the speech signal. If desired, a high pass tilted filter is used to perform the weighting on the high frequency components of the speech signal in certain embodiments of the invention as similarly shown in certain aspects of the speech coding method 500 illustrated in FIG. 5 dealing with applying a high pass tilted filter to the speech signal. For the second set of linear prediction coefficients (LPC 1 ) that is calculated in the block 715 , a second set of line spectral frequencies (LSF 2 ) is calculated is calculated in a block 720 .
In one embodiment of the invention, a number of auto-correlation coefficients are generated from the speech signal, then a number of reflection coefficients (K i ) are generated using the auto-correlation coefficients, then second set of linear prediction coefficients (LPC 2 ) are generated using the number of reflection coefficients (K i ), and finally the second set of line spectral frequencies (LSF 2 ) is generated using the second set of linear prediction coefficients (LPC 2 ). In this way, the generation of the second set of line spectral frequencies (LSF s ) is derivative from the second set of linear prediction coefficients (LPC s ).
After each of the first set of line spectral frequencies (LSF 1 ) and the second set of line spectral frequencies (LSF 2 ) are calculated in each of the blocks 710 and 720 corresponding to the first set of linear prediction coefficients (LPC 1 ) and the second set of linear prediction coefficients (LPC 2 ) that are calculated in the blocks 705 and 715 , respectively, the first set of line spectral frequencies (LSF 1 ) and the second set of line spectral frequencies (LSF 2 ) are combined in a block 730 using a weighted averaging as shown below in one embodiment of the invention.
LSF hybrid =ฮฑ LSF 1 +(1โฮฑ) LSF 2
The particular value of the weighting parameter โฮฑโ that is used to perform the weighted averaging of the first set of line spectral frequencies (LSF 1 ) and the second set of line spectral frequencies (LSF 2 ) is defined by the user employing the speech coding method 700 . If desired, the weighting parameter โฮฑโ is adaptively adjusted to various parameters of the speech signal and the weighting of various portions of the speech signal is modified as a function of the speech signal.
In a more general form, the weighting parameter โฮฑโ should be seen as a parameter set (a vector) with the same dimension as the LSF parameter sets, i.e.:
( LSF hybrid ) i =ฮฑ i ( LSF 1 ) i +(1โฮฑ i )( LSF 2 ) i
where i=1, . . . , LPC_order
In this embodiment of the invention, the first set of line spectral frequencies (LSF 1 ) and the second set of line spectral frequencies (LSF 2 ) are combined into a single, hybrid set of line spectral frequencies (LSF hybrid ) in the block 730 . Then, in a block 740 , a single, hybrid set of linear prediction coefficients (LPC hybrid ) is generated from the input speech signal using the single, hybrid set of line spectral frequencies (LSF hybrid ) that is generated in the block 730 . From certain perspectives, the hybrid set of linear prediction coefficients (LPC hybrid ) of the block 740 is a function of the hybrid set of line spectral frequencies (LSF hybrid ) of the block 730 .
LPC hybrid =fnc{LSF hybrid }
The two sets of line spectral frequencies (LSFs) (the first set of line spectral frequencies (LSF 1 ) and the second set of line spectral frequencies (LSF 2 )) are used to perform linear combination as combination using line spectral frequencies (LSFs) can be more stable than performing a straightforward linear combination of the linear prediction coefficients (LPCs) in certain embodiments of the invention. Alternatively, the linear prediction coefficients (LPCs) can be linearly combined directly as shown above in the various embodiments of the invention, but the intervening use of the line spectral frequencies (LSFs) to perform the linear combination of the linear prediction coefficients (LPCs) is operable without departing from the scope and spirit of the invention.
FIG. 8 is a functional block diagram illustrating an embodiment of a speech coding method 800 that calculates line spectral frequencies corresponding to an indefinite number of sets of linear prediction coefficients and uses the line spectral frequencies to generate a hybrid set of linear prediction coefficients corresponding to an input speech signal.
In a block 805 , a first set of linear prediction coefficients (LPC 1 ) is calculated using a first weighting function on the speech signal. If desired, a low pass tilted filter is used to perform the first weighting function on the speech signal in certain embodiments of the invention as similarly shown in certain aspects of the speech coding method 500 illustrated in FIG. 5 dealing with applying a low pass tilted filter to the speech signal and as shown in the speech coding method 700 of FIG. 7 . Any other weighting function is applied to the speech signal in the block 805 to help calculate the first set of linear prediction coefficients (LPC 1 ); the specific use of either a low pass tilted filter or a high pass tilted filter is merely exemplary of one type of weighting that is performed to the speech signal in calculating the first set of linear prediction coefficients (LPC 1 ) as shown in the block 805 . For the first set of linear prediction coefficients (LPC 1 ) that is calculated in the block 805 , a first set of line spectral frequencies (LSF 1 ) is calculated is calculated in a block 810 . Extracting line spectral frequencies from a speech signal is known in the art of speech signal processing.
In one embodiment of the invention, a number of auto-correlation coefficients are generated from the speech signal, then a number of reflection coefficients (K i ) are generated using the auto-correlation coefficients, then first set of linear prediction coefficients (LPC 1 ) are generated using the number of reflection coefficients (K i ), and finally the first set of line spectral frequencies (LSF 1 ) is generated using the first set of linear prediction coefficients (LPC 1 ). In this way, the generation of the first set of line spectral frequencies (LSF 1 ) is derivative from the first set of linear prediction coefficients (LPC 1 ).
If desired, a filter is employed to calculate the first set of line spectral frequencies (LSF 1 ) as shown by the filter in a block 821 . In the block 821 , a filter is applied to the input speech signal to determine its line spectral frequencies as shown by the following single poled filter in one embodiment of the invention.
A ( z )=1 โa i z โi
Subsequently, in a block 815 , a second set of linear prediction coefficients (LPC 2 ) is calculated using a second weighting function on the speech signal. If desired, a high pass tilted filter is used to perform the first weighting function on the speech signal in certain embodiments of the invention as similarly shown in certain aspects of the speech coding method 500 illustrated in FIG. 5 dealing with applying a low pass tilted filter to the speech signal and as shown in the speech coding method 700 of FIG. 7 . Any other weighting function is applied to the speech signal in the block 815 to help calculate the second set of linear prediction coefficients (LPC 2 ); the specific use of either a low pass tilted filter or a high pass tilted filter is merely exemplary of one type of weighting that is performed to the speech signal in calculating the second set of linear prediction coefficients (LPC 2 ) as shown in the block 815 . For the second set of linear prediction coefficients (LPC 2 ) that is calculated in the block 815 , a second set of line spectral frequencies (LSF 2 ) is calculated is calculated in a block 820 . If desired, the filter of the block 821 is also employed to calculate the second set of line spectral frequencies (LSF s ) as shown in the block 820 .
In one embodiment of the invention, a number of auto-correlation coefficients are generated from the speech signal, then a number of reflection coefficients (K i ) are generated using the auto-correlation coefficients, then second set of linear prediction coefficients (LPC 2 ) are generated using the number of reflection coefficients (K i ), and finally the second set of line spectral frequencies (LSF 2 ) is generated using the second set of linear prediction coefficients (LPC 2 ). In this way, the generation of the second set of line spectral frequencies (LSF s ) is derivative from the second set of linear prediction coefficients (LPC s ).
Subsequently, in a block 823 , an n th set of linear prediction coefficients (LPC n ) is calculated using an n th weighting function on the speech signal. If desired, a low pass tilted filter, or a high pass tilted filter is used to perform the first weighting function on the speech signal in certain embodiments of the invention as similarly shown in certain aspects of the speech coding method 500 illustrated in FIG. 5 dealing with applying a low pass tilted filter to the speech signal and as shown in the speech coding method 700 of FIG. 7 . Any other weighting function is applied to the speech signal in the block 823 to help calculate the n th set of linear prediction coefficients (LPC n ); the specific use of either a low pass tilted filter or a high pass tilted filter is merely exemplary of one type of weighting that is performed to the speech signal in calculating the n th set of linear prediction coefficients (LPC n ) as shown in the block 823 . For the n th set of linear prediction coefficients (LPC n ) that is calculated in the block 823 , an n th set of line spectral frequencies (LSF 2 ) is calculated is calculated in a block 827 . If desired, the filter of the block 821 is also employed to calculate the n th set of line spectral frequencies (LSF n ) as shown in the block 827 .
In one embodiment of the invention, a number of auto-correlation coefficients are generated from the speech signal, then a number of reflection coefficients (K i ) are generated using the auto-correlation coefficients, then second set of linear prediction coefficients (LPC 2 ) are generated using the number of reflection coefficients (K i ), and finally the n th set of line spectral frequencies (LSF n ) is generated using the n th set of linear prediction coefficients (LPC n ). In this way, the generation of the n th set of line spectral frequencies (LSF n ) is derivative from the n th set of linear prediction coefficients (LPC n ).
After each of the first set of line spectral frequencies (LSF 1 ), the second set of line spectral frequencies (LSF 2 ), and the n th set of line spectral frequencies (LSF n ) are calculated in each of the blocks 810 , 820 , and 827 corresponding to the first set of linear prediction coefficients (LPC 1 ), the second set of linear prediction coefficients (LPC 2 ), and the n th set of linear prediction coefficients (LPC n ) that are calculated in the blocks 805 , 815 , and 823 , respectively, the first set of line spectral frequencies (LSF 1 ), the second set of line spectral frequencies (LSF 2 ), and the n th set of line spectral frequencies (LSF n ) are combined in a block 830 using a weighted averaging as shown below in one embodiment of the invention.
LSF
hybrid
=ฮฑ LSF
1
+ฮฒLSF
2
+. . . +ฯLSF
n
The particular values of the weighting parameters โฮฑโ, โฮฒโ, and โฯโ that are used to perform the weighted averaging of the first set of line spectral frequencies (LSF 1 ), the second set of line spectral frequencies (LSF 2 ), and the n th set of line spectral frequencies (LSF n ) are defined by the user employing the speech coding method 800 . If desired, the weighting parameters โฮฑโ, โฮฒโ, and โฯโ are adaptively adjusted to various parameters of the speech signal and the weighting of various portions of the speech signal is modified as a function of the speech signal.
In this embodiment of the invention, the first set of line spectral frequencies (LSF 1 ), the second set of line spectral frequencies (LSF 2 ), and the n th set of line spectral frequencies (LSF n ) are combined into a single, hybrid set of line spectral frequencies (LSF hybrid ) in the block 830 . Then, in a block 840 , a single, hybrid set of linear prediction coefficients (LPC hybrid ) is generated from the input speech signal using the single, hybrid set of line spectral frequencies (LSF hybrid ) that is generated in the block 830 . From certain perspectives, the hybrid set of linear prediction coefficients (LPC hybrid ) of the block 840 is a function of the hybrid set of line spectral frequencies (LSF hybrid ) of the block 830 .
LPC hybrid =fnc{LSF hybrid }
The multiple sets of line spectral frequencies (LSFs) (the first set of line spectral frequencies (LSF 1 ), the second set of line spectral frequencies (LSF 2 ), and the n th set of line spectral frequencies (LSF n )) are used to perform linear combination as combination using line spectral frequencies (LSFs) can be more stable than performing a straightforward linear combination of the linear prediction coefficients (LPCs) in certain embodiments of the invention. Alternatively, the linear prediction coefficients (LPCs) can be linearly combined directly as shown above in the various embodiments of the invention, but the intervening use of the line spectral frequencies (LSFs) to perform the linear combination of the linear prediction coefficients (LPCs) is operable without departing from the scope and spirit of the invention.
In view of the above detailed description of the present invention and associated drawings, other modifications and variations will now become apparent to those skilled in the art. It should also be apparent that such other modifications and variations may be effected without departing from the spirit and scope of the present invention.
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A speech coding system that employs hybrid linear prediction coding during extraction of linear prediction coefficients within ITU-Recommendation speech coding standards. The present invention is operable within linear prediction speech coding systems including code-excited linear prediction speech coding systems, and it provides for a substantially improved perceptual quality of reproduced speech signals when compared to conventional speech coding methods that employ the commonly known auto-correlation method that is based on minimizing the linear prediction coding (LPC) prediction error energy. The invention is operable to provide for high perceptual quality of reproduced speech signals having substantial differences of energy in various frequency bands. For example, for speech signals having information dispersed broadly across the frequency spectrum, such as having a significant amount of information at low frequency and a significant amount of information at high frequency, the invention provides a way to maintain a high perceptual quality across the broad frequency range. The invention generates a single set of linear prediction coefficients (LPCs) either directly from the speech signal in certain embodiments of the invention, or alternatively, interveningly through the use of line spectral frequencies (LSFs) that are generated from different sets of linear prediction coefficients (LPCs) generated from the speech signal itself in other embodiments of the invention.
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This is a continuation-in-part of--application Ser. No. 07/619,368, filed Nov. 28, 1990, now abandoned.
FIELD OF THE INVENTION
This invention relates to modular office systems, and in particular to panels used to provide separate working areas for persons employed in offices, factories and other places of employment.
BACKGROUND OF THE INVENTION
Panels are widely used in commerce and industry to define separate working areas, sometimes referred to as work stations or cubicles, for workers in offices, factories and the like. Such panels have several advantages. They allow for a relatively open workplace, with free distribution of air and light over a large area, thereby avoiding the rigidly compartmentalized environment that would result from a maze of separate rooms and hallways. At the same time, they define a separate working area which each employee can call his or her own, and they provide a modicum of privacy for each employee. Most importantly, panels are relatively inexpensive to install and, being fabricated as separate units, can be readily moved from place to place as the needs of the workplace change. Typically, such panels rest on short legs or glides and range in height from 34 inches to 80 inches, with the most predominant size being approximately 60 inches.
While, as noted, panels provide a certain amount of privacy for each worker, in the past this feature has been limited by the presence of an open entryway into each work station. As a result, each worker is subject to unwanted intrusions and disturbances from other workers and has no way of clearly indicating that he or she does not wish to be disturbed. This has numerous deleterious effects on the quality of work product and environment. For example, a worker may need to concentrate on a particular task in order to complete it on time. Interruptions may break his or her "train of thought" and result in wasted time and stress. Privacy may be desirable during certain meetings or conferences, in particular those relating to performance reviews and other personnel matters. Workers in telemarketing and/or sales need uninterrupted time to communicate with company clients. Health needs may also need to be addressed; workers who are suffering from colds or other ailments may want more privacy for a duration of several days, and this coincides with the interests of other workers in minimizing the risk of contagion.
SUMMARY OF THE INVENTION
In accordance with this invention, a sliding privacy panel is enclosed within a stationary panel on one side of an entryway to a work station. When the privacy panel is not in use, it rests in a cavity inside the stationary panel, the cavity being open on one lateral edge of the stationary panel. When an employee in the work station desires privacy, he or she slides the privacy panel out of the stationary panel to close off the entryway, thereby reducing interference from outside noise and indicating to other workers that he or she does not want to be disturbed. The sliding privacy panel may slide out of the mother panel on ball bearing slides. Magnets may be provided to hold the panel in an open or closed position. A foot containing a roller or skid may be provided to support the privacy panel on the floor when it is in a closed position.
A privacy panel in accordance with this invention is simple and relatively inexpensive.
In another embodiment, the top of the privacy panel slides in a channel mounted in the stationary panel and the bottom of the privacy panel glides on a series of rollers. A V-shaped structure is provided to guide the privacy panel into latching contact with the stationary panel on the opposite side of the entryway.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows top and side views of a privacy panel in accordance with this invention.
FIG. 2 detailed perspective view of a portion of a privacy panel in accordance with the invention.
FIG. 3 is a side view of another embodiment according to invention.
FIG. 4 is a cross-sectional view of the structures for guiding the top and bottom of the privacy panel of FIG. 3.
FIG. 5 is a side view of the structure for guiding the bottom of privacy panel of FIG. 3.
FIG. 6 a top view of the V-shaped guide for bringing the edge of a privacy panel into contact with the stationary panel on the opposite side of the entryway.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a privacy panel 10 is mounted within a stationary panel 11 beside an entry 12 to a work station. Privacy panel 10 is supported by a ball bearing slide 13 and by a roller foot 14, which together support panel 10 as it glides between open and closed positions. Magnets 15 make contact with a metal strip 16 to hold panel 10 in an open position, and magnets 17 contact a metal strip 18 on a stationary panel 19 across entry 12 to hold panel 10 in a closed position.
FIG. 2 is a more detailed perspective view of a portion of privacy panel 10 and in particular shows a finger grip 20, which can be used to grip privacy panel 10 when opening or closing it. FIG. 2 also shows a cavity 21 which is open on a lateral edge 22 of stationary panel 11 and within which privacy panel 10 rests when it is in a open position.
Privacy panel 10 thus answers a long unfilled need for a simple, effective and inexpensive means of providing reasonable privacy to workers and others who occupy areas that are defined by modular partitions. While a major application of this invention is in the workplace, it also is usable in health care facilities, homes and other locations where partitions are found.
It will be understood that the embodiment shown in FIGS. 1 and 2 is illustrative only, and that several of the elements shown therein are optional or can be replaced by other known elements having a similar function. For example, ball bearing slide 13 can be replaced by other known mechanisms for permitting adjacent surfaces to slide or otherwise move in a direction parallel with respect to each other. Roller foot 14 may be replaced by wheels, skids or other types of moveable supports, or it may be omitted altogether if panel 10 is given sufficient support by the members which position it within panel 11. Magnets 15 and 17 may be omitted or replaced by various types of spring-loaded or other latching or retaining mechanisms. Stationary panels 11 and 19 are typically about five feet in height, but they may be either higher or lower. Moreover, stationary panel 19 may be replaced by a wall or any other physical barrier which can define one side of an entryway. In addition to the foregoing, those skilled in the art will be able to conceive of or recognize numerous alternative embodiments all of which are within the broad scope and principles of this invention.
FIG. 3 shows an alternative embodiment in accordance with the invention. A privacy panel unit 30 contains a privacy panel 31 with a leading edge 31a and a trailing edge 31b. A fixed edge 32 of privacy panel unit 30 is designed to be attached to existing stationary panels in an office work station or cubicle, for example. Privacy panel unit 30 has two legs 33, which rest on a floor 34. Floor 34 may or may not be carpeted.
The upper edge of privacy panel 31 slides in a channel 35, which is mounted near the top of privacy panel unit 30. The bottom edge of privacy panel 31 rests on a roller rail 36, which is mounted near the bottom of privacy panel unit 30. Leading edge 31a of privacy panel 31 is supported by a roller 37, which is similar to the casters used on office desk chairs, with the vertical supporting shaft fixed so that the caster may not swivel as panel 31 is opened and closed. Roller 37 is designed to roll on floor 34, without the need for any complementary structure (e.g., a track) to be mounted on or in the floor. Thus, since neither legs 33 nor roller 37 is attached to floor 34, privacy panel unit 30 is a portable, modular unit which may be installed and removed without any structural modifications to the building.
The side wall of privacy panel unit 30 is cut away in region 38 so as to expose a recessed handle 39 in privacy panel 31, thereby allowing the occupant of the work station or cubicle easily to grasp privacy panel 31 when it is in its fully open position. A cord 40 is attached to the trailing edge 32b of privacy panel 31 and to edge 32 so as to prevent privacy panel 31 from sliding completely out of privacy panel unit 30. This is particularly important during shipment of the privacy panel unit 30. At edge 32, cord 40 is inserted through a hole and knotted, thereby allowing cord 38 to be detached should privacy panel 31 need to be removed for repairs or maintenance.
On the other side of entryway E, a latch panel 41 is attached to a stationary panel 42, which is part of the existing partition structure. Latch panel 41 contains a guide 43 and latch mechanism 44, which may or may not be keyed, and which may be omitted altogether.
The details of channel 35 and roller rail 36 are shown in the cross-sectional view of FIG. 4. Channel 35 may preferably be formed of a plastic, such as high density polyethylene. Privacy panel 31 has a metal top cap 45, which slides within channel 35. It has been found that a clearance of approximately 1/16 inch between the sides of top cap 45 and the inner surfaces of channel 35 provides good stability as privacy panel 31 is withdrawn from privacy panel unit 30. Roller rail 36 comprises a metal rail 46 into which a series of plastic rollers 47 are mounted rotatably on axles 48. Privacy panel 31 has a metal bottom cap 49, which is similar to top cap 45 and rests on rollers 47. Guide bars 50 are mounted on either side of roller rail 36 to keep bottom cap 49 riding on rollers 47. A product called the Kenrailโข, manufactured by Keneco, Inc. of Kenilworth, N.J., has been found suitable for use as roller rail 36. Guide bars 50 may be made from 18 gage sheet metal and riveted to the sides of the Kenrail.
FIG. 5 is a side view of roller rail 36, with guide bars 50 removed, showing in detail the manner in which bottom cap 49 rides upon roller rail 36.
To provide good stability, the width W of privacy panel 31 should be at least 6 inches greater than the width of entryway E. Nonetheless, as privacy panel 31 is withdrawn from unit 30, the leading edge 31a may tend to wander slightly as a result of the inherent play in the connections with channel 35 and roller rail 36. Accordingly, it is useful to have some means of assuring that leading edge 31a is properly aligned when it reaches latch panel 41 on the opposite side of the entryway. Guide 43, which is illustrated in FIG. 6, performs this function. FIG. 6 is a top view of guide 43 and shows the manner in which privacy panel is guided into proper alignment as it approaches latch panel 41. Guide 43 has two outwardly extending flanges 43a and 43b shaped generally in the form of a "V", which engage panel 31 and guide it into proper alignment with a jamb 41a of latch panel 41, should it get slightly out of line. Thus, privacy panel 31 makes proper contact with jamb 41a, and the user need not be concerned about adjusting the position of privacy panel 31 in order to get secure closure or to operate latching mechanism 44. Latching mechanism 44 may be a Model 5017 Deadlock, manufactured by Adams Rite Manufacturing Co. of California, although any type of latch which provides a firm linkage between privacy panel 31 and latch panel 41 can be used. Latch mechanism 44 may or may not be keyed, as the application dictates.
Privacy panel unit 30 and latch panel 41 are modular units which may easily be conjoined with partition panels in an existing open office arrangement.
The embodiment illustrated in FIGS. 3-6 is illustrative only, and is not intended to be limiting. Many modifications of this embodiment and other embodiments in accordance with the invention will be apparent to those skilled in the art, all of which are intended to be included within the broad principles of this invention.
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A moveable panel is described for providing privacy for a person in a work station or other location behind an arrangement of one or more stationary panels.
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BACKGROUND OF THE INVENTION
This invention relates to a blanking and forming press for sheet metal caps.
In traditional presses of the aforesaid type, the blanking and forming are carried out by a punch which moves relative to a counter-punch or die against the return force of elastic springs. The stroke of the punch gives rise to considerable squashing of the springs which, thus subjected to repeated high stress, are frequently fractured.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a press in which said disadvantages are effectively obviated.
This object is attained by a press comprising a fixed cross member, at least one cylindrical seat provided in said cross member, a sleeve slidably housed in said seat and with a terminal portion projecting from said seat and shaped externally as a circular edge constituting the blanking knife, elastic means acting axially on the sleeve and arranged to keep it resting against a stop in said seat, a shoulder provided on said seat against which the sleeve abuts when moved in opposition to said elastic means, a rod guided axially in the sleeve and connected at its upper end to a first cross member supported mobile relative to said fixed cross member, a forming and blanking punch connected to the free end of said rod, a second cross member supported mobile relative to said fixed cross member on the side opposite that on which the first mobile cross member is situated, a cylindrical die supported by said second cross member mobile coaxially to the rod and defining by means of an inner edge a blanking knife cooperating with the outer knife defined by said sleeve, a cylindrical element positioned inside said die and comprising an upper surface in the form of a circular rim arranged to abut against the lower end of said sleeve and a well to receive the punch during the cap forming, motor means for driving said first and second cross members in a reciprocating manner relative to the fixed cross member such that firstly, when the mobile cross members and fixed cross member are spaced apart, the sheet metal is positioned between the sleeve and die, and then as the cross members approach each other the sheet metal is locked between the edge of the die and a presser element which can be loaded against return springs, then a discoidal element is cut by the sleeve penetrating into the die, the discoidal element is gripped between the opposing surfaces of the sleeve and cylindrical element, the punch penetrates into the well in the cylindrical element consequently forming the cap by permanent deformation of the discoidal element, the peripheral edge of said cap is trimmed by a cutting edge of the punch cooperating with the inner edge of the cylindrical element, and finally the mobile cross members are withdrawn from the fixed cross member and the cap is removed.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics of the present invention will be more evident from the detailed description given hereinafter of one embodiment illustrated by way of example in the accompanying drawings, in which:
FIG. 1 is an elevation on a transverse plane of those parts of the press which relate to the blanking and forming members;
FIG. 2 is a section on the line II--II of FIG. 1, and
FIGS. 3, 4, 5, 6, 7, 8, 9 and 10 show different stages in the operation of the press.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to said figures, a stationary cross or base member 1 is supported laterally by respective shoulders, not shown on the drawing but constructed in accordance with known methods.
The cross member 1 comprises two parallel rows, 2 and 3, of seats each of which supports blanking and forming members.
In the description given hereinafter only the members relative to a single blanking and forming unit are described.
In relation to such a unit, the seat in the cross member 1 is indicated by 4. This seat is of cylindrical shape and houses a tube 5 which projects partially from the upper and lower surfaces of the cross member 1. The projecting parts of the tube 5 are provided with outer threads on which ring nuts 6, 7 are screwed for axially locking the tube 5.
The upper portion of the tube 5 is provided internally with a thread into which is screwed a bush 8 provided upperly with a toothed collar 9 for engagement with a tightening key.
The lower end of the bush 8 provides an abutment shoulder 10 for a sleeve 11 guided in that portion of the tube 5 lying below the bush 8.
The top of the sleeve 11 comprises a outer collar 12 of diameter greater than the underlying portion and guided between the shoulder 10 and a step 13 shown in FIG. 2.
The bush 8 is threaded internally over its upper portion and a gland 14 is screwed therein provided with teeth for engagement with a suitable operating tool. Between the gland 14 and head of the sleeve 11 there is a spring 15 subjected to compression, which keeps the collar 12 resting on the step 13 when the press is not operating.
A cylindrical rod 16 with its upper end shaped as an enlargement 17 is guided in the gland 14 and sleeve 5. This upper end is connected to a mobile ram or cross member 18 of the press which, by means of members which are not shown, but for example of reciprocating type, is moved relative to the fixed cross member 1.
The rod 16 rests by the enlargement 17 against a nut 19 threaded into the cross member 18 and fixed by a locking nut 20.
The rod 16 is retained at the cross member 18 by a spring 21 disposed between the annular portion of the enlargement 17 which projects from the rod 16, and a step 22 provided in the mobile cross member 18.
In the lower end of the rod 16 there is provided an axial seat in which engages the cylindrical shank 23 of a forming punch 24.
A cutting ring 25 is disposed between the forming punch 24 and rod 16, and in practice constitutes the guide support for the rod 16 in the sleeve 11. The outer diameter of the ring 25 is slightly greater than the diameter of the punch 24, and its lower peripheral edge constitutes the cutter for trimming the edge of the formed cap, as will be evident hereinafter.
The punch 24 is provided with a plurality of channels 26 which open at its lower surface and which branch from a single axial channel 27 extending in the rod 16 to a position above the sleeve 11. A channel 28 branches radially from the channel 27 and opens in the interspace defined by the rod 16 and bush 8. The interspace, indicated by 29, communicates by way of holes 30 in the bush 8 and holes 31 in the tube 5, with a duct 32 provided in the fixed cross member 1 and connected by a connector 33 to a source of compressed air. Annular grooves provided in the outer periphery of the tube 5 and bush 8 connect the duct 32 to the holes 31 and these latter to the holes 30 respectively.
Below the cross member 1 there is provided a plate 34 acting as a presser element for the sheet metal from which the caps are to be formed. The plate 34 is suspended from a plurality of stems 35 (FIG. 2) guided in the fixed cross member 1. Each stem is connected to the plate 34 by ring nuts 36 and urged to descend by springs 37 housed in a seat 38 in the cross member 1. The springs 37 act on a shoulder 39 of the stem 35, and at the other end abut on a shoulder 40 in the seat 38. The upper end of the stems is threaded and a nut 41 is screwed thereon, and locked by a dowel 42. The nut 41 has a smooth outer surface and is able to slide in a hole 43 provided in the cross member 1.
It is apparent that by adjusting the position of the nut 41 on the stem 35, the vertical height of the plate 34 relative to an underlying reference plane may be fixed.
Below the plate 34 there is a second mobile cross member 44 driven with reciprocating motion relative to the fixed cross member 1.
Seats are provided in rows, 2, 3 in the mobile ram or cross member 44 for housing the other parts of the press which cooperate with the punch 24 and sleeve 11 in blanking and forming the caps. These seats are indicated by 45 and dies 46 are guided therein. The dies 46 have an inner diameter to receive the lower end of the sleeve 11 with minimum possible tolerance, and rest lowerly on a ring 47 screwed into a threaded portion of the seat 45. The dies 46 comprise a lower inner step 48 on which a perfectly aligned cylindrical drawing element 49 rests, this being of the same thickness as the sleeve 11 and traversed axially by a bore. A sleeve 50 is screwed into the bottom of the cylindrical element 49 and rests by an enlarged lower portion against a flat surface 50a of the mobile cross member 44.
The sleeve 50 acts as a guide for an expelling unit indicated overall by 51. This expelling unit comprises a rod 52 to the bottom of which are screwed a ring nut and locking nut 53 which act as a stop for a spring 54 wound about the rod 52 and resting by its top on an inner lip of a bush 55 screwed into the sleeve 50.
A head 56 screwed on to the threaded extension of the rod 52 rests on the bush 55. The head 56 is guided in the cylindrical element 49 and comprises three axial holes distributed at an angle of 120ยฐ, in which pins 57 projecting from the upper surface of the head 56 are guided. The pins 57 are of mushroom shape and are loaded by springs 58 which rest on a dowel 59 screwed into the head 56 to close said axial holes. The rod 52 is arranged to rest on a stop 60 during the descent of the mobile cross member 44 for expelling the caps which otherwise would remain retained inside the cylindrical element 49.
The operation of the press described will be more evident from a description of its stages of operation, as shown by the sequence of FIGS. 3 to 10.
At the beginning of the operational cycle, the press is as shown in FIG. 3, i.e., with the mobile cross members 18 and 44 spaced apart from the fixed cross member 1, i.e., raised and lowered respectively.
The sheet metal from which the caps are to be shaped is indicated by 61 in FIG. 3. This is fed so as to be practically tangential to the lower plane of the plate 34. After positioning the sheet metal below the punches, the cross member 44 is raised so that the dies 46 are brought into contact with the lower surface of the plate 34, so as to firmly hold the sheet metal 61 (FIG. 4).
Continuing the upward stroke of the cross member 44, the plate 34 is raised against the force of the springs 37, until the sheet metal rests on the lower surface of the cutting sleeve 11. In the meantime, because of the simultaneous descent of the cross member 18, the forming punch 24 has approached the upper surface of the sheet metal (see FIG. 5). As the cross member 44 raises still further, a disc 62 is cut and falls into the well defined by the upper edge of the die 46 lying above the end surface of the cylindrical elements 49 (FIG. 6).
During this stage, the sleeve 11 which had been thrust downwards by the spring 15 is now raised by the effect of the lifting thrust exerted by the dies 46, until it abuts against the shoulder 10 of the bushes 8. In this manner, as the cross member 18 is lowered, the cutting force provided thereby is able to directly discharge itself on to the sheet metal and is not neutralised by the yielding of the springs 15.
Examining now the cycle of operations from FIG. 7, it will be seen that the disc 62 remains locked between the opposing ends of the sleeves 11 and the cylindrical elements 49 by the effect of the elastic pressure exerted by the springs 15 on the sleeves 11. As the punch 24 descends, see FIG. 8, the disc 62 is deformed to assume the shape of a cylindrical cap 64 complementary to the shape of the punch 24. When the punch 24 has completely penetrated into the cylindrical element 49, the ring 25 trims off a portion 63 which remains held between the opposing ends of the sleeve 11 and cylindrical element 49. When formation of the cups 64 is complete (FIG. 8) the mobile cross members again withdraw from the fixed cross member. The expelling member 51 makes contact at 60 before the mobile cross member 44 has reached the end of its lower stroke and brakes the descent of the cap 64 which consequently remains raised above the edges of the cylindrical element 49 as shown in FIGS. 9 and 10. The caps 64 and trimmed portions 63 are then removed from the press at this point by suitable removal means such as compressed air jects. It should be noted that, as usual, to facilitate the forming operations the metal sheets are coated with a liquid which facilitates their sliding but which can create a sucker effect when the cap is in the position of FIG. 10. To prevent this, pins 57 are provided to maintain a layer of air between the caps and the surface of the heads 56.
The invention completely attains the stated objects. In particular, during blanking and forming there are no parts highly stressed by a large punch stroke. In this respect, the cutting sleeve 11 has to make only a stroke which is limited at one end by the shoulder 10 and at the other end by the step 13. Because of the reduced sleeve stroke, the compression of the spring 15 is not appreciable.
The expulsion of the caps formed by the punches 24 is facilitated both by the slightly conical shape of these latter and by feeding compressed air through the ducts 26-33, so that the caps 64 remain inside the cylindrical elements 49.
In the practical embodiment of the invention the technical details, may vary according to requirements.
This particularly applies to the thickness and material of the caps.
Particular attention must therefore be given to the shape of the edges of the punch 24 and the cylindrical elements 49 in order to obtain uniform sliding of the sheet metal during the stage in which the punch 24 penetrates into the well defined by the cylindrical elements 49, in order to prevent puckering, bending and other similar defects.
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A blanking and forming press for sheet metal caps having a fixed cross member, a sleeve constituting the blanking knife housed in the fixed cross member, first and second cross members supported mobile relative to the fixed cross member on its opposed sides, a rod connected at its one end to the first cross member and at its other end to a forming and blanking punch, a cylindrical die supported by the second cross member mobile coaxially to the rod and defining a blanking knife cooperating with the knife defined by the sleeve to form, as the mobile cross members approach each other, a cap member by permanent deformation of a discoidal element cut by the sleeve penetrating into the die.
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[0001] Research leading to the completion and reduction to practice of the invention was supported in part by Grant No. EEC-9402989 awarded by the National Science Foundation (NSF). The United States Government has certain rights in and to the invention claimed herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a process for the treatment of wastepaper. More particularly, the present invention relates to a process for de-inking wastepaper. Most particularly, the present invention relates to a process for enhanced removal of ink particles and non-ink contaminants from wastepaper. Finally, the present invention relates to an improvement over the invention described in U.S. Pat. No. 6,217,706, the entire contents and disclosure of which is incorporated herein by reference.
[0004] 2. Description of the Prior Art
[0005] In modern times, with the ecological concerns about conservation of raw materials and the rapid decline of available landfill space, it has become increasingly desirable to recover and recycle used raw materials. Thus, recovered wastepaper represents a valuable source of raw material for the paper industry. In order for the wastepaper to be regenerated into a viable starting material and to produce a commercially acceptable paper, the wastepaper must be treated to remove any ink particles and non-ink contaminants.
[0006] Wastepaper has long served as a source of the raw fiber materials used in paper-making. Traditionally, fiber from wastepaper was utilized only in the production of low grade paper and paperboard products. Today, however, greater utilization of reclaimed fiber has provided incentive for taking steps to upgrade the reclaimed product These steps include treatment to effectively remove ink from waste fibers in order to permit their use in the manufacture of newsprint and high quality papers. Because of its quantity, waste newsprint is a particularly important feedstock to such reclamation processes.
[0007] In the course of the conventional paper reclamation process of interest, de-inking procedures include steps for converting the wastepaper to pulp and contacting the pulp with an alkaline aqueous de-inking medium containing a chemical de-inking agent The physical pulping and the alkalinity of the aqueous medium cause the partial removal of ink from the pulp fiber and the de-inking agent completes this removal and produces a suspension and/or dispersion of the ink particles thus removed from the pulp.
[0008] The resulting mixture is subsequently treated by flotation or washing to separate the suspended ink from the pulp.
[0009] In most conventional de-inking processes, the wash and/or flotation steps are carried out at an alkaline pH, usually 8.5 to 10.5. Conducting the washing or flotation steps at an alkaline pH is convenient because the fluid carried over from the pulping step is alkaline. In addition, many wash de-inking and flotation de-inking processes use fatty acids as surfactants and these fatty acids are capable of functioning as surfactants only when the aqueous medium is sufficiently alkaline to ionize them.
[0010] Typically, reclamation is accomplished in two steps:
1. refining the wastepaper, i.e., fiberizing in water in the presence of the chemicals required for detachment of the printing ink particles, and 2. removal of the detached printing ink particles form the fiber suspension.
[0013] The second step can be carried out by washing or flotation [Ullmanns Encyclopaedie der technischen Chemie, 4th Edition, Vol. 17, pages 570-571(1979)]. In flotation, which utilizes the difference in wettability between printing inks and paper fibers, air is forced or drawn through the fiber suspension. Small air bubbles attach themselves to the printing ink particles and form a froth at the surface of the water which is removed.
[0014] The de-inking of wastepaper is normally carried out at alkaline pH values in the presence of alkali metal hydroxides, alkali metal silicates, oxidative bleaches and surfactants at temperatures in the range of from 30.degree. to 50.degree. C. Anionic and/or non-ionic surfactants, for example, soaps, ethoxylated fatty alcohols and/or ethoxylated alkyl phenols, are mainly used as surfactants [Wochenblatt fuer Papierfabrikation, Vol. 17, pages 646-649 (1985)].
[0015] Many prior art processes are known for de-inking wastepaper, many of which are directed to the development of de-inking agents. In U.S. Pat. No. 4,586,982 (Poppel et al), there is described a process comprising treating the wastepaper in a pulper at an alkaline pH with alkali silicate, an oxidatively active bleaching agent, an acid selected from the group consisting of fatty acids and resinic acids containing more than ten carbon atoms and a dispersing agent wherein the acid and dispersing agent are employed together in an oil-in-water emulsion.
[0016] Additional disclosures of de-inking agents are set forth by, for example, Wood et al in U.S. Pat. No. 4,618,400 (thiol ethoxylate compounds); Wood et al in U.S. Pat. No. 4,561,933 (a mixture of C.sub.8 to C.sub.16 alkanols and alcohol ethoxylates); DeCeuster et al in U.S. Pat. No. 4,343,679 (compounds capable of liberating ions with a positive charge equal or greater than 2); Bridle in U.S. Pat. No. 4,483,742 (pine oil and a soap-making fatty acid); and Tefft in U.S. Pat. No. 4,786,364 (a hydrolyzed copolymer of dimethyldiallyl ammonium chloride and acrylamide).
[0017] Other prior art processes are directed to improvements in either washing or flotation methods of separating ink particles from wastepaper fibers.
[0018] In U.S. Pat. No. 4,548,673, Nanda et al describe a de-inking flotation method comprising the steps of independently introducing air into a fiber stock slurry, mixing the air bubbles and slurry, and separating the ink-laden air bubbles from the fiber slurry, where each of these steps is independently controlled. In U.S. Pat. No. 4,749,473, Shiori et al describe introducing air bubbles into the wastepaper pulp slurry through a number of orifices formed on a peripheral surface of at least one rotatable horizontal cylinder located in the bottom portion of a flotation vessel. In U.S. Pat. No. 4,277,328, Pfalzer et al describe employing an impeller at the bottom of a flotation apparatus for dispersing air into the wastepaper pulp slurry.
[0019] U.S. Pat. Nos. 4,162,186 and 4,518,459 disclose additional methods.
[0020] Such methods were reasonably satisfactory and adequate a number of years ago when there was no need to de-ink and reclaim wastepaper having little or no quantities of ground wood. Such papers were printed with standard inks which are more readily removed or saponified with chemicals at elevated temperatures.
[0021] In recent years, however, methods of de-inking which involve cooking and the use of chemicals in aqueous media have become increasingly unsatisfactory for a number of reasons. Ink formulations have become more and more complex and involve an increasing use of a wide variety of synthetic resins and plasticizers; with each ink having its own special formulation. Also, increasing amounts of synthetic resins and plasticizers are being used in a wide variety of sizings, coatings, plastic binding adhesives, thermoplastic resins and pressure sensitive label adhesives. Furthermore, the use of multi-colored printing and multi-colored advertisements have become increasingly popular in recent years and these involve a wide variety of new ink formulations. Many of the new ink formulations incorporate new pigments, dyes and toners which are difficult to remove by conventional aqueous de-inking chemicals. The former methods of de-inking and reclaiming wastepaper by chemical and cooking techniques are not adapted for, or adequate for, removing the new types of inks and coating resins. Due to high contents of thermoplastic resins, the softening action of heat and chemicals alone makes their separation from the fibers very difficult Additionally, the action of heat and chemicals tends to irreversibly set and more firmly bond some of the present day pigments to the fibers and fix dyes and toners to the fibers through staining.
[0022] The challenges that the pulp and paper industry is trying to meet today in the recycling area are to (1) economically produce quality paper meeting the consumer demands and also the legislative demands for the content of recycled paper; and (2) increase the process efficiency in order to make use of recovered paper which currently cannot be processed economically. Currently, most recycling processes are geared only to use high quality recovered paper costing over $150 per ton. Such material is limited in quantity and is in high demand due to the regulations governing the incorporation of certain percentages of recycled fiber in many paper commodities. There exists a need for new recycling processes which are more economical and can handle a wider range of recovered paper. One of the most important steps in recycling the recovered paper is that of de-inking. There also exists a need for methods of de-inking that can handle (1) a wider variety of printed material (newsprint to high quality glossy magazine paper) and (2) a higher pulp density than the conventional processes.
[0023] For the above and other reasons, conventional de-inking techniques used in reclaiming processes for wastepaper are no longer efficient or effective for many current needs.
[0024] The need for a satisfactory de-inking process has become increasingly important due to greatly expanded utilization of paper and difficulty in disposal of the old papers due to projected lack of landfill sites.
[0025] Such a process is disclosed in U.S. Pat. No. 6,217,706. Therein, there is disclosed a method of de-inking cellulosic fibrous materials comprising:
a. admixing an alkaline reagent selected from the group consisting of ammonium hydroxide and sodium bicarbonate or mixture thereof with hydrogen peroxide and an aqueous suspension of inked cellulosic fibrous material in amounts whereby the ammonium hydroxide and hydrogen peroxide react at the ink particle/cellulosic fiber interfaces to dislodge the ink particles from the cellulosic materials; and b. removing the dislodged ink particles from the aqueous suspension.
[0028] In this regard, to preserve natural resources and minimize environmental problems, the need for developing other useful and efficient paper recycling processes becomes of critical importance.
SUMMARY OF THE INVENTION
[0029] The present invention solves the need for more efficient processes for recycling cellulosic materials by providing an improved and novel method for de-inking such material.
[0030] One embodiment of the invention relates to a method of de-inking cellulosic fibrous materials comprising:
1) admixing an alkaline reagent with hydrogen peroxide and an aqueous suspension of inked cellulosic fibrous material in amounts whereby the alkaline reagent and hydrogen peroxide react at the ink particle/cellulosic fiber interfaces to dislodge the ink particles from the cellulosic materials; and 2) removing the dislodged ink particles from the aqueous suspension, wherein the alkaline reagent comprises sodium carbonate or a mixture of sodium carbonate and a) ammonium hydroxide, b) sodium bicarbonate or c) mixtures of sodium carbonate and ammonium hydroxide.
[0033] Another embodiment of the invention concerns an improved method for recycling waste cellulosic material, the improvement comprising de-inking cellulosic fibrous materials by a method comprising:
1) admixing an alkaline reagent with hydrogen peroxide and an aqueous suspension of inked cellulosic fibrous material in amounts whereby the alkaline reagent and hydrogen peroxide react at the ink particle/cellulosic fiber interfaces to dislodge the ink particles from the cellulosic materials; and 2) removing the dislodged ink particles from the aqueous suspension, wherein the alkaline reagent comprises sodium carbonate or a mixture of sodium carbonate and a) ammonium hydroxide, b) sodium bicarbonate or c) mixtures of sodium carbonate and ammonium hydroxide.
[0036] Still another embodiment of the invention relates to a composition for de-inking cellulosic fibrous materials in kit form comprising separately packaged effective amounts of: a) an alkaline reagent and b) hydrogen peroxide.
[0037] Another embodiment of the invention relates to an article of manufacture comprising separate packages and an alkaline reagent contained within one of the packages and hydrogen peroxide contained within another of the packages, wherein the packaged materials are effective for de-inking cellulosic fibrous materials, and wherein the packages also comprise a label which indicates that the packaged materials can be used for de-inking cellulosic fibrous materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a flow chart of a process according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present invention is predicated on the discovery that the improved process of the invention enables the de-inking of a broad spectrum of printed products including newspaper, laser written paper, xerographic paper, rotogravure, heat-set, including coated and uncoated stock and high gloss multi-colored paper, such as magazines. Moreover, the process enables the de-inking of higher pulp densities than typical prior art methods.
[0040] The crux of the invention resides in the discovery that all or part of the alkaline reagents employed in the process described in U.S. Pat. No. 6,217,706 may be replaced with sodium carbonate.
[0041] In the patented process, ammonia and/or sodium bicarbonate were used as components of the reagents recipe. It has been found according to the present invention that sodium carbonate โsoda ashโ can be used to replace these two reagents or any combination thereof. The alkaline reagent (whether it consists of sodium carbonate or a mixture with sodium bicarbonate and/or ammonia) can be added at a total dosage of 0.5 to 1.0% of the dry weight of the pulp. The use of soda ash has several advantages including the its cost. Soda ash is much cheaper than either or both of ammonia and sodium bicarbonate. This will render the process very attractive from an economic standpoint. Also, soda ash is environmentally friendly. This makes it attractive to the user since it is safer during handling and use than ammonia for example.
[0042] The results of some experiments using sodium carbonate are set forth below in table 2. From the lower part of the results table, it can be seen that 0.5-1.0% soda ash are optimal for usage since higher dosages lead to loss of pulp yield as indicated by the higher amounts of floated pulp.
[0043] As noted above, in conventional de-inking processes, the waste paper is first pulped and the ink particles are removed by using a flotation technique. In this step, the pulp at a solids loading of 1.0-1.25 wt % is treated with various reagents to separate the ink particles from the fiber. The pH of the pulp is adjusted using NaOH. Reagents are then added to emulsify or discharge the ink particles from the fiber interface and a collector is added to float the liberated ink particles. Air is sparged into the pulp stream in order to aid the flotation process. Typical de-inking process chemicals currently used are shown in Table 1.
TABLE 1 DE-INKING PROCESS CHEMICALS JOHN K. BORCKHARDT, CHEMISTRY AND INDUSTRY, VOL. 19, PAGE 273 (APRIL 1993) PROCESS STAGE CHEMICAL FUNCTION Pulper Sodium Hydroxide Raises pH to 8-10 (typically about 9 to promote fiber swelling and ink removal, as well as disaggregation of paper into separate fibers (pulp) Sodium Silicate Dispersant for detached ink particles, raises pH Hydrogen Peroxide Prevents lignin yellowing of pulp promoted by high pH Complexing Agent Stabilizes hydrogen peroxide so it does not react with oxidizable dissolved metal ions. Usually diethylenepentaminetetraacetic acid (DTPA) or ethylenediaminetetraacetic acid (EDTA) Surfactant Promotes ink detachment from cellulose fiber Flotation Cell Fatty Acid Renders ink particles hydrophobic and stabilizes foam. Used in combination with a soluble calcium salt, usually calcium chloride, to generate a calcium soap in situ Synthetic Surfactant Renders ink particles hydrophobic and stabilizes foam. May be added at the pulper to promote ink detachment from fiber and carried forward to the flotation stage Washing Synthetic Surfactant Added in the pulper to promote ink dispersion into small Stage(s) particles that are readily removed by washing Bleaching Hydrogen Peroxide a Whitens the pulp and increases paper sheet brightness Sodium Hypochlorite a Chloride Dioxide a Sodium Hydrosulphite b,c FAS b,d a Oxidative bleach b Reductive bleach c Sodium dithionite d Formamidine sulphinic acid
[0044] In the method of the invention, in the de-inking step, the pulp is treated with a novel reagent according to a scheme which is far less costly than the use of conventional de-inking and flotation reagents. Briefly, to a pulp stream are added a soluble peroxide and a soluble alkaline agent capable of undergoing a reaction with the peroxide to liberate a bubble of gas which functions to float the ink particles in the pulp stream to the surface.
[0045] FIG. 1 depicts a flow sheet of a typical de-inking process of the invention. The pulp stream is reagentized with 0.5-1.0 wt. % hydrogen peroxide and 0.5-1.0 wt % alkaline reagent. The pH in this stage is about 9.5-10.0. These reagents undergo a chemical interaction at the fiber/particle interface and generate bubbles of ammonia or carbon dioxide gas which dislodges the ink particles and floats them to the top of the vessel. The advantage of this process is that it does not use any expensive collectors as in conventional processes. In addition, there is little need to sparge the system with air as the reagents used generate the bubbles necessary to flotate the ink particles. Additionally, unlike conventional reagent schemes which can handle only 1.0-1.2% solids loading during flotation, the method of the invention can handle up to 2.0% solids loading efficiently. This will nearly double the output of any existing de-inking unit (i.e., reduces the equipment size to half). Additionally, the method of the invention can handle a wider variety of recovered paper than conventional process schemes.
[0046] It will be understood by those skilled in the art that any combination of soluble peroxide and soluble alkaline agent which reacts in the pulp stream to generate a bubble of gas may be employed in the practice of the invention. In the case described above ( FIG. 1 ), the reagents react according to the following scheme:
2NH 4 OH+H 2 O 2 โNH 3 โ+2H 2 O+O+NH 4 + +OH โ
The liberated ammonium gas operates to flotate the ink particles to the surface.
[0047] The combination of a peroxide with an alkali metal bicarbonate reacts according to the scheme:
NaHCO 3+2 H 2 O 2 โNa + +OH โ 2H 2 O+2O+CO 2 โ
The liberated carbon dioxide bubbles would then work to float the ink particles to the surface. Since two molecules of nascent oxygen are formed in the system, some will readily combine to form molecular oxygen as well as to bleach the pulp. The molecular oxygen formed would function as an additional flotation agent.
[0048] The critical parameters of the method of the invention, therefore, are the use of soluble peroxides and alkaline agents which react under the conditions in the pulp stream to form a gas which bubbles up through the pulp stream and acts to dislodge and float the ink particles present in the pulp stream to the surface.
[0049] It is a further feature of the invention that the nascent oxygen released by the reaction between the alkaline agent and the peroxide functions to bleach the pulp and increase its brightness. In addition, the nascent oxygen works to break the oils present in the pulp stream into shorter chain length molecules which function to stabilize the froth in the pulp stream for flotation of the ink particles.
[0050] In the cases of combinations of alkaline agents and peroxides which do not react with each other to liberate gas bubbles, the process is much less efficient. For example, where alkali metal hydroxides and hydrogen peroxide are utilized (as in the case of some prior art methods), the reagents react according to the scheme
NaOH+H 2 O 2 โNa + +OH โ +H 2 O+O
Although nascent oxygen is formed which aids in brightening the pulp, no gas bubbles are formed to float the ink particles to the surface of the pulp stream. In this case, a gas such as air must be separately sparged through the system to float the particles which increases the overall cost of the system and decreases the efficiency thereof.
[0051] Peroxides other than hydrogen peroxide may also be utilized in the practice of the invention. An alkali metal peroxide would react with ammonium hydroxide according to the following scheme:
2NH 4 OH+Na 2 O 2 โ2NH 3 โ+H 2 O+O+2Na + +20H โ
Again, the liberated ammonia gas bubbles would dislodge and float the ink particles to the surface of the pulp stream.
[0052] If desired, adjuvants such as polypropylene glycol may be added to the reaction mixture to enhance flotation and increase pulp brightness.
EXAMPLE
[0053] Newspaper is first cut into shreds and homogenized. The paper is then pulped at a solids loading of 2 wt. % in a Hamilton Beach blender for two minutes. Hydrogen peroxide is added during the pulping stage at a dosage of 0.5-1.0 wt. % of dry paper. The reagentized pulp is then transferred to a flotation cell and the pH is adjusted to 9.5-10.0 using sodium carbonate. The flotation is performed using a Denver flotation unit for fifteen minutes at 900 rpm. The ink particles are collected in the froth using a manual skimmer. The floated ink particles and the de-inked pulp are then filtered at 0.5 atm vacuum. The filtrate is recycled to subsequent flotation experiments to reduce the reagent consumption by recycling the unreacted reagents. The dewatered pulp is air dried in a convection oven at a temperature of 40ยฐ C. for 4-5 hours. In conventional methods, the dewatered pulp is washed and bleached to increase the brightness of the pulp. However, in this example, post flotation processes to increase the pulp brightness have not been performed as they are invariant with the flotation scheme. High pulp yields (approximately 90%) were achieved. The results of several runs of the example are set forth in Table 2.
TABLE 2 Exp. Wt % Brightness No. Float unfloat Float unfloat Chemicals 1 16.5 83.5 30.7 51-8 Sod. 2 15 85 30.3 51.4 Bicarbonate 3 22.36 77.64 33.2 52.4 4 14.74 85.26 30.5 51.2 โ 16.16 83.84 30.8 51.7 6 15.95 84.05 32.1 51.4 7 30.58 69.42 31.4 55.4 8 20.21 79.79 33.4 52.2 9 25.71 74.29 31.5 54.1 10โ 26.48 73.52 32.1 53.9 11โ 26.74 73.26 32.5 53.7 1 16.82 83.18 30.5 52.3 2 17.41 82.6 31.3 52.2 Sod. 3 21.96 78.04 31 53.3 Carbonate 4 27.83 72.17 30.8 54.1 Pulp brightness = 41.1 (just pulping without any washing or separation) Carbonate experiments 1, 2, 3, and 4 are at 0.5, 1, 2, 3% Na2C03 respectively. Pulping time + 3.0 min. and flotation time, 5.0 minutes.
[0054] The key measures of de-inking are yield, pulp brightness, ash content and dirt count. The current process has been demonstrated to produce a pulp yield of 83+% which is much higher than the 74-78% yield achieved in the existing industrial processes. A brightness number of 55 is required for the de-inked newsprint pulp to be successfully recycled. An increase in the brightness number of the pulp from 30 to 52 was observed in this example. The required brightness levels can be easily achieved by a post flotation bleaching step which is a common practice in the industry. The ash content of the recycled pulp can be easily controlled by varying the flotation time. In the current example, the dirt count was significantly reduced employing a flotation time of five minutes.
[0055] All dosages including hydrogen peroxide are calculated on the basis of percentage of dry weight of paper and refer to the active ingredients. For example, in the case of peroxide, 0.5% indicates weight of pure peroxide to weight of dry paper.
[0056] Although the method of the invention has been illustrated with reference to waste newspaper, it will be understood by those skilled in the art that it is equally applicable to the recovery and de-inking of any inked or printed cellulosic material such as, e.g., magazines and the like.
[0057] The de-inking process of the invention is a new reagent scheme which is a novel combination of chemicals and reagents each of which is already in use in various sections of the pulping process industry. This reagent scheme can be employed in existing de-inking plants without equipment modifications.
[0058] The de-inking process of the invention employs a novel procedure to produce bubbles in situ at the fiber/ink interface which dislodges the ink particles from the fiber surface. This is more efficient than conventional de-inking processes which rely only on mechanical methods to dislodge and liberate the ink particles.
[0059] Better liberation of ink particles results in higher yield of de-inked pulp. Additionally, this ensures flotation at higher solids loading. The solids loading used in the current process is 2 wt. %, unlike the existing industrial flotation schemes which operate at a solids loading of 1 wt %. Hence, the current process can double the existing throughput of the industry.
[0060] The proposed reagent scheme employs fewer reagents than in current industrial processes and, hence, is less complicated. The build-up of any unreacted reagents in the proposed scheme is beneficial and does not play havoc with, e.g., the environment as in existing industrial processes.
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A method of de-inking cellulosic fibrous materials comprising: 1) admixing an alkaline reagent with hydrogen peroxide and an aqueous suspension of inked cellulosic fibrous material in amounts whereby the alkaline reagent and hydrogen peroxide react at the ink particle/cellulosic fiber interfaces to dislodge the ink particles from the cellulosic materials; and, 2) removing the dislodged ink particles from the aqueous suspension, wherein the alkaline reagent comprises sodium carbonate or a mixture of sodium carbonate and a) ammonium hydroxide, b) sodium bicarbonate or c) mixtures of sodium carbonate and ammonium hydroxide.
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BACKGROUND OF THE INVENTION
Fluid flow control regulators are used to provide a constant flow rate by means of a pressure differential regulating device that senses changes in upstream or downstream pressure and compensates for the change. Conventional regulating devices use an impeller that is sensitive to a variable incoming fluid pressure, P 1 , and a downstream fluid pressure, P 3 . The impeller reduces a valve opening when the differential pressure between P 1 and P 2 increases, and enlarges the valve opening, when the differential between P 1 and P 2 is reduced.
An impeller spring biases the impeller against P 1 . A lesser fluid pressure P 2 acts on the opposite side of the impeller from P 1 . The impeller assumes a balanced condition when P 2 plus the impeller spring force equals P 1 . This occurs when P 1 and P 2 have reached a stable condition.
If P 1 increases, the impeller moves from its stable position because P 1 is greater than P 2 plus the spring force, thereby reducing the valve opening. P 2 then increases until P 2 plus the spring force again equal P 1 at a new stable impeller position.
If P 1 reduces, the impeller moves in the opposite direction from its stable position because P 2 plus the spring force are greater than P 1 . The impeller moves until P 2 reduces to a level where P 2 plus the spring force equal P 1 at a new impeller position corresponding to a valve position that restores the desired flow rate. The impeller thereby automatically adjusts to restore a predetermined pressure difference between P 1 and P 2 which is determined by the force characteristic of the spring.
The impeller is also indirectly sensitive to the difference between P 2 and P 3 (the downstream pressure). The impeller does not directly sense P 3 . However, the required area of the outlet valve opening must increase or decrease based on the differential pressure between P 2 and P 3 . As P 3 increases, the efficiency of the valve hole decreases and thereby reduces the flow which increases P 2 affecting the pressure balance on the impeller which then moves in the opposite direction from its stable position because P 2 plus the spring force exceeds P 1 . The flow accuracy of the regulating device is not significantly affected by P 3 , however when the difference between P 2 and P 3 becomes very large, for example, 12,000 p.s.i., then the impeller must travel a greater distance, increasing the compression of the spring, which changes the pressure differential and creates an error in the regulating device.
Another problem with conventional flow regulating devices used to accommodate a high pressure but low flow rate condition is the capacity of the sensing orifice device through which the incoming fluid passes as it flows from the high pressure side (P 1 ) to the low pressure side (P 2 ) of the impeller. The orifice device can be adjusted to increase or reduce the desired flow rate.
The orifice hole size is critical. A high pressure, low flow situation requires a very small hole. However, a small hole size tends to become plugged with material carried by the fluid. Therefore it is desirable to have a hole with the largest area possible. An example is where the flow rate must be maintained between a fraction of a gallon and 1250 gallons per day, with incoming pressures as high as 12,900 p.s.i.g.
Hole size can be increased by providing a resistance to flow through the device by means other than reducing the hole size, such as by using a capillary device.
Capillary devices have been used in other types of technology, by using a threaded member inside a tube which may be either smooth or internally threaded to form a very small, but long, capillary path. See for example: U.S. Pat. Nos. 2,265,888, issued Dec. 9, 1941, to Rudolf Beck for "Liquid Level Indicator"; 2,568,123, issued Sep. 18, 1951, to Herman M. Goldberg for "Pressure Reducing Device for Refrigerating Apparatus"; 3,841,354, issued Oct. 15, 1974, to Roy Edward McDonnel for "Flow Regulating Device"; 3,791,619, issued Feb. 12, 1974, to Alfred W. Pett for "Valve Construction"; 3,143,145, issued Aug. 4, 1964, to James M. Kauss for "Method and Means of Controlling the Rate of Fluid Flow" and 2,850,038, issued Sep. 2, 1958, to Hubert A. Shabaker for "Flow Control Device"; and Norwegian Patent No. 923962.
As far as we are aware, no such capillary device has been used to adjust the flow rate in a differential pressure operated flow control device.
SUMMARY OF THE INVENTION
One of the purposes of the invention is to provide a constant differential pressure flow regulator that will operate accurately at very high pressures, for example, where P 1 may be 12,900 p.s.i., P 2 is 12,896 p.s.i. and P 3 is zero and just as accurately when P 1 is 100 p.s.i., P 2 is 96 p.s.i. and P 3 is zero.
A typical commercially available constant flow regulator is available from W. A. Kates Company of Clawson, Mich. A Kate's regulator has a valve sleeve connected to the impeller. The sleeve slides on an apertured valve tube to form a variable outlet valve opening. The valve tube usually has three holes which pass fluid from the impeller chamber through the valve opening. Present technology, as described above, controls P 2 in relation to P 1 , and P 3 can be whatever the system usage creates. This works extremely well when the pressure differential between P 1 and P 3 is less than 5000 p.s.i.g. When the ฮP is greater than 5000 p.s.i.g., the required travel of the impeller and the valve sleeve is too great and the flow accuracy cannot be maintained. In addition the required orifice area of the valve tube which is required to pass 10 gallon/minute with a 100 p.s.i. differential is too many times greater than the required area to pass 0.3 gallon/day with a 12,900 p.s.i. differential.
The inventive regulating device will control P 3 (now defined as the pressure of the fluid passing from the impeller chamber) to always be within a given pressure difference of P 1 despite extremely high pressures such as 12,900 p.s.i. For example, if P 3 can be controlled to be within 600 p.s.i. of P 1 , we can maintain a ฮP of 20 p.s.i. between P 1 and P 2 , and the ฮP between P 2 and P 3 never greater then 580 p.s.i., thereby reducing the required travel of the valve sleeve, the compression of the spring, and consequently the error in flow accuracy.
A second differential pressure control valve is connected between the incoming fluid at pressure P 1 , and the outlet opening of the primary impeller chamber which is discharging fluid at pressure P 3 . The second control valve maintains P 3 within 600 p.s.i. or some predetermined pressure difference from P 1 .
The second control valve has an impeller in a second impeller chamber. The incoming pressure P 1 is introduced on the high side of the second impeller. A 600 p.s.i. compression impeller spring is used. P 3 the fluid pressure on both the low side of the second impeller and the outlet of the primary impeller chamber, is maintained at P 1 minus the force of the second impeller spring. The second control valve will require a long stroke when regulating between a range of 100 p.s.i. to 12,900 p.s.i., which will produce an error due to the spring compression. However, the first control valve can easily handle an error (range) of 100% or plus/minus 600 p.s.i.
The error of the flow regulator is reduced because the ฮP of P 2 and P 3 is always within an acceptable range, for example, 600 p.s.i. The second impeller, in effect, controls P 3 and thereby reduces the error usually caused by an extreme fluctuation in high incoming fluid pressure, or extreme fluctuations of the usual downstream pressure.
Another object of the invention is to provide a capillary device for sensing, and providing an adjusted flow rate, in a differential pressure operated flow regulating device. The capillary device uses a helical fluid flow path having an adjustable length to accommodate a high pressure, low flow rate.
In its simplest form, the preferred capillary device comprises a helical threaded member mounted in a chamber having a cylindrical wall. The threads engage the cylindrical wall to form a helical flow path. Fluid is received in one end of the chamber and passed along the flow path to the opposite end of the chamber. The length of the flow path can be changed to adjust the flow rate through the flow regulating device by changing the position of the threaded member in the chamber.
The threaded member can be mounted in a chamber having one section with a relatively close fitting cylindrical surface, and another section with an enlarged cylindrical surface. The flow rate is adjusted by moving the threaded member between the two sections to either shorten or lengthen the flow path.
In some cases it may be desirable to provide a longer capillary flow path in a relatively compact structure. The threaded member can be formed in several telescopically mounted sections so that the incoming fluid passes along a short helical flow path in a first axial direction, then flows in a reverse direction through a second helical flow path, and reverses flow again through a third helical flow path and so forth.
Still further objects and advantages of the invention will become readily apparent to those skilled in the art to which the invention pertains upon reference to the following detailed description.
DESCRIPTION OF THE DRAWINGS
The description refers to the accompanying drawings in which like reference characters refer to like parts throughout the several views, and in which:
FIG. 1 is a sectional view through a high pressure, low flow regulator illustrating the preferred embodiment of the invention; and
FIG. 2 is a sectional view through another embodiment of a preferred capillary sensing device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, FIG. 1 illustrates a preferred flow regulator having a housing 10 with an inlet port 12 for receiving fluid under a variable pressure, P 1 , in the direction of arrow 14 from any suitable source, and an outlet port 16 for discharging fluid in a direction 18 at a constant flow rate. The housing has an internal fluid passage 20 which opens at inlet port 12, continues through a first cylindrical impeller chamber 22 and then to one end of a second cylindrical impeller chamber 24. Passage 20 is also fluidly connected to a cylindrical capillary chamber 26.
A pressure balanced impeller 27 is mounted in impeller chamber 22. Impeller 27 has a disc shaped head 28 with a peripheral edge slidably engaging the cylindrical wall of chamber 22. The edge of impeller 27 that contacts the chamber wall has a curvature formed along the surface of an imaginary sphere, to prevent the impeller from becoming cocked in the chamber. Impeller 27 is movable along chamber axis 30.
Impeller 27 is connected to a sleeve 32 which in turn is slidably mounted on a valve tube 34. Valve tube 34 is fastened to housing 10. The valve tube has an internal axial outlet port 36, and three lateral valve openings 38 disposed around the longitudinal axis of the tube.
The arrangement is such that as the impeller moves upwardly as viewed in FIG. 1, the lower edge of the sleeve enlarges valve openings 38 to discharge fluid from the low side 40 of the impeller chamber having a pressure P 2 , less than pressure P 1 . As the impeller moves in the opposite direction, the lower sleeve edge progressively reduces valve openings 38.
The area 42 of the impeller chamber, above the impeller head, will be referred to as the high pressure side of the chamber because the incoming fluid is at a pressure P 1 which is higher than in low pressure side 40.
The valve sleeve and the valve tube have an internal spring chamber 44 housing a helical impeller spring 46. Spring 46 has its lower end seated on the valve tube and its upper end engaging the valve sleeve to bias the impeller toward the high pressure side of the impeller chamber, as viewed in FIG. 1.
Valve sleeve 32 has port means 45 which permit fluid to pass between the low pressure side of the impeller chamber and spring chamber 44 to accommodate the changing volume of the spring chamber as the sleeve moves along the valve tube, and to make certain that the entire effective area of impeller 27 sees pressure P 2 .
The position of impeller 27 depends upon the fluid pressure in the high pressure side, P 1 , the fluid pressure in the low pressure side, P 2 , and the force of spring 46 which combines with P 2 to bias the impeller toward a balanced position. The ฮP between P 1 and P 2 is determined by the spring force of spring 46. The impeller is in a stable position when P 1 equals P 2 plus the bias of spring 46.
The flow rate through the flow regulator is determined by a capillary control device 48 disposed between inlet port 12, and capillary chamber 26. Capillary chamber 26 has an upper portion 50 with a cylindrical side wall, and a lower portion 52 with a larger diameter cylindrical side wall formed about the same axis as upper portion 50.
A screw member 54, mounted in capillary chamber 26, has a continuous helical thread 56 formed around its outer annular surface. Thread 56 slidably engages the cylindrical side wall of the upper portion of chamber 26. The screw member and the chamber side wall form a helical flow passage 58 for passing fluid from inlet port 12 to the lower portion 52 of the capillary chamber and then out through a passage 60 to the low pressure side of the impeller chamber.
The fluid flow rate along passage 58 depends upon the flow restriction formed by the capillary device. The flow restriction, in turn, depends upon the diameter, the helical shape, and the length of capillary passage 58 which can be adjusted by moving screw member 54 downwardly into chamber portion 52. Moving a selected number of threads into chamber portion 52 shortens the total length of the capillary path. Reducing the length of the flow path increases the flow rate. Increasing the length of the flow path reduces the flow rate, for the same pressure difference across the impeller.
The threads are illustrated as having the shape of conventional helical threads, however, the threads could be formed on the inner surface of the chamber with screw member 54 having a smooth cylindrical surface. Other alternatives are possible such as forming a pair of mating internal and external threads, with the tip of the threads on one or both parts flattened or otherwise shaped to adjust the flow restriction produced along the flow passage. Different geometric shapes of the cross sections of the helical opening will create different flow resistances. Flow passage 58 is triangular but it could be square, rectangular, oblong, etc.
For illustrative purposes, screw member 54 is connected to a shaft 62 which may be connected to a suitable electrical motor, hydraulic motor or pneumatic device, not shown, for remotely adjusting the position of the screw member. Shaft 62 is connected by a threaded connection 64 to housing 10. Alternatively, shaft 62 could have a smooth sealed engagement with the housing, and pushed and pulled by a suitable power device, not shown.
The second impeller chamber 24 houses an impeller assembly 66 which is similar to impeller assembly 27 in chamber 22. This includes a disc-shaped impeller 68 which has its peripheral edges slidably engaging the cylindrical side wall of the impeller chamber for movement along a horizontal chamber axis 70 as viewed in FIG. 1. Impeller 68 also has a peripheral surface formed along the surface of an imaginary sphere to prevent the impeller from becoming cocked in the impeller chamber. Impeller 68 is fastened to the head of a cylindrical valve sleeve 72 so that the impeller and the sleeve move together as a unit.
Valve tube 74 is attached to housing 10 and has a cylindrical outer surface, and a hollow bore 76 fluidly connected with outlet port 16. Tube 74 has three (more or less) port means 78 disposed equi-angularly about the longitudinal axis of the valve tube for passing fluid from the low pressure side 80 of impeller chamber 24 to the outlet port.
Sleeve 72 slides along valve tube 74. The left edge of sleeve 72, as shown in FIG. 1, overlaps port means 78 to form a valve opening having a variable size. The total valve opening size depends upon the position of the impeller in the second impeller chamber which in turn depends upon fluid pressure, P 1 , in high pressure side 82, the fluid pressure in the low pressure side, P 3 , and the bias or force of impeller spring 84. Spring 84 is disposed in a spring chamber formed between valve tube 74 and valve sleeve 72.
Port means 86 in the valve tube permit fluid to pass into and out of the spring chamber as the valve sleeve moves along the valve tube to accommodate the changing volume of the spring chamber, and to make certain that the low pressure side of impeller 68 sees P 3 .
Assuming the incoming fluid pressure P 1 is 12,900 p.s.i., then this pressure will exist on the high pressure sides of both impeller chambers 22 and 24.
The low pressure side 40 of the primary impeller chamber will have a pressure P 2 that is dictated by the effective force of impeller spring 46. Assuming a 20 p.s.i. impeller spring, P 2 will be 12,880 p.s.i. Impeller 27 will then be disposed in a stable position when P 1 =P 2 plus the force of the impeller spring.
The fluid passing through valve openings 38 to the low pressure side of the second impeller chamber will be at a pressure P 3 that is dictated by the bias of spring 84 in the second impeller chamber. Assuming that spring 84 is a 100 pound spring (100 p.s.i. bias), then pressure P 3 existing on the low side of the second impeller chamber will be 12,800 p.s.i. that is 100 p.s.i. less than P 1 . Outlet pressure P 4 may vary but will not affect the performance of the regulator. This permits us to reduce the necessary travel of valve sleeve 32 and consequently the compression of spring 46 thereby reducing the error in the flow accuracy of the regulator. The reason is that P 3 is limited to the pressure differential across the second impeller defined by spring 84. If P 1 is less than the force of spring 84, port means 78 will remain open and have no effect on the flow regulator.
In summary, the incoming fluid enters the device through inlet port 12 at pressure P 1 . Passage 20 transmits the same pressure P 1 to the high pressure side of both impeller chambers. The fluid passes along capillary flow passage 58 into the bottom of capillary chamber 26. It then flows into the low pressure side 40 of impeller chamber 22, at pressure P 2 where the impeller is in a balanced position. The fluid then passes through valve openings 38 where its pressure is reduced to P 3 , the same as the low pressure side 80 of impeller chamber 24. The fluid then passes through port means 78 and outlet port 16 where its pressure becomes P 4 , the existing downstream pressure which is controlled by means of a device other than this regulator.
The accuracy of the regulator to maintain a constant flow rate is achieved by limiting the maximum difference in pressure between P 2 and P 3 , even though the incoming pressure P 1 may be several thousand p.s.i.
In some situations it may be desirable to provide a greater range of adjustability in high pressure, low flow rates. Existing regulations require 30 different valves to accommodate flow ranges from 0.3 to 1200 gallons per day. Prior art capillary devices require a relatively long axial length at the low flow rates. A long axial length usually requires a long housing structure. FIG. 2 illustrates a capillary device 100 having a short housing which may be substituted for the capillary device illustrated in FIG. 1.
Capillary device 100 includes a body 102 having an internal capillary chamber 104 with inlet port 106 for receiving incoming fluid in the direction of arrow 108, and a discharge port 110 for discharging fluid in the direction of arrow 112. Discharge port 110 may be connected by a conduit, not shown, to the low pressure side of an impeller chamber.
Capillary chamber 104 has a cylindrical internal wall 114 formed about an axis 116. A hollow piston 122 is mounted in chamber 104 and is axially moveable in the direction of arrows 124 along axis 116 by any suitable power means, not shown. Piston 122 has an annular array 126 of helical threads which slidably engage cylindrical wall 114. The threads on piston 122 and cylindrical wall 114 define a capillary flow path 128 extending from inlet port 106 to an upper chamber 130.
The fluid passes from upper chamber 130 through a port 132 in the piston into an internal piston chamber 134. Piston chamber 134 has a cylindrical side wall 136. A second piston 138 is disposed in chamber 134 and is connected to an axial shaft 139. The height of piston 138 is shorter than the height of chamber 134 so that piston 138 can be moved axially a short distance. Piston 138 has a second helical array of threads 140 slideable engaged with cylindrical wall 136.
The fluid passes axially from the top part of chamber 134 along a second helical flow path 142 down to a port 144 that passes through the wall of the piston into another chamber 146 inside piston 138. Chamber 146 also has a cylindrical side wall 148 formed about axis 116. Another piston 150 is disposed inside chamber 146 and carries a third section of helical threads 152 that slidably engage cylindrical wall 148. The fluid passes from port 144 upwardly along a helical flow path 154 formed between threads 152 and the cylindrical wall 148 to the top part of chamber 146, then exits through a passage 156 downwardly as viewed in FIG. 2 into the bottom of chamber 104. The fluid then passes through discharge port 110 to its destination.
This capillary device produces a desired fluid flow rate that depends upon the overall length of the multiple capillary flow paths as well as the diameter of the flow path. The length of the flow path is adjusted by moving piston 138 in chamber 134 to either increase or reduce the effective length of flow path 142.
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A low flow, high pressure fluid regulator in which fluid is passed successively through two impeller chambers, each having a pressure differential operated impeller for monitoring changing inlet and outlet fluid pressures to maintain a constant fluid flow rate. The impeller in the second impeller chamber limits the pressure drop of fluid discharged from the first impeller chamber.
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This is a division of application Ser. No. 925,775, filed Oct. 30, 1986.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a process and apparatus for the preparation of polycrystalline silicon and its apparatus. Particularly, the invention relates to a process and apparatus for the preparation of high-purity polycrystalline silicon deposited by thermal decomposition or hydrogen reduction of a gaseous halogenated silicon compound such as silane(SiH 4 ), dichlorosilane(SiH 2 Cl 2 ), trichlorosilane(SiHCl 3 ) and tribromosilane(SiHBr 3 ) on high-purity silicon particles in a fluidized bed reactor heated by microwave.
2. Description of the Prior Art
Typical processes and apparatuses are disclosed in Siemens process where silicon is deposited by hydrogen reduction of trichlorosilane or dichlorosilane on a silicon bar heated by the electrical resistance method as described in U.S. Pat. No. 3,286,685, and the Komatsu process where silicon is deposited by thermal decomposition of silane as described in U.S. Pat. Nos. 4,148,814 and 4,150,168.
In the former, a silicon bar is heated to about 1000ยฐ to 1200ยฐ C. by resistance heating, while in the latter, it is heated to a thermal decomposition temperature of about 800ยฐ C. The reactors of both processes have the same type of quartz, or stainless steel bell jar, which has an advantage that the reactor wall is cooled below 300ยฐ C. by a coolant such as water or air so that silicon is not deposited on the inner wall, but has a disadvantage in that the polysilicon deposition rate is low, while the unit energy consumption is high because of the batch process using silicon bar which provides small surface areas for deposition.
To reduce the effects of these disadvantages, a fluidized bed process has been proposed, where silicon in the silicon-containing gas is deposited onto silicon particles while silicon particles having a large depositing area are fluidized by silicon-containing gas and carrier gas.
The fluidized bed process as mentioned above, however, generally employs an external heating method, e.g., a resistance heater as described in U.S. Pat. Nos. 3,102,861, 3,012,862, 4,207,360 and 3,963,838 and Japanese Patent Laid-Open Application (KOKAI) Nos. 59-45916, 59-45917 and 57-135708, where the temperature of the reactor is higher than that of the materials to be heated, which brings about wall deposition. This heating method normally brings about a large amount of heat loss to the environment from the system, and also, it makes it very difficult to build a large diameter reactor due to limitation of the heat supply needed for CVD(chemical vapor deposition). Particularly, thermal decomposition of silane or dichlorosilane causes silicon deposition onto the inner wall of the reactor, whereby not only is the reactor inner volume reduced but also heat conduction becomes worse, so that it is difficult or impossible to carry out further operations. Moreover, in the case of a quartz reactor, it may be cracked, when the reactor is cooled, due to different thermal expansion between the quartz reactor and deposited silicon(U.S. Pat. No. 3,963,838).
Internal installation of a heater instead of external heating in the system has been proposed as a means of reducing the effect of the disadvantages mentioned above. However, in the process using an internal installation, silicon is deposited on the heater surface, which makes it impossible to use the process for a long time, and there still remain inherent problems related to maintenance and exchange of the heater in the case of immersion of a polysilicon resistance heater in the reactor. Particularly, internal installation of a heater is limited, since the heater itself causes some problems in making good fluidization and in eliminating contamination due to direct contact with silicon particles, and also it occupies some volume of the reactor which reduces efficiency of the reactor and the effect of heating.
SUMMARY OF THE INVENTION
The inventors engaged in research in order to solve the above problems/disadvantages and concluded that a microwave direct heating process is the most effective heating method. A microwave heater has the advantage of keeping the temperature of the wall lower than that of the materials to be heated, because heat is not generated within the quartz due to transmission of microwaves through the wall. On the other hand, heat is generated within the materials to be heated by molecular friction due to polarized vibration within an electromagnetic field formed by the microwaves. Moreover, it is possible to prevent depositing silicon onto the inner wall by virtue of cooling the reactor wall to the desired temperature by coolant injection outside the reactor wall. Microwaves are utilized to heat the silicon particles within a fluidized bed reactor which provides a large heating surface. Therefore, according to the present invention, long-period operation is possible, and a large quantity of high-purity polycrystalline silicon can be continuously prepared.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is hereinafter further described with reference to the accompanying drawings, in which:
FIG. 1 illustrates an embodiment of an apparatus according to the invention;
FIG. 2 illustrates important parts of FIG. 1;
FIG. 3 illustrates another embodiment of an apparatus according to the invention; and
FIG. 4 illustrates the portion of the FIG. 3 embodiment encircled by a dotted line.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the embodiment of an apparatus for the preparation of high-purity polycrystalline silicon by the heating method for a fluidized bed reactor according to the present invention. A heating applicator 1 is made of metal such as stainless steel that resists high temperature and reflects microwaves without loss. A cylindrical quartz reactor 2 is located at the center of applicator 1. The top of quartz reactor 2 joins with a gas outlet 3 at the upper portion of applicator 1. Gas outlet 3 projects out and is installed in a non-fixed form, and a graphite gasket 4 is inserted between the joints with quartz reactor 2. Graphite gasket 4 is kept on in situ position by holder 5 located at the side of gas outlet 3, while holder 5 is subject to a resilient force in an axial direction by spring 6. Therefore, the jointed portion is kept tight by spring pressure to quartz reactor 2 through holder 5 even when the reactor moves in a small range. Seed injection tube 7 extends within gas outlet tube 3. The lower of the two ends of seed injection tube 7 is extended to an inner part of quartz reactor 2 and the other of the two ends is projected outwardly to hopper 8. Top portion of applicator 1 through which gas outlet tube 3 passes is sealed by a Teflon seal 9 and gas cut-off holder 10 to keep it gas-tight. Teflon is a trademark for tetrafluoroethylene fluorocarbon polymers.
Gas inlet tube 11 is connected to the lower portion of applicator 1, and gas distribution plate 12 is inserted between the gas inlet tube 11 and the lower portion of quartz reactor 2. Coolant path 13 is contained in gas distribution plate 12. Particle outlet tube 14 is connected into a lower portion of quartz reactor 2 and extends to a silicon collecting vessel 15. Graphite gasket 16 is installed to prevent leakage of reacting gas from the quartz reactor 2 to applicator 1.
Evaporator/preheater 17 is installed near gas inlet 11. Microwave generators 18 are installed at both sides of applicator 1. E-cornered microwave guide tube 20 and H-cornered microwave guide tube 21 from microwave generators 18 are symmetrically connected to lower side portions of applicator 1. Microwave guide tubes 20 and 21 are preferably made of aluminum rectangular tubes which give negligible loss of power in microwave transfer. They guide oscillated microwaves from a magnetron (not shown) of microwave generators 18 to applicator 1.
On the way to E-cornered microwave guide tube 20 and H-cornered microwave guide tube 21, there are more than one gas cut-off membranes 22. The gas cut-off membrane 22 serves to prevent coolant for quartz reactor wall 2 in applicator 1 from flowing into microwave generator 18, and preferably employs a plate such as quartz, pyrex or Teflon, which has good microwave transfer characteristics. Moreover, microwave shield 23 is installed at an inner middle portion of applicator 1. Microwave shield 23 is made of a metal reflecting microwaves, whereby the microwave penetration volume is limited within the material to be heated, which thereby makes the microwave penetrating density high enough to carry out good microwave heating of the material.
In the above apparatus of the present invention, silicon seed is introduced into quartz reactor 2 through seed injection tube 7 from hopper 8.
Microwave generator 8 produces microwaves which penetrate into quartz reactor 2 within applicator 1 and into silicon particles forming fluidized bed A. By the electromagnetic field formed, polarized vibrating friction takes place in the seed silicon to be heated by itself to reaction temperatures from 600ยฐ to 1200ยฐ C. Usually microwave of 915 or 2450 MHz is used.
Silicon-containing gas 19a as a reactant is injected through gas injection tube 11 with carrier gas 19b such as hydrogen after being preheated to about 300ยฐ C. in evaporator/preheater 17. Injected reactant gas disperses in quartz reactor 2 by gas distribution plate 12 to mix and fluidize bed A. Thus, fluidizing gas undertakes thermal decomposition or hydrogen reduction by contacting hot silicon seed and deposits on the seed surface by chemical vapor deposition. Seed particles thus become larger. Adequately large particles pass through particle outlet tube 14 and are collected in polysilicon collecting vessel 15.
In the aforementioned process, silicon particles are produced continuously because silicon seed and reacting gas are supplied continuously. Moreover, by-product gas or non-reacted gas in the above reaction can be recovered and used again by gas outlet tube 3 and recovery apparatus (not shown).
As the reaction proceeds, gas distribution plate 12 is heated by heat transfer from hot silicon particles, and silicon particles in fluidized bed A are not normally fluidized after a long period of reaction, because silicon is deposited on the surface of distribution plate 12 by reacting gas passing through the plate.
These problems can be removed by cooling gas dispersion plate 12 below 400ยฐ C. with circulating coolant such as water or nitrogen, as shown in FIG. 1. The same problems as above can take place in the quartz reactor wall. Thus, deposited silicon on the inner wall forces the inner volume to be reduced. Therefore, the temperature of the inner wall of quartz reactor 2 should be cooled below the reaction temperature of silicon-containing gas by circulating coolant in cooling path 25 formed between the inner wall of applicator 1 and the outer wall of quartz reactor 2 to prevent these problems. Moreover, quartz reactor 2 can contain separate cooling path 26 between double tubes.
When silicon seed is heated by microwaves in the quartz reactor 2, the reactor is expanded thermally by heat transfer. But applicator 1 is not thermally expanded, and therefore quartz reactor 2 may crack. According to the present invention, the spring 6 supporting the holder 5 of gas outlet tube 3 is pressed, ad prevents any damage incurred by thermal expansion when the quartz reactor 2 expands.
FIG. 2 illustrates a construction related to E-cornered microwave guide tube 20 and H-cornered microwave guide tube 21. Both E-cornered and H-cornered microwave guide tubes 20 and 21 have a rectangular shape and face each other in different orientations, as shown in FIG. 2. Microwave orientations 24a and 24b introduced from the microwave generators to applicator 1 cross each other in the opposite direction so that the microwaves coming from two opposite directions do not interfere. Moreover, E-cornered and H-cornered microwave guide tubes are installed to face each other so that the size of the microwave generators can be reduced and energy consumption can also be decreased.
In the aforementioned embodiment of the present system, it is necessary to install at least one pair of microwave generators to form uniform heating. If microwaves are introduced from the upper side of applicator 1, one microwave generator may suffice.
FIGS. 3 and 4 illustrate another embodiment of the above apparatus which can transmit microwaves from the upper side of applicator 1. The same numerals as used in FIG. 1 are applied to the identical parts in this embodiment as those of the aforementioned embodiments.
Microwave guide tube 190' is jointed to the top of applicator 1. The cross section of the tube 190' is usually in the shape of a rectangle or circle. If a circular tube is used, joining tube 190 is used to connect to applicator 1. Gas outlet tube 3 and the seed injection tube 7 pass through microwave guide tube 190', and are connected to quartz reactor 2.
Particularly, the upper portion of quartz reactor 2 is directly connected to gas outlet tube 3, and the lower part has a gas seal that prevents reacting gas from leaking into applicator 1. That is, as seen especially well in FIG. 4, O-ring graphite gasket 300 is inserted between flange 100 at the lower portion of applicator 1 and flange 200 of quartz reactor 2, and another graphite gasket 400 is inserted between flange 200 and gas distribution plate 12 to keep it completely gas-tight.
The above embodiment requires only one microwave heating apparatus 18 so as to obtain the merits of saving installation, maintenance, and energy costs.
According to the above embodiment of the invention, a high-purity silicon reactor can be used instead of quartz reactor 2. However, in this case, quartz material or any other material through which microwaves can penetrate must be used at the upper side 30 of the reactor.
Processes for the preparation of high-purity polycrystalline silicon, according to the present invention are exemplified below.
EXAMPLE 1
A quartz reactor of 48 mm ID, 2.5 mm thickness and 1000 mm height was installed inside the applicator of FIG. 1. Microwave as a heating source was introduced through the quartz reactor wall into the fluidized bed containing silicon particles of 60/100 mesh and the temperature of the fluidized bed kept at above 700ยฐ C. by polarized vibrating friction of silicon molecules.
On the other hand, reacting gas comprising 20 mole % of silane and 80 mole % of hydrogen was supplied to the fluidized bed at the rate of 13.3 l/min at room temperature through a distribution plate cooled by water after being preheated to 300ยฐ C. in a preheater. The quartz reactor tube wall was cooled by flowing nitrogen gas into the applicator. Deposited polysilicon granules flowed out through the outlet tube by which the height of the fluidized bed wa kept at about 150 mm.
Polycrystalline silicon at the average rate of 162.5 g/hr was obtained over a 10 hour operation. Silicon deposition on the quartz reactor wall was not found.
EXAMPLE 2
Example 1 was repeated except that reacting gas comprising 10 mole % of silane and 90 mole % hydrogen was directly supplied to the fluidized bed at the rate of 13.9 l/min at room temperature, not through a preheater. Polycrystalline silicon at an average rate of 82.8 g/hr was obtained over a 10 hour operation.
EXAMPLE 3
Using the same apparatus as in Example 1, a fluidized bed containing a silicon particle size of 40/60 mesh was kept at 150 mm high, and reacting gas containing a mixture of 22 mole % of silane and 78 mole % of hydrogen was supplied to the fluidized bed at 36.4 l/min and at the room temperature after being preheated at 300ยฐ C. through the preheater.
Polycrystalline silicon at the average of 268.1 g/hr was obtained over a 10 hour operation.
EXAMPLE 4
This example was carried out in the same apparatus as used in Example 1, and the height of the fluidized bed having a silicon particle size of 40/60 mesh was about 150 mm. Reaction gas containing 10 mole % of silane and 90 mole % of hydrogen was supplied to the fluidized bed at 11.5 l/min without passing through the preheater.
Polycrystalline silicon at an average 63 g/hr was obtained over a 20 hour operation.
EXAMPLE 5
A quartz reactor of 98 mm ID, 3 mm thickness and 1500 mm height was installed in the cylindrical microwave guide tube applicator of FIG. 3 and microwaves as a heating source supplied from the upper portion of the fluidized bed.
2400 g of silicon having a particle diameter of 60/100 mesh was charged to the quartz reactor through the seed injection tube to be fluidized, and the temperature of the bed kept at 670ยฐ C. Reacting gas comprising 10 mole % of silane and 90 mole % of hydrogen was supplied into the fluidized bed at the rate of 22.8 l/min at room temperature through the preheater. The quartz reactor wall was cooled by nitrogen. Polycrystalline silicon of 151 g was obtained after a 1 hour operation, and no deposition of silicon was found on the inner wall of the quartz reactor.
EXAMPLE 6
A fluidized bed was charged with 3200 g of silicon having a particle diameter of 60/100 mesh, as used in Example 5, and the temperature of the fluidized bed kept at 700ยฐ C. Reacting gas comprising 20 mole % of silane and 80 mole % of hydrogen was supplied into the fluidized bed at the rate of 31.9 l/min at room temperature via the preheater. There was no cooling of the quartz reactor wall by cooling gas. Polycrystalline silicon of 335 g was obtained after a 1 hour operation, and a little silicon deposited onto the wall of quartz reactor was observed.
EXAMPLE 7
3200 g of silicon having a particle diameter of 40/60 mesh was introduced into the same reactor as used in Example 5, and the temperature of the fluidized bed kept at 700ยฐ C. Reacting gas comprising 10 mole % of silane and 90 mole % of hydrogen was supplied into the fluidized bed at the rate of 42.4 l/min at room temperature after being preheated to 350ยฐ C. in the preheater. At the same time, the quartz reactor wall was cooled by nitrogen gas. 270 g of polycrystalline silicon was obtained after a 1 hour operation, yet no trace of deposited silicon on the inner wall of the quartz reactor was found.
The scope of the present invention includes not only the embodiments of the illustrated drawings, examples, and detailed description of the invention, but also all embodiments related directly or indirectly thereto.
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An apparatus for preparing high-purity polycrystalline silicon is constructed with a heating applicator, a vertical fluidized bed quartz reactor within the applicator, a microwave generator, microwave guide tubes for conveying microwaves from the microwave generator to the applicator, a reacting gas inlet and outlet, a gas distribution device for distributing reacting gas within the reactor, a silicon seed inlet for introducing silicon seed into the reactor, and an outlet for withdrawing polycrystalline silicon from the reactor. The microwaves provide the heat for the fluidized bed reaction.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to tools and methods for accessing and deaccessing a medical device implanted under the skin of a patient, and particularly tools and methods which reduce the risk of a nurse accidentally sticking herself or himself with a needle used with the implanted medical device.
2. Background Discussion
Implanted medical devices, such as vascular access devices, are commonly used to allow medication to be administered to patients. One such implant device is sold under the trademark "BardPort" by C. R. Bard, Inc. These devices include a housing enclosing a chamber which has an inlet covered with a silicone or latex seal. An outlet in communication with the chamber allows fluid in the chamber to flow through the outlet into a tube which, typically, is inserted into the vein of a patient.
These devices are accessed periodically by a nurse who inserts a needle through the patient's skin overlying the device and then into and through the seal. The nurse palpates, or feels, the device through the skin overlying the implanted device, and presses downward to locate the position of the implanted device. While holding or pressing against the device through the skin with one hand, the nurse with the other hand inserts the needle through the skin, and into and through the seal. Once properly inserted through the skin, the tip of the needle penetrates the seal and is lodged within the chamber. A "click" sound can sometimes be heard when the tip of the needle touches the bottom of the chamber, or the nurse can feel the tip contact the bottom of the chamber. Typically, the needle penetrates a depth of from about 1/4 inch to about 1 inch. Medication now flows through the needle into the chamber and then out the outlet through the tube into the vein of the patient. Sometimes, however, the nurse, while attempting to introduce the needle into the seal of the implanted device, accidently sticks herself or himself with the needle. These accidental needle sticks occur while either accessing or deaccessing the implanted device with the needle.
Needle sticks occur most frequently while deaccessing the needle. The needle sometimes remains in the implanted medical device for several hours, and sometimes even for several days. These needles must be periodically flushed and removed from the device. The removal is accomplished by the nurse, with one hand, pressing against the skin overlying and around the device, and, with the other hand, grasping the needle and withdrawing it from the device. Frequently, there is an involuntary muscular recoil as the needle escapes from the implanted medical device as it is withdrawn. It is thought that this recoil is due to proprioceptive neuro-muscular activity. The recoil sometimes results in the nurse accidentally sticking a finger of the hand which is pressing against the skin adjacent to the implanted medical device. If the source patent has an infectious and or contagious disease such as disseminated TB, Hepatitis B or C, or is HIV positive or has Aids, the nurse may contract the disease directly from this needle stick.
After such a needlestick, even if the source patient has no communicable and/or infectious disease or condition identified at the time of the needlestick, the nurse must undergo intensive and expensive follow-up testing intermittently for up to 1 year. The source patient must be tested, if they consent, for infectious or communicable disease as set forth in the OSHA regulations and CDC (Center for Disease Control) recommendations, under Employee Exposure to Bloodborne Pathogens. The nurse must also be counseled as to certain restrictions in his or her own lifestyle, particularly sex practices, until his or her own freedom from communicable/infectious disease or condition is determined. This places an incredible strain on the nurse's marital relationships and lifestyle. The partner often demands that the nurse quit nursing rather than face the risks.
Needle sticks also occur while accessing the implanted device. The problem of contracting an infectious, contagious disease also is sometimes encountered. For example, the needle, which is typically sterile initially, has in some reported instances completely penetrated the finger of the nurse and entered the body of the patient. The now contaminated needle can only be removed by withdrawing it from the patient's body into and through the nurse's finger, possibly infecting the nurse.
Recent guidelines promulgated by the CDC prohibits medical acts which require manipulating needles using both hands in the act, or any other technique that involves directing the point of a needle toward any part of the Health Care Workers body. Under the current protocols for using the implanted device, the nurse's hand which secures the implanted device in place during accessing and deaccessing is always in direct line with the needle during accessing, and also in line with the needle tip during deaccessing when one considers the frequency of the known recoil phenomenon.
The problem of needle sticks while deaccessing the needle has been recognized by workers at the University Hospital in Antwerp, Belgium, who published an article in Infection Control and Hospital Epidemiology, Volume 14, No. 10 (October 1993). In this article it is suggested to use a tool, rather than the nurse's hand, to hold the implanted device during removal of the needle. The suggested tool includes a guard with a slot in it. The guard has a relatively small area. It appears to be less than 1 square inch, and it appears to be made of an opaque material. There is a short handle attached to the guard used to grasp the tool which does not permit the hand of the nurse to be located far enough away from the needle to insure avoiding needle sticks if a recoil occurs.
SUMMARY OF THE INVENTION
It is the objective of this invention to provide tools and methods which allow a nurse to access and deaccess safely a needle used with an implanted medical device. This invention has several features, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention as expressed by the claims which follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled, "DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS," one will understand how the features of this invention provide its benefits, which include low cost manufacture, simplicity of use, and, most importantly, nurse and patient safety by avoiding accidental needle sticks and the ensuing medical costs and risks such as, for example, loss of health or life, ability to work, and sometimes spousal support.
The first feature of the tool of this invention is that it may be used for assisting in both accessing and deaccessing a needle used with a medical device implanted under the skin of a patient. In one embodiment it has the general configuration of a spatula and it includes an elongated body having a handle section and an enlarged guard section. There is an elongated slot extending from an edge of the guard section into the guard section, terminating at an internal portion of the guard section. The guard section has an area in excess of 1.25 square inches, typically the area is from about 1.25 square inches to about 18 square inches. This relatively large guard area prevents the patient from being stuck with the needle, if there is a recoil during removal of the needle from the implanted medical device.
The second feature is the dimensions and other physical characteristics of the guard section. The guard section has a forward edge terminating at opposed ends and side edges at each opposed end which extend rearward to the handle section. The guard section has a floor including the forward edge, opposed sides, and a rear end. There is a raised rear wall connected to the rear of end of the floor, and a pair of raised side walls, each connected to one side of the floor. Preferably, the side walls taper down from their highest distance above the floor near the rear end to essentially level with the floor near the forward edge. The forward edge has a length of from about 1 to about 6 inches. The side edges have a length of from about 0.5 to about 3 inches. The guard section has a smooth, generally planar underside surface and a thickness of from 1/32 to 3/16 inch. The walls have a maximum height of about 1/4 inch.
The third feature is the dimensions and other physical characteristics of the slot. The slot extends from an edge of the guard section inward a distance in excess of 1/4 inch, preferably having a length of from about 0.25 to about 3 inches, and it has a width that is slightly broader than the diameter of the needle, typically from about 1/16 to about 1/4 inch. Preferably, the slot is at a right angle with respect to the forward edge, and the slot and the handle section are in substantial alignment with each other, both lying along a common longitudinal axis. Preferably, the minimum distance between the slot and a side edge is about 1 inch and the maximum distance between the slot and a side edge is about 3 inches. The elongated slot preferably has tapered edges. These tapered edges assist in removal of the needle from the implanted medical device.
The fourth feature is that the guard section is made of a transparent material. In most instances the entire tool is injected molded from a polymeric material such as, for example, polycarbonate, sold under the trademark LEXAN by General Electric, Inc. Because the guard section is transparent, the nurse may more easily align the tool with the implanted medical device. This is especially advantageous during accessing the implanted device. In one embodiment especially designed to assist in accessing the implanted device, the slot has along it's length an enlarged open portion with an area in excess of 0.0036 square inch. Preferably, the open portion is circular having a diameter greater than 1/16 inch, typically from 1/8 to 1/4 inch. The nurse inserts the needle through this enlarged open portion when accessing the implanted medical device. Preferably, the enlarged open portion is about midway between the forward edge and the bite of the slot. Preferably, there are indicia on the guard section which assist the nurse in aligning the guard section with the implanted medical device during accessing. For example, there may be a pair of marks on the guard disposed along the slot which are spaced apart a distance approximately equal to the width of the implanted medical device, typically from 3/4 to 1 1/2 inch. Alternately, the indicia may be at least partially encompassing the enlarged open portion along the slot. For example, the indicia may be a circle with its center coincident with the center of the enlarged circular open portion.
The fifth feature is that the tool is designed to enable the nurse to keep his or her hand a safe distance away from the needle during removal of the needle from the implanted device. The tool typically has a length of from 4 to 11 inches, and the handle section typically has a length of from 3 to 8 inches. The handle section has an elongated depression therein extending lengthwise along this handle section into which the thumb is placed during use. This depression provides a lever platform to enhance manipulative control of the tool. Thus, even someone with poor finger dexterity may easily manipulate the tool of this invention. In the preferred embodiment of this invention, the handle section has a marker on it indicating that the hand of the nurse should be behind this marker. The marker is at a distance to position the hand of the nurse at least 3 inches away from the needle during use. The handle section may include an intermediate neck section, and the guard section is joined to the intermediate neck. The handle section and the intermediate neck are at an acute angle of from 0 to 20 degrees, and the intermediate neck section and the guard section are at an acute angle of from 10 to 40 degrees.
The sixth feature is that a special tool is provided for assisting in the manual insertion of a needle into the implanted medical device of a predetermined width. This tool includes a handle section and a holder section, with the holder section having a pair of fork elements spaced apart a distance which is slightly greater than the width of the medical device. Typically, this distance is from about 1/2/ inch to about 2 inch. The fork elements are of equal length, each having a length of from about 0.5 inch to about 3 inch. The holder section has a length of from 0.5 to 3 inches and the handle section has a length of from 3 to 8 inches. The longitudinal axis of the handle section bisects the holder section, with each fork element being equidistance from the longitudinal axis. The holder section has a smooth, generally planar underside surface, and the handle section has a marker thereon indicating that the hand of the nurse should be behind this marker.
The seventh feature is that the handle section and guard section may be detachable, enabling the guard section to be discarded after use and the handle section reused. There is a locking mechanism that engages the handle section upon inserting the handle section into a track on the guard section and a manually releasable element that upon being released allows the handle section to be detached from the guard section.
This invention also includes a number of methods for accessing and deaccessing the implanted medical device. The first method is for manually removing a needle from a medical device implanted under the skin of a patient. It includes the following steps:
(a) grasping with the one, typically the nondominant, hand a handle section of a tool having a guard section having an area in excess of 1.25 square inches and a slot therein,
(b) sliding the slot along the needle to bring the guard section into an overlying relationship with the implanted medical device,
(c) maintaining the one hand a minimum distance away from the needle of at least 3 inches and exerting sufficient pressure to stabilize the guard area holding the implanted medical device preventing said device from moving,
(d) with the other, typically the dominant hand, withdrawing the needle free of the implanted medical device.
The deaccessing tool discussed above is used in performing this method.
The second method is for manually inserting a needle into a medical device implanted under the skin of a patient. It includes the following steps:
(a) grasping with one hand, typically the non-dominant hand, a tool with a holder section and a handle section, and holding a tool by the handle section and pressing the holder section against the skin overlying the medical device, and
(b) gripping the needle with the other hand, typically the dominant hand, and inserting said needle through said skin into the medical device, and
(c) maintaining said one hand a distance of at least 3 inches away from the needle as said needle is inserted into the medical device.
Either the tool discussed above which is designed especially for accessing the implanted medical device or the tool for deaccessing the needle may be used to conduct the second method. It is preferable that the guard sections of these tools be transparent and have indicia thereon which assist the nurse aligning the slot with the implanted device. These tools with transparent guard sections and indicia thereon may be used for both accessing and deaccessing the needle.
DESCRIPTION OF THE DRAWING
The preferred embodiments of this invention, illustrating all its features, will now be discussed in detail. These embodiments depict the novel and non-obvious accessing and deaccessing tools and methods of this invention as shown in the accompanying drawing, which is for illustrative purposes only. This drawing includes the following figures (FIGS.), with like numerals indicating like parts:
FIG. 1 is a perspective view illustrating a nurse being accidentally stuck with a needle that is being removed from an implanted medical device in the conventional manner.
FIG. 2 is a perspective view showing the needle inserted into an implanted medical device in the conventional manner.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 4.
FIG. 4 is a perspective view illustrating using the tool of this invention to safely remove a needle from an implanted medical device.
FIG. 5 is a plan view taken along line 5--5 of FIG. 4.
FIG. 6 is a plan view of the tool of this invention.
FIG. 7 is a side elevational view of the tool of this invention.
FIG. 8 is a plan view illustrating a nurse using an accessing tool of this invention to hold steady an implanted medical device while a needle is being inserted through the patient's skin into the implanted medical device.
FIG. 9 is a plan view of the accessing tool of this invention.
FIG. 10 is a side elevational view of the accessing tool of this invention.
FIG. 11 is a fragmentary plan view of a second embodiment of the tool of this invention, showing a modified guard section.
FIG. 12 is a fragmentary plan view of a third embodiment of the tool of this invention, showing a modified guard section for a right handed nurse.
FIG. 13 is a fragmentary plan view of a fourth embodiment of the tool of this invention, showing a modified guard section for a left handed nurse.
FIG. 14 is a top plan view of a fifth embodiment of the tool of this invention, showing a modified guard section with a sunken floor.
FIG. 14A is a top plan view of a sixth embodiment of the tool of this invention, showing a modified guard section similar to the guard shown in FIG. 14, except including an opening along the slot for providing easy access to the needle when inserting the needle into the implanted device.
FIG. 15 is a bottom plan view of the fifth embodiment of the tool of this invention shown in FIG. 14.
FIG. 16 is a perspective view illustrating a nurse using a tool similar to that shown in FIG. 14A to remove a needle from an implanted medical device, except modified to facilitate using the tool for both accessing and deaccessing the needle.
FIG. 17 is a perspective view similar to that shown in FIG. 16 where the nurse is using the tool shown in FIG. 16 to access a needle into an implanted medical device.
FIG. 18 is a perspective view of a seventh embodiment of the tool of this invention which is similar to that shown in FIG. 17, except modified to so that the handle and guard sections are detachable.
FIG. 19 is a plan view of the tool shown in FIG. 18 showing the handle and guard sections detached.
FIG. 20 is a side elevational view of the detached handle section illustrated in FIG. 18.
FIG. 21 is a side elevational view of the detached guard section illustrated in FIG. 18.
FIG. 22 is a sectional view taken along line 22--22 of FIG. 21.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Prior Art
As illustrated in FIGS. 1 and 2 a conventional vascular access device 10 has been implanted in the conventional manner under the skin 12 of a patient. As best shown in FIG. 3, this vascular access device 10 includes a housing 14 having an inlet 16 sealed by a latex seal 18. There is an outlet 20 in the device 10 remote from the inlet 16 with a fluid retention chamber 22 between the inlet and outlet. A tube 24 connected to the outlet 20 is inserted using a catheter (not shown) into a vein 26 of the patient.
A non-coring needle 30 is employed to administer medication through the vascular access device 10. The needle 30 has a generally 90 degree angle bend with one end of the needle being in communication through a tube 32 with the medication (not shown). A pair of flexible wings 34 extend outward from a hub 36. The nurse grasps these wings 34 when inserting or removing the needle 30 from the vascular access device 10. The shaft 30a of the needle 30 extends through the patient's epidermal layer of skin 12 and penetrates the seal 18, with the tip 30b of the needle entering the chamber 22. The medication flows through the needle 30 into the chamber 22 and then out the chamber through the tube 24 into the patient's vein 26. When the needle is removed as illustrated in FIG. 1, there sometimes occurs an involuntary recoil of the nurse's hand as she or he withdraws the needle from the seal 18 and skin 12. This often happens when exudate from the wound produced by insertion of the needle 30 hardens or the needle is left in the device for a number of days. The recoil many times results in the nurse being stuck with the needle. Such a needle stick can result in infection with AIDS, Hepatitis B, or other infectious diseases.
First Embodiment
In accordance with this invention, a tool 40 is employed to remove safely the needle 30 from the vascular access device 10. As best illustrated in FIGS. 4 through 7, this tool 40 includes a handle section 42 and an enlarged guard section 44 connected by an intermediate neck section 46. The intermediate neck is at an acute angle of about 35 degrees with respect to the guard section 44, and at an acute angle of about 15 degrees with respect to the handle section 42. The area of the guard section 44 is in excess of 1.25 square inches, and in the embodiment illustrated has an area of 3-4 square inches. The guard section 44 has the general configuration of a spatula with the guard section 44 providing a shield which covers or overlies the skin area adjacent the vascular access device 10. The tool 40 includes a forward edge 48 which preferably is beveled or tapered. At the opposed ends of this forward edge 48 are side edges 50 and 52 which extend rearward toward the handle section 42. There is an elongated slot 50 which extends from the forward edge 48 rearward towards the handle section 42 and terminates at a bite 54 which acts as a stop.
As best shown in FIGS. 4 and 5, the nurse grasps the handle section 42 with the left hand, if their dominant hand is the right hand, placing the thumb in a thumb depression 56 (FIGS. 5 and 6) in the handle section. The tool 40 is positioned next to the needle 30, and moved towards the needle, sliding the slot 50 along the shaft 30a of the needle until the shaft abuts the bite 54 of the slot. The nurse presses gently downward against the surface of the skin 12 with the generally flat, smooth underside 60 (FIG. 7) of the guard section 44, pressing against the surface of the skin to prevent the vascular access device 10 from moving while the needle 30 is being slowly lifted from the device while maintaining the needle generally at a right angle with respect to the seal 18. With the dominant right hand, the nurse grasps the wings 34, pressing them together, and withdraws the needle 30 outward and away from the device 10 with a smooth steady motion. If there is a recoil, the guard section 44 prevents the needle 30 from sticking the patient and, because the left hand is now remote from the vascular access device 10, being at least 3 inches away from the needle when lodged in the device 10, it is virtually impossible for the nurse to stick him or herself with the needle 30 upon withdrawing the needle from the device. Although the thumb depression 56 serves to position the left hand of the nurse a safe distance away from the needle 30 lodged in the device 10, a mark 62 (FIG. 6) may also be used to indicate the proper hand position. If the thumb depression 56 is eliminated, such a mark 62 indicates to the nurse that his or her hand should remain placed behind this mark on the side of the mark furthest away from the needle 30.
The tool 40 preferably is made of a transparent material such as polycarbonate plastic which enables the tool to be injection molded, and therefore inexpensively mass produced. The tool 40, particularly when the guard section 44 is made of a transparent material, may be used to insert the needle into the vascular access device 10. In this case of accessing the device 10, the nurse first locates the implanted device 10 by palpating the skin 12, and then tool 40 is placed over the implanted device and pressed downward against the skin 12 overlying the device 10, and the needle is inserted through the slot 50 into the skin 12 and seal 18.
The dimensions of this tool are very important to ensure the proper safe performance of the device. These dimensions are set forth in the following table with references to FIG. 6.
TABLE I______________________________________ITEM DIMENSION RANGE______________________________________1.sub.1 0.5 inch-3 inch1.sub.2 3 inch-8 inch1.sub.3 1 inch -6 inch1.sub.4 .5 inch-5 inch1.sub.5 0.25 inch-2 13/16 inch______________________________________
Second Embodiment
Also in accordance with this invention, there is provided as shown in FIGS. 8 through 10 a specially designed tool 70 for safely inserting the needle 30 into the vascular access device 10. Although this procedure is not as dangerous, because the needle 30 is ordinarily sterile, a needle stick may under some circumstances cause transmission of disease. Thus, it is highly desirable to avoid a needle stick when accessing the implanted device 10.
The accessing tool 70 comprises an elongated body 72 having a holder section 74 attached to a handle section 76. The holder section 74 includes two outwardly extending fork elements 78 and 80 which are spaced apart a distance equal to the width of the vascular accessing device 10. Preferably there is a thumb depression 56 in the handle similar to that illustrated in connection with the tool 40 to insure maintaining the safe distance away from the needle 30 as it is inserted into the implanted device 10.
As best shown in FIG. 8, the nurse holds the accessing tool 70 in the left hand while grasping the wings 34 of the needle 30 with the right hand. The nurse pushes the tip 30b of the needle 30 through the layer of skin 12 into and through the latex seal 18. Simultaneously, the holder section 74 is placed over the skin, with the forks 78 and 80 straddling the vascular accessing device 10, enabling the nurse to hold the device steady and virtually immovable while the needle 30 is being inserted into the device.
The important dimensions of the accessing tool are set forth in the following table with reference to FIGS. 9 and 10.
TABLE II______________________________________ITEM DIMENSION RANGE______________________________________1.sub.6 1 inch-6 inch1.sub.7 0.5 inch-3 inch1.sub.8 1/2 inch-2 inch1.sub.9 1/2 inch-3 inch1.sub.10 1 1/2 inch-5 inch______________________________________
Third Embodiment
As illustrated in FIG. 11, the tool 40 has been modified so that the length of slot 50a is substantially shorter than shown in FIG. 6. The use of such a short slot 50a may be desirable in certain applications, such as deaccessing a difficult to remove embedded needle. The shorter slot 50a may be used as a wedge to pry the needle away from the patient skin.
Fourth Embodiment
The fourth embodiment includes a tool 40a with a circular shaped guard section 44a. In FIG. 12, the slot 50c is curved inward from a portion of the edge of the guard section 44a near the handle section 42a. This tool 40a is used with the left hand. This fourth embodiment also includes a tool 40b with a circular shaped guard section 44b. In FIG. 13, the slot 50d is curved inward from a portion of the edge of the guard section 44b near the handle section 42b. This tool 40b is used with the right hand.
Fifth Embodiment
As illustrated in FIGS. 14 and 15, the fifth embodiment includes a tool 100 with a modified guard section 102. The guard section 102 employs a recessed floor 104. This floor 104 has a wall 106 attached to its rear end and a side wall 108 along each side edge of the floor. The side walls 108 merge with the rear wall 106 to partially enclose the floor. Only the forward edge 110 of the floor 104 is free for use in accessing or deaccessing the needle 30. The side walls 108 preferably taper downward from their highest elevation at the rear wall 106 towards the forward edge 110.
There is a slot 112 extending from the forward edge 110 towards the central section of the floor. The edges 112a of the slot 112 and the forward edge 110 are beveled or tapered. Such a taper assist the nurse in wedging the tool 100 underneath the needle 30 inserted and sometimes flush against the skin 12. When the needle is difficult to remove, these tapers edges of the forward edge and slot serve as a wedge to lift the needle up slightly off the surface of the skin.
Sixth Embodiment
As depicted in FIGS. 14A, and 16 and 17, the tool 100 has been modified to better enable it to be used for both accessing and deaccessing the needle 30. The principal difference between the tool 100 and the sixth embodiment of this invention, the tool 150, is that the slot 112 has along its length about midway between the forward edge 110 and the bite 152 of the slot, an enlarged open portion 154 encircled by a dotted circular red line 156. This circular line 156 has its center coincident with the center of the enlarged open portion 154. The guard section 102 of the tool 150 is made of a transparent material.
As illustrated in FIG. 16, the tool 150 is used to deaccess the needle already inserted into the device 10 by positioning the guard section 102 so that the needle shaft 30 a abuts the bite 152 of the slot 112. As discussed above, the nurse then grasps the wings 34 of the needle 30 and withdraws the needle from the vascular accessing device 10. As illustrated in FIG. 17, to use this same tool 150 for accessing the needle 30, the nurse first palpates the skin 12 to locate the device 10. Then the nurse positions the tool 150 with the guard overlying the implanted device. Because the guard section 102 is transparent, this is more readily accomplished than when using a guard of opaque material. The nurse uses the circular dotted red line as a sighting mechanism, bring the guard section into a position where the center of the implanted device 10 is coincident with the center of the enlarged open portion 154. The nurse then directs the needle through the open portion 154, and into the skin and device. The needle 30 is aligned at an angle of about 90 degrees with respect to the surface of the skin 12. Because the open portion 154 is substantially larger than the diameter of the needle 30, the nurse will be able to move the needle through the open portion 154 without touching the guard member, thereby avoiding contaminating the needle. Typically, the area of the open portion 154 is greater than 0.0036 square inch, and is circular having a diameter greater than 1/16 inch.
Seventh Embodiment
The seventh embodiment depicted in FIGS. 18 through 22 illustrate an accessing and deaccessing tool 180 which has a guard section 182 detachably connected to a handle section 184. Preferably, the guard section 182 is made of an inexpensive, transparent material, and is sterile prior to use and may be discarded after use. The handle section 184 preferably is made of an opaque, durable material and may be reused several times.
The handle section 184 has an elongated handle 184a with a thumb depression 210 in an intermediate portion. A tongue 212, integral with the forward end of the handle 184a, and having a generally rectangular configuration with a width slightly less than the width of the guard section, serves as the connector for attaching the handle section 184 to the guard section 182. The back end 212a of the tongue 212 is chamfered, and as will be discussed in greater detail subsequently, interacts with a tab 204 on the guard section 182 when the handle and guard sections engage.
The guard section 182 (FIG. 18) is similar to the guard section 102 (FIG. 16) of the tool 150. It has an elongated slot 186 extending inward that terminates in an enlarged circular opening 188 that is aligned with the vascular access device 10 when the tool is to be used to access the vascular access device. The leading edges 190 and sides 192 of the slot 186 and opening 188 are tapered to assist in slipping the guard section 182 under a needle 30 in the vascular access device 10 when the tool 180 is used for deaccessing the needle 30. The lateral sides 194 and 196 (FIG. 22) are raised and each has an inwardly directed lip 194a and 196a, respectively. These lips 194a and 196a serve as tracks for holding the handle section 184 upon attaching the handle section to the guard section 182. There is a stop member 198 (FIG. 19) between the inward ends of the lips 194a and 196a and the circular opening 188 that limits the inward movement of the handle section 184.
As best illustrated in FIGS. 19 and 22, at the rear 182a (FIG. 19) of the guard section 182 the tab 204 that engages the handle section 184 upon inserting the tongue 212 of the handle section under the tracks provided by the lips 194a and 196a. This tab 204, which is manually released by depressing it, is integral with the rear 182a of the guard section 182 and pivots along a hinge formed along the line of connection with the rear 182a of the guard section 182. When depressed, the tab 204 is moved downward to allow the tongue 212 to be slipped beneath the lips 194a and 196a until the forward end 212b of the tongue engages the stop member 198. Upon release, it springs back into its normal position depicted in solid lines in FIG. 21 to grasp the chamfer edge 212a of the tongue 212 of the handle section 184. To disconnect the handle section 184, the tab 204 is manually depressed and the handle section is simply pulled away from the guard section 182, with the tongue 212 sliding along the lips 194a and 196a until clear. Thus, the tab 204 and chamfer edge 212a provide a locking mechanism which is manually released.
General Procedures
Conventional aseptically clean techniques are followed in using the tools and methods of this invention, and the needle 30 is flushed with saline and Heparin solutions to avoid clogging. Clean or sterile rubber gloves should be worn when accessing and deaccessing the needle 30, and all used needles 30 are disposed of in sharps safety containers.
SCOPE OF THE INVENTION
The above presents a description of the best mode contemplated of carrying out the present invention, and of the manner and process of making and using it, 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 this invention. This invention is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this invention to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the invention as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the invention:
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Disclosed are tools and methods for assisting in the manual insertion of a needle into a medical device implanted under the skin of a patient and for assisting in the manual removal of the needle from this implanted medical device. The same tool may be used for both accessing and deaccessing the needle, or a special tool may be used for just assisting in the insertion of the needle into the implanted medical device. This special tool includes a holder section with a pair of fork elements spaced apart a distance which is slightly greater than the width of the implanted medical device. The tool for assisting in the manual removal of the needle from the implanted medical device includes an elongated body having a handle section and an enlarged guard section with an elongated slot extending from an edge of the guard section into the guard section, terminating at an internal portion of the guard section. The guard section of this tool is transparent, and preferably has indicia thereon which assist aligning the tool with the implanted medical device during needle accessing. The handle section and guard section may be detachable.
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This application claims priority to U.S. Provisional Application Serial No. 60/137,660, filed Jun. 4, 1999, which for purposes of disclosure is incorporated herein by specific reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to bath sponges and, more specifically, methods for manufacturing bath ruffles or sponges.
2. Description of the Related Art
In the manufacture of low cost items such as bath ruffles or sponges by unskilled manual labor, it is essential that assembly procedures be standardized and simplified to the extent that labor content is minimized while maintaining complete consistency of product to meet the demands of marketers and retailers.
Typically, imported bath ruffles or sponges are made from extruded polyethylene diamond mesh netting of the type used for fruit or vegetable bags. These bath ruffles or sponges are characterized by a generally misshapen appearance and a prematurely short service life due to unravelling of the ruffle or sponge material from a knotted binding cord.
Consumer demands have led to the requirement for bath sponges or ruffles to be made in a wide variety of colors and the incorporation of a pigment or dye to the base polymer adds substantially to the retail cost of the item.
Moreover, as these bath ruffles or sponges come into intimate contact with tender skin regions of a bather, it is generally not possible to utilize regrind waste polymer due to the risk of contamination which might otherwise manifest itself as sharp lumps or protrusions on the extruded net filaments which could scratch tender skin tissues leading to skin infections.
Even with frequent extruder screen changes to capture particulate contamination, it is extremely difficult to maintain color consistency due to the variations in color in the regrind feedstock without the use of excessive dark pigment to mask the feedstock color variations.
U.S. Pat. No. 4,034,443 is concerned with a knot-tying device in the form of a triangular plate having a small aperture adjacent an apex of the plate and a larger aperture in the center of the plate. A free end of a line or cord is passed through the smaller aperture and knotted on one side of the plate to secure the line or cord thereto. The line or cord is then looped around an object to be secured and a further looped portion of line or cord is pushed through the larger central aperture and looped over the two corners of the plate opposite the apex. Tension on the loop secured around the object secures the knot and the divergent sides of the plate prevent accidental disengagement of the looped portion of line or cord from the plate.
The main application described for this device is to secure a small boat to a mooring post with a tensioned loop.
Another prior art knot tying device is described in U.S. Pat. No. 4,112,551 relating to a draw strings puller and fastener for shoes or bags. The draw strings puller and fastener comprises a hollow frusto conical body with the free ends of a loop extending through opposed apertures in the side wall of the hollow body and emerging from a divergent open end thereof. The free ends of the loop are secured in a tapered plug which is inserted into the open end of the body when the loop is tensioned to wedgingly engage the drawstring between the tapered plug and body walls.
Other securing devices for cords or ribbons are described in U.S. Pat. No. 2,585,781, U.S. Pat. No. 2,849,821, U.S. Pat. No. 3,922,407 and U.S. Pat. No. 4,585,676.
U.S. Pat. No. 5,295,280 describes a body scrubber in the form of an elongate body in the nature of chain formed from a plurality of inter-looped links with a loop-like gripping handle at each end. The body portion is comprised of a polymeric netting in a tubular form, typically of Nylon (Trade Mark) or polyethylene.
U.S. Pat. No. 5,144,744 describes a bath ruffle or sponge made from extruded diamond mesh polyethylene of the type used to make fruit and vegetable bags. In this patent, the bath ruffle or sponge is made by stretching a number of netting tubes over respective pairs of spaced upright supports, binding the plurality of tubes together intermediate their ends with a plastic tie strip and then releasing the ends of the tubes from respective supports whereby due to the resiliency of the net material, the tubes rebound to form a sponge shape around the central binding.
Although such prior art bath ruffles or sponges are generally effective for their intended purpose, they do suffer from a number of practical disadvantages.
The use of a plastic tie strip is labor intensive and cannot be secured tightly enough to prevent premature unravelling of the bath ruffle or sponge. To overcome this problem a braided cord of cotton or the like was knotted around the netting tubes but again this was a very labor intensive exercise and was difficult to knot tightly enough to prevent premature unravelling.
Sponges of this type have not found favor due to a mis-shapen โdog-boneโ appearance and a relatively coarse texture which can irritate sensitive skin tissue.
Accordingly, there is a need for a cost-effective manufacturing process for bath ruffles or sponges from extruded polymeric netting wherein the end product has an aesthetically pleasing appearance, is securely fastened and otherwise which can be adapted to a variety of appearances and functionalities.
The present invention seeks to overcome or ameliorate at least some of the disadvantages associated with prior art bath ruffles or sponges and to provide a greater variety of products.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved method for the manufacture of bath ruffles or sponges of the type comprising extruded polymeric netting fabric secured in a generally spherical shape.
It is a further object of the present invention to provide a method for the manufacture of bath ruffles or sponges having more than one texture and/or color.
According to the present invention there is provided a method for the manufacture of bath ruffles or sponges, said method comprising the steps of:
radially stretching over spaced upright supports one or more lengths of resilient extruded polymeric netting tube to form a telescopically gathered continuous band around said supports;
tightly securing over opposed portions of said band centrally between said upright supports a loop securing device comprising, in combination, a body having a generally circular base and one or more centrally located apertures therein and a flexible line or cord frictionally engaged within said one or more apertures to form a closed loop extending from said base, the closed loop in use being extendible around said opposed portions of said band with the body and remainder of the flexible line or cord extending through the closed loop to form a double strand loop around the opposed portions of said band whereby the body engages against the looped end of the line or cord to prevent disengagement therebetween; and,
progressively releasing separately over respective upper ends of said spaced supports opposed portions of said telescopically gathered continuous band to form a generally spherical bath ruffle or sponge.
Preferably said telescopically gathered continuous band is progressively released by drawing, in opposite directions, opposed portions of said telescopically gathered continuous band over respective upper ends of said spaced supports at an angle acute to a plane between said opposed supports whereby regions of localized stretch are imparted to said netting tube.
If required said one or more lengths of netting tube may comprise at least two tubes telescopically gathered one above the other on said spaced supports.
Suitably said at least two tubes are formed from polymers having differing resiliencies.
Preferably one of said at least two tubes is comprised of a low density polyethylene polymer and the other of said at least two tubes is comprised of a low density polyethylene/ethylene-vinyl-acetate blend or co-polymer.
If required each of said at least two tubes is of a color differing from an adjacently telescopically gathered tube.
Alternatively said one or more lengths of netting may comprise at least two tubes, one of which is axially located within the other.
Suitably where one tube is axially located within another tube each of said one tube and said another tube is of a resilience and/or color differing from the other.
The inner tube may be formed from a netting of differing polymeric composition.
Alternatively the inner tube may be formed from a netting of differing mesh and/or filamentary size.
Preferably the inner tube is formed from a netting having a color darker than an outer tube.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which 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:
FIG. 1 shows schematically a side elevation of an apparatus used to perform the method of the invention.
FIG. 2 shows schematically a top plan view of the apparatus of FIG. 1 .
FIG. 3 is a side elevation of the arrangement of FIG. 1 showing the attachment of a loop fastening device according to the invention.
FIG. 4 shows an alternative embodiment of the method.
FIG. 5 shows a bath ruffle or sponge made in accordance with the embodiment illustrated in FIG. 4 .
FIG. 6 shows schematically yet another embodiment of the invention.
FIG. 7 shows an enlarged partial cross sectional view of a loop fastener employed in the invention.
FIG. 8 shows a cut away view of a bath ruffle or sponge made in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is shown an apparatus comprising a base 1 and spaced upright cylindrical support members 2 each having a rounded end 3 .
Typically the support members 2 are from about 20 mm-30 mm in diameter and are spaced at about 150 mm to about 250 mm apart.
A length of extruded low density polyethylene diamond mesh tubing is axially stretched at one end over support members 2 and is telescoped in a concertina-like fashion to form a continuous gathered band 4 as shown.
Referring to FIGS. 2 and 3, a loop fastening device 5 as generally described in co-pending patent application 08/695,222 is secured over the band 4 and tightened by supporting the conical disc body 6 between thumb and forefinger while drawing the free end of loop 7 therethrough.
When the loop fastener 5 is secured,portions of the gathered band 4 are drawn upwardly over the ends 3 of support members 2 in opposite directions at an angle acute to a plane between the upright axes of support members 2 as shown by arrows 8 and 8 a . Because portions of the gathered band 4 are drawn in opposite directions at an angle acute to a plane defined by the upright axes of support member 2 , it will be appreciated that the stretched portions are stretched such that at least some of the portions of the stretched end portions do not overlie the same location prior to releasing. This progressive stretching of selected regions of the mesh tubing followed by resilient relaxation causes a โbulkingโ of the relaxed mesh in a random manner.
When all of the gathered band has been progressively removed from the support members 2 , a substantially spherical bath ruffle or sponge with randomly distributed ruffles or folds in the mesh is formed with a hanging loop 7 firmly secured in the center of the ruffle or sponge body.
The diamond mesh netting may be comprised of low density polyethylene formed by a known process on a known mesh extruder. Typically the diamond mesh may comprise in an unstretched state a tube of about 75 mm in diameter with a mesh aperture of about 6 mm in an axial direction and about 1 mm in a circumferential direction.
The filament size corresponds to a tube mass of about 10 gm/meter and about 5 meters of mesh tubing is employed to obtain a bath ruffle of about 100 mm to 125 mm in diameter and a mass of about 50 gm.
FIG. 4 shows schematically alternative embodiments of the method according to the invention.
In FIG. 4 separate continuous bands 9 , 10 of telescopically concertinered are placed over support members 2 , one above the other.
Bands 9 , 10 may be formed from differing colors of mesh to achieve a bath ruffle or sponge having differently colored hemispheres for purely aesthetic reasons. It will be apparent to a person skilled in the art that more than two differently colored lengths of mesh may be employed to achieve bath ruffles or sponge with more than two colors.
More importantly however this alternative method is used to form bath ruffles or sponges having opposed hemispheres of differing softness to suit certain delicate skin tissues.
For example, one band 9 may be formed from low density polyethylene mesh and the other band 10 may be formed from EVA (ethylene-vinyl-acetate) polymer or EVA/LDPE mixtures or co-polymers. If required each polymer may be colored differently to indicate differences in softness in each hemisphere of the resultant bath ruffle or sponge.
FIG. 5 illustrates a bath ruffle or sponge 11 made in accordance with the alternative manufacturing method illustrated in FIG. 4 .
FIG. 6 shows yet another embodiment of the invention wherein one length of tubular mesh 12 is located inside a second length of tubular mesh 13 .
The inner length of mesh 12 simply may be threaded into outer layer 13 or alternatively inner layer 12 may be supported on a mandrel or former (not shown) while the outer layer 13 is drawn thereover.
The double layer of mesh is then drawn onto the supports 2 of the apparatus as shown in FIG. 1 and the bath ruffle or sponge is manufactured as hereinbefore described with reference to FIGS. 1 to 3 .
Several advantages accrue from the method employing a double layer of mesh.
The time required to progressively โpluckโ the telescopically gathered band of net from the supports 2 is reduced as only 2.5 meters of the double layered mesh is required to achieve a bath ruffle or sponge having the same bulk and mass as one formed from a single mesh tube of 5 meters in length.
By employing a double layer of mesh it is possible to manufacture the inner tube from regrind or second grade, less expensive material and still have a bath ruffle or sponge with the external feel and appearance of a ruffle or sponge made entirely from virgin polymer.
Similarly it is possible to employ an inner tube of, say, less expensive polyethylene to obtain bulk and resilience while the outer cover may be of EVA or EVA modified polymers to provide soft skin contact.
The inner mesh tube may be constructed to a coarse mesh with a relatively large filament diameter while the outer mesh may be finer with a smaller filament diameter.
By careful selection of polymers, mesh size and filament diameter of the inner and outer meshes respectively, substantial variations may be achieved in the โfeelโ of a bath ruffle or sponge without compromise to cost or user convenience.
Moreover, by utilizing a natural unpigmented, translucent or white pigmented outer mesh over a dark colored inner mesh, color variations normally obvious with the use of pigmented regrind material are much less obvious with the resultant bath ruffle or sponge having a unique โthree dimensionalโ effect.
The loop fastener used in accordance with the manufacturing process comprises a metal or, preferably, a plastics disc with a slotted aperture through which the free ends of a line or cord extend to form closed loops on the opposite side of disc.
The size of the slotted aperture and the line or cord are chosen to permit a slidable frictional engagement between the aperture and the line or cord. Similarly the thickness of disc 1 may be increased if required to provide a greater frictional contact between the aperture wall and the line or cord. Instead of a slotted aperture to accommodate paired strands of line or cord, separate or adjoining apertures may be provided.
Either or both of disc and line or cord may be resiliently deformable to enhance frictional engagement between the inner wall(s) of the aperture(s) and the strands of line or cord.
The line or cord may be chosen from a plastics monofilament which is at least partially resilient in a radial direction. Preferably the line or cord comprises a soft knitted or braided cord made from natural fibers such as cotton or synthetic fibers such as polyethylene, polypropylene or PET (Polyethylene-terephthalate) which is capable of substantial radial compression as it passes through a restricted aperture.
To assist in attaching the line or cord to disc, the aperture may be formed in a frusto-conical shape with an enlarged entry on one side of the disc and a restricted exit on the other side of the disc. The angle formed between the aperture wall and the disc face at the exit is an acute angle providing a relatively sharp edge to enhance frictional engagement with the line or cord, particularly when the plane of the disc is tilted relative to a plane normal with the longitudinal axes of the strands passing through the disc.
The disc may be of any desired shape but preferably is circular to avoid sharp pointed edges which could cause injury when coming into contact with a user. Similarly, the disc may be of any desired diameter but needs only to be of a diameter sufficient to cover the looped end where it engages about the paired strands passing therethrough.
FIG. 7 shows a particularly preferred form of loop fastener for use with the invention.
In this embodiment the loop fastener comprises a hollow, generally conical wall 6 with a slotted aperture 16 a at the apex thereof.
A loop 17 of a radially compressible braided or knitted cord of PET is conveniently inserted through aperture 7 from within the convergently tapering conical wall 6 .
For use with bath ruffles or sponges, the free ends 9 of the cord may be knotted to retain the conical member captive or they could be joined together by knotting or fusion welding to form a continuous loop.
As shown in FIG. 7 the looped end 7 , as it wraps around paired strands 9 a under tension is partially enclosed within the hollow interior of conical member 6 to increase the locking effect of the loop fastener by enhancing the frictional engagement between the loop 17 and the paired strands 19 a.
The conical members 16 are conveniently and inexpensively formed by injection molding from a rigid or semi-rigid plastics composition such as nylon, polycarbonate, polystyrene, ABS (acrylonitrilebutadienestyrene) or the like.
FIG. 8 shows in partial cross-section of a bath ruffle or bathing sponge 22 for personal hygiene.
Bath ruffle or sponge 22 comprises an extruded net 23 of polyethylene or the like which is formed in accordance with the method hereinbefore described and is secured in one step about its central region 24 by a loop fastener 16 as shown in FIG. 7 .
Not only does the loop fastener according to the invention provide a secure, slip free means of securing the bath ruffle or sponge, its configuration is such that there are no protruding edges to cause injury to a bather during use.
The present invention has been shown and described herein in what are considered to be the most practical and preferred embodiments. It is recognized however that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.
For example the body of the loop securing device may be in the form of a spherical shape or an inverted cone wherein the base of the body is at the convergent end of the cone although these embodiments are considered to form a less secure closure than the preferred embodiments.
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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A method is provided for manufacturing bath ruffles or sponges. The method includes radially stretching over spaced upright supports one or more lengths of resilient extruded polymeric netting tube to form a telescopically gathered continuous band around the supports. A loop securing device is then positioned around opposed portions of the band centrally between the upright supports such that the opposed portions of the band are securely held together. Opposed portions of the telescopically gathered continuous band are then progressively released separately over respective upper ends of the spaced supports to form a generally spherical bath ruffle or sponge.
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RELATED APPLICATIONS
This application claims priority to Taiwan Application Serial Number 101141318, filed on Nov. 7, 2012, which is herein incorporated by reference.
BACKGROUND
Field of Invention
The present invention relates to a photosensitive resin composition and a color filter formed by using the same. More particularly, the present invention relates a photosensitive resin composition having a high adhesiveness without pre-bake process.
Description of Related Art
In the conventional method of producing a color filter using a photosensitive resin composition, the photosensitive resin composition was coated on a substrate or a substrate having patterns of a light-shielding layer. The coated photosensitive resin composition was firstly subjected to a pre-bake process to form a dried film. And then, an exposing process and a developing process were performed to form a predetermined pattern, so as to form colorful pixels. The methods of producing colorful pixels were disclosed in some methods such as Japanese Patent Laid-Open Publication No. 1990-144502 and No. 1991-53201.
Moreover, in the technical field of producing a color filter in recent years, there is an improvement of the decreased production time by using low exposure. As to the requirements of a high contrast and a high color purity of the colorful liquid crystal display (LCD) device, more pigments need to add into the photosensitive resin composition. In such condition, during the production of the color filter, irregular stains occurs on the pixel pattern layer at a finished stage of a water-washing step after a developing process. The irregular stains will cause a potential delay of the subsequent checking process, for raising issues such as the decreased production efficiency.
Furthermore, there are some methods to save more production time. In addition to the use of decreased exposure, an omission of the prebake step is recently developed in this industry field. There is a strong need to develop such photosensitive resin composition that is available to the omission of the prebake step and has excellent properties.
The aforementioned specific photosensitive resin composition was disclosed in Japanese Patent Laid-Open Publication No. 2009-180949, which comprised a compound containing epoxypropane and cation polymerized initiator. The photosensitive resin composition could improve the irregular stains and be available to the omission of the pre-bake step.
However, during the omission of the pre-bake step in the pixel process, the pixels formed by the aforementioned photosensitive resin composition were adhered onto the substrate poorly, which was unlikely accepted by the industry field.
Accordingly, there is a need to provide a photosensitive resin composition and an application of the same for improving the disadvantages of the adhesiveness during the omission of the pre-bake step in the pixel process.
SUMMARY
Therefore, an aspect of the present invention provides a photosensitive resin composition. The photosensitive resin composition includes an alkali-soluble resin (A), a compound (B) containing vinyl unsaturated group(s), a photo initiator (C), an organic solvent (D), a pigment (E), and a metal chelating agent (F).
Another aspect of the present invention provides a color filter. The color filter is a pixel color layer formed by the aforementioned photosensitive resin composition after a photolithography.
A further aspect of the present invention provides a liquid crystal display device. The liquid crystal display device includes the aforementioned color filter.
The photosensitive resin composition comprising an alkali-soluble resin (A), a compound (B) containing vinyl unsaturated group(s), a photo initiator (C), an organic solvent (D), a pigment (E), and a metal chelating agent (F) all of which are described in detail as follows.
Alkali-Soluble Resin (A)
The alkali-soluble resin (A) of the present invention includes a compound polymerized by a mixture, and the mixture includes a first unsaturated monomer (a-1) containing a carboxylic acid group, a second unsaturated monomer (a-2) containing an alicyclic group, and a third unsaturated monomer (a-3).
The aforementioned first unsaturated monomer (a-1) is selected from the group consisting of acrylic acid, methacrylic acid, 2-methyl-acryloyl ethoxy acid esters, crotonic acid, ฮฑ-chloro acrylic acid, ethyl acrylic acid, cinnamic acid, maleic acid, maleic acid anhydrate, fumaric acid, itaconic acid, itaconic acid anhydrate, citraconic acid, citraconic acid anhydrate and a combination thereof. Preferably, the first unsaturated monomer (a-1) is selected from the group consisting of acrylic acid, methacrylic acid, 2-methyl-acryloyl ethoxy acid esters and a combination thereof.
Based on the mixture as 100 parts by weight, the amount of the first unsaturated monomer (a-1) is 5 to 50 parts by weight, preferably 8 to 45 parts by weight, and more preferably 10 to 40 parts by weight. When the amount of the first unsaturated monomer is 5 to 50 parts by weight, the photosensitive resin composition has a better developing ability while photolithography process, such as exposing and developing, is performed.
The second unsaturated monomer (a-2) is selected from the group consisting of an unsaturated compound containing dicyclopentanyl group, a unsaturated compound containing dicyclopentenyl group and a combination thereof.
More specifically, the second unsaturated monomer (a-2) could be dicyclopentyl acrylate, dicyclopentyl ethoxy acrylate, dicyclopentenyl acrylate, dicyclopentenyl ethoxy acrylate, dicyclopentyl methacrylate, dicyclopentyl ethoxy methacrylate, dicyclopentenyl methacrylate, dicyclopentenyl ethoxy methacrylate and a combination thereof.
Based on the mixture as 100 parts by weight, the amount of the second unsaturated monomer (a-2) is 1 to 20 parts by weight, preferably 3 to 18 parts by weight, and more preferably is 5 to 15 parts by weight. When the amount of the second unsaturated monomer (a-2) is 2 to 20 parts by weight, the pixel color layer formed by the photosensitive resin composition has a better heat resistance after the photolithography process.
The third unsaturated monomer (a-3) is selected from the group consisting of styrene, ฮฑ-methyl styrene, vinyl toluene, chloro styrene, divinyl benzene, benzyl methacrylate, benzyl acrylate, phenyl methacrylate, phenyl acrylate, 2-nitrophenyl acrylate, 4-nitrophenyl acrylate, 2-nitrobenzyl acrylate, 2-nitrobenzyl methacrylate, 2-nitrophenyl methacrylate, 2-chlorophenyl methacrylate, 4-chlorophenyl methacrylate, 2-chlorophenyl acrylate, 4-chlorophenyl acrylate, phenoxyethyl methacrylate, phenoxy polyethylene glycol acrylate, phenoxy polyethylene glycol methacrylate, nonyl phenoxy polyethylene glycol acrylate, nonyl phenoxy polyethylene glycol methacrylate, N-phenyl maleimide, N-o-hydroxyphenyl maleimide, N-m-hydroxyphenyl maleimide, N-p-hydroxyphenyl maleimide, N-o-methoxyl phenyl maleimide, N-m-methyl phenyl maleimide, N-p-methyl phenyl maleimide, N-o-methoxyl phenyl maleimide, N-m-methoxyl phenyl maleimide, N-p-methoxyl phenyl maleimide, o-vinyl phenol, m-vinyl phenol, p-vinyl phenol, 2-methyl-4-vinyl phenol, 3-methyl-4-vinyl phenol, o-isopropenyl phenol, m-isopropenyl phenol, p-isopropenyl phenol, 2-vinyl-1-naphthol, 3-vinyl-1-naphthol, 1-vinyl-2-naphthol, 3-vinyl-2-naphthol, 2-isopropenyl-1-naphthol, 3-isopropenyl-1-naphthol, o-methoxy styrene, m-ethoxy styrene, p-methoxy styrene, o-methoxy methyl styrene, m-methoxy methyl styrene, p-methoxy methyl styrene, o-(vinyl benzyl)epoxypropyl ether, m-(vinyl benzyl)epoxypropyl ether, p-(vinyl benzyl)epoxypropyl ether, indene, acetyl naphthalene, N-cyclohexyl maleimide, methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, test-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 3-hydroxypropyl acylate, 2-hydroxybutyl acrylate, 3-hydroxybut acrylate, 4-hydroxybutyl acrylate, allyl acrylate, triethylene glycol dimethoxy acrylate, N,N-dimethyl amino ethyl acrylate, N,N-diethyl amino propyl acrylate, N,N-dibutyl amino propyl acrylate, epoxypropylacrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 3-hydroxypropyl methacrylate, 2-hydroxybutyl methacrylate, 3-hydroxybutyl methacrylate, 4-hydroxybutyl methacrylate, allyl methacrylate, triethylene glycol methoxyl dimethacrylate, dodecy 2-methacrylate, myristyl methacrylate, cetyl methacrylate, octadecyl methacrylate, eicosyl methacrylate, behenyl methacrylate, N,N-dimethyl amino ethyl methacrylate, N,N-dimethyl amino propyl methacrylate, N-isobutyl amino ethyl methacrylate, epoxy propyl methacrylate, vinyl acetate, vinyl propionate, vinyl butyrate, methoxyethene, ethoxyethene, allyl glycidyl ether, methallyl glycidyl ether, acrylonitrile, methacrylonitrile, ฮฑ-chloro acrylonitrile, vinylidene cyanide, acrylamide, methacrylamide, ฮฑ-chloro acrylamide, N-hydroxyethyl acrylamide, N-hydroxyethyl methacrylamide, 1,3-butadiene, isoamylene, chloroprene and a combination thereof. Preferably, the third unsaturated monomer (a-3) is styrene, ฮฑ-methyl styrene, phenyl methacrylate, phenyl acrylate, N-phenyl maleimide, N-o-hydroxy phenyl maleimide, N-m-hydroxy phenyl maleimide, N-p-hydroxy phenyl maleimide, methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, epoxypropyl methacrylate, vinyl acetate, acrylonitrile, methyl acrylonitrile, 1,3-butadiene, isoamylene and a combination thereof.
Based on the mixture as 100 parts by weight, the amount of the third unsaturated monomer (a-3) is 30 to 94 parts by weight, preferably 37 to 89 parts by weight, and more preferably 45 to 85 parts by weight. When the amount of the third unsaturated monomer (a-3) is 30 to 94 parts by weight, the pixel color layer formed by the photosensitive resin composition has a better anti-sputtering ability.
A Compound (B) Containing Vinyl Unsaturated Group(s)
The compound (B) containing vinyl unsaturated group(s) of the present invention is selected from the group consisting of a first compound (B-1), a second compound (B-2) and a combination thereof.
The first compound (B-1) is a (meth)acrylic ester compound synthesized from a caprolactone-modified polyol, a (meth)acrylic acid and a combination thereof.
The caprolactone-modified polyol is synthesized from a caprolactone and a polyol with at least four functional groups. The aforementioned caprolactone could be ฮณ-caprolactone, ฮด-caprolactone, or ฮต-caprolactone. Preferably, the caprolactone is ฮต-caprolactone. The polyol with at least four functional groups could be pentaerythritol, ditrimethylolpropane and dipentaerythritol. Preferably, based on the polyol with at least four functional groups as 1 mole, the amount of the caprolactone is 1 to 12 mole.
The first compound (B-1) is selected from the group consisting of pentaerythritol caprolactone modified tetra(meth)acrylate compound, di(trimethylolpropane) caprolactone modified tetra(meth)acrylate compound, dipentaerythritol caprolactone modified poly(meth)acrylate compound and a combination thereof. Moreover, the dipentaerythritol caprolactone modified poly(meth)acrylate compound can be dipentaerythritol caprolactone modified di(meth)acrylate compound, dipentaerythritol caprolactone modified tri(meth)acrylate compound, dipentaerythritol caprolactone modified tetra(meth)acrylate compound, dipentaerythritol caprolactone modified penta(meth)acrylate compound, dipentaerythritol caprolactone modified hexa(meth)acrylate compound and a combination thereof.
Furthermore, the aforementioned first compound (B-1) has a structure of the formula (I):
In formula (I), R 1 and R 2 respectively is a hydrogen atom or a methyl group, m is an integer of 1 to 2, a is an integer of 1 to 6, b is an integer of 0 to 5, wherein (a+b) is an integer of 2 to 6, preferably 3 to 6, more preferably 5 to 6, and yet more preferably is 6.
More specifically, the first compound (B-1) is a product made by Nippon Kayak Co., Ltd., and the trade name is KAYARADยฎDPCA-20, DPCA-30, DPCA-60, or DPCA-120.
Based on the alkali-soluble resin as 100 parts by weight, the amount of the first compound is 5 to 100 parts by weight, preferably 8 to 90 parts by weight, more preferably 10 to 80 parts by weight. The caprolactone in the first compound (B-1) could dismiss the defects of bubble-displaying. When the compound (B) containing vinyl unsaturated group(s) do not include the first compound (B-1), the developing ability is worse.
The second compound (B-2) comprising a functional group of the formula (II):
In the formula (II), R 3 is a hydrogen atom or a methyl group.
The second compound (B-2) is selected from acrylamide, (meth)acrylate morpholine, 7-amino-3,7-dimethyloctyl(meth)acrylate, isobutoxy methyl(meth)acrylamide, isobornyl ethoxy(meth)acrylate, isobornyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, ethylene diglycol(meth)acrylate, tert-octyl(meth)acrylamide, diacetone(meth)acrylat, dimethyl amino(meth)acrylate, dosecyl(meth)acrylate, dicyclopentenyl ethoxy(meth)acrylate, dicyclopentenyl(meth)acrylate, N,N-dimethyl(meth)acrylamide, tetrachloro phenyl(meth)acrylate, 2-tetrachloro phenoxy ethyl(meth)acrylate, tetrahydrofurfuryl(meth)acrylate, tetrabromo phenyl(meth)acrylate, 2-tetrabromo phenoxy ethyl(meth)acrylate, 2-trichloro phenoxy ethyl(meth)acrylate, tribromo phenyl(meth)acrylate, 2-tribromo phenoxy ethyl(meth)acrylate, 2-hydroxy ethyl(meth)acrylate, 2-hydroxy propyl(meth)acrylate, vinyl vaprolactam, N-ethylene pyrrolidone carboxylate, phenoxy ethyl(meth)acrylate, pentachloro phenyl(meth)acrylate, pentabromo phenyl(meth)acrylate, polyethylene glycol mono(meth)acrylate, polypropylene glycol mono(meth)acrylate, bornyl(meth)acrylate, diethylene glycol di(meth)acrylate, dicyclopentenyl di(meth)acrylate, triethylene glycol di(meth)acrylate, tetraethylene glycol di(meth)acrylate, tri(2-hydroxyethylene)isocyanate di(meth)acrylate, tri(2-hydroxyethylene)isocyanate tri(meth)acrylate, caprolactone modified tri(2-hydroxyethylene)isocyanate tri(meth)acrylate, trihydroxymethylene tri(meth)acrylate, ethylene oxide (hereinafter abbreviated as EO) modified trihydroxymethylene tri(meth)acrylate, propylene oxide (hereinafter abbreviated as PO) modified trihydroxymethylene tri(meth)acrylate, dineopentyl glycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, pentaerythrite tri(meth)acrylate, pentaerythrite tetra(meth)acrylate, polyester di(meth)acrylate, polyethylene glycol di(meth)acrylate, dipentaerythrite hexa(meth)acrylate, dipentaerythrite penta(meth)acrylate (a product made by Nippon Toagosei Co., Ltd., and the trade name is TO-1382), dipentaerythrite tetra(meth)acrylate, caprolactone modified dipentaerythrite hexa(meth)acrylate, EO modified dipentaerythrite hexaacrylate, caprolactone modified dipentaerythrite penta(meth)acrylate, di(trihydroxymethylene)tetra(meth)acrylate, EO modified bisphenol A di(meth)acrylate, PO modified bisphenol A di(meth)acrylate, EO modified hydrogenated bisphenol A di(meth)acrylate, PO modified hydrogenated bisphenol A di(meth)acrylate, PO modified tripropionin, EO modified hydrogenated isophenol F di(meth)acrylate, phenolic polyglycerols (meth)acrylate, trimethylolpropane triacrylate, EO modified trimethylolpropane triacrylate, PO modified trimethylolpropane triacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate, dipentaerythritol pentaacrylate, dipentaerythritol tetraacrylate, caprolactone modified dipentaerythritol hexaacrylate, di(trihydroxymethylene)tetraacrylate and a combination thereof.
Preferably, the second compound (B-2) is selected from trimethylolpropane triacrylate, EO modified trimethylolpropane triacrylate, PO modified trimethylolpropane triacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate, dipentaerythritol pentaacrylate, dipentaerythritol tetraacrylate, caprolactone modified dipentaerythritol hexaacrylate, di(trihydroxymethylene)tetraacrylate, PO modified tripropionin, a product made by Nippon Toagosei Co., Ltd., and the trade name is TO-1382, and a combination thereof.
Based on the alkali-soluble resin (A) as 100 parts by weight, the amount of the second compound (B-2) is 5 to 400 parts by weight, preferably 8 to 350 parts by weight, and more preferably 10 to 300 parts by weight, so as to improve the developing ability of the photosensitive resin composition.
Based on the alkali-soluble resin (A) as 100 parts by weight, the amount of the compound (B) containing vinyl unsaturated group(s) is 10 to 500 parts by weight, preferably 20 to 450 parts by weight, more preferably 30 to 400 parts by weight, so as to improve the developing ability of the photosensitive resin composition.
Photo Initiator (C)
The photo initiator (C) is selected from the group consisting of acetophenone, biimidazole, acyl oxime and a combination thereof.
The aforementioned acetophenone is selected from the group consisting of p-dimethylamino-acetophenone, ฮฑ,ฮฑโฒ-dimethoxyazoxy-acetophenone, 2,2โฒ-dimethyl-2-phenyl-acetophenone, p-methoxy-acetophenone, 2-methyl-1-(4-methylthiophenyl)-2-morpholino-1-propanone, 2-benzyl-2-N,N-dimethylamino-1-(4-morpholinophenyl)-1-butanone and a combination thereof.
The aforementioned biimidazole is selected from the group consisting of 2,2โฒ-bis(o-chlorophenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(o-fluorophenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(o-methylphenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(o-methoxyphenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(o-ethylphenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(p-methoxyphenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(2,2โฒ,4,4โฒ-tetramethoxyphenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(2-chlorophenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, 2,2โฒ-bis(2,4-dichlorophenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole and a combination thereof.
The aforementioned acyl oxime is selected from the group consisting of {Ethanone, 1-[9-ethyl-6-(2-methylbenzoyl)-9H-carbazole-3-yl]-, 1-(O-acetyl oxime)} [for example, the product made by Ciba Specialty Chemicals Co., Ltd., and the trade name is CGI-242 which comprises a structure of the formula (III)], 1-[4-(benzoyl)phenyl]-heptane-1,2-dione 2-(O-benzoyloxime) [for example, the product made by Ciba Specialty Chemicals Co., Ltd., and the trade name is CGI-124 which comprises a structure of the formula (IV)], {Ethanone, 1-[9-ethyl-6-(2-chloro-4-benzyl-thio-benzoyl)-9H-carbazole-3-yl]-, 1-(O-acetyl oxime)} [for example, the product made by Adeka Corporation, and the product comprises a structure of the formula (V)]:
Preferably, the photo initiator (C) is selected from the group consisting of 2-methyl-1-(4-methylthiophenyl)-2-morpholine-1-propanone, 2-benzyl-2-N,N-dimethylamino-1-(4-morpholinophenyl)-1-butanone, 2,2โฒ-bis(o-chlorophenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole, [Ethanone, 1-[9-ethyl-6-(2-methylbenzoyl)-9H-carbazole-3-yl]-, 1-(O-acetyl oxime)] and a combination thereof.
The photo initiator (C) of the present invention further comprises: benzophenone such as thioxanthone, 2,4-diethyl-thioxanthanone, thioxanthone-4-sulfone, benzophenone, 4,4โฒ-bis(dimethylamino)benzophenone, 4,4โฒ-bis(diethylamino)benzophenone and the like; ฮฑ-diketone such as benzil, acetyl and the like; acyloin such as benzoin and the like; acyloin ether such as benzoin methylether, benzoin ethylether, benzoin isopropyl ether and the like; acyphosphineoxide such as 2,4,6-trimethyl-benzoyl-diphenyl-phosphineoxide, bis-(2,6-dimethoxy-benzoyl)-2,4,4-trimethyl-benzyl-phosphoneoxide and the like; quinone such as anthraquinone, 1,4-naphthoquinone and the like; tris(trichloromethyl)-s-triazine such as phenacyl chloride, tribromomethyl-phenylsulfone and the like; peroxide compound such as di-tertbutylperoxide and the like. Among those photo initiator (C), benzophenone is preferred, and 4,4โฒ-bis(diethylamino)benzophenone is more preferred.
Based on the alkali-soluble resin (A) as 100 parts by weight, the amount of the photo initiator (C) is 2 to 100 parts by weight, preferably 3 to 175 parts by weight, and more preferably 5 to 150 parts by weight.
Organic Solvent (D)
The organic solvent (D) can soluble the alkali-soluble resin (A), the compound (B) containing vinyl unsaturated group(s), and the photo initiator (C), and the organic solvent (D) does not react with the aforementioned compounds. Moreover, the organic solvent has a suitable volatility.
The organic solvent (D) can be (poly)alkylene glycol monoalkylether such as ethylene glycol monomethylether, ethylene glycol monoethylether, diethylene glycol monomethylether, diethylene glycol monoethylether, diethylene glycol n-propylether, diethylene glycol n-butylether, triethylene glycol monomethylether, triethylene glycol monoethylether, propylene glycol monomethylether, propylene glycol monoethylether, dipropylene glycol monomethylether, dipropylene glycol monoethylether, dipropylene glycol n-propylether, dipropylene glycol n-butylether, tripropylene glycol monomethylether, tripropylene glycol monoethylether and the like; (poly)alkylene glycol monoalkylether acetate such as ethylene glycol monomethylether acetate, ethylene glycol monoethylether acetate, propylene glycol monomethylether acetate, propylene glycol monoethylether acetate and the like; ether such as diethylene glycol dimethyl ether, diethylene glycol ethyl methyl ether, diethylene glycol diethyl ether, tetrahydrofuran and the like; ketone such as methyl ethyl ketone, cyclohexanone, 2-heptanone, 3-heptanone and the like; lactic alkoxycarbonyl such as methyl 3-hydroxypropanoate, ethyl 2-hydroxypropanoate and the like; ester such as methyl 2-hydroxy-2-methylpropionate, ethyl 2-hydroxy-2-methylpropionate, methyl 3-methoxypropionate, ethyl 3-methoxypropionate, methyl 3-ethoxypropionate, ethyl 3-ethoxypropionate, ethoxy ethyl acetate, hydroxy ethyl acetate, methyl 2-hydroxy-3-methylbutyrate, 3-methyl-3-methoxybutyl acetate, 3-methyl-3-methoxybutyl acrylic acid, ethyl acetate, n-butyl acetate, n-propyl acetate, isopropyl acetate, isobutyl acetate, n-pentyl acetate, isopentyl acetate, n-butyl propionate, ethyl butyrate, n-propyl butyrate, isopropyl butyrate, n-butyl butyrate, methyl pyruvate, ethyl pyruvate, n-propyl pyruvate, methyl acetoacetate, ethyl acetoacetate, 2-oxide-butyric acid ethyl ester and the like; aromatic hydrocarbons such as toluene, dimethylbenzene and the like; carboxylic acid amide such as N-methyl-pyrrolidinone, N,N-dimethyl formamide, N,N-dimethyl acetamide and the like.
Preferably, the organic solvent (D) can be propylene glycol monomethylether acetate, ethyl 3-ethoxypropionate or can be used in combination of two or more.
Based on the alkali-soluble resin (A) as 100 parts by weight, the amount of the organic solvent (D) is 500 to 5000 parts by weight, preferably 800 to 4000 parts by weight.
Pigment (E)
The pigment (E) can be an inorganic pigment, an organic pigment and a combination thereof.
The aforementioned inorganic pigment is metallic compound such as metallic oxide compound, metallic complex salt and the like. The inorganic pigment is selected from metallic oxide compound and complex oxide compound containing iron, cobalt, aluminum, cadmium, lead, copper, titanium, magnesium, chromium, zinc, antimony and the like.
The aforementioned organic pigment is selected from C.I. pigment yellow 1, 3, 11, 12, 13, 14, 15, 16, 17, 20, 24, 31, 53, 55, 60, 61, 65, 71, 73, 74, 81, 83, 93, 95, 97, 98, 99, 100, 101, 104, 106, 108, 109, 110, 113, 114, 116, 117, 119, 120, 126, 127, 128, 129, 138, 139, 150, 151, 152, 153, 154, 155, 156, 166, 167, 168, 175; C.I. pigment orange 1, 5, 13, 14, 16, 17, 24, 34, 36, 38, 40, 43, 46, 49, 51, 61, 63, 64, 71, 73; C.I. pigment red 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14, 15, 16, 17, 18, 19, 21, 22, 23, 30, 31, 32, 37, 38, 40, 41, 42, 48:1, 48:2, 48:3, 48:4, 49:1, 49:2, 50:1, 52:1, 53:1, 57, 57:1, 57:2, 58:2, 58:4, 60:1, 63:1, 63:2, 64:1, 81:1, 83, 88, 90:1, 97, 101, 102, 104, 105, 106, 108, 112, 113, 114, 122, 123, 144, 146, 149, 150, 151, 155, 166, 168, 170, 171, 172, 174, 175, 176, 177, 178, 179, 180, 185, 187, 188, 190, 193, 194, 202, 206, 207, 208, 209, 215, 216, 220, 224, 226, 242, 243, 245, 254, 255, 264, 265; C.I. pigment purple 1, 19, 23, 29, 32, 36, 38, 39; C.I. pigment blue 1, 2, 15, 15:3, 15:4, 15:6, 16, 22, 60, 66; C.I. pigment green 7, 36, 37; C.I. pigment brown 23, 25, 28; and C.I. pigment black 1, 7.
An average particle size of primary particle in the pigment (E) is 10 to 200 nm, preferably 20 to 150 nm, more preferably 30 to 130 nm.
Based on the alkali-soluble resin (A) as 100 parts by weight, the amount of the pigment (E) is 100 to 800 parts by weight, preferably 120 to 750 parts by weight, more preferably 150 to 700 parts by weight.
Alternatively, the pigment (E) selectively comprises a dispersing agent, for example surfactant such as cationic surfactant, ionic surfactant, nonionic surfactant, amphoteric surfactant, polysiloxane surfactant, fluorine surfactant and the like.
The aforementioned surfactant can be used alone or in combination of two or more selected from follows: polyoxyethylene alkyl ether such as polyoxyethylene lauryl ether, polyoxyethylene stearyl ether amide, polyoxyethylene oleyl ether and the like; polyoxyethylene alkyl ether surfactant such as polyoxyethylene octyl phenyl ether, polyoxyethylene nonyl phenyl ether and the like; polyethylene glycol diester such as polyethylene glycol bislaurate, polyoxyethylene stearate and the like; sorbitan fatty acid ester surfactant; fatty acid modified polyester surfactant; tertiary amines modified polyurethane surfactant; a product made by Shin-Etsu Chemical Co., Ltd., and the trade name is KP; a product made by Toray Dow Corning Silicon Co., Ltd., and the trade name is SF-8427; a product made by Kyoeisha Chemical Co., Ltd., and the trade name is Polyflow; a product made by Tochem Products Co., Ltd., and the trade name is F-Top; a product made by Dainippon Ink and Chemicals Co., Ltd., and the trade name is Megafac; a product made by Sumitomo 3M Co., Ltd., and the trade name is Fluorade; a produce made by Asahi Glass Co., Ltd., and the trade name is Asahi Guard or Surflon.
Metal Chelating Agent (F)
The metal chelating agent (F) comprises a structure of the formula (VI):
(R 4 ) p M(OR 5 ) j-p โโ(VI)
In the formula (VI), M is metal, R 4 is a ligand group, R 5 is an alkyl group of 2 to 5 carbons or an aryl group of 6 to 20 carbons, p is an integer of 1 to j, and j is a values of metal. When the numbers of R 4 or R 5 are two or more, every R 4 or R 5 can be the same or be different.
The alkyl group of 2 to 5 carbons can include but are not be limited ethyl group, propyl group, isopropyl group, or butyl group. The aryl group of 6 to 20 carbons includes but are not be limited benzene.
The metal includes but is not limited aluminum, titanium, zirconium, beryllium, calcium, cobalt, copper, iron, hafnium, iridium, palladium, manganese, molybdenum, niobium, nickel, platinum, tin, ruthenium, tantalum, vanadium, tungsten, or zinc, preferably is selected from aluminum, titanium, or zirconium.
Preferably, the ligand group is selected from the group consisting of ฮฒ-diketones chelating group, ฮฒ-ketoester chelating group, amino chelating group, sulfonic acid chelating group, or phosphoric acid chelating group.
The ฮฒ-diketones chelating group includes but is not limited acetylacetonate, 2,2,6,6-tetramethyl-3,5-heptanedionate, benzoyl acetonate, 1,3-diphenyl-1,3-propanedionate, tetramethylheptanedionate, hexanedionate, or heptanedionate.
The ฮฒ-ketoester chelating group includes but is not limited ethyl acetoacetate, methyl acetoacetate, benzoyl acetoacetate, methacryloxy ethyl acetate, allyl acetoacetate, methyl benzoyl acetate, ethyl benzoyl acetate, or benzoyl acetate.
The amino chelating group includes but is not limited N-aminoethyl aminoethyl.
The sulfonic acid chelating group includes but is not limited dodecylbenzenesulfonic acid.
The phosphoric acid chelating group includes but is not limited dioctyl pyrophosphate, dioctyl phosphate, or tridecyl phosphate.
The metal chelating agent (F) can be used alone or in combination of two or more. The metal chelating agent (F) includes but is not limited aluminum chelate compound such as tris(acetylacetonato)aluminum, tris(ethyl acetoacetate)aluminum, (di-i-propoxy)monoacetylacetonato aluminum, (di-i-propoxy)monomethylacetoacetato aluminum, (d-i-propoxy)monoethylacetoacetate aluminum, bis(ethyl acetoacetato)monoacetylacetonato aluminum and the like; titanium chelate compound such as triethoxy monoacetylacetonato titanium, tri-n-propoxy monoacetylacetonato titanium, tri-i-propoxy monoacetylacetonato titanium, di-i-propoxy bisacetylacetonate titanium, di-i-propoxy bis(ethyl acetoacetato)titanium, tri-n-butoxy monoacetylacetonato titanium, tri-sec-butoxy monoacetylacetonato titanium, tri-t-butoxy monoacetylacetonato titanium, diethoxy bisacetylacetonato titanium, di-n-propoxy bisacetylacetonato titanium, di-i-propoxy bisacetylacetonato titanium, di-n-butoxy bisacetylacetonato titanium, di-sec-butoxy bisacetylacetonato titanium, di-t-butoxy bisacetylacetonato titanium, monoethoxy trisacetylacetonato titanium, mono-n-propoxy trisacetylacetonato titanium, mono-i-propoxy trisacetylacetonato titanium, mono-n-butoxy trisacetylacetonato titanium, mono-sec-butoxy trisacetylacetonato titanium, mono-t-butoxy trisacetylacetonato titanium, tetrakis(acetylacetonato)titanium, triethoxy monoethyl acetoacetato titanium, tri-n-propoxy monoethyl acetoacetato titanium, tri-i-propoxy monoethyl acetoacetato titanium, tri-n-butoxy monoethyl acetoacetato titanium, tri-sec-butoxy monoethyl acetoacetato titanium, tri-t-butoxy monoethyl acetoacetato titanium, diethoxy bisethyl acetoacetato titanium, di-n-propoxy bisethyl acetoacetato titanium, di-i-propoxy bisethyl acetoacetato titanium, di-n-butoxy bisethyl acetoacetato titanium, di-sec-butoxy bisethyl acetoacetato titanium, di-t-butoxy bisethyl acetoacetato titanium, monoethoxy trisethyl acetoacetato titanium, mono-n-propoxy trisethyl acetoacetato titanium, mono-i-propoxy trisethyl acetoacetato titanium, mono-n-butoxy trisethyl acetoacetato titanium, mono-sec-butoxy trisethyl acetoacetato titanium, mono-t-butoxy trisethyl acetoacetato titanium, tetrakisethyl acetoacetato titanium, mono acetylacetonato trisethyl acetoacetate titanium, bisacetylacetonate bisethyl acetoacetato titanium, trisacetylacetonato monoethyl acetoacetate titanium, di-n-propoxy bis(triethanolamine)titanium, di-n-butoxy bis(triethanolamine)titanium, isopropyl tris(dodecylbenzenesulfonyl)titanium, isopropyl tris(dodecylbenzenesulfonyl)titanate, isopropyl tris(dioctyl pyrophosphate)titanate, tetraisopropyl bis(dioctyl phosphate)titanate, tetraoctyl bis(di-tridecyl phosphate)titanate, tetra(2,2-diallyloxymethyl-1-butyl)bis(di-tridecyl)phosphate titanate, bis(dioctyl pyrophosphate)oxyacetate titanate, bis(di-octyl pyrophosphate)ethylene titanate, isopropyl tri(dioctyl phosphate)titanate, isopropyl tri(N-aminoethyl aminoethyl)titanate and the like; zirconium chelate compound such as triethoxy monoacetylacetonato zirconium, tri-n-propoxy monoacetylacetonato zirconium, tri-i-propoxy monoacetylacetonato zirconium, tri-n-butoxy monoacetylacetonato zirconium, tri-sec-butoxy monoacetylacetonato zirconium, tri-t-butoxy monoacetylacetonato zirconium, diethoxy bisacetylacetonato zirconium di-n-propoxy bisacetylacetonato zirconium, di-i-propoxy bisacetylacetonato zirconium, di-n-butoxy bisacetylacetonato zirconium, di-sec-butoxy bisacetylacetonato zirconium, di-t-butoxy bisacetylacetonato zirconium, monoethoxy trisacetylacetonato zirconium, mono-n-propoxy trisacetylacetonato zirconium, mono-i-propoxy tris acetylacetonato zirconium, mono-n-butoxy trisacetylacetonato zirconium, mono-sec-butoxy trisacetylacetonato zirconium, mono-t-butoxy trisacetylacetonato zirconium, tetrakisacetylacetonato zirconium, triethoxy monoethyl acetoacetato zirconium, tri-n-propoxy monoethyl acetoacetato zirconium, tri-i-propoxy monoethyl acetoacetato zirconium, tri-n-butoxy monoethyl acetoacetato zirconium, tri-sec-butoxy monoethyl acetoacetato zirconium, tri-t-butoxy monoethyl acetoacetato zirconium, diethoxy bisethyl acetoacetato zirconium, di-n-propoxy bisethyl acetoacetato zirconium, di-i-propoxy bisethyl acetoacetato zirconium, di-n-butoxy bisethyl acetoacetato zirconium, di-sec-butoxy bisethyl acetoacetato zirconium, di-t-butoxy-bisethyl acetoacetato zirconium, monoethoxy trisethyl acetoacetato zirconium, mono-n-propoxy trisethyl acetoacetato zirconium, mono-i-propoxy trisethyl acetoacetato zirconium, mono-n-butoxy trisethyl acetoacetato zirconium, mono-sec-butoxy trisethyl acetoacetato)zirconium, mono-t-butoxy-trisethyl acetoacetato zirconium, tetrakisethyl acetoacetato zirconium, monoacetylacetonate trisethyl acetoacetato zirconium, bisacetylacetonate bisethyl acetoacetato zirconium, trisacetylacetonato monoethyl acetoacetate zirconium and the like.
Based on the alkali-soluble resin (A) as 100 parts by weight, the amount of the metal chelating agent (F) is 1 to 50 parts by weight, preferably 2 to 45 parts by weight, more preferably 3 to 40 parts by weight.
When the photosensitive resin composition does not comprise the metal chelating agent (F), the adhesiveness between the substrate and the pixel formed by the photosensitive resin composition is worse in the process for fabricating pixels, wherein the process does not comprise a pre-baking step.
As the amount of the metal chelating agent (F) is excess, the developing ability of the photosensitive resin composition is worse. In the situation, the first compound (B-1) is simultaneously added as the compound (B) containing vinyl unsaturated group(s), the first compound (B-1) can dissolve the defect of the developing ability.
Preparation of Photosensitive Resin Composition for Color Filter
In general, the photosensitive resin composition of the present invention is prepared by mixing the aforementioned alkali-soluble resin (A), the compound (B) containing vinyl unsaturated group(s), the photo initiator (C), the organic solvent (D), the pigment (E), and the metal chelating agent (F) in a conventional mixer uniformly until all compositions are formed into a solution state, optionally adding a filling, agent, an antioxidant, a UV-absorption agent, an anti-agglutinating agent, a surfactant and the like thereto if necessary, so as to obtain the photosensitive resin composition.
Forming Method for Pixel Color Layer of Color Filter
The color filter of the present invention comprises a pixel color layer formed by the photosensitive resin composition treated by a photolithography process.
When the pixel color layer is formed, the aforementioned solution state of the photosensitive resin composition can be coated on a substrate by various coating method, for example, spin-coating, cast coating or roll coating and the like. The substrate can include but is not limited to alkali-free glass, NaโCa glass, hard glass (Pyrex glass), a quartz glass or those having an electrically conductive transparent film disposed thereon; a substrate of light-to-electricity conversion (for example, silicone substrate) utilized in solid-camera device and the like. Before the photosensitive resin composition is coated on the substrate, the black matrixes for separating the pixel color layer of red, green, blue and the like have been formed on the substrate.
After coating process, the organic solvent in the coated photosensitive resin composition is removed by drying process under reduced pressure. The drying process under reduced pressure is carried out in various conditions, for example, the drying process under reduced pressure is performed under 0 to 200 mmHg for 1 to 60 seconds, which depend upon the kinds and the mixing ratio of the compounds.
After the drying process under reduced pressure, the coated film is exposed under a mask having specific patterns. The exposure light is preferably UV light such as g-line, h-line, l-line and so on, which may be generated by a UV illumination device such as (super) high-pressure mercury lamp or metal halide lamp.
After exposing process, the coated film is immersed in a developing solution at 23ยฑ2ยฐ C. for 15 seconds to 5 minutes, thereby remove undesired areas and forming a given pattern. The developing solution includes but not limited to alkaline compounds such as sodium hydroxide, potassium hydroxide, sodium carbonate, sodium silicate, sodium methyl silicate, ammonia solution, ethylamine, diethylamine, dimethylethylanolamine, tetramethylammonium hydroxide, tetraethylammonium hydroxide, choline, pyrrole, piperidine, 1,8-diazabicyclo-[5,4,0]-7-undecene and the like. The concentration of the developing solution is 0.001 weight percent (wt %) to 10 wt % preferably 0.005 wt % to 5 wt %, and more preferably 0.01 wt % to 1 wt %.
Thereafter, the patterns on the substrate are washed by water, and then dried by using compressed air or nitrogen gas. Then, the patterns are subjected to a post-bake process with heating device such as a hot plate or an oven. The post-bake process can be carried out at 150ยฐ C. to 250ยฐ C. for 5 to 60 minutes on the hot plate or for 15 to 150 minutes in the oven, thereby curing the patterns and forming a pixel color layer.
The pixel color layers such as red, green, blue and the like can be formed on the substrate by repeating the aforementioned steps.
Method of Producing Color Filter
An ITO protective film is sputtered on the surface of the pixel color layer at 220ยฐ C. to 250ยฐ C. under vacuum environment. The ITO protective film is etched and patterned if necessary, and then an alignment film is applied on the surface of the ITO protective film, so as to produce the color filter of the present invention.
Method of Producing Liquid Crystal Display Device
The liquid crystal display device, for example liquid crystal panel, comprises the aforementioned color filter. A glass substrate which have been inlaid thin film transistor (TFT) and been applied an alignment film is oppositely disposed the aforementioned color filter, and the spacers are disposed between the glass substrate and the color filter. Next, the liquid crystal molecule is injected into the spacer. And then, polarized plates are respectively adhered on the outer surface of the color filter and the glass substrate, so as to produce the liquid crystal display device.
Several embodiments are described below to illustrate the application of the present invention. However, these embodiments are not used for limiting the present invention. For those skilled in the art of the present invention, various variations and modifications can be made without departing from the spirit and scope of the present invention.
DETAILED DESCRIPTION
Preparation of Alkali-Soluble Resin (A)
Hereinafter, the alkali-soluble resin (A) of Synthesis Examples A-1 to A-6 were prepared according to Table 1 as follows.
Synthesis Example A-1
A 1000 mL four-necked conical flask equipped with a nitrogen inlet, a stirrer, a heater, a condenser and a thermometer was purged with nitrogen gas. According to table 1, the kinds and the mixing ratio of the components were prepared to synthesis the alkali-soluble resin (A). The aforementioned components comprised the first unsaturated monomer, the second unsaturated monomer, the third unsaturated monomer, the polymerized initiator and the solvent.
During polymerization is performed, 5 parts by weight of 2-methacryloyloxyethyl succinate monoester (HOMS), 5 parts by weight of dicyclopentenyl acrylate (FA-511A), 40 parts by weight of styrene monomer (SM) and 50 parts by weight of methyl methacrylate (MMA) were firstly added into the four-necked conical flask and stirred to form a solution state. Simultaneously, the oil bath temperature of the four-necked conical flask was elevated to 100ยฐ C. Furthermore, 6 parts by weight of 2,2โฒ-azobis-2-methyl butyronitrile (AMBN) was dissolved in 200 parts by weight of ethyl 3-ethoxypropionate (EEP), and the solution containing AMBN was separated to five equal parts. One of the five parts was added into the four-necked conical flask every one hour. The reaction temperature of the polymerization process was kept 100ยฐ C., and the polymerization time was continued for 6 hrs. After the polymerization process, the polymerized product was taken out, and the solvent was volatilized, so as to produce the alkali-soluble resin (A).
Synthesis Examples A-2 to A-6
Synthesis Examples A-2 to A-6 were synthesized with the same method as in Synthesis Example A-1 by using various kinds or amounts of the reactants for the alkali-soluble resin (A). The formulations of Synthesis Examples A-2 to A-6 were listed in Table 1 rather than focusing or mentioning them in details.
Preparation of Photosensitive Resin Composition for Color Filter
The photosensitive resin compositions of Examples 1 to 7 and Comparative Examples 1 to 4 were prepared according to Table 2 as follows.
Example 1
100 parts by weight of the alkali-soluble resin (A-1), 5 parts by weight of DPCA-120 made by Nippon Kayaku Co., Ltd. (hereinafter abbreviated as B-1-1), 200 parts by weight of Dipentaerythritol hexaacrylate (DPHA; hereinafter abbreviated as B-2-1), 3 parts by weight of 2-methyl-1-(4-methylthiophenyl)-2-morpholino-1-propanone (hereinafter abbreviated as C-1), 5 parts by weight of 2,2โฒ-bis(2,4-dichlorophenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole (hereinafter abbreviated as C-2), 150 parts by weight of C. I. Pigment R254/C. I. Pigment Y139=80/20 (hereinafter abbreviated as E-1), and 1 part by weight of tris(ethyl acetoacetato)aluminum (hereinafter abbreviated as F-1) were added into 1000 parts by weight of Propylene glycol monomethyl ether acetate (hereinafter abbreviated as D-1). The aforementioned components was mixed in a conventional mixer uniformly, so as to produce the photosensitive resin composition for color filter. The resulted photosensitive resin composition was evaluated according to the following evaluation methods, and the result thereof was listed as Table 2. The evaluation methods of the developing ability, heat resistance and the adhesiveness were described as follows.
Examples 2 to 7 and Comparative Examples 1 to 4
Examples 2 to 7 and comparative examples 1 to 4 were practiced with the same method as in Example 1 by using various kinds or amounts of the components for the photosensitive resin composition. The formulations and detection results thereof were listed in Table 2 rather than focusing or mentioning them in details.
Evaluation Methods
1. Developing Ability
The photosensitive resin composition was coated on a glass substrate (100 mmร100 mm) by spin-coating method, and then a drying process under reduced pressure is performed for 30 seconds under 100 mmHg, so as to form a coated film. The thickness of the coated film is 2.5 ฮผm.
Next, 2 wt % of Potassium hydroxide was dropped on the coated film, and the dissolving time t of the coated film was evaluated. The aforementioned time (t) was equal to the developing time, and an evaluation was made according to the following criterion.
โฏ: tโฆ10 seconds.
x: 10 seconds<t.
2. Heat Resistance
The aforementioned coated film (thickness 2.5 ฮผm) of the evaluation method 1 was exposed under 100 mJ/cm 2 (the trade name of the exposing device is Canon PLA-501F). Then, the film was immersed in developing liquid at 23ยฐ C. for 1 min, and washed by water. And then, the film was baked at 235ยฐ C. for 30 minutes, so as to form a pixel color layer on the glass substrate. The thickness of The pixel color layer is 2.0 ฮผm. Next, the chromaticity (L*, a*, b*) of the pixel color layer as measured by the chromaticity meter made by Otsuka Electronics Co., LTD. (the trade name is MPCD). Thereafter, the film was baked at 250ยฐ C. for 60 minutes, and the chromaticity was measured again. A chromaticity difference (ฮEab*) was calculated according to the following formula (VII), and an evaluation was made according to the following criterion.
ฮ Eab *=[(ฮ L ) 2 +(ฮ a ) 2 +(ฮ b ) 2 ] 1/2 โโ(VII)
โฏ: ฮEab*<3.
ฮ: 3โฆฮEab*<6.
x: 6โฆฮEab*.
3. Adhesiveness
The aforementioned coated film (thickness 2.5 ฮผm) of the evaluation method 1 was exposed under 100 mJ/cm 2 (the trade name of the exposing device is Canon PLA-501F). Then, the film was immersed in developing liquid at 23ยฐ C. for 1 min, and washed by water. And then, the film was baked at 235ยฐ C. for 30 minutes, so as to form a pixel color layer on the glass substrate. The thickness of the pixel color layer was 2.0 ฮผm.
Next, according to the adhesiveness testing method, JIS.5400(1900)8.5, the pixel color layer was cut to 100 grid patterns by a knife. Next, the grid patterns were adhered by a tape, and then the tape was removed. An evaluation was made according to the residual grid patterns and the following criterion.
โฏ: 5B to 4B, and
x: 3B to 0B,
wherein, 5B: the grid patterns do not fall.
4B: 0%<the amount of the fallen grid patternsโฆ5%. 3B: 5%<the amount of the fallen grid patternsโฆ0.15%. 2B: 15%<the amount of the fallen grid patternsโฆ35% 1B: 35%<the amount of the fallen grid patternsโฆ65%. 0B: 65%<the amount of the fallen grid patternsโฆ100%.
The evaluation results of the developing ability, heat resistance, and the adhesiveness of the above Examples and Comparative Examples were shown in Table 2.
According to Table 2, in the method of producing pixels with the omission of the pre-bake process, when the photosensitive resin composition comprised the metal chelating agent (F), the color filter had a better adhesiveness with the substrate. Moreover, when the polymerized monomer of the alkali-soluble resin (A) comprised the first unsaturated monomer (a-1), the developing ability of the color filter was improved. When the polymerized monomer of the alkali-soluble resin (A) comprised the second unsaturated monomer (a-2), the color filter was provided with a better heat resistance, so as to achieve the purpose of the invention.
It should be supplemented that, although specific compounds, components, specific reactive conditions, specific processes, specific evaluation methods or specific equipments are employed as exemplary embodiments of the present invention, for illustrating the photosensitive resin composition and the application of the same of the present invention. However, as is understood by a person skilled in the art instead of limiting to the aforementioned examples, the photosensitive resin composition and the application of the same of the present invention also can be manufactured by using other compounds, components, reactive conditions, processes, analysis methods and equipment without departing from the spirit and scope of the present invention.
As is understood by a person skilled in the art, the foregoing preferred embodiments of the present invention are illustrated of the present invention rather than limiting of the present invention. In view of the foregoing, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims. Therefore, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structure.
TABLE 1
Composition (Parts by Weight)
Monomer for Polymerization
Synthesis
(a-1)
(a-2)
(a-3)
Initiator
Solvent
Example
HOMS
MAA
AA
FA-511A
FA-512A
FA-512M
FA-513M
SM
BzMA
MMA
AA
AMBN
EEP
A-1
5
5
40
50
6
200
A-2
15
10
20
55
6
200
A-3
25
15
20
40
6
200
A-4
30
5
10
10
45
6
200
A-5
20
20
โ1
20
39
6
200
A-6
50
20
30
6
200
HOMS 2-methacryloyloxyethyl succinate monoester
MAA methacrylic acid
AA acrylic acid
FA-511A dicyclopentenyl acrylate
FA-512A dicyclopentenyloxyethyl acrylate
FA-512M dicyclopentenyloxyethyl methacrylate
FA-513M dicyclopentenyl methacrylate
SM styrene monomer
BzMA benzyl methacrylate
MMA methyl methacrylate
MA methacrylate
AMBN2,2โฒ-azobis-2-methyl butyronitrile
EEP ethyl 3-ethoxypropionate
TABLE 2
Example
Comparative Example
Composition (Parts by Weight)
1
2
3
4
5
6
7
1
2
3
4
Alkali-soluble
A-1
100
50
100
Resin
A-2
100
50
100
A-3
100
100
A-4
100
A-5
100
A-6
100
100
Compound
First
B-1-1
5
40
100
100
Containing
Compound
B-1-2
20
40
100
20
Vinyl
B-1-3
40
Unsaturated
B-1-4
60
Group(s)
Second
B-2-1
200
100
200
Compound
B-2-2
150
150
B-2-3
100
100
Photo
C-1
3
3
10
5
8
3
3
3
3
10
3
Initiator
C-2
5
8
5
5
5
5
C-3
5
10
7
7
5
7
C-4
4
4
Solvent
D-1
1000
2000
1000
1000
2000
1000
2000
2000
D-2
2000
500
1000
3000
2000
Pigment
E-1
150
100
300
150
E-2
200
200
200
E-3
250
200
250
200
Metal
F-1
1
5
20
25
Chelating
F-2
10
20
Compound
F-3
20
F-4
30
F-5
50
Evaluation
Developing Ability
โฏ
โฏ
โฏ
โฏ
โฏ
โฏ
โฏ
X
โฏ
X
โฏ
Method
Heat Resistance
โฏ
โฏ
โฏ
โฏ
โฏ
ฮ
โฏ
โฏ
โฏ
โฏ
ฮ
Adhesiveness
โฏ
โฏ
โฏ
โฏ
โฏ
โฏ
โฏ
โฏ
X
X
X
B-1-1 DPCA-120 (made by Nippon Kayaku Co., Ltd.) caprolactone modified dipentaerythrite hexaacrylate
B-1-2 DPCA-60 (made by Nippon Kayaku Co., Ltd.) caprolactone modified dipentaerythrite hexaacrylate
B-1-3 DPCA-30 (made by Nippon Kayaku Co., Ltd.) caprolactone modified dipentaerythrite hexaacrylate
B-1-4 DPCA-20 (made by Nippon Kayaku Co., Ltd.) caprolactone modified dipentaerythrite hexaacrylate
B-2-1 DPHA dipentaerythrite hexaacrylate
B-2-2 TO-1382 (made by Toagosei Co., Ltd.) dipentaerythrite pentaacrylate
B-2-3 DPEA-12 (made by Nippon Kayaku Co., Ltd.) EO modified dipentaerythrite hexaacrylate
C-1 2-methyl-1-(4-methylthio phenyl)-2-morpholino-1-propanone
C-2 2,2โฒ-bis(2,4-dichlorophenyl)-4,4โฒ,5,5โฒ-tetraphenyl-biimidazole
C-3 4,4โฒ-bis(diethylamino)benzophenone
C-4 1-[4-(benzoyl)phenyl]-heptane-1,2-dione 2-(O-benzoyloxime)
D-1 propylene glycol monomethylether acetate
D-2 ethyl 3-ethoxypropionate
E-1 C.I. Pigment R254/C.I. Pigment Y139 = 80/20
E-2 C.I. Pigment G36/C.I. Pigment Y150 = 60/40
E-3 C.I. Pigment B15:6
F-1 tris(ethyl acetoacetato) aluminum
F-2 di-i-propoxy bisacetylacetonato zirconium
F-3 di-n-butoxy bis(triethanolamine) titanium
F-4 isopropyl tris(dodecylbenzenesulfonyl) titanium
F-5 tetraisopropyl bis(dioctyl phosphate) titanate
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A photosensitive resin composition and application of the same are provided. The photosensitive resin composition comprises an alkali-soluble resin (A), a compound (B) containing vinyl unsaturated group(s), a photo initiator (C), an organic solvent (D), a pigment (E) and a metal chelating agent (F). During a pixel process with an omission of a prebake step, the photosensitive resin composition, which is added with the metal chelating agent (F), can be formed to pixels that is adhered tightly to a substrate.
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TECHNICAL FIELD
[0001] The present invention relates to the field of gaseous breath detection systems, and methods for using the same, and more particularly, to the field of portable personal gaseous breath detection apparatus and methods for using same.
BACKGROUND OF THE INVENTION
[0002] There are several methods for determining the alcohol content (or level) of a person's breath. A common method is to use a tin-oxide semiconductor alcohol sensor. It has the advantage of low cost at the expense of accuracy, alcohol specificity, and electrical power consumption. Another method is to employ the use of an electrochemical fuel cell alcohol sensor. While this type of sensor tends to be more accurate, more alcohol specific, and utilizes less electrical power, the sensor itself is significantly more expensive and has traditionally required the use of an active sampling mechanism such as a pump. The pump adds cost and size to the device, and utilizes electrical power. Both methods also typically require the use of a pressure sensor to determine when the user is blowing into the device.
[0003] Accordingly, it is desirable to have a breath detection apparatus that utilizes an electrochemical fuel cell alcohol sensor for accuracy, alcohol specificity, and low power consumption, and eliminates the need for a sampling mechanism, saving more in cost, power consumption, and size. Furthermore, it is desirable to have such breath detection apparatus with the traditional pressure sensor eliminated in favor of a configuration that utilizes a temperature sensor as a flow sensor, thus saving in the size and cost of the device.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is an object of the present invention to provide an improved breath alcohol tester. In particular, it is a benefit of the present invention to provide a breath alcohol tester that combines low cost, small size, low power consumption, and alcohol specificity.
[0005] One embodiment of the present invention comprises an apparatus for detecting gaseous component levels in breath. The apparatus comprises: a breath channel; an electrochemical sensor in fluid communication with the breath channel; a processor in electrical communication with the electrochemical sensor; and computer readable storage medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; wherein the apparatus is configured to calculate approximate gaseous components levels in a breath without utilizing a sampling pump.
[0006] Another embodiment of the present invention comprises a breath detection apparatus for detecting gaseous component levels in breath. The apparatus comprises: a gas sensor; a processor in electrical communication with the gas sensor; and a computer readable storage medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; and a wireless transmitter; wherein the wireless transmitter transmits a signal to an external receiver.
[0007] Yet another embodiment of the present invention comprises an apparatus for detecting gaseous component levels in breath. The apparatus comprises: a breath channel; a gas sensor in fluid communication with the breath channel; a processor in electrical communication with the gas sensor; computer readable storage medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; and temperature sensor in fluid communication with the breath channel; wherein the temperature sensor is utilized to determine breath flow rate.
[0008] Still another embodiment of the present invention comprises a method for detecting gaseous component levels in breath, The method comprises: obtaining an initial signal from a temperature sensor; monitoring the temperature sensor for a temperature change; calculating airflow rate utilizing the temperature sensor signal; and calculating gaseous component levels in breath utilizing airflow rate.
[0009] Yet another embodiment of the present invention comprises a method for detecting gaseous component levels in breath. The method comprises: receiving a breath stream in a breath channel; obtaining a signal from an electrochemical sensor; and calculating a gaseous component level in breath utilizing the electrochemical sensor.
[0010] One embodiment of the present invention comprises an apparatus for detecting gaseous component levels in breath. The apparatus comprises: a breath passage having a flowpath, a proximal end and a distal end, wherein the proximal end comprises an inlet for accepting a person's breath and the distal end comprises an outlet for venting the breath; a temperature sensor in fluid communication with the flowpath; an electrochemical sensor in fluid communication with the flowpath; a processor in electrical communication with the temperature sensor and the electrochemical sensor; and a computer readable storage medium in electrical communication with the processor, wherein the computer readable medium contains executable instructions for the processor; wherein the apparatus is configured to approximate gaseous component level in the breath without utilizing a sampling pump.
[0011] Another embodiment of the present invention comprises an apparatus for detecting gaseous component level in breath. The apparatus comprises: a breath channel; a gas sensor in fluid communication with the breath channel; a processor in electrical communication with the gas sensor; a computer readable storage medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; and wherein the apparatus is configured to approximate gaseous component level in a breath without utilizing a sampling pump; and further wherein the apparatus is configured to cease functioning at a pre-determined time.
[0012] Yet another embodiment of the present invention comprises an apparatus for detecting gaseous component level in breath. The apparatus comprises: a breath channel; a gas sensor in fluid communication with the breath channel; a processor in electrical communication with the gas sensor; a computer readable storage medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; and wherein the apparatus is configured to approximate gaseous component level in a breath without utilizing a sampling pump; and further wherein the apparatus is configured to cease functioning outside a pre-determined temperature range.
[0013] One embodiment of the present invention comprises an ignition interlock system. The system comprises: the breath detection apparatus and a wireless receiver; a computing device in electrical communication with the wireless receiver; a computer readable storage medium in electrical communication with the computing device, wherein the computer readable medium contains executable instructions for the computing device; a switch in electrical communication with the computing device and ignition control line of a vehicle; wherein the wireless receiver is configured to receive signals from the breath detection apparatus.
[0014] Yet another embodiment of the present invention comprises an identification system for a breath detection interlock system. The system comprises: a wireless transmitter and receiver; a processor in electrical communication with the transmitter and receiver; a computer readable medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; and wherein the executable instruction comprise instructions to maintain a continuous signal between the transmitter and receiver.
[0015] Still another embodiment of the present invention comprises an identification method for a breath detection system. The method comprises: confirming a user's identity; maintaining a continuous signal between the transmitter and receiver after the identity has been confirmed; and if the signal between the transmitter and receiver is not continuous, aborting the breath detection system and restart the system.
[0016] Another embodiment of the present invention comprises an identification system for a breath detection interlock system. The system comprises: a passive infrared detector; a processor in electrical communication with the detector; a computer readable medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; and wherein the executable instruction comprise instructions to monitor infrared signals utilizing the passive infrared detector.
[0017] Yet another embodiment of the present invention is an identification method for a breath detection system. The method comprises: confirming a user's identity; maintaining a continuous signal between the user and the passive infrared detector; and if the signal received by the passive infrared detector is not continuous, aborting the breath detection system and restart the system.
[0018] Another embodiment of the present invention is an identification system for a breath detection interlock system. The system comprises: a motion sensor; a processor in electrical communication with the motion sensor; a computer readable medium in electrical communication with the processor, wherein the computer readable storage medium contains executable instructions for the processor; and wherein the executable instruction comprise instructions to monitor the movement of the motion sensor.
[0019] Still yet another embodiment of the present invention is an identification method for a breath detection system. The method comprises: confirming a user's identity; monitoring a motion sensor output; and if the signal received by the motion sensor exceeds a pre-determined threshold, abort the breath detection system and restart the system.
[0020] Another embodiment of the present invention is an identification method for a breath detection system. The method comprises: confirming a user's identity; and initiating a countdown timer executable instructions, wherein if a breath test has not been initiated by the lapse of the count down timer, abort the breath detection system and restart the system.
[0021] In one aspect of the present invention, when the user blows into the device, a temperature sensor which is connected to a controller and is situated in the breath channel portion of the device detects that the user is blowing and at what flow rate. The breath channel is also directly connected to a electrochemical fuel cell ethanol sensor that gives an electrical output when it is exposed to ethanol in the breath. The positioning of the ethanol sensor directly in the breath channel eliminates the need for a mechanical sampling system. The ambient temperature of the device is determined by the controller from the breath temperature sensor before the user starts blowing. After the user has stopped blowing, an algorithm contained within the controller can calculate the user's breath alcohol content by taking into account the flow rate, the length of time the user was blowing, and the temperature of the ethanol sensor.
[0022] In another aspect of the present invention, one or more safety mechanisms, prevent the device from giving an erroneous reading. The controller can shut down the device to prevent the user from taking a test if the ambient temperature is outside of a range within which the ethanol sensor can give an accurate reading. The controller can also shut down the device if the length of time that has expired since the device was constructed and calibrated is such that the output of the ethanol sensor has drifted and will no longer give an accurate reading.
[0023] In another aspect of the present invention, the system further includes a breath alcohol ignition interlock device. In this embodiment, a wireless transmitter is incorporated into the controller circuit. A physically separate controller which contains a wireless receiver is installed in the vehicle and attached to the vehicle's ignition circuit. After the user takes a breath test, the transmitter sends a signal to the receiver in the controller in the vehicle, which allows the vehicle to start if the breath alcohol level is below a predetermined level, and not allowing the vehicle to start otherwise.
[0024] The present invention also provides a method for using the breath tester as an ignition interlock for the consumer market. A separate wireless transmitter is used that allows the supervising agent (whether it be the parent, spouse, etc.) to enable the vehicle's ignition without having to take a breath test. This transmitter also allows the supervising agent to program the device with various options.
[0025] Another aspect of the present invention provides an ignition interlock for the court-mandated market. A voice recognition circuit is employed in the breath tester that requires the user to speak one or more words into the device before taking the breath test. If the controller in the device matches the spoken words to those that were previously stored in the device when it was trained by the intended user during installation, then a subsequent breath test will be allowed. If the words are not matched, then a breath test is not allowed. To insure that the device cannot be passed to another individual after the words are spoken by the intended user, several methods may be employed: allowing a short interval of time between the spoken words and the breath test; using a transmitter and receiver combination that bounces energy off the user's face and detects when the transmitted beam is interrupted; using a motion sensor that detects if the device is moved quickly; using an infrared heat sensor that detects a change in sensed body heat.
[0026] Still other objects and advantages of the present invention will become apparent to those skilled in this art from the following description wherein there is shown and described exemplary embodiments of this invention, including a best mode currently contemplated for the invention, simply for purposes of illustration. As will be realized, the invention is capable of other different aspects and embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood from the following description taken in conjunction with the accompanying drawings in which:
[0028] [0028]FIG. 1 is an operational block diagram of a breath alcohol tester apparatus in accordance with the present invention;
[0029] [0029]FIG. 2 is an operational block diagram of an interlock ignition system in accordance with the present invention;
[0030] [0030]FIG. 3 is an operational block diagram of a wireless master transmitter in accordance with the present invention;
[0031] [0031]FIG. 4 is a flowchart depicting an exemplary embodiment of the method of detecting breath alcohol levels;
[0032] [0032]FIG. 5 is a flowchart depicting and exemplary embodiment of voice verification method in accordance with the present invention; and
[0033] [0033]FIG. 6 is a flowchart depicting an exemplary embodiment of another method in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Reference will now be made in detail to the present exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like numerals indicate the same elements throughout the views.
[0035] Referring to FIG. 1, the personal breath tester 200 comprises a breath passage 1 having a flowpath 120 , a proximal end 100 and a distal end 102 , wherein the proximal end 100 comprises an inlet 105 for accepting a person's breath and the distal end 102 comprises an outlet 110 for venting the breath. A temperature sensor 2 is in fluid communication with the flowpath 120 of the breath passage 1 . In addition, an alcohol sensor 3 is in fluid communication with the flowpath 120 of the breath passage 1 . In an exemplary embodiment, the temperature sensor 2 and/or alcohol sensor 3 are physically contained within the flowpath 120 of the breath passage 1 . Since the alcohol sensor 3 is in fluid communication with the flowpath 120 , the need for a mechanical pump or sampling system is eliminated.
[0036] In one exemplary embodiment, the temperature sensor 2 comprises a thermistor sensor and the alcohol sensor 3 comprises an electrochemical fuel cell with an ethanol sensor. The temperature sensor 2 is in electrical communication with two resistors 13 and 14 . The resistor 14 is in electrical communication with an electrical switch 15 , which in turn is in electrical communication with a computing device 4 . The temperature sensor 2 is also in electrical communication to an amplifier 10 for generating a signal representative of flow rate. The output signal of the flow amplifier 10 is in electrical communication with the analog-to-digital converter 16 , which converts the output signal into a digital number that can be interpreted by the computing device 4 , such as a microprocessor.
[0037] The alcohol sensor 3 is in electrical communication with an amplifier 11 . The output signal of the amplifier is in electrical communication with the analog-to-digital converter 16 , which converts the output signal into a digital number. The output signal of the analog-to-digital converter is connected to the computing device 4 .
[0038] A display 5 , which in one exemplary embodiment comprises an alphanumeric display, is driven by a display driver circuit, 18 . The display driver circuit 18 is in electrical communication and is controlled by the computing device 4 . In another exemplary embodiment, the present invention further comprises a speaker 7 , which is controlled by an amplifier 17 , wherein the amplifier is controlled by the computing device 4 . A momentary switch 6 and a communication channel 8 are in electrical communication with the computing device 4 .
[0039] In one exemplary embodiment of the present invention depicted by FIG. 4, a breath test is initiated when a person depresses the switch 6 (step 305 ) of the personal breath tester 200 . When the computing device 4 determines that the switch 6 has been depressed, the computing device 4 obtains the initial temperature of the temperature sensor 2 by opening the switch 15 , converting the temperature sensor 2 output signal into a digital number with the analog-to-digital converter 16 , and recording that number as the starting value of the temperature sensor 2 (step 310 ). If the recorded starting value of the temperature sensor 2 is less than 32ยฐ C. or greater than 36ยฐ C., the switch 15 is left open and the personal breath tester 200 is ready to begin testing breath samples. If the recorded starting value is equal to or more than 32ยฐ C. and less than or equal to 36ยฐ C. (step 315 ), then switch 15 is turned on (closes circuit) by the computing device 4 (step 320 ) to increase the temperature level to that greater than expected human breath (i.e. 34ยฐ C.).
[0040] When switch 15 is turned on, the resistor 14 is placed in electrical communication with the temperature sensor 2 , causing a significant increase in current to flow through the temperature sensor 2 . After a short amount of time, this causes heating of the temperature sensor 2 , and the internal temperature will rise significantly above 34ยฐ C.
[0041] Once a suitable initial temperature has been obtained (i.e. less than 32ยฐ C. or greater than 36ยฐ C.), whether switch 15 is on or off, a person blows into the breath passage 1 of the personal breath detector 200 . The temperature of the person's breath is typically 34ยฐ C. The stream of air blown into the breath passage will cause the temperature of the temperature sensor 2 to change.
[0042] If the initial temperature of the temperature sensor 2 immediately before blowing is below 32ยฐ C., then the temperature will rise with blowing. Similarly, if the initial temperature of the temperature sensor 2 is above 36ยฐ C., then the temperature will fall with blowing.
[0043] This change in temperature is amplified by the flow amplifier 10 , converted into a digital signal by the analog-to-digital converter 16 , and then sent to the computing device 4 . The change in temperature is an indication that the user is blowing, and the rate at which this temperature change occurs is an indication of the flow rate (step 325 ). A quick change in temperature indicates a higher flow rate than a slow change in temperature. Once the computing device 4 detects that the user is blowing, it converts the alcohol sensor amplifier 11 output into a digital number by way of the analog-to-digital converter 16 , and records that number as the baseline value of the alcohol sensor 3 (step 328 ). In an exemplary embodiment, the baseline value is stored in a computer readable memory unit 160 .
[0044] The computing device 4 calculates the flow rate (step 330 ) and compares it to a minimum flow threshold value, which is stored in the computing device or computer readable memory unit 160 . If the flow rate is higher than the minimum (step 335 ), then the computing device 4 starts an internal flow timer (step 345 ). Once the person stops blowing air into the breath passage and/or the air flow rate drops below the minimum threshold value (step 350 ), then the computing device 4 records the flow timer value as an indication of how long the person was blowing air into the breath passage at an acceptable rate (i.e. above minimum threshold value) (step 355 ). If the recorded flow timer value is less than a minimum timer threshold value (step 360 ), stored in the computing device, then the computing device 4 aborts the breath test (step 370 ), and sends a visual abort indication to the user. In one exemplary embodiment, the abort indication is a visual indication on the personal breath tester (i.e., such as a display 5 ). In another exemplary embodiment, the abort indicator is an audible signal through a speaker 7 (step 375 ). If the recorded flow timer value is less than the minimum timer threshold another breath test must be initiated by the person. The minimum flow rate and flow timer threshold values exist to insure that the person taking the test is providing a minimum volume of deep-lung (alveolar) air into the device.
[0045] As long as the minimum flow rate and flow timer threshold values are exceeded, the computing device 4 calculates the blood alcohol level (step 380 ). In one exemplary embodiment, the fuel cell alcohol sensor sends a signal to the amplifier 11 . The amplifier 11 sends an amplified signal to the analog/digital converter 16 . The analog/digital converter 16 sends the digital signal to the computing device 4 . The computing device 4 retrieves from a computer readable memory storage unit 160 , the previously recorded baseline value for the alcohol sensor. The computing device 4 then calculates an equivalent breath alcohol level using an algorithm incorporating the baseline value, the flow rate, the length of time blowing, the temperature of temperature sensor 2 and a calibration factor accounting for variations in output from sensor to sensor. The breath alcohol level is then indicated on the display 5 as a digital number (step 385 ), along with an audible indication on speaker 7 that the test is completed.
[0046] If the embodiment includes an ignition interlock device, the computing devices would then transmit the level and/or a signal to the ignition interlock system (step 390 ).
[0047] [0047]FIG. 2 depicts an exemplary ignition interlock system. The ignition interlock system 65 is located in the vehicle, and contains a computing device 20 , a wireless receiver 19 , and a relay 21 that controls the vehicle's ignition circuit 22 . When the receiver 19 receives the breath alcohol level from the personal breath tester 200 , the computing device 20 compares the breath alcohol level to a stored predetermined level. If the received level is below the predetermined level, the relay 21 is engaged by the computing device 20 , allowing the ignition control line 22 to enable starting of the vehicle. If the received level is at or above the predetermined level, then the relay is not engaged and the vehicle will not start.
[0048] In another exemplary embodiment depicted in FIG. 5, the personal breath tester is used as an ignition interlock device for a court-mandated market. When the user depresses switch 6 (step 500 ), the computing device 4 will send instructions to the voice identification circuit 23 that it should listen for a word spoken by the user (step 505 ). The computing device 4 will also give an indication to the user via the display 5 and the speaker 7 that the user is to hold the device in close proximity to his or her lips and say the word that the circuit has been trained for. After the user says the word, the voice identification circuit 23 will send a signal to the computing device 4 that either confirms or denies the correct identity of the user (step 510 ). If the correct identity is denied, then the computing device 4 will give such an indication to the user via the display 5 and the speaker 7 (step 515 ), and will then power down (step 516 ). If the correct identity is confirmed, then the computing device 4 will start an internal count down timer (step 520 ). If the timer expires before the user starts blowing into the device, then the computing device will indicate an abort situation to the user via the display 5 and the speaker 7 , and then power down (step 525 ). The starting timer value is set short enough as to not allow the user to speak the verifying word and then pass the device to another person for the breath test. As alternate methods, if the correct identity is confirmed, then the computing device 4 will look for: 1) an interruption of the received infrared signal as indicated by the infrared transmitter/receiver circuit 24 before blowing has started; 2) an interruption of the received infrared energy from the passive infrared detector circuit 25 before blowing has started; or 3) the indication of excessive motion as indicated by the motion detector 26 before blowing has started. If there is no abort indication from the appropriate method indicating that the device is being passed to another person, then the breath test will proceed as described above (step 530 ).
[0049] In yet another embodiment of the present invention, the personal breath tester is to be used as an interlock device for the consumer market. FIG. 3 depicts a master transmitter device 60 utilized in the present embodiment which overrides the ignition interlock system 65 . It consists of a computing device 27 connected to a wireless transmitter 28 and also to switch 29 and switch 35 . When the user presses on the switch 29 , the computing device 28 sends a bypass code to the transmitter 28 . The ignition interlock system 65 of FIG. 2, which is mounted in the vehicle, receives the bypass code by way of the wireless receiver 19 . When the computing device 20 detects the bypass code, it turns on relay 21 to enable the ignition and to allow starting of the vehicle. The bypass code also puts the computing device 20 into a state wherein it will recognize the activation of any number of switches 30 attached to the computing device. The switches 30 represent programming options, such as whether or not a breath test will be required of the user while the vehicle is running. In this manner, the supervisor can program various options into the interlock that the normal user cannot access. In one embodiment of the present invention, the consumer interlock may record a violation, meaning that a breath test was not taken and passed when requested either before starting the vehicle or after the vehicle was running. If this occurs, the violation will be recorded. Pressing switch 35 on the master transmitter will reset the violation.
[0050] An exemplary method of programming the consumer ignition interlock system 65 is depicted in FIG. 6. The computing device 20 continuously monitors the wireless receiver 19 to determine if any data has been received (step 600 ). If data is received, the computing device 20 determines whether the data is blood alcohol content results (step 610 ). If the data is blood alcohol content results, the computing device 20 determines whether the results exceed the threshold (step 620 ). If the results are less than the threshold, the relay 21 is engaged allowing the vehicle to be started (step 625 ). If the results exceed the threshold, the relay remains โoffโ preventing the vehicle from being started (step 630 ).
[0051] If the data received does not contain blood alcohol content results (step 650 ), the computing device 20 determines whether the data contains a bypass code (step 660 ). If the data does not contain a bypass code, the computing device 20 clears the data and returns to continuously monitoring the wireless receiver 19 (step 670 ).
[0052] If the data received does contain a bypass code, the relay 21 is engaged (step 680 ). In a further embodiment of the present invention, the switch 30 of the ignition interlock system 65 can be utilized to reconfigure the program options of the ignition interlock system 65 (step 690 ).
[0053] One skilled in the art will appreciate the various components of the personal breath tester may be obtained from a multitude of sources known to those skilled in the art. For example, ethanol fuel cell sensors may be obtained from Guth Laboratories of Harrisburg, Pa. and from Draeger Safety of Houston, Tex. Typical microprocessors that may be utilized in the present invention may be obtained from Texas Instruments of Dallas, Tex. and NEC of Santa Clara, Calif. Temperature sensors utilized in the present invention may be obtained from NIC of Melville, N.Y. and Murata of Smyrna, Ga. Typical wireless transmitters/receivers which may be utilized in the present invention may be obtained from Atmel of Heilbronn, Germany and RF Microdevices of Greensboro, N.C. Voice identification circuitry may be obtained from Sensory Circuits of Santa Clara, Calif.
[0054] The foregoing description of the exemplary embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive nor to limit the inventor to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
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Apparatus for detecting blood alcohol level in breath. Apparatus has a breath channel; and electrochemical fuel cell in communication with the breath channel; a temperature sensor in communication with the breath channel; a processor in communication with the temperature sensor and electrochemical fuel cell; and a computer readable storage medium containing executable instructions for the processor.
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BACKGROUND OF THE INVENTION
Steering gears for boats, usually consisting of an oil pressure operated pump activated by the steering wheel are well known; this steering wheel controls, through its own valve set, all oil pressure operated double acting cylinder, axially acting by its mobile shaft on the direction of the engine or rudder of the boat.
SUMMARY OF THE INVENTION
The valve set of this oil pressure operated pump features essentially two, so-called non-return valves which also control the fluid supply and discharge in the two cylinder chambers features, two relief-valves of the maximum pressure and several channels connecting these valves to the pumping pistons, to the pump tank and to the chambers of the cylinder controlling the direction of the engine and of the rudder of the boat.
This invention specifically concerns the valve set which, in known steering gears, consists of one single machined metal housing in which the lodgment of these valves and the necessary channels form a geometrically complex arrangement with very close tolerances and their machining requires the utilization of numerically controlled multi-axis tooling machines involving very expensive equipments and long working hours.
This invention has the aim to obtain the valve set of the oil pressure operated pump for marine steering gears in a faster and much cheaper way.
According to this invention, the valve set consists of three separate elements which can be easily assembled by suitable junction means, for example by bolts. These three elements are:
the valve housing mounted under the pump, the cover closing the lower end of the valve housing, the valve set lodged in the valve housing.
According to this invention, the valve housing and lower closing cover are obtained by pressure die-casting, preferably in aluminium alloy or zinc alloy or injection moulded in thermoplastic material.
These pressure die-casting or pressure moulded valve housings and lower cover are complete with all their necessary channels and holes for bolt-assembly. Threading of these holes through which to pass the bolts is the only one operation required.
The third element, i.e. the valve set, consists of a set of components lodged in a preferably parallelepiped shaped housing with square section and central through hole. This housing features necessary channels machined on a lathe with motor-driven X-Y-Z tools at a much lower cost than required for machining at the above mentioned job centers.
This solution according to the invention, not only permits to cut the production costs, as already explained before, but also facilitates maintenance of the non-return valves which can be easily replaced, whereas the known valve sets require cumbersome disassembly of its various components with the risk to cause damage to the valve packing.
Furthermore, according to this invention, the pump shaft on which the steering wheel of the boat is keyed, is provided with an easily replaceable seal kept in place on this shaft by a special shaped snug fitting cap to prevent the penetration of dust or water as normally happens with known gaskets. This shaft seal also protects the pump better from being damaged.
BRIEF DESCRIPTION OF THE DRAWINGS
The oil pressure operated pump, according to this invention, is illustrated for exemplification purpose in the enclosed drawings in which:
FIG. 1 shows a top view of the valve housing,
FIG. 2 shows a view from below of the valve housing illustrated in FIG. 1 ,
FIG. 3 shows a section of the valve housing according to 3 โ 3 in FIG. 1 ,
FIG. 4 shows a section of the valve housing according to 4 โ 4 in FIG. 1 ,
FIG. 5 shows a section of the valve housing according to 5 โ 5 in FIG. 1 ,
FIG. 6 shows a top view of the cover closing the lower end of the valve housing,
FIG. 7 shows a view from below of the bottom cover in FIG. 6 ,
FIG. 8 shows the section of the bottom cover according to 8 โ 8 in FIG. 6 ,
FIG. 9 shows the section of the bottom cover according to 9 โ 9 in FIG. 6 ,
FIG. 10 shows the section of the bottom cover according to 10 โ 10 in FIG. 6 ,
FIG. 11 shows the central longitudinal section of the tubular shell of the set of non-return valves,
FIG. 12 shows a lateral top view of the tubular shell of the non-return valve set illustrated in FIG. 11 ,
FIG. 13 shows the longitudinal central section of the mobile piston axially controlling the non-return valves,
FIG. 14 shows the central cross section according to 14 โ 14 in FIG. 12 of the tubular shell of the non-return valve set,
FIG. 15 shows the central longitudinal section according to 15 โ 15 in FIG. 12 of the non-return valve set,
FIG. 16 shows the central vertical section of the bottom flange of the oil pressure operated pump,
FIG. 17 shows a top view of the, cap blocking the seal on the control shaft of the steering wheel,
FIG. 18 shows the central vertical section of the cap illustrated in FIG. 17 ,
FIG. 19 shows the central vertical section of the oil pressure pump assembly with the relevant valve set and seal on the steering wheel shaft according to this invention.
DETAILED DESCRIPTION
With reference to the FIGS. 1 thru 5 , 1 shows the valve housing obtained by pressure die-casting, preferable in aluminium alloy or zinc alloy or injection moulded with thermoplastic material. The valve housing features oil its upper surface, two small valves 2 respectively lodged in a recess 3 and each fitted with a tab 4 housing the valve spring. These small valves 2 are located rather peripherally so that they can be connected to the oil tank 5 and they are used to fill the pump with the oil before its utilization and for later topping tip of the pump. The said recesses 3 permit axial shifting of the ducts 6 communicating with the valve set 7 towards the centre of the valve housing 1 ; these ducts 6 being the suction and compression lines of the oil pump 8 , as will be explained hereinafter. Two relief valves 9 are also lodged in the valve housing 1 , which relief valves 9 are connected by small channels 10 , 35 and branch pipes 11 to the oil pressure operated cylinder chambers as will be explained hereinafter.
The valve housing 1 also features a boring 12 for pressure compensation and balancing of the valve set 7 , debouching, through radial recessing 13 of the offset borings, into the pipe 14 connected to the pump tank 5 . This branch pipe 14 has also the function, together with a similar pipe 15 , if provided, to install two or more oil pressure operated pumps complete with steering wheels located in different parts of the ship.
The top view of the valve housing 1 shows suitably threaded holes 16 to secure the housing 1 by bolting it to the bottom of the pump 8 , while the view from below of the valve housing 1 shows threaded holes 17 for fastening the housing by bolting it to the lower cover 18 closing the valve set.
The upper surface of the valve housing 1 also features a dowel 19 for its centering with the lower surface of the pump 8 during assembly, while three blank holes 20 , in which to insert the centering dowels 21 for assembly of the lower cover 18 , are bored in the outer bottom surface of the valve housing.
A preferably rectangular shaped recess 22 is machined inside the valve housing 1 in which to lodge oiltight the valve set 7 which should also preferably be rectangular shaped.
Internally, the valve housing 1 also features some zones 23 to lighten the structure.
In the FIGS. 11 thru 15 , the valve set 7 acts as non-return, supply and discharge valve of the two oil pressure operated cylinder chambers. This valve set 7 features a preferably parallelepiped square section shell 24 with a tubular internal shape 25 in which two ball valves 26 are lodged fitted with the relative thrust/spring and relative seat. Furthermore, a mobile plunger 27 provided with end shanks 28 resting on the balls 26 acting as valves are also mounted in the tubular shell 24 . The valves 26 and the relative plunger 27 are acting as non return valves to prevent the fluid from flowing to or from the cylinder chambers when the steering wheel is in rest position and to let the fluid flow to and from the cylinder chambers when the steering wheel is actuated, as will be explained hereinafter.
The delivery or return flow of the pump 8 passes through the valve housing 1 by means of surface machined recesses 3 and ducts 6 and then reaches the axially centred radial ducts 29 of the valve set 7 . The delivery or return flow passes through the ball valves 26 to reach the radial ducts 30 which are axially disaligned to save space, and then to reach the bottom cover 18 , as explained hereinafter.
The raceway 31 is branched off from the inside 25 of the valve set 7 and is radially disaligned with respect to the centre line of the tubular shell 24 and this raceway 31 is connected to the channel 12 of the valve housing 1 , which in turn is connected to the tank 5 of the pump 8 .
The above mentioned raceway 31 is also connected to the ducts 32 and circumferential channels 33 of the plunger 27 so as to permit discharging of any overpressure, generated in the valve set 7 and in the hydraulic fluid circuits, into the pump tank 5 .
The FIGS. 6 thru 10 show the bottom cover 18 of the valve housing 1 featuring on its upper surface two channels 34 corresponding to the radial and offset ducts 30 of the valve set 7 . These channels 34 terminate at the lower surface of the bottom cover 18 with threaded holes 11 branched to the two chambers of the oil pressure operated cylinder. An additional duct 35 is provided adjacent to the said duct 34 inside the hole 11 connecting each cylinder. By means of a surface machined recess 36 by which the ducts are disaligned, the duct 35 is connected to the ducts 10 of the relief valve 9 discharging in the tank 5 of the pump 8 . Any overpressure generated in the cylinders and valve set is automatically discharged into the tank of the pump 8 through these relief valves 9 .
The bottom cover 18 also features two channels 37 connected to the ducts 14 , 15 which in turn are connected by threaded holes 38 to one or more other oil tanks if a multiple steering gear is provided.
For information purposes, most of the elements previously described are assembled in FIG. 19 in order to explain how the pump in question is operating. The part of the pump 8 to be secured to the valve set 1 is flange shaped 39 , featuring two ducts 40 matching the disaligned recesses 3 and the ducts 6 of the valve housing 1 . The ducts 40 communicate by two separate radial and opposed recesses 41 with the chambers 45 of the pump pistons 42 .
As is known, the steering wheel 100 ( FIG. 19 ) is mounted at the external end of the shaft 43 of this pump. By means of a cam device 44 , the said shaft 43 drives several small pistons 42 for intake or compression of the oil in their chambers 45 as illustrated by the arrows, thus filling or emptying the chambers of the oil pressure operated cylinder driving the engine or steering gear of the boat.
This lower end of this flange 39 closes the bottom of the oil tank 5 and features through holes 46 for the feed valves 2 of the equipment.
The oil taken in or compressed by the pump pistons is conveyed through the threaded fitting 11 in connection with the chambers of the flow dynamic cylinder and thus reaches the ball valve 26 . The fluid, pressurized in one of the cylinder chambers (at the left in FIG. 19 ), pushes the ball valve 26 outwards and the plunger 27 in the opposite direction, thus pushing with its shank 28 the opposite ball valve 26 causing it to open and let the return fluid flow from the other cylinder chamber. This is achieved by turning the wheel in a given direction, whereas the inlet and return flows of the oil will be reversed when turning the wheel in the opposite direction, causing a similar reversed operation of the valve set. By the way, the ball valves 26 are at rest in closed position when the wheel is not moved, thus creating a set of non-return valves and this is particularly important to keep the engine or the rudder of the boat stopped, without any undesired movement of the engine or rudder in either direction.
The above described oil pressure operated pump features a valve set directly secured to the pump, but it is also possible to keep this valve set separated from the pump, but in such case, proper ducts shall be provided for connection to the pump and to the cylinder, as well as an element in which to lodge the suction valve connected to the inner part of the tank 5 . The pump is provided with a seal 47 of any type such as a Corteco or O-ring fitted between the wheel shaft 43 and the pump casing 8 to prevent dust or fluids from entering the pump.
According to this invention, this seal 47 is easy to install, to fix, to remove and to replace, by means of the cap 48 provided with holes 49 through which to pass the fastening screws and fitted with a metal or thermoplastic insert 50 . The outer edge 51 of this cap 48 has the shape of an inwards turned peak adherent to the wheel shaft 43 , thus creating a perfect seal between the shaft and the outer pump walls.
Obviously, the invention here generally described, but without limiting, may be subject to variations and adjustments; some of its parts may be replaced by others having the same aims, based upon the various circumstances and on the nature of the oil pressure operated control pump.
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An oil pressure operated pump for marine steering gears includes a multiple piston oil pressure operated pump controlled by a steering wheel, a valve housing mounted under the pump, a bottom cover closing the valve, the valve housing and the cover each including channels, threaded holes for reciprocal fastening thereof, non-threaded bores for oil pressure connections, a valve set lodged in the valve housing for non-return and adjustment of oil flow, the valve set including a generally parallelepiped shaped tubular shell having a generally external square shape, a central tubular through-hole, and lathe-turned ducts, a double acting oil pressure cylinder including a shaft movable in the central tubular through-hole for controlling a direction of an engine or rudder of a boat, and valves for controlling fluid flow and thereby movement of the shaft.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a wet friction material used in a frictional engagement device such as a clutch and a brake used in oil in an automatic transmission and others of a vehicle such as an automobile.
[0003] 2. Description of the Related Art
[0004] An automatic transmission of a vehicle, for example an automobile, normally includes a multiple disc clutch in which plural friction plates each of which is obtained by bonding a wet friction material to the surface of a metallic substrate (a core plate) and plural separator plates formed by a single plate such as a metallic plate as a subject material of friction are alternately arranged. A driving force is transmitted or disconnected by mutually pressing or releasing these plates in automatic transmission fluid (ATF) used for lubricating oil.
[0005] For such wet friction material used in the frictional engagement device used in oil, a paper wet friction material called a paper friction material is generally used. The wet friction material contains: a fiber base material such as a natural pulp fiber, an organic synthetic fiber and an inorganic fiber; a filler; a friction adjuster; and a binder, and a phenol resin is generally used as the binder, and diatomaceous earth is generally used as the filler. Such wet friction material is bonded to both surfaces of the friction plate in a wet multiple disc clutch. The wet multiple disc clutch is normally provided with four to five friction plates. Therefore, 8 to 10 wet friction materials equivalent to the double of them are used.
[0006] Recently, the miniaturization and the weight saving of automobile parts are promoted. The situation of the wet multiple disc clutch is similar, and by the reduction of the number of friction plates used in the wet multiple disc clutch, the reduction of an axial dimension (the miniaturization) and the weight saving of the wet multiple disc clutch are reviewed. From such a background, it is required that wet friction material with smaller number of friction plates undertakes the same torque as the above-mentioned conventional type wet friction material and has the same or a more superior frictional characteristic, heat resistance and durability, as compared with the conventional type.
[0007] Recently, a wet friction material having a high coefficient of friction is developed, and includes as a filler, a hard metallic powder such as alumina and silicon nitride. However, lately, a still higher coefficient of friction is required in a wet friction material.
[0008] It is generally known that the above-mentioned hard metallic powder has a problem that the powder attacks the frictional face of the subject material (that is, chips the face of the subject material such as the surface of a separator). In the meantime, while a granular diatomaceous earth used heretofore has no problem that it attacks the frictional face, it is difficult to acquire a high coefficient of friction.
[0009] Further, the wet friction material including alumina and silicon nitride as a filler to enhance the coefficient of friction of the wet friction material has a characteristic that the final coefficient of dynamic friction: ฮผo is high, and thus there is a problem that when the wet friction material is used in a clutch, a shock at a gear shifting generates. A part of the wet friction material has a problem to absorb a moisture in air by the action of the hygroscopicity and the water absorption during storing products or transportation and generate the change in dimension.
SUMMARY OF THE INVENTION
[0010] The object of the invention is to provide a wet friction material having a high coefficient of friction.
[0011] Another object of the invention is to provide a wet friction material: having a high coefficient of friction; hardly damaging the mating frictional face; having an excellent heat resistance and durability; and further, having the small initial fluctuation of a coefficient of friction.
[0012] The other object of the invention is to provide a wet friction material: having a higher coefficient of friction, compared with conventional type wet friction material; showing a positive gradient in a ฮผs-V property [(the coefficient of static friction)-(the number of rotation)] so that the final coefficient of dynamic friction is kept low; and further, having an excellent dimensional stability.
[0013] (1) A wet friction material comprising:
[0014] a fiber base material;
[0015] a filler containing a disc-shaped diatomaceous earth; and
[0016] a binder (hereinafter also referred to as a โfirst wet friction materialโ).
[0017] (2) The wet friction material according to the item (1), wherein the disc-shaped diatomaceous earth has an average diameter of 6 to 17 ฮผm.
[0018] (3) The wet friction material according to the item (1) or (2), which comprises the disc-shaped diatomaceous earth in an amount of 30 wt % to 50 wt %, based on total weight of the wet friction material.
[0019] (4) The wet friction material according to any one of the items (1) to (3), wherein the fiber base material contains cotton.
[0020] (5) A wet friction material comprising:
[0021] a fiber base material;
[0022] a filler containing at least one of a filler having Mohs hardness of 8 to 9.5 and a diatomaceous earth; and
[0023] a binder containing a silicone resin, the silicone resin being a hardened product of a hydrolyzed solution containing a silane coupling agent (hereinafter also referred to as a โsecond wet friction materialโ).
[0024] (6) the wet friction material according to the item (5), wherein the diatomaceous earth is a disc-shaped diatomaceous earth.
[0025] (7) The wet friction material according to the item (5) or (6), wherein the filler having Mohs hardness of 8 to 9.5 is alumina.
[0026] (8) The wet friction material according to any one of the items (5) to (7), wherein the silane coupling agent is represented by formula (1):
(R 1 ) (R 2 ) n Si (OR 3 ) 3โn โโ(1)
[0027] wherein R 1 represents an alkyl amino group having primary amine at the terminal end; R 2 and R 3 each independently represents an alkyl group having 1 to 3 carbon atoms; and n represents an integer of 0 or 1.
[0028] (9) A wet friction material comprising:
[0029] a fiber base material;
[0030] a filler; and
[0031] a binder containing a silicone resin, the silicone resin being a hardened product of a hydrolyzed solution containing a mixture of a silane coupling agent represented by formula (1) below and a silane coupling agent represented by formula (2) below:
(R 1 ) (R 2 ) n Si (OR 3 ) 3โn โโ(1)
[0032] wherein R 2 represents an alkyl amino group having primary amine at the end; R 2 and R 3 each independently represents an alkyl group having 1 to 3 carbon atoms; and n represents an integer of 0 or 1,
(R 4 ) m Si (OR 5 ) 4โm โโ(2)
[0033] wherein R 4 and R 5 each independently represents an alkyl group having 1 to 3 carbon atoms; and m represents an integer of 1 or 2 (hereinafter also referred to as a โthird wet friction materialโ) .
[0034] (10) The wet friction material according to the item (9), wherein at least one of the silane coupling agents represented by formulae (1) and (2) has three hydrolyzable groups.
[0035] (11) The wet friction material according to the item (9) or (10), wherein a molar ratio of the silane coupling agent represented by formula (2) to that represented by formula (1) is 0.1 to 10.
[0036] (12) The wet friction material according to any one of the items (9) to (11), wherein the hydrolyzed solution contains water in an amount not smaller than the amount permitting hydrolyzing for half the number of hydrolysable groups contained in the silane coupling agents, but not larger than twice as much as the amount permitting hydrolyzing for all the number of hydrolysable groups contained in the silane coupling agents.
[0037] (13) The wet friction material according to any one of the items (9) to (12), wherein the filler contains at least one of a filler having Mohs hardness of 8 to 9.5 and a diatomaceous earth.
[0038] (14) The wet friction material according to the item (13), wherein the diatomaceous earth is a disc-shaped diatomaceous earth.
[0039] (15) The wet friction material according to the item (13), wherein the filler having Mohs hardness of 8 to 9.5 is alumina
[0040] The term โwet friction materialโ used hereinafter includes all of the first wet friction material, the second wet friction material and the third wet friction material.
[0041] In the third wet friction material, the inventors paid their attention to a fact that a silane coupling agent was widely utilized for enhancing the performance of composite materials composed of an organic polymer and inorganic metallic material and earnestly reviewed the hydrolyzed solution of the silane coupling agent. A silane coupling agent is represented by formula: YโSiX 3 , wherein Y represents a reactive organic functional group such as an amino group, an epoxy group, a vinyl group, a methacrylic group and a mercapt group; and X represents a hydrolyzable group such as an alkoxy group. For a mechanism of the action, a hydrolyzable group: X such as an alkoxy group reacts with water to generate a silanol group and it is bonded to a hydroxyl group on the surface of inorganic material. In the meantime, a reactive organic functional group; Y such as an amino group reacts with the reactive group in an organic polymer and is chemically bonded (is covalently bonded). That is, the silane coupling agent functions as an intervening agent between the inorganic material and the organic material and produces effects such as the enhancement of physical strength, the enhancement of the affinity of inorganics to the organic resin and the inhibition of the deterioration of physical strength under high temperature and high humidity. The binder is required to permeate uniformly the whole wet friction material when the silane coupling agent having such a characteristic applies to the paper wet friction material. Thus, the silane coupling agent is required to be particularly excellent in permeability and wettability to fine porous paper base material. From such a viewpoint, as a result of earnestly researching the hydrolyzed solution of a silane coupling agent, the inventors found that a silane coupling agent represented by formula: YโSiX 3 , in which Y represents an amino group; and X represents an alkoxy group, was particularly excellent in permeability and wettability to the paper base material. Also, there is a slight problem in the dimensional stability of wet friction material because of the action of water absorption and hygroscopicity caused by the hydrophilicity of the hardened product of the hydrolyzed solution of the aminosilane. The simultaneous use of a silicon alkoxide having an alkyl group as means to solve the problem was effective and completed the third wet friction material of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] [0042]FIG. 1 is a graph comparing a coefficient of friction in an embodiment of the invention and in a comparative example;
[0043] [0043]FIG. 2 shows a photograph showing a state of a mating member in the embodiment of the invention after a test;
[0044] [0044]FIG. 3 shows a photograph showing a state of the mating member in the comparative example after a test;
[0045] [0045]FIG. 4 is a graph showing relation between the compounding amount of diatomaceous earth and a coefficient of friction;
[0046] [0046]FIG. 5 is a graph showing the comparison of a coefficient of friction between the diatomaceous earth and diatomaceous earth in another shape;
[0047] [0047]FIG. 6 shows an enlarged photograph showing disc-shaped diatomaceous earth used in the embodiment of the invention;
[0048] [0048]FIG. 7 is a graph showing the comparison of ฮผs-V property at the oil temperature of 40ยฐ C.;
[0049] [0049]FIG. 8 is a graph showing the comparison of ฮผs-V property at the oil temperature of 100ยฐ C.;
[0050] [0050]FIG. 9 is a graph showing the comparison of torque waveforms;
[0051] [0051]FIG. 10 is a graph comparing the variation of thickness;
[0052] [0052]FIG. 11 is a graph showing the comparison of ฮผs-V property at the oil temperature of 40ยฐ C.; and
[0053] [0053]FIG. 12 is a graph showing the comparison of ฮผs-V property at the oil temperature of 100ยฐ C.
DETAILED DESCRIPTION OF THE INVENTION
[0054] Embodiments of the invention will be concretely described below. Wet friction material according to the invention includes a fiber base material, a fiber and a binder. For the fiber base material, a natural pulp fiber such as wood pulp, an organic synthetic fiber such as an aramid fiber and an inorganic fiber such as glass and carbon respectively heretofore used can be used. The fiber base material in the first wet friction material preferably includes cotton.
[0055] It is desirable that for the filler, at least one of diatomaceous earth and the filler of 8 to 9.5 in Mohs hardness is used. It is desirable that the diatomaceous earth used for filler is substantially disc-shaped. It is presumed that this reason is that the superficial smoothness of the wet friction material is enhanced by using disc-shaped diatomaceous earth, contact with the frictional face of the subject material becomes satisfactory and as a result, the coefficient of friction is enhanced. Even if pressure is applied to the wet friction material, the wet friction material is seldom broken and it is presumed that the wet friction material is harder, compared with that using granular diatomaceous earth. It is desirable that the average of the diameter of the disc-shaped diatomaceous earth is approximately 5 to 50 ฮผm. The average diameter of disc-shaped diatomaceous earth is more preferably approximately 6 to 17 ฮผm.
[0056] The reason why diatomaceous earth having the average diameter of 6 to 17 ฮผm is used is that the diatomaceous earth having the diameters in such a range is suited to enhance the coefficient of frictions
[0057] For the filler of 8 to 9.5 in Mohs hardness, silicon nitride, alumina, aluminum silicate and others are used. In case the above-mentioned each filler is separately used-and in case the above-mentioned each filler is arbitrarily combined and used, a satisfactory result can be also acquired and, the combination of disc-shaped diatomaceous earth and alumina is extremely excellent. The above-mentioned filler also functions as a friction adjuster.
[0058] For the binder of the fiber base material of the wet friction material, the hardened product of the hydrolyzed solution of a silane coupling agent is preferable, the product is excellent in heat resistance and durability and the initial variation of the coefficient of friction of which is small.
[0059] In the invention, the hydrolyzed solution of a silane coupling agent which is the source of binder is acquired by putting a silane coupling agent which is main material, water and if necessary, a solvent in a reactor, mixing and agitating them at room temperature or at relatively low temperature [below the boiling point of a solvent (lower alcohol), for example at approximately 40 to 50ยฐ C.] for fixed time (for example, for approximately 3 to 5 hours).
[0060] For the silane coupling agent, it is desirable that aminosilane excellent in permeability and wettability to paper base material and represented by the following formula 1 is used.
(R 1 ) (R 2 ) n Si (OR 3 ) 3โn โโ(1)
[0061] (In the formula (1), R 1 represents an alkyl amino group having primary amine at the terminal ends R 2 and R 3 respectively independently represent an alkyl group having 1 to 3 carbon atoms and n represents an integer of 0 or 1.)
[0062] Concretely, for aminosilane having three alkoxy groups in one molecule, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, N-2-(aminoethyl) 3-aminopropyltrimethoxysilane and others can be given and one type or two or more types of mixture of these can be used. For aminosilane having two alkoxy groups in one molecule, 3-aminopropylmethyldimethoxysilane, 3-aminopropylmethyldietoxysilane, N-2-(aminoethyl) 3-aminopropylmethyldimethoxysilane, N-2-(aminoethyl) 3-aminopropylmethyldiethoxysilane and others can be given and one type or two or more types of mixture of these can be used.
[0063] Only aminosilane having three alkoxy groups in one molecule (n=0) may be also used or the mixture of aminosilane having three alkoxy groups in one molecule (n=0) and aminosilane having two alkoxy groups in one molecule (n=1) may be also used.
[0064] It is desirable that minosilane having three alkoxy groups in one molecule and aminosilane having two alkoxy groups in one molecule are mixed in a range in which the molar ratio of aminosilane having two alkoxy groups in one molecule to the aminosilane having three alkoxy groups in one molecule does not exceed 10. In case the molar ratio of exceeds 10, the bridge density of the hardened product is small, as a result, the heat resistance is not enough and it is undesirable.
[0065] In the third wet friction material, the silane coupling agent is the mixture of a silane coupling agent excellent in permeability and wettability to paper base material and represented by the above-mentioned formula (1) and a silane coupling agent contributing to the dimensional stability of the wet friction material and represented by the following formula (2).
(R 4 ) m Si (OR 5 ) 4โm โโ(2)
[0066] (In the formula (2), R 4 and R 5 respectively independently represent an alkyl group having 1 to 3 carbon atoms and m represents an integer of 1 or 2.)
[0067] For the silane coupling agent represented by the formula (2), trifunctional methyltrimethoxysilane, trifunctional methyltriethoxysilane, bifunctional dimethyldimethoxysilane, bifunctional dimethylethoxysilane and others can be given and one type or two or more types of mixture of these monomers or their low condensation products (for example, approximately dimer to 5-mers) can be used.
[0068] At least one of the silane coupling agents represented by the formulas (1) and (2), preferably has three hydrolyzable groups. In case the number of hydrolyzable groups of the silane coupling agents represented by the formulas (1) and (2) is both 2, the heat resistance of the hardened product is not enough and is undesirable.
[0069] It is desirable that the molar ratio of the silane coupling agent represented by the formula (2) to that represented by the formula (1) is in a range of 1 to 10. In case the molar ratio is below 0.1, the dimensional stability of the wet friction material is deteriorated by the hygroscopicity and the action of water absorption caused by the hydrophilicity of a hardened product and it is undesirable. In the meantime, since permeability and wettability to paper base material are deteriorated and the physical strength of the wet friction material is deteriorated in case the molar ratio exceeds 10, it is undesirable.
[0070] The quantity of added water is not less than quantity in which the haploid number of hydrolyzable groups.(alkoxy groups) in a silane coupling agent can be hydrolyzed, and is not more than double of quantity in which the total number of hydrolyzable group can be hydrolyzed. The quantity of added water is preferably not less than quantity in which the haploid number of hydrolyzable groups (alkoxy groups) in a silane coupling agent can be hydrolyzed and is not more than quantity in which the total number of the hydrolysable group can be hydrolyzed. In case added water is smaller than the above-mentioned quantity, multiple alkoxy groups not reacted yet remain in hydrolyzed solution, the hardenability is deteriorated and it is undesirable in view of the productivity and in addition, energy saving. In the meantime, in case the quantity of added water is much, excess water remains in the hydrolyzed solution, in heat hardening, the excess water causes a phenomenon that the density of a resin component becomes dense from the inside to a surface layer, the percentage content of a hardened product becomes ununiform in the direction of the thickness of the friction material and it has a bad effect upon the physical strength and the frictional characteristic. When the quantity of added water exceeds the double of quantity in which the total number of hydrolyzable groups (alkoxy groups) can hydrolyze, excess water remains in large quantity in the hydrolyzed solution, the above-mentioned phenomenon becomes remarkable and it is undesirable. As excess water remains in the hydrolyzed solution when the quantity of added water exceeds quantity in which the total number of hydrolyzable groups (alkoxy groups) can be hydrolyzed, the above-mentioned phenomenon occurs, however, the degree is in an allowable range. In case the quantity of added water is quantity in which the total number of hydrolyzable groups (alkoxy groups) can be hydrolyzed, the quantity of water remaining in the hydrolyzed solution is small and as uniform friction material is acquired, it is preferable.
[0071] A solvent is not necessarily an essential component, however, it is normally used to homogeneously mix a silane coupling agent and water in start mixed solution. It is desirable that the concentration of the silane coupling agent in start mixed solution is diluted by lower alcohol such as methanol, ethanol and propanol to be 80 percentage by weight or less. At concentration which exceeds this, the condensation reaction of a silanol group generated by hydrolysis travels and the storage stability of the hydrolyzed solution may be impaired.
[0072] To manufacture the wet friction material according to the invention, first, a paper body is formed. This paper body may be acquired by drying, slurry acquired by dispersing fiber base material (including a natural pulp fiber such as wood pulp, an organic synthetic fiber such as an aramid fiber and an inorganic fiber such as glass), filler (such as diatomaceous earth) and a friction adjuster in water at predetermined ratio according to a normal method, but is not particularly limited. The hydrolyzed solution of the silane coupling agent is impregnated this paper body at the rate of 20 to 120 weight for a part of 100 weight of the base material, after the material is dried, it is heated and hardened at approximately 100 to 300ยฐ C. for 15 to 30 minutes and the wet friction material is acquired. Next, the wet friction material is punched in a predetermined shape, is integrated with a substrate (a core plate) to which an adhesive is applied, by a heat press and a friction plate can be acquired, however, the above-mentioned process is not particularly limited and another process may be also used.
[0073] The silane coupling agent (aminosilane) is made a compound having a silanol group and an amino group in the same molecule by hydrolysis, the condensation polymerization of silanol groups is inhibited because of bipolar ionic structure in a molecule by the amino group and becomes relatively stable solution. The hydrophilic compound having a low molecular weight fully permeates the capillary space of the paper base material, thereafter, the condensation polymerization reaction of the silanol groups is repeated by the evaporation of a solvent and heating, a siloxane bond is formed and is hardened, and both organic and inorganic components of the paper base material are firmly bonded and physical strength exceeding that of phenol resin is acquired. As the hardened product has a siloxane bond (โOโSiโOโ) in a main framework, and in the siloxane bond, bond distance between a silicon atom and an oxygen atom is long and the electron density is low, and as a result, the turn of the bond is easy, the hardened product is flexible and elastic. When such a hardened product of the hydrolyzed solution of aminosilane is used for the binder of the wet friction material, the contact area of the surface of the friction material is increased by the enhancement of elasticity, a burn called a heat spot of the mating friction material (a separator plate) caused by a local hit is eliminated, the initial variation of the coeefficient of friction is also slight and the high and stable coefficient of friction is acquired. The binding energy of SiโO in the siloxane bond is 444 kJ/mol (106 kcal/mol) and is very large, compared with 356 kJ/mol (85 kcal/mol) of the binding energy of CโC forming the main framework of organic resin such as phenol resin. Even if the hardened product of the hydrolyzed solution of aminosilane is held under high temperature for a long time, it is stable for frictional heat caused on a frictional slid face because of the magnitude of the binding energy without being deteriorated such as being dissolved and being discolored easily and the heat resistance and the durability of the wet friction material are also satisfactory.
[0074] The invention will be described based upon embodiments further concretely below, however, these are examples and the scope of the invention is not limited.
EXAMPLE 1
[0075] A first embodiment of the invention will be described below. First, for fiber base material which is a component of raw paper, cotton fiber (35% by weight) and aramid fiber (20% by weight) are used and for filler, the above-mentioned disc-shaped diatomaceous earth (MNPP, manufactured by Celite Corporation) is used by 45% by weight. Raw paper is acquired by dispersing these in water and paper-making. Further, wet friction material is acquired by impregnating the hydrolyzed solution of a silane coupling agent in this paper body, heating and hardening it.
[0076] To compare with the first embodiment, a comparative example 1 will be described below. For filler, the above-mentioned disc-shaped diatomaceous earth (MNPP, manufactured by Celite Corporation) (25% by weight) and alumina (20% by weight) are used. A part except the filler is similar to that in the first embodiment.
[0077] [0077]FIG. 1 shows the comparison of the first embodiment and the comparative example 1 in a coefficient of friction. As shown in FIG. 1, the y-axis shows a coefficient of friction and the x-axis shows the number of relative rotation.
The condition of this comparison test is as follows. Oil temperature 100ยฐ C. Number of static rotation 0.72 to 20 r.p.m Oil level (from axis) 0.18 l./m. Oil pressure 784 kPa
[0078] [0078]FIG. 1 shows relation between the number of relative rotation and a coefficient of friction in case the wet friction material is fitted to the mating frictional face, being relatively revolved, a curve A shows the first embodiment and a curve B shows the comparative example 1. As the coefficient of friction in the first embodiment is higher, compared with that in the comparative example 1, it can be verified that the wet friction material in the first embodiment has a coefficient of friction not inferior and high enough, compared with that of wet friction material using alumina for filler.
[0079] [0079]FIGS. 2 and 3 are photographs respectively showing a state of the frictional face of the mating member after a test of 2000 cycles is made under the similar condition to the above-mentioned test condition, FIG. 2 shows a state of the frictional surface of a separator plate used for the mating member in the first embodiment of the invention and FIG. 3 shows a state of the frictional surface of a separator plate used for the mating member in the comparative example 1.
[0080] As clear from FIGS. 2 and 3, though the frictional face of a separator plate which is the mating member in the first embodiment of the invention is not rough, the frictional face of the mating member in the comparative example 1 is considerably rough.
[0081] As described above, it is known from FIGS. 1 to 3 that the wet friction material according to the invention has a coefficient of friction not inferior and high enough, compared with conventional type wet friction material and in addition, has an excellent character that the mating frictional face is seldom damaged.
[0082] [0082]FIG. 4 is a graph showing relation between a coefficient of friction and the number of rotation in case the compounding amount of disc-shaped diatomaceous earth (MNPP, manufactured by Celite Corporation) is changed in the embodiment of the invention. The condition of this test is similar to the above-mentioned case.
[0083] A test is respectively made selecting aramid fiber (90%) and disc-shaped diatomaceous earth (10%) in example 2, selecting aramid fiber (70%) and disc-shaped diatomaceous earth (30%) in example 3 and selecting aramid fiber (50%) and disc-shaped diatomaceous earth (50%) in example 4.
[0084] A curve A shows the example 4, a curve B shows the example 3 and a curve C shows the example 2. As known from the curves A and B, the examples 3 and 4 show approximately the same value and the coefficient of friction is 0.15 ore more, while the coefficient of friction in the example 2 is shown by the curve C, is between 0.14 and 0.15, is clearly low and it is known that for the compounding amount of disc-shaped diatomaceous earth, 30% or more is desirable.
[0085] In the example 1 of the invention, as described above, cotton fiber of 35% by weight is included in fiber base material, however, as this reason is that the coefficient of friction of cotton fiber is higher, compared with that of aramid fiber and in addition, the cotton fiber is low-priced, it has high practicability.
[0086] [0086]FIG. 5 is a graph showing the respective coefficients of friction in case disc-shaped diatomaceous earth according to the invention and conventional type granular diatomaceous earth are respectively used for filler. A curve A shows the example 1. In this case, in diatomaceous earth, the average diameter of discs is 6 to 17 ฮผm and the standard deviation of the diameter of discs is approximately 8.813. (The reason why the average diameter has width is that the average diameter of each lot of diatomaceous earth is different.)
[0087] A curve B shows a comparative example 2. The compounding amount of each component in the comparative example 2 is the same as that in the example 1, however, diatomaceous earth is granular, the average of the particle diameters is 2 to 4 ฮผm, the standard deviation is approximately 5.20 and a curve C shows a comparative example 3. in the comparative example 3, the compounding amount is also the same, diatomaceous earth is granular, mean particle diameter is 2 to 12 ฮผm and the standard deviation is approximately 8.28.
[0088] It is known from the drawing that though much different in the diameter of a disc and a particle diameter is not made between the case of the disc-shaped diatomaceous earth and the comparative example 3, the coefficient of friction is higher in the case of disc-shaped diatomaceous earth, compared with that of granular one.
[0089] [0089]FIG. 6 shows the enlarged photograph of disc-shaped diatomaceous earth used in the embodiment of the invention.
EXAMPLE 5
[0090] For a component of fiber base material, cellulose fiber (25% by weight) and aramid fiber (25% by weight) are used and a paper body is acquired by drying slurry acquired by dispersing disc-shaped diatomaceous earth (MNPP, manufactured by Celite Corporation) (30% by weight) and alumina (20% by weight) for filler in water and paper-making. In the meantime, the hydrolyzed solution of 3-aminopropyltriethoxysilane (a silane coupling agent) is acquired by adding ethanol of 93 by weight and water of 54 by weight in 3-aminopropyltriethoxysilane of 221 by weight and reacting them at 40ยฐ C. for 5 hours. Wet friction material including a paper body of 100 by weight and binder of 40 by weight is acquired by diluting this solution with ethanol, drying after the paper body is impregnated with it, heating at 200ยฐ C. for 30 minutes and hardening. Next, the wet friction material is integrated with a core plate in the shape of a ring and made of metal by punching the wet friction material in the shape of a ring the outside diameter of which is 130 mm and the inside diameter of which is 100 mm and holding it in a die heated up to 200ยฐ C. under the pressure of 4.9 MPa or more for 30 seconds, and a friction plate the diameter of which is 130 mm and the thickness of which is 2.3 mm is acquired. For reference, an enlarged photograph showing disc-shaped diatomaceous earth used in this embodiment is shown in FIG. 6.
Comparative Example 4
[0091] A paper body is acquired by drying slurry acquired by dispersing cellulose fiber of 25% by weight, aramid fiber of 25% by weight respectively for a component of fiber base material, diatomaceous earth of 30% by weight and graphite of 20% by weight respectively for filler in water and paper-making. In the meantime, wet friction material including a paper body of 100 by weight and binder (phenol resin) of 40 by weight is acquired by diluting genuine liquid phenol resin including a non-volatile matter of 50% with methanol, drying after the paper body is impregnated with it, heating at 180ยฐ C. for 30 minutes and hardening. A friction plate the diameter of which is 130 mm and the thickness of which is 2.3 mm is acquired by the similar process to that in the example 5.
Comparative Example 5
[0092] A paper body is acquired by drying slurry acquired by dispersing cellulose fiber of 25% by weight, aramid fiber of 25% by weight respectively for a component of fiber base material and alumina of 50% by weight for filler in water and paper-making. Wet friction material including a paper body of 100 by weight and binder (phenol resin) of 40 by weight is acquired by the similar process to that in the comparative example 4. A friction plate the diameter of which is 130 mm and the thickness of which is 2.3 mm is acquired by the similar process to that in the example 5.
[0093] (ฮผs-V property test)
[0094] The ฮผ s-V property of the wet friction material respectively acquired in the example 5 and the comparative examples 4 and 5 was evaluated under the following test condition using a friction performance tester (SAE No. 2). FIGS. 7 and 8 show the results.
Number of rotation 0.72, 2, 5, 10, 15, 20 rpm Surface pressure 785 kPa Inertia 0.343 N ยท m ยท s 2 Number of frictional faces 6 Oil level Oil bath 700 ml Oil temperature 40ยฐ C. (FIG. 7), 100ยฐ C. (FIG. 8) Frictional area 47.38 cm 2 /face
[0095] As known from FIGS. 7 and 8, the value of ฮผs in the comparative example 5 is higher, compared with that in the comparative example 4. However, it is lower, compared with that in the example 5. The values of ฮผs in the example 5 and in the comparative example 4 have a positive grade, that is, as the number of rotation increase, a coefficient of friction increases, however, the values of ฮผs in the comparative example 5 reversely have a negative grade. Further, when FIGS. 7 and 8 are compared, the values of ฮผs shown in FIG. 8, that is, under nigh temperature are lower as a whole. However, it is known that the degree of the decrease of the values of ฮผs in the invention is extremely small, compared with that in the comparative examples 4 and 5. That is, in the example 5, a high coefficient of friction is also maintained under high temperature.
[0096] [0096]FIG. 9 shows torque waveforms in the example 5 and in the comparative examples 4 and 5. The condition of a test is the same as that in the above-mentioned ฮผs-V property test except that the number of rotation is 3600 rpm (oil temperature is 100ยฐ C.) It is known from FIG. 9 that the waveform of a coefficient of dynamic friction in a final part ฮผo of the torque waveform in the comparative example 5 rises, however, the waveform in ฮผo in the example 5 and the comparative example 4 does not rise. In the example 5, the coefficient of friction is higher, compared with that in the comparative example 4. Dependency upon heat resistance and surface pressure in the example has the similar performance to that in the comparative example 4.
[0097] (Adjustment of Paper Body)
[0098] A paper body A is acquired by drying slurry acquired by dispersing the mixture of cellulose fiber of 35% by weight, aramid fiber of 20% by weight respectively for a component of fiber base material and diatomaceous earth of 45% by weight for filler in water and paper-making.
[0099] Also, a paper body B is acquired by the similar process except that disc-shaped diatomaceous earth (MNPP, manufactured by Celite Corporation) of 25% by weight and alumina of 20% by weight are used for filler. For reference, FIG. 6 shows an enlarged photograph showing the disc-shaped diatomaceous earth.
[0100] (Adjustment of Hydrolyzed Solution)
[0101] Ethanol of 156 by weight and water of 90 by weight are added in 3-aminopropyltriethoxysilane of 221 by weight and dimethyldiethoxysilane of 148 by weight, are reacted at 40ยฐ C. for 5 hours and hydrolyzed solution A is acquired.
[0102] Also, ethanol of 93 by weight and water of 54 by weight are added in 3-aminopropyltriethoxysilane of 221 by weight, are reacted at 40ยฐ C. for 5 hours and hydrolyzed solution B is acquired.
EXAMPLE 6
[0103] Wet friction material including the paper body of 100 by weight and binder of 40 by weight is acquired by diluting the hydrolyzed solution A with ethanol, drying after the paper body A is impregnated with it, heating at 150ยฐ C. for 30 minutes and hardening. Next, the wet friction material is integrated with a core plate in the shape of a ring and made of metal by punching the wet friction material in the shape of a ring the outside diameter of which is 130 mm and the inside diameter of which is 100 mm and holding it in a die heated up to 200ยฐ C. under the pressure of 4.9 MPa (50 kg/cm 2 ) or more for 30 seconds, and a friction plate the diameter of which 130 mm and the thickness of which is 2.3 mm is acquired.
EXAMPLE 7
[0104] Wet friction material including the paper body of 100 by weight and binder of 40 by weight is acquired by diluting the hydrolyzed solution A with ethanol, drying after the paper body B is impregnated with it, heating at 150ยฐ C. for 30 minutes and hardening. A friction plate the diameter of which is 130 mm and the thickness of which is 2.3 mm is acquired by the similar process to that in the first embodiment.
Comparative Example 6
[0105] Wet friction material including the paper body of 100 by weight and binder of 40 by weight is acquired by diluting undenatured resol-type liquid phenol resin with ethanol, drying after the paper body A is impregnated with it, heating at 150ยฐ C. for 30 minutes and hardening. A friction plate the diameter of which is 130 mm and the thickness of which is 2.3 mm is acquired by the similar process to that in the example 6.
Comparative Example 7
[0106] Wet friction material including the paper body of 100 by weight and binder of 40 by weight is acquired by diluting the hydrolyzed solution B with ethanol, drying after the paper body A is impregnated with it, heating at 150ยฐ C. for 30 minutes and hardening. A friction plate the diameter of which is 130 mm and the thickness of which is 2.3 mm is acquired by the similar process to that in the example 6.
[0107] (Evaluation Test)
Evaluation of Dimensional Stability
[0108] Each friction plate acquired in the examples 6 and 7 and the comparative examples 6 and 7 is left for seven days as it is, in a thermo-hygrostat bath adjusted so that inside temperature is 23ยฐ C. and inside humidity is 60% and the variation of the thickness is measured. FIG. 10 shows the results. It is known from FIG. 10 that in the examples 6 and 7, the variation of the thickness is smaller, compared with that in the comparative example 7 and each friction plate acquired in the examples 6 and 7 is excellent in dimensional stability.
ฮผs-V Property Test
[0109] The ฮผs-V property of the wet friction material respectively acquired in the examples 6 and 7 and the comparative examples 6 and 7 was evaluated under the following test condition using a friction performance tester (SAE No. 2). FIGS. 11 and 12 show the results.
Number of rotation 0.72, 2, 5, 10, 15, 20 rpm Surface pressure 785 KPa Inertia 0.343 N ยท m ยท s 2 Number of frictional faces 6 Oil level Oil bath 700 ml Oil temperature 40ยฐ C. (FIG. 11), 100ยฐ C. (FIG. 12) Frictional area 47.28 cm 2 /face
[0110] As known from FIGS. 11 and 12, the value of As of the wet friction material in the examples 6 and 7 is higher, compared with that in the comparative example 6, the value of ฮผs also hardly lowers under high temperature and dependency upon temperature is very small. It is also known that the value of ฮผs of the wet friction material in the example 7 is higher, compared with that in the comparative example 7. The ฮผs-V property of the wet friction material in the examples 6 and 7 has a positive grade, that is, as the number of rotation increases, the coefficient of friction increases (similarly in the comparative examples 6 and 7).
[0111] The wet friction material according to the invention is configured as described above and has a high coefficient of friction.
[0112] The first wet friction material has a high coefficient of friction in addition without damaging the frictional face of the subject material, is excellent in heat resistance and durability and hardly has the initial variation of the coefficient of friction.
[0113] According to the second wet friction material according to the invention, it has a higher coefficient of friction, compared with conventional type wet friction material and satisfactory effect that the ฮผs-V property has a positive grade is acquired.
[0114] According to the third wet friction material according to the invention, it has a higher coefficient of friction, compared with conventional type wet friction material (phenol resin is used for binder), the ฮผs-V property has a positive grade and further, the dimensional stability is also satisfactory.
[0115] The entire disclosure of each and every foreign patent application from which the benefit of foreign priority has been claimed in the present application is incorporated herein by reference, as if fully set forth.
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A wet friction material comprises a fiber base material, a filler and a binder: wherein the filler contains a disc-shaped diatomaceous earth; wherein the filler contains at least one of a filler having Mohs hardness of 8 to 9.5 and a diatomaceous earth and the binder contains a specific silicone resin binder; or wherein the binder contains another specific silicone resin binder.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/674,862, filed Sep. 30, 2003, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/222,062, now U.S. Pat. No. 6,637,050, filed Aug. 16, 2003 and a Continuation-In-Part of U.S. patent application Ser. No. 10/229,533, now U.S. Pat. No. 6,675,406, filed Aug. 28, 2002, which is a Continuation of abandoned U.S. patent application Ser. No. 09/593,724, filed Jun. 13, 2000. This application is a Continuation-In-Part of U.S. patent application Ser. No. 10/732,726, filed Dec. 10, 2003, which is a Continuation-In-Part of U.S. patent application Ser. No. 09/954,420, now U.S. Pat. No. 6,691,411, filed Sep. 17, 2001. This application is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/721,694, filed Nov. 25, 2003, which is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/247,247, filed Sep. 19, 2002. This application is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/971,895, filed Oct. 22, 2004. This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/161,933, now U.S. Pat. No. 7,503,083, filed Aug. 23, 2005. The entire disclosures of which are incorporated by reference herein.
This application is also related to U.S. patent application Ser. No. 11/873,200 filed Oct. 16, 2007, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/423,996, filed Jun. 14, 2006, which is a Continuation of U.S. patent application Ser. No. 10/370,545, now U.S. Pat. No. 7,185,529, filed Feb. 20, 2003. The entire disclosures of which are incorporated by reference herein.
FIELD OF THE INVENTION
Embodiments of the present invention are generally related to components of a plumbing system that is used in conjunction with a bathtub, shower stall, since, etc. More specifically, embodiments of the present invention relate to a kit that includes devices that facilitate interconnection of the plumbing system to the bathtub, that allows for testing of the interconnection, and protects finished hardware associated with the bathtub.
BACKGROUND OF THE INVENTION
During new building construction or renovation of an existing building structure, plumbers often must connect or reconnect bathroom fixtures to the plumbing system.
Often plumbers find that interconnecting common bathroom fixtures, such as a bathtub, is difficult and time consuming. โBathtubsโ as referred to herein include a tub with a drain port and an overflow port such that if the drain port is plugged, water will flow into the overflow port and drain through the plumbing system and not out of the tub. Generally, the bathtub is interconnected to the plumbing system of a structure by a main drain pipe which associated to the drain port of the bathtub via a horizontal segment and which is associated with the overflow port of the bathtub via a vertical segment. These two drain segments merge at a tee connector that is also interconnected to the main drain pipe that feeds into a sewer line. During construction, the often heavy bathtub must be aligned properly to interconnect with the drain pipe segment (horizontal) and the overflow pipe segment (vertical) of the drain pipe. Often the drain pipe segments are near a wall, awkwardly oriented, etc. and are thus difficult to associate with the bathtub.
Once the drain pipe segments are aligned with the bathtub, the drain pipes must usually be blocked for testing. In the past, a plug, bladder or cap has been employed to facilitate testing. Plugs and/or caps are easily misplaced, and are often difficult to install, thereby increasing the time and difficulty of testing a plumbing system.
Another drawback of bathtub assemblies of the prior art is that the finishing hardware generally associated with a drain of a bathtub often becomes damaged during construction. Traditionally, finishing hardware is interconnected to the bathtub drain port during construction since a rigid interconnection between the drain pipe and the bathtub is required. Thereafter, workers may damage the often expensive chrome or brass hardware by marring, scratching, or even urinating on the same. Thereafter the plumbing contractor must replace the finished hardware and retest the integrity of the new connection, which adds expense.
Thus it is a long felt need in plumbing to provide a system that facilitates the interconnection of a bathtub to a plumbing system, enhances the testing of the system and protects expensive hardware after the assembly is complete.
SUMMARY OF THE INVENTION
Traditionally, an overflow system of a bathtub includes an overflow port that is interconnected to a vertical drain pipe via an elbow.
It is one aspect of the present invention to facilitate this interconnection by providing an elbow with a flange protruding therefrom. More specifically, embodiments of the present invention employ a flange that is spaced from an end of the elbow that will be associated with the bathtub. The end, thus, defines a shoulder that is adapted to receive a cylindrical adapter having an obstructed end that prevents the flow of fluid through the cylindrical fitting and elbow. In one embodiment, the cylindrical fitting includes exterior threads that receive a nut.
In operation, one end of the elbow is interconnected to the drain pipe and the other end, which is located adjacent to the flange, is placed within the perimeter of the overflow port such that the flange abuts an outer surface of the bathtub. The cylindrical fitting is then interconnected to the elbow which locates the other, closed end of the cylindrical fitting within the bathtub. The nut is used to sandwich the bathtub between the nut and the flange, thereby providing a generally rigid connection. Some embodiments of the present invention also employ a washer between the tub and the nut. The nut may also provide the ability to interconnect a decorative cap.
It is a related aspect of the present invention to selectively block fluid flow through the overflow assembly. More specifically, the closed portion of the cylindrical fitting acts as a plug to aid in testing of the plumbing system. After testing is complete the closed portion may be cut, or otherwise removed, to allow fluid flow through the overflow assembly. If additional testing is required traditional methods of plugging the overflow assembly may be employed, which will be described in further detail below.
It is another aspect of the invention to provide a method of installing a drain assembly that can be accomplished by a single individual. A related aspect of the invention is to provide a method of installing a bathtub drain assembly that allows for ease in field testing for leaks. Yet another aspect of embodiments of the present invention is to provide a method of installing the drain assembly that eliminates the need for the removal of a strainer body often associated with drain assemblies. In accordance with these and other aspects, one method includes inserting an L-shaped drain pipe having a threaded upper end and an annular flange covered by a membrane, through a drain port of the bathtub, such that the annular flange rests on a bottom surface of the bathtub. Next, a lock washer is threadingly engaged to the inner end of the drain pipe to the threaded portion. The other end of the L-shaped drain pipe is then connected to the drain system of the building. The assembly can then be tested for leaks. Once it is determined that no leaks are present, the membrane is removed from the flange on the upper end of the drain pipe. Finally, a finished cover is installed on the annular flange.
It is yet another aspect of the present invention to provide a bathtub drain pipe assembly that facilitates integration of the various drain pipes mentioned thus far to the bathtub. Embodiments of the present invention thus include a flexible hollow tube instead of rigid drain pipes that simplifies the installation of the bathtub to the plumbing system. The flexible tube of embodiments of the present invention has the added benefit of being easily modifiable and possesses a smooth inner surface to prevent the often unsanitary trapping of fluid with the flexible hollow tube.
It is still yet another aspect of the present invention to provide a protective cover that interconnects to the installed drain assembly. More specifically, a flange of the protective drain cover is superimposed over the flange of a waste water strainer located in a bathtub, sink or the like. A lip located about the outer perimeter of the flange of the cover fits over the outer periphery of the flange of the waste water strainer and centers the cover on the strainer. A cylindrical wall, which extends from the flange of the cover, is positioned downwardly through a cylindrical wall of the waste water strainer. The two cylindrical walls are spaced from each other by one or more seals that are positioned in grooves.
It is an aspect of the embodiment of the present invention to combine some or all of the above-described aspects to provide a system that facilitates interconnection of the bathtub to the plumbing system of a structure. More specifically, it is contemplated to use aspects described above, provided below, or apparent to one skilled in the art in conjunction to alleviate all of the difficulties noted above that are associated with interconnecting a bathtub to a plumbing system of a structure. For example, one skilled in the art will appreciate the overflow assembly can be easily integrated with the flexible pipes described above to expand the interconnection options available to a plumber. In addition, the protective drain cover may also be used. It is contemplated that the above described aspects of the present invention will provide a complete kit wherein all of the necessary components will be included to aid the plumber in interconnecting a bathtub to the plumbing of a structure, facilitate testing of the same and protecting fragile and expensive components thereof, which will increase efficiency and decreasing costs of the operation.
The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
FIG. 1 is a partial perspective view of a bathtub;
FIG. 2 is a cross-sectional view of FIG. 1 ;
FIG. 3 is an exploded perspective view of an overflow assembly of one embodiment of the present invention;
FIG. 4 is a cross-sectional assembled view of the overflow assembly shown in FIG. 3 ;
FIG. 5 is an exploded perspective view of an alternate embodiment of an overflow assembly;
FIG. 6 is a cross-sectional, assembled view of the overflow assembly shown in FIG. 5 ;
FIG. 7 is a perspective view of a cylindrical fitting employed in overflow assemblies of some embodiments of the present invention;
FIG. 8 is an exploded view of an alternate embodiment of an overflow assembly that employs a one-piece overflow pipe and cylindrical fitting;
FIG. 9 is a perspective view of the one-piece overflow pipe and cylindrical fitting shown in FIG. 8 ;
FIG. 10 is an exploded perspective view of a drain assembly of one embodiment of the present invention;
FIG. 11 is a side elevation view of the drain assembly shown in FIG. 10 interconnected to the bathtub;
FIG. 12 is a side elevation view of a prior art interconnection horizontal and vertical drain pipes;
FIG. 13 is a perspective view of a flexible overflow pipe;
FIG. 14 is a side elevation view of the flexible conduit of FIG. 13 interconnected to the bathtub;
FIG. 15 is a side elevation of horizontal and vertical flexible conduits interconnected to the bathtub;
FIG. 16 is a partial perspective view of a bathtub showing a test cap interconnected to the overflow port;
FIG. 17 is a perspective view of a test cap of one embodiment of the present invention;
FIG. 18 is a cross-sectional view of the test cap of FIG. 17 interconnected to an overflow pipe;
FIG. 19 is a perspective view of an alternative embodiment of a test cap;
FIG. 20 is a cross-sectional view of the test cap of FIG. 19 shown interconnected to an overflow pipe;
FIG. 21 is a side elevation view of an alternative embodiment of the test cap interconnected to an overflow pipe;
FIG. 22 is a front elevation view of another embodiment of the test cap having a removable diaphragm;
FIG. 23 is a rear perspective view of the test cap shown in FIG. 22 ;
FIG. 24 is a perspective view of a protective cover and drain;
FIG. 25 is a cross-sectional view of the protective cover shown in FIG. 23 ; and
FIG. 26 is a cross-sectional view of an alternate embodiment of the protective cover.
To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein:
#
Component
2
Overflow assembly
6
Bathtub
10
Drain port
14
Overflow port
18
Elbow
22
Overflow pipe
26
Tee connector
30
First end
34
Second end
38
Flange
42
Shoulder
46
Cylindrical fitting
50
Threads
54
Diaphragm
58
Outer surface
62
Wall
66
Inner surface
70
Washer
74
Nut
78
Lug
82
Threads
86
Cap
90
Notch
94
Protrusions
98
Ring
102
Cutting tool
106
Opening
110
Drain assembly
112
Edge
114
Tub floor
118
Drain pipe flange
122
Nut
126
Cylindrical portion
130
Threads
134
Drain pipe
138
Membrane
140
Cover
144
Drain closure
176
Test cap
180
Cylindrical body
184
Flange
188
Face
192
Interior threads
196
Inner surface
200
Protective cover
204
Opening
208
Flange
212
Tubular wall
216
Groove
220
Seal
224
Strainer
228
First portion
232
Second portion
236
Conical portion
It should be understood that the drawings are not necessarily to scale. In certain instances, details which are not necessary for an understanding of the invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
Referring now to FIGS. 1-9 an overflow assembly 2 adapted for interconnection to a bathtub 6 is provided. The overflow assembly 2 is adapted to be used in conjunction with a bathtub 6 having a drain port 10 and an overflow port 14 . The overflow port 14 receives an L shaped elbow 18 that leads into an overflow pipe 22 that eventually feeds into a tee-connector 26 . The tee-connector 26 also receives fluid from the drain port 10 of the bathtub 6 and has an opening that connects to the sewer system of the structure.
Turning now specifically to FIGS. 2-4 , an overflow assembly of one embodiment of the present invention is provided. Here, the elbow 18 includes a first end 30 and a second end 34 wherein a flange 38 is spaced from the first end 30 . Thus, the first end 30 comprises a lip that protrudes from the flange 38 . The first end 30 is adapted to receive a shoulder 42 of a cylindrical fitting 46 that also includes an outer surface with a plurality of threads 50 and may have a diaphragm 54 situated on one end thereof.
In operation, the flange 38 is adapted to abut an outer surface 58 of the bathtub 6 , thereby placing the first end 30 at least partially within the thickness of the bathtub wall 62 or away from an inner surface 66 of the bathtub 6 which facilitates alignment of the overflow port and the overflow assembly 2 . After the elbow 18 is properly aligned and engaged within the overflow port 14 of the bathtub 6 , the cylindrical fitting 46 is interconnected thereto wherein the shoulder 42 is placed in contact with the first end 30 of the elbow 18 . A washer 70 is then placed around the cylindrical fitting 46 and in abutting relationship with the inner surface 66 of the bathtub 6 . A nut 74 having a plurality of externally protruding lugs 78 and internal threads 82 is then screwed on to the threads 50 of the cylindrical fitting 46 , thereby sandwiching the wall 62 of the bathtub 6 between the flange 38 and the washer 70 . The lugs 78 of the nut 74 are adapted to receive an inner surface of a cap 86 . The cap 86 also employs at least one notch 90 that allows for water to flow from the cap 86 through the elbow 18 and into the overflow pipe 22 of the plumbing system.
After the overflow system is interconnected to the bathtub, testing it is often required. Often such testing of the overflow assembly 2 must be blocked. Thus, as briefly described above, the cylindrical fitting 46 may include a diaphragm 54 that prevents flow of liquid therethrough. After testing is complete the diaphragm 54 may be cut away to provide a flow path from the notch 90 of the cap 86 into the elbow 18 . No additional hardware, such as a test cap, is needed to perform testing.
Referring now to FIGS. 5 and 6 , an alternate embodiment of an overflow assembly 2 is provided. More specifically, the nut 74 described above includes a plurality of protrusions 94 aligned on a ring 98 that is positioned adjacent to the plurality of the lugs 78 . The protrusions 94 allow for enhanced interconnectability between the nut 74 and the cylindrical fitting 46 by providing a plurality of finger holds.
Referring now to FIG. 7 , the cylindrical fitting 46 of the overflow assembly 2 of one embodiment of the present invention is provided. As mentioned above, it is often desirous to maintain the integrity of the overflow assembly 2 such that fluids or air are maintained within the plumbing assembly, i.e. plugged. After any required testing is complete, a cuffing tool 102 is employed to remove the diaphragm 54 of the cylindrical fitting 46 , thereby providing an opening 106 for fluids.
Referring now to FIGS. 8 and 9 , yet another variation of the above-identified overflow assembly is provided. Here, a one-piece unit is provided wherein the cylindrical fitting 46 and the elbow 18 are rigidly interconnected. In addition, one skilled in the art will appreciate that at least a portion of the overflow pipe 22 may also be rigidly interconnected to the elbow 18 . This configuration omits at least two joints in the system, which reduces the likelihood of leaks between components. One skilled in the art will also appreciate that a diaphragm may also be included in this embodiment of the present invention that is cut away to provide an opening 106 after testing is performed.
Referring now to FIGS. 10 and 11 , the drain assembly 110 for interconnecting the bathtub to the plumbing system of one embodiment of the present invention is shown. Here, similar to the overflow assembly, the drain assembly must be rigidly interconnected to the bathtub 6 . Thus embodiments of the present invention employ a drain assembly 110 wherein the tub floor 114 is sandwiched between a drain pipe flange 118 and a nut 122 . In operation, the drain pipe flange 118 includes a cylindrical portion 126 extending therefrom that includes a plurality of threads 130 . The drain pipe flange 118 is mated with a drain pipe 134 wherein the nut 122 is threaded on the drain pipe 134 prior to the marriage of the cylindrical portion 126 and the drain pipe 134 . The nut 122 is brought up to the threads 130 and tightened such that the tub floor is sandwiched between the drain pipe flange 118 and the nut 122 to secure the drain assembly to the drain port 10 of the bathtub 6 . To test the system a membrane 138 may be employed to block flow to the drain pipe 134 . After testing is completed, a cover 140 and drain closure 144 , which are common in the art, may be incorporated.
Referring now to FIGS. 12-15 , a method of facilitating interconnection of the overflow pipe 22 and the drain pipe 134 is provided. FIG. 12 shows the prior art method of interconnecting drain pipes and flow pipes to a bathtub 6 wherein the rigid overflow pipe 22 is interconnected to the elbow 18 of the overflow assembly 2 and a rigid drain pipe 134 is horizontally interconnected from a connector associated with the drain port 10 . These two rigid pipes merge at a tee-connector 26 and into the main drain pipe of the plumbing system. As one skilled in the art will appreciate, interconnection of these rigid pipes is often difficult, especially when they are misaligned due to engineering errors or errors in interconnecting of the individual pipes to the tee-connectors 26 , for example. Often, the interconnection of the bathtub to the overflow pipe 22 and drain pipe 134 will cause frustration, delays and increased costs.
Referring now to FIGS. 13 and 14 , this problem has been addressed by an embodiment of the present invention that provides a flexible conduit 148 that leads from the elbow 18 of the overflow assembly 2 to the tee-connector 26 . It is envisioned that the flexible conduit 148 of this embodiment of the present invention be corrugated, however, be not susceptible to the drawbacks of using a corrugated tube. More specifically, as one skilled in the art will appreciate, the use of corrugated tubing, to allow for selective adjustments of tube bends is common. However, the use of a corrugated surface is not desirable and is often counter building codes since waste and fluid can gather in the corrugations provided in the inner diameter of the conduit thereby providing a breeding ground for a mold and germs. Thus the flexible conduit 148 of embodiments of the present invention employ a coating that maintains flexibility but yet eliminates at least the corrugations in the inner surface of the flexible conduit 148 .
Referring now specifically to FIG. 15 , the flexible conduit 148 as described above may be employed in another way. That is, FIG. 14 shows the flexible conduit 148 extending from the overflow assembly 2 into the tee-connector 26 that is associated directly with the drain port 10 . More often, it is desirable to provide a vertical overflow pipe 22 and a horizontal drain pipe 134 . These pipes may be made of the flexible conduit as described above and interconnected as traditionally done to the tee-connector 26 that is associated with the main drain pipe of the plumbing system. Since the flexible conduit 148 as provided is pliable, it is easily cut. Thus plumbers may use the flexible conduit 148 as they would use rigid conduit and selectively cut them to lengths to interconnect to traditionally located tee-connectors 26 .
Referring now to FIGS. 16-23 , a test cap 176 of one embodiment of the present invention is provided. As mentioned above, it is often desirous to plug the overflow port 14 and/or drain port 10 of the bathtub to facilitate testing. As also described above, this is most preferably done with a diaphragm that omits the need for a test cap 176 . However, if testing needs to be performed subsequent to removal of a diaphragm, a test cap 176 can be used.
Referring now to FIGS. 17 and 18 , a test cap 176 of one embodiment of the present invention is provided with a cylindrical body 180 having a flange 184 positioned thereon. The flange 184 has a face 188 that receives a diaphragm 54 and includes internally located threads 192 that receive the threads of the cylindrical fitting 42 of the overflow assembly 2 , similar to that described above. The test cap 176 of this nature can be used on overflow assemblies as described above that include a diaphragm 54 if further testing is required. After testing is completed, the diaphragm 54 of the test cap 176 of this embodiment of the present invention may be cut away to provide an opening 106 as described above.
Referring now to FIGS. 19 and 20 a test cap 176 of one embodiment of the present invention is shown. Here, a traditional plug having threads is used. However, this embodiment of the present invention also includes a diaphragm 54 positioned on one end that may be cut-away after testing is complete.
Referring now to FIGS. 21-23 , yet another version of the test cap 176 is provided with an inner surface 196 of malleable material that helps seal the interconnection of the test cap 176 and the overflow elbow 18 . That is, by interconnecting the test cap 176 onto the external threads of the overflow elbow 18 , the end of the overflow assembly 2 will deform the inner surface of the test cap 176 somewhat to create a seal. It is also envisioned that a test cap 176 of this embodiment of the present invention employs a diaphragm 54 that can be cut away if needed.
Referring now to FIGS. 24-26 , a protective drain cover 200 is provided. Here, the protective cover 200 having an opening 204 therethrough and a flange 208 is shown. Emanating from the flange 208 is the tubular wall 212 having a groove 216 positioned therearound. The groove 216 is adapted to receive at least one seal 220 . The protective cover 200 is adapted to be associated with a strainer 224 of the drain assembly, thereby positioning the flange 208 of the protective cover 200 over the flange 118 of the strainer 224 . In addition, the protective cover 200 includes an edge 112 that slightly curves downwardly to protect an edge of the strainer 224 . As described above, the strainers 224 are often made of a brass or chrome which is easily damaged. Thus in operation, the tubular wall 212 of the drain cover 200 feeds into an opening of the strainer 224 . The seals 220 are then disposed between the outer surface of the tubular wall 212 and the inner surface of the strainer 224 . Thus the drain assembly 110 is protected during construction. After construction is completed, the protective cover 200 is removed and the drain assembly 110 remains within the bathtub 6 .
As disclosed in U.S. Pat. No. 7,503,083, numeral 200 may also be viewed as a waste water insert. Insert 200 has a flange 208 with the periphery thereof terminating in a downwardly extending lip 112 . As shown in FIGS. 25 and 26 , the lip 112 extends downwardly and over the outer perimeter of the strainer flange 118 . The lip 112 engages the tub floor 114 (see FIG. 11 ) when installed.
Insert 200 has a downwardly extending wall 212 which surrounds a center opening 204 . The diameter of wall 212 is less than the diameter of the cylindrical wall of strainer 224 so that a space exists between the two walls. The lip 112 on the outer perimeter of the flange 208 of insert 200 centers the cylindrical wall 212 within the cylindrical wall of strainer. In one embodiment, the waste water insert 200 includes a wall 212 with a cylindrical first portion 228 and a cylindrical second portion 232 with a conical portion 236 therebetween. The diameter of the cylindrical first portion 228 is greater than the diameter of the cylindrical second portion 232 such that the space between the insert and the strainer is reduced adjacent to the cylindrical first portion 228 .
The wall 212 extends downwardly and has a first groove 216 in the lower end. The groove 216 receives a resilient ring member 220 that engages the cylindrical wall 212 of the strainer 224 to hold the insert 200 in place. In one embodiment, the resilient ring member 220 is an O-ring. Alternatively, the waste water insert 200 , as shown in FIG. 26 , has a second groove in spaced relation to the first groove 216 with a raised surface therebetween. The second groove receives a second resilient ring member 220 that also engages the cylindrical wall 212 of strainer 200 . Additional grooves and rings may be added as desired.
The insert is installed by inserting the cylindrical wall 212 of the insert 200 into the opening 10 of the strainer 224 until the insert is in place. At this point the resilient ring or rings of the insert will engage the cylindrical wall of the strainer 224 to hold the insert 200 in place. No tools are required and the inserts are quickly, easily, and securely installed to achieve their required purpose.
While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims.
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A system is provided for enhancing the interconnectability of a bathtub to a plumbing system. More specifically, provided is a flexible conduit and an overflow assembly that allows for a portion of the overflow assembly to be easily located with the wall of a bathtub. The flexible conduit provided allows for adjustability of the conduit to the openings of the bathtub. In addition, provided are methods and apparatus that facilitate testing of a plumbing assembly. Finally, an apparatus and methods are provided that protect portions of the finished bathtub assembly to decrease in the need for replacing said hardware. It is envisioned that aspects and inventions disclosed herein can be used in conjunction to facilitate the interconnection and protection of hardware associated with a bathtub.
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[0001] This application claims the benefit of Taiwan application Serial No. 95117530, filed MAY 17, 2006, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates in general to a flat display and display panel thereof, and more particularly to a flat display with a cell test function, which can reduce power consumption of an ESD protection circuit in a normal dynamic display mode.
[0004] 2. Description of the Related Art
[0005] FIG. 1A shows a conventional ESD protection circuit. Referring to FIG. 1A , a thin film transistor (TFT) display panel 100 includes a positive ESD protection circuit 112 and a negative ESD protection circuit 114 coupled to each of signal lines 110 (scan lines or data lines) for respectively discharging positive and negative electrostatic charges generated as a driving chip 120 is bonded to the display panel 100 . The negative ESD protection circuit 114 includes a diode-connected TFT transistor M. The source of the TFT transistor M is coupled to the signal line 110 and the gate and drain of the TFT transistor M are coupled to a common electrode (having a common voltage Vcom) of the display panel 100 .
[0006] The driving chip 120 (scan or data driving chip) couples to the signal-line bump of the display panel 100 at module process. In the process when the driving chip 120 bonds to the display panel 100 , the negative electrostatic charges generated on the signal lines 110 can be transmitted to the common electrode Vcom for discharge via the transistor M so as to prevent the negative electrostatic charges from flowing into the signal lines 110 and damaging TFT devices of the display panel 100 .
[0007] However, for example, the signal lines 110 are scan lines. When the display panel 100 bonds to the driving chip 120 for operating in a normal dynamic display mode, as shown in FIG. 1B , in a period T 1 , the driving chip 120 outputs a scan signal Scan 1 with a voltage Vgh, such as +10V, via the first-stage scan signal line 110 and in the same period T 1 , the scan signal on the second-stage scan signal line 110 has a low voltage Vgl, such as โ10V, in the meanwhile the common voltage Vcom has an AC voltage Vch, such as +5V. Therefore, the TFT transistor M coupled to the first-stage scan signal line 110 is turned off because its negative-electrode voltage (=Vgh) is higher than its positive-electrode voltage (=Vch). Besides, the TFT transistors Mโฒof other scan signal lines 110 are turned on to generate currents I, which increases the power consumption as shown in FIG. 1A because their negative-electrode voltage Vgl (=โ10V) are lower than their positive-electrode voltage Vch or Vcl (0V).
[0008] Supposed there are N scan lines in a panel, there would be power-consuming currents (Nโ1)*I flowing by the negative ESD protection circuits in the period T 1 . Similarly, in the period T 2 , only the TFT transistor M of the second stage scan signal line 110 is turned off and the other (Nโ1) TFT transistors M are all turned on, which generates (Nโ1)*I power-consuming currents through the negative ESD protection circuits. Therefore, although the conventional negative ESD protection circuits 114 can achieve the purpose of ESD protection, these protection circuits 114 increase power consumption of the display panel 100 in a dynamic display mode.
SUMMARY OF THE INVENTION
[0009] It is therefore an object of the invention to provide a flat display and display panel thereof. When the display panel operates in a normal dynamic display mode, a low-level pin of the driving chip is coupled to one terminal of each negative ESD protection circuit to prevent generation of a power-consuming path, thereby reducing power consumption of the display panel.
[0010] The invention achieves the above-identified object by providing a display panel for bonding to a driving integrated circuit (IC). The display panel includes a number of signal lines and negative ESD protection circuits. The negative ESD protection circuits are respectively coupled to the signal lines. The negative ESD protection circuits have first ends coupled to the corresponding signal lines, second ends coupled to each other, and ESD terminals coupled to each other. When the driving IC bonds to the display panel, negative electrostatic charges generated on each of the signal lines are transmitted to the ESD terminal via the first end of the corresponding negative ESD protection circuit and further transmitted from the ESD terminals of the other negative ESD protection circuits to the corresponding first ends for discharge, and the second ends of the negative ESD protection circuits are coupled to a low-level pin of the driving IC.
[0011] The invention achieves the above-identified object by providing a flat display including a display panel and a driving IC. The display panel includes a number of signal lines and negative ESD protection circuits. The negative ESD protection circuits are respectively coupled to the signal lines. The negative ESD protection circuits have first ends coupled to the corresponding signals, second ends coupled to each other, and ESD terminals coupled to each other. The driving IC is for coupling to the signal lines as bonding to the display panel, wherein the driving IC has a low-level pin. When the driving IC bonds to the display panel, negative electrostatic charges generated on each of the signal lines are transmitted to the ESD terminal via the first end of the corresponding negative ESD protection circuit and further transmitted from the ESD terminals of the other negative ESD protection circuits to the corresponding first ends for discharge, and the second ends of the negative ESD protection circuits are coupled to the low-level pin of the driving IC.
[0012] Other objects, features, and advantages of the invention will become apparent from the following detailed description of the preferred but non-limiting embodiments. The following description is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A shows a conventional ESD protection circuit.
[0014] FIG. 1B is a timing diagram of a scan driving operation in the TFT display panel of FIG. 1A .
[0015] FIG. 2 is a block diagram of a flat display according to a preferred embodiment of the invention.
[0016] FIG. 3A is a circuit structure diagram of the negative ESD protection circuit in FIG. 2 .
[0017] FIG. 3B is a schematic diagram of a discharge path for negative electrostatic charges formed in the negative ESD protection circuit as the display panel bonds to a driving IC according to the preferred embodiment of the invention.
[0018] FIG. 3C is a schematic diagram of the negative ESD protection circuit in a turn-off state when the display panel operates in a normal dynamic display mode according to a preferred embodiment of the invention.
[0019] FIG. 4 is a stimulation timing diagram of the display panel in a normal dynamic display mode according to the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIG. 2 , a block diagram of a flat display according to a preferred embodiment of the invention is shown. A flat display 200 , such as a liquid crystal display, includes a display panel 210 and a driving chip 220 . The display panel 210 , such as a TFT panel, includes a number of signal lines 212 , positive ESD protection circuits 213 and negative ESD protection circuits 214 , and a display area 216 . The signal lines 212 are scan lines or data lines and the driving chip 220 is a scan or data driving chip. Each positive ESD protection circuit 213 is coupled between a signal line 212 and a common electrode (having a common voltage Vcom), mainly for discharging positive electrostatic charges generated as the driving IC 220 bonds to the display panel 210 .
[0021] The negative ESD protection circuits 214 have the first ends E 1 coupled to the corresponding signal lines 212 and the second ends E 2 coupled to each other. Besides, ESD terminals E 4 of the negative ESD protection circuits 214 are also coupled to each other. When the driving chip 220 is bonded to the display panel 210 , the pins of the driving chip 220 are respectively coupled to the signal lines 212 for providing the required driving signals (scan signals or data signals) for pixel display in the display area 216 . Each negative ESD protection circuit 214 has a common-connection terminal E 2 coupled to a low-level pin of the driving chip 220 .
[0022] Before the driving chip 220 bonds to the display panel 210 , the negative electrostatic charges generated on each signal line 212 can be transmitted to the ESD terminal E 4 from the first end E 1 of the corresponding negative ESD protection circuit 214 and then transmitted via the ESD terminals E 4 of other negative ESD protection circuits 214 to the corresponding first ends E 1 for discharge. That is, when negative electrostatic charges are generated on each signal line 212 , the corresponding negative ESD protection circuit 214 is used to conduct all the other signal lines 212 for discharging the negative electrostatic charges. When the display panel 210 bonds to the driving chip 220 to operate the display area 216 in a normal dynamic display mode, the driving chip 220 outputs a low voltage (such as a low-level scan or data voltage Vgl or Vdl) to the second end E 2 of each negative ESD protection circuit 214 via the low-level pin to turn off the negative ESD protection circuits 214 . By doing this, the power consumption of the display panel 210 can be reduced.
[0023] In additions, each negative ESD protection circuit 214 has a third end E 3 coupled to a first test point Test 1 of the display panel 210 and the ESD terminal E 4 coupled to a second test point Test 2 of the display panel 210 . The test points Test 1 and Test 2 are for performing a cell test function on the display panel 210 before the driving chip 220 bonds to the display panel 210 .
[0024] Referring to FIG. 3A , a circuit embodiment of the negative ESD protection circuit 214 in FIG. 2 is shown. Each negative ESD protection circuit 214 includes a TFT transistor T 1 , such as a NMOS transistor, and diode-connected #FT transistors T 2 and T 3 . The TFT transistor T 1 has a source (i.e. the end E 1 ) coupled to the corresponding signal line 212 , a gate coupled to a negative end of the diode-connected TFT transistor T 3 as the end E 3 of the negative ESD protection circuit 214 and a drain coupled to a negative end of the diode-connected TFT transistor T 2 as the ESD terminal E 4 of the negative ESD protection circuit 214 . Moreover, the diode-connected TFT transistor T 2 has a positive end coupled to a positive end of the diode-connected TFT transistor T 3 as the end E 2 of the negative ESD protection circuit 214 . As mentioned above, the ends E 3 of the negative ESD protection circuits 214 are commonly coupled to the first test point Test 1 and the ESD terminals (E 4 ) of the negative ESD protection circuits 214 are commonly coupled to the second test point Test 2 .
[0025] First, in terms of negative ESD protection, for example, negative charges (โ) are generated when the driving chip bonds to the panel, they are transmitted to the signal line through the pins of the driving chip such that the corresponding TFT transistor T 1 has its source voltage smaller than its gate voltage by at least a threshold voltage (such as 2V). Therefore, the transistor T 1 is turned on to have a negative voltage level at the ESD terminal E 4 . As shown in FIG. 3B , because the ESD terminals E 4 of the negative ESD protection circuits 214 are coupled to each other, negative electrostatic charges (โ) of each stage of signal lines 212 are propagated via the transistor T 1 of the corresponding negative ESD protection circuit 214 . Also, the voltage level of the terminal E 4 is smaller at least one threshold voltage than that of the terminal E 3 , and the transistors T 1 are turned on in other stages of the negative ESD protection circuit 214 . Therefore, the generated negative electrostatic charges can be discharged through the whole panel.
[0026] Secondly, in terms of reduction of panel power consumption, as shown in FIG. 2 , when the display panel 210 bonds to the scan (or data) driving chip 220 to operate the display area in a normal dynamic display mode, the scan (or data) driving chip 220 supplies a low voltage Vgl (or Vdl) to the end E 2 of each negative ESD protection circuit 214 via its low-level pin. As shown in FIG. 3C , owing that the transistors T 2 and T 3 are both diode-connected, the voltages at the ends E 3 and E 4 are both equal to the voltage Vgl or Vdl at the end E 2 . At the time, all the negative ESD protection circuits 214 are turned off, thereby reducing power consumption of the display panel 210 . As shown in FIG. 4 , a circuit stimulation result shows that when the display panel 210 has resolution 128*160, the scan signal Sc has the high voltage Vgh equal to +15V, and the low voltage Vgl equal to โ10V, the voltage V 3 at the end E 3 and the voltage V 4 at the end E 4 are both close to the voltage Vgl (=โ10V). It demonstrates that in the normal dynamic display mode, the transistors T 1 , T 2 and T 3 of each negative ESD protection circuit 214 are turned off.
[0027] Besides, the low-level voltage supplied by the above-mentioned driving chip 220 via its low-level pin can also be a voltage other than the low-level scan (or data) voltage Vgl or Vdl. As long as the low-level pin can be used to output a low voltage to turn off the negative ESD protection circuit 214 in the dynamic display mode, all the alternatives are not apart from the scope of the invention.
[0028] Thirdly, in terms of a cell test function, for example, the signal lines 212 are scan lines, the negative ESD protection circuits 214 shown in FIG. 2 and FIG. 3A are coupled to the scan signal lines 212 of the display panel 210 . A test voltage Vt, such as +25V is inputted to the first test point Test 1 of the negative ESD protection circuit 214 of each scan signal line 212 and a scan signal voltage Vgh equal to +15V is supplied to the second test point Test 2 of the negative ESD protection circuits 214 of the corresponding scan signal line, and then a data signal voltage Vdh equal to +5V is supplied to the corresponding data line to test a frame-display function of the display panel 210 , wherein the test voltage Vt is higher than the scan voltage Vgh by at least a threshold voltage of the transistor T 1 .
[0029] As shown in FIG. 3A , owing that the transistor T 1 of the negative ESD protection circuit 214 of the scan signal line 212 has a gate voltage (i.e. a voltage at the end E 3 ) equal to the test voltage (+25V) and a drain voltage (i.e. a voltage at the end E 4 ) equal to the high voltage Vgh (+15V), the transistor T 1 of the corresponding scan signal line 212 is turned on and the scan voltage Vgh is inputted to each stage of scan signal lines 212 and forwarded to the display area 216 , which enables pixels of the display area 216 to receive data signals from the corresponding data lines to generate the corresponding display frame. By doing this, whether the display panel 210 has line defects or broken circuits can be tested to reduce material waste and thus production cost.
[0030] Although the signal lines 212 are exemplified to be scan lines in the above cell test function, similarly, the negative ESD protection circuits 214 as shown in FIG. 2 and FIG. 3A can also be coupled to the data signal lines 212 . The test voltage Vt (+25V) is inputted to the first test point Test 1 of the negative ESD protection circuit 214 of each data signal line 212 , and the data signal voltage Vdh (+5V) is supplied to the second test point Test 2 of the corresponding data signal lines 212 , and then a scan signal with a voltage Vgh equal to +15V is supplied to the corresponding scan lines to test a frame display function of the display panel 210 , wherein the test voltage Vt is higher than the data voltage Vdh by at least a threshold voltage of the transistor T 1 . It can be reasoned by analogy that because the transistor T 1 of the negative ESD protection circuit 214 of each data signal line 212 has a gate voltage (+25V) higher than a drain voltage (+5V), when the scan signal is transmitted to the display area 216 , the transistor T 1 of the corresponding data signal line 212 is turned on to transmit the data voltage Vdh to the pixels of the display area 216 to generate the required display frame. Therefore, whether the display panel 210 has line defects or broken circuits can be tested to reduce material waste and thus production cost.
[0031] In the above cell test function, both of the scan signal lines 212 and the data signal lines 212 can also include the negative ESD protection circuits 214 as shown in FIG. 2 and FIG. 3A . The test voltage Vt (+25V) is simultaneously inputted to the first test points Test 1 of the negative ESD protection circuits 214 of the scan signal lines 212 and the data signal lines 212 , the scan signal with a voltage Vgh equal to +15V is supplied to the second test points Test 2 of the corresponding scan signal lines 212 , and the data signal with a voltage Vdh equal to +5V is supplied to the corresponding data signal lines 212 to test the frame display function of the display panel 210 . In this way, whether the display panel 210 has line defects or broken circuits can be similarly tested to achieve the purpose of reducing production cost, and thus any details is not necessary to be given here.
[0032] Besides, in the cell test function, it can separately test the odd (or even) numbers of the scan lines and the data lines of the display panel 210 to determine whether the panel 210 is a bad product. That is, the odd-stage and even-stage signal lines 212 are respectively performed a frame driving test. Or it can respectively test the red/green/blue pixel data lines to determine if the panel 210 is a bad product.
[0033] As mentioned above, although the negative ESD protection circuit 214 is exemplified to include a TFT transistor T 1 and diode-connected TFT transistors T 2 and T 3 in the invention, the display panel 210 can also use other types of negative. ESD protection circuits to discharge negative electrostatic charges on each stage of signal lines. As long as the negative ESD protection circuits have the first ends coupled to the corresponding signal lines and the second ends coupled to each other such that the negative electrostatic charges generated as the driving chip bonds to the display panel can be discharged from the second ends of the turned-on negative ESD protection circuits and after the driving chip bonds to the display panel, the second ends of the negative ESD protection circuits are commonly coupled to the low-level pin of the driving chip such that a low voltage can be supplied from the low-level pin of the driving chip to the second end of each negative ESD protection circuit to turn off the negative ESD protection circuits in a normal dynamic display mode to achieve the purpose of reducing power consumption of the panel, all the alternatives will not depart from the scope of the invention.
[0034] The flat display and display panel thereof disclosed by the above embodiment of the invention has the following advantages:
[0035] 1. When the driving chip bonds to the display panel, the common-connection terminals of the negative ESD protection circuits of each signal line are coupled to the low-level pin of the driving chip and thus when the display panel is operated in a normal dynamic display mode, the driving IC can supply a low voltage via the low-level pin to the common-connection terminal of each negative ESD protection circuit such that all the negative ESD protection circuits are turned off in the whole process of frame display. Therefore, the panel power consumption can be effectively reduction to improve production lifetime.
[0036] 2. When the driving chip is bonded to the display panel, negative electrostatic charges generated on each signal line can be transmitted to the common-connection terminal of the corresponding negative ESD protection circuit for discharge to achieve the purpose of ESD protection.
[0037] 3. A driving display test can be performed on the display panel of the invention by using the first test points and the second test points of the negative ESD protection circuits of the scan lines and data lines to ensure whether the display panel is a bad production in order to reduce material cost of the driving chip.
[0038] While the invention has been described by way of example and in terms of a preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.
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A flat display including a display panel is disclosed. The display panel includes several signal lines and ESD protection circuits whose negative ESD protection circuits have cell test function. When a driving IC bonds to the display panel, the system operates in a normal dynamic display mode, and the negative ESD protection circuits are coupled to a low-level voltage such that thin film transistors of the negative ESD protection circuit are switched off in the normal display mode. Therefore, the power consumption of the panel module can be reduced and using time of the products can be improved.
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BACKGROUND OF THE INVENTION
The invention relates to a method for manufacturing polar reinforcements formed more particularly of glass, Kevlar, carbon . . . fibers preimpregnated or not with thermoplastic or thermosetting resins and having continuous circumferential threads and radial threads as well as a weaving machine for implementing the method.
In the field of wound impeller casins, which as is known are subjected to local stresses, the structures should be reinforced particularly around an area surrounding a single point of reference such as a pole (hereinafter referred to as a polar zone). For that, disks may be placed in the polar zone formed of spirally wound threads or the bottom of the structure may be reinforced by an interrupted additional polar or satellite winding, partly cylindrical.
The term "disk" designates a reinforcement formed of threads disposed only circumferentially by spiral winding between two plates.
Another technique consists in forming such a reinforcement with a "spiralled fabric". This weaving is carried out on a loom having a conical warp thread feed roll, which causes the formation of a fabric which is wound up on a cone or on its shape developed in a plane, the ring. The circumferential threads are not continuous and overlapping is necessary for passing the tractive forces in the circumferential threads by interlayer shearing.
A technique is moreover known which consists in forming three dimensional disks by winding circumferential threads in channels formed by radially disposed composite rods, then by transversally consolidating by means of threads parallel to the generatrices. Or according to another technique the circumferential and radial threads may be disposed in channels formed by rods disposed parallel to the generatrices, then replacing the metal rods by threads by "lacing". These latter two solutions provide a product which is too thick to be suitable for polar reinforcements integrated between coiled layers.
To form a single layer reinforcement, it has been suggested to form seams on a network of radial threads. For that, the radial threads are disposed between pins supported by a tool and the circumferential threads are sewn spirally. The stitch is such that reinforcing threads disposed in the spool of the sewing machine are joined to the circumferential threads by a binding thread of low mass, made for example from nylon. Now it has discovered that the sewing and the resulting seam displace the radial threads; it is consequently difficult to adjust the parameters such as the length of the stitches or the tension of the threads so as to obtain a straight reinforcement thread. Furthermore, the thread tends to pack the path of the spool. Thus, this technology which seems simple at first sight requires considerable adjusting for results which risk not being satisfactory, in particular in so far as the positioning of the radial threads and the integrity of the circumferential threads are concerned.
U.S. Pat. No. 4,346,741 describes three dimensional woven bodies of revolution in which circumferential yarns and radial yarns are laid in helical courses. French Pat. No. 2,490,687 discloses a fabric and a process for wrapping a thread on a truncated roller using non-continuous circumferential threads. Fabrics obtained are tubular woven pieces with a constant diameter.
SUMMARY OF THE INVENTION
So as to avoid the drawbacks inherent in these different techniques, the invention proposes forming a textile article by weaving on threads and more precisely polar reinforcements by radial threads and continuous circumferential threads, by means of a method in which radial threads are stretched between a hub and alternately one or another of two superimposed plates thus forming a space in which the circumferential thread is wound, reversal of each radial thread from one plate to the other being provided at each revolution.
Another object of the present invention consists then of a machine for weaving polar reinforcements formed of radial threads and continuous circumferential threads for implementing the method, which machine includes a rotary assembly with two parallel plates mounted on a support frame and driven by a motor in which the plates define a weaving chamber therebetween, the lower plate of which has sliding fingers on its periphery and the upper plate of which has fingers fixed in line with the sliding fingers, which fingers occupy positions in which they are moved away from each other in at least one sector of the support frame and positions in contact with each other in at least another sector of the support frame for forming continuous columns closing the weaving chamber.
In accordance with the main characteristic of the invention, the fingers serve as support for platelets for fastening the radial threads, and means are provided on the periphery of the support frame for ensuring movement of the sliding fingers perpendicularly to the plate, and the movement of the platelets on said fingers as a function of their position with respect to the support frame.
In accordance with another main characteristic of the invention, the means ensuring movement of the sliding fingers perpendicularly to the plate are formed by a ramp provided on the periphery of a fixed ring integral with the support frame, and a head integral with each sliding finger which is engaged in said ramp and controls the vertical movement of the fingers as a function of their rotation with respect to said frame and it is arranged for the ramp to be horizontal in a low position in a given sector of the support frame, to be horizontal in a high position in another sector disposed facing the first one, to be inclined ascending from the low position towards the high position in a first intermediate sector and to be inclined descending from the high position to the low position in a second intermediate sector.
In a particular characteristic of the invention, at least one ring serving for fastening the radial and circumferential threads is provided about the sleeve of the upper plate and rotates with the plates, the ring being formed of two superimposed half rings fixed to each other and between which the radial threads and the circumferential thread are nipped or having an upper profiled face with a certain slant corresponding to the slant of the desired woven cone and sliding along the sleeve of the upper plate.
In accordance with another characteristic of the invention, the means for ensuring movement of the platelets on the fingers is formed of a vertical routing plate extending in a sector of the support frame and fixed to said frame externally of said ramp and cooperating with the outer end of said platelets, said routing plate being formed of a lower part whose upper cut out has two sections slanted slightly upwardly meeting at a central point, an upper part whose lower cut-out has two slightly downward slanted sections and two lateral triangular parts whose slides are parallel to the slanting sections of the lower and upper parts, these parts being slightly spaced apart so as to form two indentations which extend from one end of the plate to the opposite end after crossing at the central point, and form guide grooves for the platelets.
BRIEF DESCRIPTION OF THE DRAWINGS
Other particular features and advantages of the invention will be clear from reading the following description of embodiments, with reference to the accompanying drawings which show:
FIG. 1: a cross-sectional view of the machine according to the invention;
FIG. 2: a top view of the machine,
FIG. 3: a developed plane view of the routing plate of the machine,
FIG. 4: a central sectional view of the lower part of the machine,
FIG. 5: a top view of a part of the machine of FIG. 2,
FIGS. 6 and 10: two partial views of weaving patterns obtained,
FIG. 7: a plane view showing the evolute of the reversal mechanism,
FIGS. 8 and 9: two views of fabrics obtained using the machine,
FIG. 11: a partial central cross-sectional view of a second embodiment of the machine, and
FIG. 12: a partial view of a particular weaving pattern which can be obtained with the machine of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more precisely to FIGS. 1 and 2, it can be seen that the weaving machine comprises essentially a support frame 4 above which an upper plate 1 and a lower plate 2 are mounted parallel to one another and form cheeks which may rotate about a vertical axis AA'. The lower plate 2 rests on a centering rivet 5 through bearings 10. A ring gear 11 integral with the plate meshes with a drive pulley 12 driven by a motor 13. A fixed ring 14, of a diameter slightly less than that of the plates, is secured to frame 4 and has on its external face and over the whole of its periphery a ramp 6. The lower plate 2 is pierced at its periphery and at even intervals with orifices for the passage of mobile fingers 9a which slide vertically and are provided at their lower end with heads 15 which are engaged in the ramp 6 of ring 14.
The upper plate 1 has the form of a disk whose central part 16 in the form of a sleeve rests on the lower plate 2 to which it is fixed by a set of screws 17. A ring 3, itself formed of two superimposed half rings 3a and 3b, surrounds sleeve 16 between the two plates. The two half rings are also fixed to each other by a set of screws 18.
With the plate-ring assembly thus fixed together, it is rotated by motor 13. The annular space between the lower face of the upper plate 1, sleeve 16 and the upper face of the lower plate 2 forms the weaving chamber 19 inside which the threads to be woven are placed. Radial threads are nipped between the two rings 3a and 3b and connected to peripheral platelets 8 through tension springs 20 fixed at their ends. These platelets are each formed with an orifice by which they are fitted either on mobile fingers 9a of the lower plate 2 or on fixed fingers 9b provided at the periphery of the upper plate 1. The fixed fingers 9b are oriented downwards and are located opposite the mobile fingers 9a. On the periphery of support frame 4 and over the whole length of an angular sector II is fixed a vertical routing plate 7 whose structure is shown in a plane view in FIG. 3. This plate is formed first of all by a lower part 7d whose base is fixed to frame 4 along sector II and whose upper cut out has two slightly upwardly inclined sections meeting at a central point P. Plate 7 is also formed of an upper part 7a whose lower cut-out has two slightly downward inclined sections, and two lateral triangular parts 7b and 7c whose points are oriented towards point P and whose sides are parallel to the inclined sections of parts 7a and 7d. The elements 7a, 7b and 7c of plate 7 are held in the position shown in FIG. 3 by supports, not shown. They are moved apart from each other so as to form with elements 7d two indentations 23 and 24 which extend from one end of plate 7 to the opposite end after crossing at the central point P. These indentations form guide grooves for the end of platelets 8. It will be noted particularly in FIG. 2 that the support frame is divided into four sectors: I, II, III, IV. A circumferential thread C fed from a reel 21 is also nipped between rings 3a and 3b and penetrates into the machine in sector IV. For the sake of clarity, only a certain number of platelets 8, 8', 8", etc . . . have been shown in FIG. 2.
Before starting up the machine, the radial threads need to be positioned. This operation takes place before fixing the upper plate 1 on the lower plate 2.
Referring to FIG. 4, it can be seen that the half ring 3a is in position on the lower plate 2. A central piece 22 having a point 25 is placed on this plate at the center thereof and is oriented upwardly. The radial threads R are stretched between point 25 and the spring 20 of a platelet 8 previously engaged on a finger 9a. So as to simplify this operation and make automation thereof possible, a continuous thread may, as shown in FIG. 5, be fixed to the point, then hooked onto the spring 20, then brought back to point 25 about which it is wound before being hooked onto the spring 20' of the adjacent platelet 8' and coming back to the point . . . etc . . . until said thread R has gone right round the plate. Thus, for each platelet 8, there are two radial threads r leading towards the center. If required, to facilitate this operation, the routing plate 7 is removed. The circumferential thread C is also fixed to point 25 and extends radially in the direction of reel 21.
With the threads thus stretched, the upper half ring 3b is placed on the lower half ring 3a and is tightened by means of screws 18. The threads (r and c) are thus nipped by the rings thus making it possible to cut them to the inner diameter thereof. Then piece 22 is removed and the upper plate 1 laid on the lower plate 2 to which it is fixed by screws 17 (FIG. 1). The platelets 8, 8', 8" are positioned alternately on fingers 9a and fingers 9b. The tension exerted by springs 20 makes it possible to hold them on the fingers at the height where they are initially positioned. The circumferential thread c is then placed tangentially to the outer diameter of ring 3 and the routing plates 7 are refitted on frame 4.
The machine is ready to operate. The fixed ramp 6- sets the height of the mobile fingers 9a by means of heads 15. FIG. 1 shows a finger 9a, on the left in the low position and on the right in the high position in which its end comes into abutment against the corresponding fixed finger 9b, thus forming a continuous column 9. Ramp 6 is horizontal in the low position in zone IV of the frame, horizontal in the top position in zone II opposite zone IV, slanted ascending from the low position to the high position in zone III, and slanted descending from the high position to the low position in zone I as shown in FIG. 7.
At the time of starting up the machine, the circumferential thread c is stretched between reel 21 and rings 3 and is engaged between the thread r hooked onto platelet 8 in the low position and thread r' hooked onto platelet 8' in the high position (see FIGS. 1 and 2). When the motor 13 rotates the plates 1 and 2, the circumferential thread c unwinds from reel 21 and then is wound about two adjacent radial threads. This operation takes place in zone IV where the two fingers 9a and 9b are moved apart from each other, which allows the passage of the circumferential thread. In zone III, where the ramp 6 ascends, fingers 9a are raised under the action of the head 15. In zone II, the fingers 9a and 9b are in abutment and form a smooth continuous column on which the platelets 8 may slide from bottom to top and from top to bottom, their orifices being provided on fingers 9 with a slight clearance. In zone II, said platelets 8 ride in the guide grooves 23 and 24 of the routing plate 7 and are appropriately moved vertically. It can be seen that the platelets arriving in the top position are moved towards a low position and conversely the platelets arriving in the low position are moved towards a high position. The high and low platelets being offset angularly on the plate will arrive in an offset position at point P and will cross it without a risk of clashing (FIG. 3). The clearance between the fingers and the platelets or else an oblong hole formed in each platelet will make it possible for these latter to be inclined in the sloping part of the routing plate.
This reversal of vertical position of the platelet causes reversal of the radial threads r--r', the top thread passing downwards and conversely. That means that the circumferential thread c will be wound between two bundles of radial threads as can be seen more precisely in FIG. 1. It will be noted that the tension of the circumferential thread is adjusted so as to position this thread correctly and to determine the packing of the preceding windings. The weave obtained is then of the taffeta type such as shown in FIG. 6.
Finally, in zone I, where the ramp 6 descends, fingers 9a come back to the low position.
FIG. 7 shows the evolute of the reversal mechanism for 25 platelets numbered from 101 to 125, showing the profile of the ramp 6 in the four zones, the corresponding position of fingers 9a and 9b as well as the position of the routing plate 7.
In variants of embodiment, weaves can be obtained whose radial threads r are slanted from the radial position to the tangential position as shown in FIG. 8. This is obtained after positioning the radial threads, by offsetting ring 3 by the desired angle with respect to the plate. Each spring 20 then takes up the difference of length between the two positions.
When two identical fabrics each as shown in FIG. 8 are superimposed, as with one of them being turned over, a fabric is obtained with symmetric reinforcement as shown in the variant of FIG. 9.
Furthermore, it may be interesting to obtain a fabric with substantially constant filling, compensating for the fact that the space between two adjacent radial threads increases also with the radius. For that, radial threads must be added when the space becomes equal for example to the width of two threads, as shown in FIG. 10. This operation may be carried out by preparing the machine with the total number of radial threads, but by arranging for some of them not to take part immediately in the weaving before the weaving has reached a certain radius R. For that, a certain number of platelets 8b are mounted right at the top part of the fixed finger 9b as shown with broken lines in FIG. 1. They thus escape the action of the routing plate 7 and take no part in the weaving. A mechanism not shown places them back in a normal position when the weaving has reached radius R and all of the radial threads are then involved in the weaving.
To obtain a cone shaped or dome shaped weave instead of a flat weave as described above, the assembly shown in FIG. 11 is used. Instead of ring 3, a special ring 26 is provided whose upper face is profiled and has a certain slant corresponding to the slant of the desired woven cone. This ring is fixed to an annulus 27 by a set of screws 28, threads r and c being nipped between the two. Annulus 27 is itself fixed to a stirrup 29 which is adjustable in height by means of a knurled wheel 30. Said wheel makes it possible to adjust the height of ring 26 with respect to plates 1 and 2, as the weaving progresses, so that the weaving follows the slope of the ring. So that the weaving is applied on this shape, the tension of the lower threads r will be greater than that of the upper threads, because of a greater length so a greater tractive force is exerted by spring 20 on the lower threads.
Finally, it will be readily understood that it would be possible to form reinforcements such, for example, as the one shown in FIG. 12 by adapting the machine and more particularly rings 3a, 3b, 26, 27 to the shape of the desired reinforcement.
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A machine for weaving fibers of glass, Kevlar, carbon and the like including a rotary assembly with two plates defining therebetween a weaving chamber. The lower plate has sliding fingers at its periphery and the upper plate has fixed fingers in line with the sliding fingers occupying positions where they are moved away from each other in at least one sector of the support frame and positions in which they are in contact with each other in at least another sector of the support frame for forming continuous columns enclosing the weaving chamber. The fingers serve as support for the radial threads. Hooking platelets are provided on the periphery of the support frame for ensuring movement of the sliding fingers perpendicularly to the lower plate, and movement of the platelets on said fingers as a function of their position with respect to the support frame.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a national stage application under 35 U.S.C. ยง371 of PCT Application Number PCT/EP2014/0058727 having an international filing date of Apr. 29, 2014 which designated the United States, which claimed priority to European Application Number 13166454.2 filed in the European Patent office on May 3, 2013, the entire disclosure of each of which are hereby incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to an electrical contact element having a coating comprising at least two layers and containing tin, and a method for manufacturing such a contact element.
BACKGROUND OF THE INVENTION
[0003] In view of the concerns of climate protection, the reduction of emissions of greenhouse gases such as carbon dioxide is of particular importance. Therefore, the automotive industry is striving to develop vehicles that have a relatively low fuel consumption to reduce carbon dioxide emissions in this way and to contribute to climate protection.
[0004] One approach for reducing fuel consumption and thus carbon dioxide emission is based on the reduction of the weight of the vehicle. In order to achieve weight savings, there is an intensified search for possibilities to replace materials with relatively high weight with lighter materials, so that the vehicle components can be made of lightweight materials.
[0005] According to this concept, there are efforts to also reduce the weight of the wiring of a vehicle by replacing copper which is typically used as a conductor material in cables by lightweight alternatives. A possible conductor material is aluminum, which is in principle suitable for replacing the copper lines, which as a light metal has a low density and thus a low weight.
[0006] However, the disadvantage is that when using aluminum as conductor material in combination with electrical contact elements, which are typically made of copper, corrosion processes occur at the contact point between copper and aluminum in the presence of an electrolyte, such as salt water, and atmospheric oxygen. These corrosion processes are particularly existent in the case of direct contact of copper and aluminum, since according to the electrochemical series there is a considerable difference between the standard potentials (normal potentials) of aluminum and copper, and thus a high driving force for the corrosion reaction. Through the galvanic corrosion, the amount of aluminum as less noble metal is reduced compared to copper, which significantly reduces the electrical conductivity at the contact points between the conductor material and the contact element, and thus a demand exists for a reliable corrosion protection in the use of aluminum conductor material in combination with an electrical contact element made of copper.
[0007] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
BRIEF SUMMARY OF THE INVENTION
[0008] The invention is based on the object to provide an electrical contact element, which can be used in combination with an aluminum-containing conductor material and offers reliable protection against corrosion.
[0009] The contact element according to the invention comprises a connecting segment, which is formed of a copper sheet and has a coating comprising a first layer containing tin. Furthermore, the coating comprises a second layer which is disposed between the first layer and the copper sheet. The second layer contains at least a metal or at least a metal alloy, wherein the metal or metal alloy is selected from the group consisting of copper-containing alloys, nickel, nickel-containing alloys, palladium, palladium-containing alloys, and any combinations of the above metals and metal alloys.
[0010] The invention is based on the general idea that the electrochemical potential of the connecting segment approaches the potential of aluminum, which is lower according to the electrochemical series, by a coating of the copper sheet connecting segment of the contact element, provided for contacting with an aluminum-containing conductor material. In this way, the difference between the potentials of copper and aluminum is at least approximately compensated, and thus the driving force of the corrosion is reduced so that it is no longer in a critical range. This corrosion protection is achieved in particular in that the coating with tin contains an element, which is between copper and aluminum in the electrochemical series.
[0011] A corrosion protection function is achieved in particular by the first layer containing tin, which is between copper and aluminum in the electrochemical series.
[0012] In contrast, the second layer provides a barrier function. Due to the arrangement of the second layer between the tin-containing first layer and the copper sheet of the connecting segment, the exchange of metal atoms by diffusion between the tin-containing first layer and the copper sheet is prevented. Without this barrier layer, the risk would arise that over the life of the vehicle a diffusion of tin from the first layer into the copper sheet occurs and hollow spaces or pores in the first layer are formed. Such a formation of hollow spaces and/or cracks would facilitate the penetration of an electrolyte into the layer system and expedite undesirable corrosion. To avoid this, the second layer is arranged between the tin-containing first layer and the copper sheet of the connecting segment, which at least contains a metal or at least a metal alloy selected from the group consisting of copper-containing alloys, nickel, nickel-containing alloys, palladium, palladium-containing alloys, and any combinations of the above metals and metal alloys.
[0013] All things considered, the contact element of the invention has excellent protection against corrosion at the contact point between the contact element and an aluminum-containing conductor material with at the same time minimal contact resistance by optimal electrical conductivity of the coating, ensuring permanent optimum contact with the conductor material.
[0014] The contact element according to the invention is generally suitable for contacting aluminum-containing lines. The contact element may be used in vehicle construction, since in this way aluminum-containing lines may be used instead of copper-containing lines, thereby a reduction of vehicle weight and thus fuel savings and reduced carbon dioxide emissions can be achieved.
[0015] Advantageous embodiments of the invention are disclosed in the dependent claims, the description and the drawings.
[0016] The connecting segment of the electrical contact element is a region which is provided for receiving the conductor material of an electrical line such as a cable. This can be done for example by crimping the connection with the conductor material.
[0017] At least the connecting segment of the electrical contact element is formed of a copper sheet. However, other portions and in particular the complete contact element may be formed of a copper sheet. For example, the contact element may be a stamped/bent part.
[0018] To be able to act as corrosion protection, in each case the coating is applied to the connecting segment of the electrical contact element. However, the coating may also be present in other areas of the contact element, wherein in principle it is conceivable that the coating completely covers the surface of the contact element. However, the coating may be limited only to the connecting segment of the contact element and that the remaining areas of the contact element, in particular an area intended for contacting a complementary contact element, for example a plug or socket portion, are without coating, to ensure an optimal electrical connection between the contact elements.
[0019] Advantageous embodiments of the invention will be described in the following.
[0020] Satisfactory results in terms of the barrier function are achieved when the second layer has a thickness of 0.1 to 5 micrometers (ฮผm), preferably of 0.5 to 5 ฮผm, more preferably of 0.5 to 3 ฮผm, even more preferably of 0.7 to 2.5 ฮผm, and most preferably of 0.8 to 2.2 ฮผm.
[0021] Furthermore, the second layer may contain a copper-containing alloy. In particular, the second layer may consist of a copper-containing alloy.
[0022] For example, the copper-containing alloy may comprise a content of 35 to 97% by weight of copper, preferably a content of 40 to 90% by weight of copper, more preferably a content of 45 to 80% by weight of copper, and most preferably a content of 50 to 65% by weight of copper in relation to the copper-containing alloy to achieve good results in terms of the barrier function.
[0023] Furthermore, the copper-containing alloy may comprise a metal which is between copper and aluminum in the electrochemical series. In this way, the second layer also provides a contribution to approaching the potential of aluminum and to the reduction of the potential difference between the copper sheet of the contact element and the aluminum-containing conductor material to reduce the driving force for the corrosion reaction. For example, the copper-containing alloy may contain tin and/or zinc. Thus, a bronze alloy or brass alloy may be used as a copper-containing alloy, for example. Optionally, the bronze alloy may further comprise a zinc supplement, while conversely the brass alloy may optionally contain tin.
[0024] To form an effective diffusion barrier and to achieve good corrosion protection, the second layer may contain a copper-containing alloy, including tin and zinc, or consist of one.
[0025] Such a copper-, tin- and zinc-containing alloy contains 35 to 75% by weight of copper, 15 to 45% by weight of tin and 5 to 50% by weight of zinc, more preferably 40 to 70% by weight of copper, 20 to 40% by weight of tin and 10 to 30% by weight of zinc, even more preferably 45 to 65% by weight of copper, 25 to 35% by weight of tin and 10 to 30% by weight of zinc, most preferably 48 to 60% by weight of copper, 27 to 33% by weight of tin and 12 to 20% by weight of zinc, in relation to the copper-containing alloy, respectively. The sum of copper, tin and zinc, is preferably at least 90% by weight in relation to the copper-containing alloy. The residual weight of the copper-containing alloy may be alloy components typically used in copper-containing alloys, such as nickel, palladium, phosphorus, aluminum, iron, cobalt, manganese, tungsten, gold, silver and/or lead, for example, and/or inevitable impurities.
[0026] According to a further embodiment, the second layer may contain a copper-, tin- and zinc-containing alloy or consist of one, which comprises preferably 35 to 75% by weight of copper, 15 to 45% by weight of tin and 5 to 50% by weight of zinc, more preferably 40 to 70% by weight of copper, 20 to 40% by weight of tin and 10 to 30% by weight of zinc, even more preferably 45 to 65% by weight of copper, 25 to 35% by weight of tin and 10 to 30% by weight of zinc, most preferably 48 to 60% by weight of copper, 27 to 33% by weight of tin and 12 to 20% by weight of zinc in relation to the copper-containing alloy, respectively, wherein the sum of copper, tin and zinc is preferably at least 95% by weight of the copper-containing alloy. The residual weight of the copper-containing alloy may be alloy components typically used in copper-containing alloys, which may be, for example, the elements listed in the previous paragraph, and/or inevitable impurities.
[0027] According to yet a further embodiment, the second layer may contain a copper-, tin- and zinc-containing alloy or consist of one, which comprises preferably 35 to 75% by weight of copper, 15 to 45% by weight of tin and 5 to 50% by weight of zinc, more preferably 40 to 70% by weight of copper, 20 to 40% by weight of tin and 10 to 30% by weight of zinc, even more preferably 45 to 65% by weight of copper, 25 to 35% by weight of tin and 10 to 30% by weight of zinc, most preferably 48 to 60% by weight of copper, 27 to 33% by weight of tin and 12 to 20% by weight of the copper-containing alloy, respectively, wherein the sum of copper, tin and zinc is preferably at least 98% by weight of the copper-containing alloy. The residual weight of the copper-containing alloy may also be alloy components typically used in copper-containing alloys, which may be the elements listed in both previous paragraphs, and/or inevitable impurities.
[0028] An effective diffusion barrier and a good corrosion protection are also achieved when the second layer contains a copper- and zinc-containing alloy or consists of such an alloy.
[0029] Preferably, such a copper- and zinc-containing alloy contains 40 to 80% by weight of copper and 20 to 60% by weight of zinc, more preferably 50 to 75% by weight of copper and 25 to 50% by weight of zinc, even more preferably 55 to 70% by weight of copper and 30 to 45% by weight of zinc, most preferably 57 to 68% by weight of copper and 32 to 43% by weight of the copper-containing alloy, respectively. Thereby, the sum of copper and zinc is preferably at least 90% by weight of the copper-containing alloy. The residual weight of the copper-containing alloy may be alloy components typically used in copper-containing alloys, such as nickel, palladium, phosphorus, aluminum, iron, cobalt, manganese, tungsten, gold, silver, tin and/or lead, for example, and/or inevitable impurities.
[0030] According to a further embodiment, the second layer may contain a copper- and zinc-containing alloy, preferably with 40 to 80% by weight of copper and 20 to 60% by weight of zinc, more preferably 50 to 75% by weight of copper and 25 to 50% by weight of zinc, even more preferably 55 to 70% by weight of copper and 30 to 45% by weight of zinc, most preferably 57 to 68% by weight of copper and 32 to 43% by weight of zinc in relation to the copper-containing alloy, respectively, or consist of one, wherein the sum of copper and zinc is at least 95% by weight of the copper-containing alloy. The residual weight of the copper-containing alloy may be alloy components typically used in copper-containing alloys, which may be the elements listed in the previous paragraph, for example, and/or inevitable impurities.
[0031] According to yet a further embodiment, the second layer may contain a copper- and zinc-containing alloy, preferably with 40 to 80% by weight of copper and 20 to 60% by weight of zinc, more preferably 50 to 75% by weight of copper and 25 to 50% by weight of zinc, even more preferably 55 to 70% by weight of copper and 30 to 45% by weight of zinc, most preferably 57 to 68% by weight of copper and 32 to 43% by weight of zinc in relation to the copper-containing alloy, respectively, or consists of one, wherein the sum of copper and zinc is preferably at least 98% by weight in relation to the copper-containing alloy. The residual weight of the copper-containing alloy may be alloy components typically used in copper-containing alloys, in particular the elements listed in the two previous paragraphs, and/or inevitable impurities.
[0032] According to an alternative embodiment, the second layer may contain nickel or a nickel-containing alloy and particularly consist preferably of nickel or a nickel-containing alloy. When the second layer contains nickel or a nickel-containing alloy or consists of a nickel-containing alloy, the nickel content is preferably at least 80% by weight, more preferably at least 90% by weight, even more preferably at least 95% by weight and most preferably at least 98% by weight of the nickel-containing alloy. The residual weight of the nickel-containing alloy may be alloy components typically used in nickel-containing alloys such as copper, palladium, platinum, aluminum, cobalt, manganese, silicon, chromium, iron, zinc, molybdenum, tungsten, magnesium and/or titanium, for example.
[0033] Further alternatively, the second layer may contain palladium or a palladium-containing alloy or in particular consist of one, wherein the palladium content is preferably at least 80% by weight of palladium, more preferably at least 90% by weight of palladium, even more preferably at least 95% by weight of palladium and most preferably at least 98% by weight of the palladium-containing alloy. The residual weight of the palladium-containing alloy may be alloy components typically used in palladium-containing alloys such as, for example, copper, nickel, platinum, silver and/or gold, and/or inevitable impurities.
[0034] According to a further embodiment, the first layer of the coating is an outer layer, which is intended for direct contact with the conductor material. Furthermore, the first layer is preferably directly adjacent to the second layer, i.e., the first layer is preferably immediately above the second layer.
[0035] According to yet another embodiment, a good protection against corrosion is achieved particularly when the first layer contains at least 60% by weight of the first layer. Preferably, the first layer contains at least 70% by weight of tin, more preferably at least 80% by weight of tin and most preferably at least 90% by weight of tin in relation to the first layer. In particular, the first layer may be a high purity tin layer, for example containing at least 95% by weight of tin or at least 98% by weight of tin.
[0036] In addition, the first layer may contain zinc to further approach the potential of the first layer to the potential of the aluminum-containing conductor material by the addition of zinc, which has a lower standard potential than tin but a higher standard potential as aluminum according to the electrochemical series, and thus reduce the potential difference as a driving force for corrosion. For example, the first layer may contain 0 to 40% by weight of zinc, preferably 2 to 30% by weight of zinc, more preferably 5 to 25% by weight of zinc, and most preferably 10 to 20% by weight of zinc in relation to the first layer. When the first layer contains both tin and zinc, the sum of tin and zinc is preferably 90% by weight, more preferably 95% by weight, most preferably 98% by weight in relation to the second layer. The residual weight of the second layer may be typical components which are used in tin and/or zinc alloys, and/or inevitable impurities.
[0037] To also achieve effective corrosion protection for a life span normally expected in automotive applications, for example, the first layer preferably has a thickness of 1 to 15 ฮผm, more preferably of 2 to 10 ฮผm, even more preferably of 3 to 7 ฮผm, most preferably of 4 to 6 ฮผm, and in particular, if the second layer has a thickness of 0.1 to 5 ฮผm, preferably of 0.5 to 5 ฮผm, more preferably of 0.5 to 3 ฮผm, even more preferably of 0.7 to 2.5 ฮผm, most preferably of 0.8 to 2.2 ฮผm.
[0038] According to yet another embodiment, the coating may further comprise a third layer which is disposed between the second layer and the copper sheet and contains tin. Such a third layer is present, for example, when for manufacturing the electrical contact element, a copper sheet is used as starting material, which is provided with a tin layer applied by fire-tinning. If there is a third layer, for example in the case of a fire-tinned copper sheet, it is regarded as part of the coating and not as part of the copper sheet.
[0039] In the case of the presence of a third layer, it contains preferably at least 80% by weight of tin, more preferably at least 90% by weight of tin, even more preferably at least 95% by weight of tin and most preferably at least 98% by weight of tin in relation to the third layer. Most preferably, the third layer consists of tin.
[0040] The thickness of the third layer may be in the range of 0.01 to 5 ฮผm, preferably 0.5 to 3.5 ฮผm, and more preferably 1 to 2 ฮผm.
[0041] According to a further preferred embodiment, the third layer is directly adjacent to the second layer and/or to the copper sheet of the contact element. If no third layer is provided, the second layer may be applied directly to the copper sheet of the contact element and be adjacent to it.
[0042] Further, the coating may comprise a fourth layer, which is arranged on a side of the first layer opposite the second layer and the copper sheet and contains zinc. Such a fourth layer may be formed as an outer layer. In addition, the fourth layer may be directly adjacent to the first layer. Such a structure of the coating, in which not only an original first layer and a second layer but also a fourth layer is provided, which is formed as an outer layer and is directly adjacent to the first layer, may in itself already serve as corrosion protection. Preferably, however, such a layer structure is used as intermediate product for the preparation of a coating, in which by at least partial merging of the original first layer and the fourth layer, for example by heat treatment, a modified first layer is formed containing both tin and zinc. In particular, a tin- and zinc-containing alloy may form in such a merging.
[0043] If a fourth layer is provided additionally to the first and second layers, it contains preferably at least 80% by weight of zinc, more preferably at least 90% by weight of zinc, even more preferably at least 95% by weight of zinc, and most preferably at least 98% by weight of zinc in relation to the fourth layer. Alternatively, the fourth layer may also consist of zinc.
[0044] The thickness of the fourth layer may range from 0.1 to 3 ฮผm, preferably from 0.2 to 2 ฮผm, more preferably from 0.5 to 1.5 ฮผm and most preferably from 0.7 to 1.3 ฮผm. By selecting the thicknesses and the contents of tin and zinc of the original first layer applied before the heat treatment and of the fourth layer, the tin content and the zinc content may be adjusted in the modified first layer, which is formed by at least partial merging of the original first layer and the fourth layer by means of heat treatment.
[0045] The layers of the coating described above may be directly adjacent to one another according to one embodiment. However, it is also possible that there are regions between the respective layers comprising one or more intermetallic phases. Such intermetallic phase regions may contain metals from the respective layers adjacent to these regions and may be caused for example by diffusion processes during storage of the coating for a longer period of time or formed specifically by heat treatment. For example, intermetallic phase region may be provided between the first layer and the second layer and/or between the second layer and the third layer and/or between the third layer and the copper sheet and/or between the first layer and the fourth layer. Without wanting to be bound by theory, it is assumed that such intermetallic phase regions reinforce the barrier function to prevent in this way diffusion processes between the layers and thus to increase the life period of the coating. The thickness of said intermetallic phase regions may be from 0.01 to 3 ฮผm, preferably from 0.1 to 2 ฮผm, more preferably from 0.25 to 1.5 ฮผm, and most preferably from 0.5 to 1 ฮผm, respectively.
[0046] The total thickness of the coating may be from 1 to 25 ฮผm, preferably 2 to 20 ฮผm, more preferably 3 to 15 ฮผm and most preferably 4 to 10 ฮผm, in particular independently of the above described thicknesses of the individual layers. Thereby, the thickness of a possibly existing intermetallic phase region, which is directly adjacent to the copper sheet, counts to the total thickness of the coating.
[0047] A further object of present invention is a method for manufacturing an electrical contact element, in particular for manufacturing an electrical contact element according to one of the types described above, comprising the steps of:
providing a base body of optionally fire-tinned copper sheet, applying a second layer on the base body, wherein the second layer contains at least a metal or at least a metal alloy, wherein the metal or metal alloy is selected from the group consisting of a copper-containing alloy, nickel, palladium and any combinations of the above metals and metal alloys, and applying a first layer containing tin on a side of the second layer opposite the base body.
[0051] The shape of the base body on which the layers are applied is not particularly limited. For example, the base body can already have the final shape of the contact element. Alternatively, the base body can be brought into the final shape of the contact element only after its coating by forming steps such as stamping and/or bending, for example.
[0052] In order not to interfere with the electrical conductivity when contacting the electrical contact element, as described above, the coating is preferably applied only to an area of the base body provided as connecting segment. However, it is also conceivable to apply the coating to other areas of the base body, in particular to the complete base body.
[0053] Advantageous embodiments of the method for manufacturing a contact element are described below.
[0054] In addition to the first and second layers, optionally a third and/or fourth layer, as described above, may be applied. Preferably, the first, the second, optionally the third and/or fourth layers are applied such that the above arrangement of the layers relative to each other results. Thereby, the layers of the coating preferably are directly adjacent to one another, and the third layer preferably is directly adjacent to the copper sheet of the connecting segment.
[0055] The first layer and the second layer preferably comprise the compositions described above, particularly in terms of the respective metals or metal alloys and their concentrations used in the first and second layers. Also, the optional third and/or fourth layers preferably comprise the compositions described above, particularly in terms of the respective metals and their concentrations. Also preferably, the first, the second, the optional third and/or fourth layers have layer thicknesses according to the ranges described above for the respective layer. Also, the total thickness of the obtained coating is preferably in the ranges described above.
[0056] The method for applying the layers is not particularly limited. For example, at least one layer may be applied by a method selected from the group consisting of galvanic technique, vapor coating, sputtering, dip coating, spray coating, and any combinations of the above methods.
[0057] Good results in terms of corrosion protection and durability of the coating can be achieved, for example, if the first, the second and optional the fourth layers are applied by galvanic technique or electroplating, i.e., by the electrolytic deposition of a metal layer from an aqueous metal salt solution. The galvanic process may comprise further process steps, typically used in galvanic technique, such as degreasing, rinsing and/or the removal of surface oxides.
[0058] The third layer, if provided, is applied preferably by means of dip coating. Therefore, the base body may be fire-tinned, for example, by immersion in a bath of molten tin. As described above, the third layer may already be provided in that a commercially available base body made of fire-tinned copper sheet is used. Alternatively, the third layer may be omitted and the second layer may be applied directly to the copper sheet of the base body.
[0059] According to a further improvement of the method, a heat treatment may be carried out after application of the layers to the base body to assist in the formation of the intermetallic phase regions between the layers described above. Also, by heat treatment, as already described above, merging between the first and fourth layers to a modified first layer may be carried out. With such a merging of the first and fourth layers by means of heat treatment, in particular a tin- and zinc-containing alloy can be formed.
[0060] The heat treatment may be carried out in a temperature range of 50 to 350ยฐ C., preferably of 80 to 300ยฐ C., more preferably of 200 to 280ยฐ C., even more preferably of 220 to 270ยฐ C. and most preferably of 230 to 250ยฐ C. Thereby, the temperature after the heating process is preferably maintained for a time period of 1 second to 48 hours, more preferably of 3 seconds to 12 hours, even more preferably of 5 seconds to 5 minutes and most preferably of 5 seconds to 2 minutes. More preferably, the heat treatment is carried out at a temperature in the range of 200 to 280ยฐ C. which is held for a time period of 5 seconds to 5 minutes. Most preferably, the heat treatment is carried out at a temperature in the range of 220 to 270ยฐ C. which is held for a time period of 5 seconds to 2 minutes.
[0061] If the manufacturing of the electrical contact element according to any one of the methods described above requires a forming of the base body, the sequence of the forming steps and the steps for applying the coating is not particularly defined. For example, the method may comprise the steps that the base body is stamped from a copper band and bent over to a contact element, wherein at least one layer of the coating is applied between the stamping and the bending or following the bending. It is also possible to carry out the heat treatment after applying the layers before or after bending.
[0062] Also, an object of the present invention is an electrical contact element, which is obtainable by one of the methods described above.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0063] The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
[0064] FIG. 1 is a perspective view of an embodiment of an electrical contact element according to the invention prior to the connection of an electrical line,
[0065] FIG. 2 is a perspective view of the contact element shown in FIG. 1 with a connected electrical line,
[0066] FIG. 3 shows schematically a connecting segment of an electrical contact element with a coating according to a first embodiment,
[0067] FIG. 4 shows schematically a connecting segment of an electrical contact element with a coating according to the first embodiment following heat treatment,
[0068] FIG. 5 shows schematically a connecting segment of an electrical contact element with a coating according to a second embodiment,
[0069] FIG. 6 shows schematically a connecting segment of an electrical contact element with a coating according to the second embodiment following heat treatment,
[0070] FIG. 7 shows schematically a connecting segment of an electrical contact element with a coating according to a third embodiment,
[0071] FIG. 8 shows schematically a connecting segment of an electrical contact element with a coating according to the third embodiment following heat treatment.
DETAILED DESCRIPTION OF THE INVENTION
[0072] FIGS. 1 and 2 show an electrical contact element 1 , comprising a contact portion 3 for contacting a complementary contact element, and a connecting segment 5 for connecting an electrical line 15 . The connecting segment 5 in turn is divided into a crimping portion 7 having crimping wings 9 and a holding portion 11 having holding wings 13 , which are provided for fixing the electrical line 15 . For this purpose, the crimping wings 9 of the crimping portion 7 are crimped to stripped conductor material 17 of the electrical line 15 , while the holding wings 13 of the holding portion 11 are crimped to the insulation 19 of the electrical line 15 ( FIG. 2 ).
[0073] The connecting segment 5 is formed of a copper sheet 21 and provided with a coating 23 .
[0074] According to a first embodiment shown schematically in FIG. 3 , the coating 23 comprises a third layer 29 of tin applied by fire-tinning to a surface of the copper sheet 21 . On the surface of the third layer 29 opposite the copper sheet 21 , a galvanically applied second layer 27 is arranged made of bronze alloy containing copper, tin and zinc. Alternatively, the second layer 27 may also be formed of a brass alloy containing copper and zinc. In addition, on the surface of the second layer 27 opposite the copper sheet 21 , a first layer 25 of tin is applied galvanically, which forms an outer layer, which is provided for the contacting of the conductor material 17 ( FIG. 2 ).
[0075] As shown in FIG. 4 , between the layers 25 , 27 , and 29 there may be provided additional regions 31 , 33 and 35 of intermetallic phases that form itself over time or can be specifically produced by heat treatment. In this case, a first intermetallic phase region 31 is disposed between the first layer 25 and second layer 27 , a second intermetallic phase region 33 between the second layer 27 and third layer 29 , and a third intermetallic phase region 35 between the third layer 29 and the copper sheet 21 .
[0076] FIG. 5 shows a second embodiment of the coating 23 comprising four layers. First, a third layer 29 of tin, applied by fire-tinning, is disposed directly on the surface of the copper sheet 21 , on which surface, opposite the copper sheet 21 , immediately follows a galvanically applied second layer 27 of nickel. On the surface of the second layer 27 opposite the copper sheet 21 a galvanically applied first layer 25 is provided. Further, on the surface of the first layer 25 opposite the copper sheet 21 a galvanically applied fourth layer 37 of zinc is provided which forms an outer layer.
[0077] FIG. 6 shows the state of this second embodiment following heat treatment. Due to the heat treatment, the originally existing first layer 25 of tin and the fourth layer 37 of zinc have been merged into a modified first layer 39 containing both tin and zinc. Still, the second layer 27 of nickel and the third layer 29 of tin are present. Further, following heat treatment an intermetallic phase region 35 is present between the third layer 29 and the copper sheet 21 .
[0078] FIG. 7 shows a coating 23 according to a third embodiment, which has no third layer 29 of tin applied by fire-tinning. Rather, a galvanically applied second layer 27 of bronze alloy, containing copper, tin and zinc, is provided directly on the surface of the copper sheet 21 . On the surface of the second layer 27 opposite the copper sheet 21 a galvanically applied first layer 25 of tin follows. Further, on the surface of the first layer 25 opposite the copper sheet 21 , a galvanically applied fourth layer 37 of zinc is provided which forms an outer layer.
[0079] FIG. 8 shows the state of said third embodiment following heat treatment. Due to the heat treatment, the original first layer 25 and the original fourth layer 37 have been merged into a modified first layer 39 containing tin and zinc. Further provided are the second layer 27 of the bronze alloy, an intermetallic phase region 31 between the modified first layer 39 and the second layer 27 as well as another intermetallic phase region 41 between the second layer 27 and the copper sheet 21 .
[0080] In the following, the manufacturing of the above embodiments of the contact element 1 will be described:
[0081] According to a first embodiment shown in FIG. 3 , a copper band, comprising preforms with a fire-tinned third layer 29 stamped of copper sheet 21 , which may be brought into the form of the electrical contact element 1 by bending, is initially subjected to a pretreatment prior to galvanizing. For this purpose, the portions of the preform, which form the connecting segment 5 , are successively hot-degreased, rinsed, electrolytically degreased, rinsed, cleaned of surface oxides and rinsed again. A bronze alloy is then galvanically applied by electroplating as second layer 27 on the thus pretreated connecting segment 5 of the fire-tinned preform, wherein the electroplating is carried out for 4 minutes at 60ยฐ C. and a current density of 1 ampere/square decimeter (A/dm 2 ) in an aqueous bath having a copper ion concentration of 14 grams/liter (g/L), a tin ion concentration of 20 g/L and a zinc ion concentration of 4 g/L (e.g. using BRONZEXยฎ WJ-SP available from Enthone, Inc. of West Haven, Conn.). In this way, a second layer 27 of bronze alloy is obtained having a composition of 50 to 55% by weight of copper, 28 to 32% by weight of tin and 15 to 19% by weight of zinc and having a thickness of 1 ฮผm.
[0082] Alternatively, instead of the second layer 27 of the bronze alloy, a second layer 27 made of a brass alloy may be galvanically applied by electroplating onto the pretreated connecting segment 5 of the fire-tinned preform, wherein the electroplating is carried out for 8 minutes at 50ยฐ C. and a current density of 0.5 A/dm 2 in an aqueous bath, having a copper ion concentration of 18 g/L and a zinc ion concentration of 21 g/L (e.g. using TRIUMPF 10 available from Enthone, Inc). In this way, a second layer 27 of brass alloy is obtained having a thickness of 1 ฮผm.
[0083] Subsequently, the portions of the preform comprising the second layer 27 are rinsed, cleaned of surface oxides and rinsed again, before a first layer 25 of tin is galvanically applied by electroplating onto the second layer 27 . In practice, this tinning is carried out for 11 minutes at room temperature and at a current density of 1 A/dm 2 in an aqueous bath having a tin ion concentration of 80 g/L (e.g. using STANNOSTARโข HMM 2 LF, a non-fluoroborate matte tin electrolyte available from Enthone, Inc.). The first layer 25 of tin thus obtained has a thickness of 5 ฮผm.
[0084] After the tinning, the preform is rinsed again and dried for 3 minutes at 40ยฐ C. For completion of the electrical contact element 1 , the preform is separated from the copper band by stamping and brought in its final shape by bending.
[0085] The contact element 1 thus obtained can now be connected with the electrical line 15 by crimping.
[0086] Optionally, the contact element 1 may be subjected to a heat treatment beforehand, in which the contact element 1 is heated within 2 minutes to 240ยฐ C. and held for 1 minute at this temperature before cooling to room temperature again. Due to the heat treatment, the intermetallic phase regions 31 , 33 and 35 between the first layer 25 of tin and the second layer 27 of bronze or brass, between the second layer 27 and the fire-tinned third layer 29 , and between the third layer 29 and the copper sheet 21 are specifically formed ( FIG. 4 ).
[0087] According to a second embodiment shown in FIG. 5 , a copper band, comprising preforms with a fire-tinned third layer 29 stamped of copper sheet 21 , which may be brought into the form of the electrical contact element 1 by bending, is initially subjected to a pretreatment prior to galvanizing. For this purpose, those portions of the preform, which form the connecting segment 5 , are successively hot-degreased, rinsed, electrolytically degreased, rinsed, cleaned of surface oxides and rinsed again. A nickel layer is then galvanically applied by electroplating as second layer 27 on the thus pretreated connecting segment 5 of the fire-tinned preform, wherein the electroplating is carried out for 7 minutes at 60ยฐ C. and a current density of 1 A/dm 2 in an aqueous bath having a nickel ion concentration of 113 g/L (e.g. using LECTRO-NICโข 10-03 HSX available from Enthone, Inc.). In this way, a second layer 27 of nickel is obtained, having a thickness of 1 ฮผm.
[0088] Subsequently, the portions of the preform comprising the second layer 27 are rinsed, cleaned of surface oxides and rinsed again, before a first layer 25 of tin is galvanically applied by electroplating onto the second layer 27 . In practice, this tinning is carried out for 11 minutes at room temperature and at a current density of 1 A/dm 2 in an aqueous bath having a tin ion concentration of 80 g/L (e.g. using STANNOSTARโข HMM 2 LF, a non-fluoroborate matte tin electrolyte available from Enthone, Inc.). The first layer 25 of tin thus obtained has a thickness of 5 ฮผm.
[0089] After the tinning, the portions of the preform comprising the first layer 25 are rinsed, cleaned of surface oxides and rinsed again, before a fourth layer 37 of zinc is galvanically applied by electroplating onto the first layer 25 . In practice, this zinc plating is carried out for 3 minutes at room temperature and at a current density of 1.5 A/dm 2 in an aqueous bath having a zinc ion concentration of 160 g/L (e.g. using ENTHOBRITE acidic zinc electrolyte available from Enthone, Inc.). The fourth layer 37 of zinc thus obtained has a thickness of 1 ฮผm.
[0090] After the zinc plating, the preform is rinsed again and dried for 3 minutes at 40ยฐ C. For completion of the electrical contact element 1 , the preform is separated from the copper band by stamping and brought in its final shape by bending.
[0091] Optionally, the contact element 1 , before being connected with the electrical line 15 by crimping, may be subjected to heat treatment, in which the contact element 1 is heated within 2 minutes to 240ยฐ C. and held for 1 minute at this temperature before cooling to room temperature again. By the heat treatment, the original first layer 25 and the original fourth layer 37 are merged to the modified first layer 39 and the intermetallic phase region 35 between the fire-tinned third layer 29 and the copper sheet 21 is specifically formed ( FIG. 6 ).
[0092] According to a third embodiment shown in FIG. 7 , a copper band, comprising preforms without fire-tinning stamped of copper sheet 21 , which may be brought into the form of the electrical contact element 1 by bending, is initially subjected to a pretreatment prior to galvanizing. For this purpose, those portions of the preform, which form the connecting segment 5 , are successively hot-degreased, rinsed, electrolytically degreased, rinsed, cleaned of surface oxides and rinsed again. A bronze alloy is then galvanically applied by electroplating as second layer 27 on the thus pretreated copper sheet 21 of the connecting segment 5 of the preform, wherein the electroplating is carried out for 4 minutes at 60ยฐ C. and a current density of 1 A/dm 2 in an aqueous bath having a copper ion concentration of 14 g/L, a tin ion concentration of 20 g/L and a zinc ion concentration of 4 g/L (e.g. using BRONZEXยฎ WJ-SP available from Enthone, Inc.). In this way, a second layer 27 of bronze alloy with a composition of 50 to 55% by weight of copper, 28 to 32% by weight of tin and 15 to 19% by weight of zinc is obtained, having a thickness of 1 ฮผm.
[0093] Subsequently, the portions of the preform comprising the second layer 27 are rinsed, cleaned of surface oxides and rinsed again, before a first layer 25 of tin is galvanically applied by electroplating onto the second layer 27 . In practice, this tinning is carried out for 11 minutes at room temperature and at a current density of 1 A/dm 2 in an aqueous bath having a tin ion concentration of 80 g/L (e.g. using STANNOSTARโข HMM 2 LF, a non-fluoroborate matte tin electrolyte available from Enthone, Inc.). The first layer 25 of tin thus obtained has a thickness of 5 ฮผm.
[0094] After the tinning, the portions of the preform comprising the first layer 25 are rinsed, cleaned of surface oxides and rinsed again, before a fourth layer 37 of zinc is galvanically applied by electroplating onto the first layer 25 . In practice, this zinc plating is carried out for 3 minutes at room temperature and a current density of 1.5 A/dm 2 in an aqueous bath having a zinc ion concentration of 160 g/L (e.g. using ENTHOBRITE acidic zinc electrolyte available from Enthone, Inc.). The fourth layer 37 of zinc thus obtained has a thickness of 1 ฮผm.
[0095] After the zinc plating, the preform is rinsed again and dried for 3 minutes at 40ยฐ C. For completion of the electrical contact element 1 , the preform is separated from the copper band by stamping and brought in its final shape by bending.
[0096] Optionally, the contact element 1 , before being connected with the electrical line 15 by crimping, may be subjected to heat treatment, in which the contact element 1 is heated within 2 minutes to 240ยฐ C. and held at this temperature for 1 minute before cooling to room temperature again. Due to the heat treatment, the original first layer 25 and the original fourth layer 37 are merged to the modified first layer 39 and the intermetallic phase regions 31 and 41 between the modified first layer 39 and the second layer 27 and between the second layer 27 and the copper sheet 21 are specifically formed ( FIG. 8 ).
[0097] While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
LIST OF REFERENCE NUMERALS
[0000]
1 Contact element
3 Contact portion
5 Connecting segment
7 Crimping portion
9 Crimping wings
11 Holding portion
13 Holding wings
15 Electrical line
17 Conductor material
19 Insulation
21 Copper sheet
23 Coating
25 First layer
27 Second layer
29 Third layer
31 Intermetallic phase region
33 Intermetallic phase region
35 Intermetallic phase region
37 Fourth layer
39 Modified first layer
41 Intermetallic phase region
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An electrical contact element and a method of manufacturing an electrical contact element having a connecting segment which is formed of a copper sheet and comprising a coating overlaying the copper sheet having at least two layers. A first layer contains at least 60% by weight of tin. A second layer is disposed between the first layer and the copper sheet. The second layer contains a copper-containing alloy. The copper-containing alloy contains 40 to 80% by weight of copper and 20 to 60% by weight of zinc. The combined percentage by weight of copper and zinc in the second layer is at least 90%. A third layer containing tin may be disposed between the second layer and the copper sheet. A fourth layer containing zinc may be disposed on a side of the first layer opposite the second layer.
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BACKGROUND OF THE INVENTION
The present invention relates to mechanisms for securing and leveling appliance type structures and other similar structures. More particularly it relates to a mechanism adapted for convenient, reliable use in structures such as mobile homes, recreation vehicles and the like, to permit the appliances and similar mechanisms in such structures to be secured and leveled.
It is generally known that vehicles such as recreational vehicles are frequently moved from one location to another as the occupants seek the new environments and new experiences to be found in new locations. Many of the more scenic locations are found in locations which have uneven terrain and essentially all recreational vehicles are at one time or another on such uneven terrain. It is frequently the case in such scenic areas that the vehicle is parked on a slope because the terrain does not present a prefectly flat and level parking space. The vehicles themselves are frequently about 8 feet wide and 40 feet long so that the finding of a perfectly flat parking space is frequently difficult or simply not possible. Many of the parks which cater to such RV's are themselves on uneven terrain and the rented spaces which are provided for use by the RV's are on significant slopes and are therefore not themselves horizontal. For these and other reasons it is frequently the case that such vehicles spend the night on a sloped parking space. And then spend the next night on a space with a different slope. So that frequent leveling adjustment of the vehicle is needed as the vehicle goes from one location to another.
The leveling of an entire recreational vehicle requires substantial energy and the mechanism which can accomplish such leveling must be capable of exerting considerable force. Such leveling can be accomplished with a set of vehicle jacks. For a recreational vehicle the lower level cost of such a set of jacks is about $3000.00 and they can cost as much as $4500.00 or more. There is a need for a lower cost mechanism for accomplishing the leveling which is needed in connection with recreation vehicle use.
A refrigerator is one of the appliances with is most sensitive to non-level support. Where the refrigerator is not in a true upright position the condensed freon coolant can get trapped where it should not be in the condenser tubing, or evaporator tubing, or other part of the cooling mechanism of the refrigator, and block the gravity flow of liquid and interfere with the proper movement of the gas. A first result of this blockage is that the cooling mechanism simply does not cool the refrigerator interior. A second result is that the compressor, which liquifies the gas to a liquid to remove its heat, becomes overloaded and this can cause damage to the refrigerator mechanism. Recreational vehicle users who do not level their vehicles properly can find that their refrigerators are damaged and have to be repaired or replaced. The type of refrigerator which operates in a recreational vehicle can operate from a 12 volt power supply or from a 110 volt conventional household power supply or it can alternatively operate from a supply of propane. Repair or replacement of such mechanisms is expensive.
A number of U. S. patents have been issued dealing with various types of mechanisms for aligning various structures and assemblies. The following such patents are known to the inventor: U.S. Pat. Nos. 4,549,710; 4,483,503; 4,365,779; 4,500,060; 2,922,609; 4,354,654; 2,893,674; 4,554,590; 4,068,961 and 4,564,166. However none of these patents discloses or describes a mechanism which is suitable or satisfactory for solving the problem which confronts the occupants of a recreational vehicle, or even provides information which makes the solution of the problem readily evident or obvious.
BRIEF STATEMENT OF THE INVENTION
It is accordingly one object of the present invention to provide a mechanism for leveling and securing appliances in recreational and similar vehicles.
Another object is to substantially reduce the cost of bringing portable appliances into upright position for operation.
Another object is to assist the occupants and users of recreational vehicles in maintaining the operation of the vehicle appliances free from hazard and damage.
Another object is to simplify the overall operation of recreational and similar vehicles.
Still another object is to provide a leveling mechanism for portable appliances and similar mechanisms.
Other objects and advantages of the invention will be in part apparent and in part pointed out in the description which follows.
In one of its broader aspects objects of the invention can be achieved by providing an appliance leveling mechanism which is particularly adapted to use in connection with mobile homes, recreational vehicles and similar vehicles. The mechanism includes a base member adapted to be secured to a horizontal surface within the vehicle and this base member attains the same pitch as the floor of the vehicle. The base member preferably has the form of a less than hemispherical convex dish with an enlarged top opening. There is mounted over the convex dish in nesting relation a less than hemispherical concave dish having an outer diameter substantially less than that of the convex dish. The radius of curvature of the mating surfaces of both dishes is the same. A lubricious surface is provided between the two confronting surfaces of the dishes so that the sliding movement of the concave dish on the convex dish results in an articulated motion whereby the concave dish can attain any desired position on the convex dish. An appliance supporting platform is mounted on the back of the concave dish and is adapted for movement with the concave dish. A threaded bolt is attached to and depends centrally from the center of the concave dish and platform and extends downward through the central opening of the convex dish. A lock washer is supported on the depending bolt by a lock nut threaded onto the lower end of the bolt. The diameter of the lock washer is larger than that of the enlarged top opening in the convex plate so that if the lock nut is tightened onto the bolt it forces the washer against the underside of the convex dish and locks the two dishes together temporarily against further articulated movement. When the lock nut is loosened again the lockwasher is released and the two plates may again be articulated. The lock nut is adapted to be turned by hand. To provide access to the locknut at least one pair of aligned hand access openings are provided in the concave and convex dishes respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
The description of the invention which follows will be understood with greater clarity if reference is made to the accompanying drawings in which:
FIG. 1 is a schematic side elevation of a recreational vehicle parked on an incline with the front end elevated.
FIG. 2 is a schematic rear elevation of the vehicle of FIG. 1 parked on a similar incline but facing so that one side is elevated relative to the other.
FIG. 3 is a partial front elevation of a refrigerator within the vehicle of FIG. 1 and showing that it is inclined from true vertical just as the vehicle is.
FIG. 4 is a similar partial elevation of the refrigerator of FIG. 3 after the refrigerator has been aligned to a true upright position in accordance with this invention.
FIG. 5 is a vertical sectional view of a leveling mechanism as provided pursuant to this invention.
FIG. 6 is a top plan view of the mechanism of FIG. 5 having some of the parts of the mechanism in phantom.
FIG. 7 is a front elevation illustrating a flush housing of a refrigerator in a vehicle.
FIG. 8 is a front elevation of the refrigerator of FIG. 7 after the alignment of the refrigerator has been changed to allow for the uneven terrain on which the vehicle is parked.
FIG. 9 is a vertical sectional view of a base aligning mechanism for a flush mounted refrigerator.
FIG. 10 is a top plan view of the top aligning mechanism for a flush mounted refrigerator.
FIG. 11 is an exploded vertical sectional view of the mechanism of FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
The problems of the non-working appliance which are described above in the background statement of this application can be overcome in accordance with this invention by realigning the individual appliances themselves rather than trying to realign the vehicle either through adjustment of the parking location or through the use of the high strength and high price jacks. The present invention provides a leveling mechanism which is particularly adapted and useful in connection with vehicles such as the recreational type vehicles.
To explain the invention reference is first made of FIG. 1. In this figure a schematic illustration of a recreational vehicle 10 is provided. The vehicle 10 has an enclosure 12 adapted for human habitation and pairs of wheels 14 and 16 to facilitate locomotion. Within the vehicle a typical appliance 18 is illustrated as positioned along one side of the long body of the vehicle. In FIG. 2 a rear view of the vehicle 10 is provided. In this rear view the rear portion of enclosure 12 is illustrated as being supported by the rear wheels 14. The appliance 18 is positioned as it is in most such vehicles at one side of the vehicle. It is particularly noteworthy in these illustrations that both the vehicle shown in side view and that shown in end view are not shown to be parked on level ground as represented by line 20. Rather they are parked on an incline, represented by line 22, as is very common to uneven terrain. An incline 22 of the character illustrated is sufficient to cause an appliance 18, such as a refrigerator, to operate improperly or to cause it to be damaged in its operation. As is indicated above it is for this reason that users of such recreational vehicles and of similar vehicles employ expensive jacks to level their vehicles and to bring the appliances therein into full and true upright positions.
The manner in which the present invention may be practiced may be illustrated with reference next to FIGS. 3 and 4.
Referring first to FIG. 3 the appliance 18 is seen to have a cabinet 24 and a handle 26 for opening the cabinet. The cabinet rests on a platform 28 and may be securely fastened thereto as explained more fully below. The platform is mounted onto a concave dish 30 shown partly in phantom in FIG. 3. Concave dish 30 is mounted in turn onto the convex base 32. Base 32 is secured to a suitable horizontal support surface 34 within the enclosure 12 of the recreational vehicle 10. The surface 34 may be, for example, the floor of the recreation vehicle 10. However as the vehicle is not horizontal but rather is on an incline 22 of FIG. 1, the floor of the vehicle is also not horizontal but is inclined from the horizontal by an angle 36 from the true horizontal 38.
With reference next to FIG. 4 the appliance 18 may be seen to be positioned in a true upright position even though the base 19 on which the appliance is mounted is inclined from the vertical. Thus although the appliance 18 is still mounted on a floor surface 34 which is still inclined from true horizontal 38 by the same angle 36 as the floor illustrated in FIG. 3 never the less the appliance is supported by the uneven floor in a true upright position. All of the other parts of the appliance remain the same even though the appliance is by the illustration of FIG. 4 in a full upright position.
The manner in which the levelling of the appliance is accomplished is described next with reference to FIGS. 5 and 6. Referring first now to FIG. 5 a vertical view, in part in section, of a levelling mechanism is illustrated. In this figure an anchor plate 50 of the mechanism is disposed on a support surface 52. A convex dome shaped dish 54 of a selected radius of curvature is attached, as by welding, to anchor plate 50. Alternatively the anchor plate 50 and the convex dish 54 may be formed of a single sheet of metal by conventional metal forming techniques. The dish 54 has an oversize top opening 56. By oversize here is meant that the opening is larger than that needed to admit a bolt 58 so that the bolt may be located at various positions within the opening 56 as will be readily evident from the figure. A concave dish 60 having a radius of curvature matching that of dish 54 is nested over to be supported by the convex dish 54. The concave dish 60 forms a part of an upper support mechanism for an appliance. The mechanism 62 includes the concave dish 60 and a platform 64 supported on the dish 60 in part by contact with the middle of dish 60 and in part by a number of braces such as 66 and 68 which are attached to the underside of the platform 64 and the upperside of the concave plate 60. A lip 70 may be formed or attached at the outer edge of platform 64 to facilitate the location and support of an appliance on the platform. Screw fasteners 71 are threaded through lip 70 and may be used to secure an appliance onto platform 64.
Bolt 58 is attached as by welding to the underside of the platform 64 and concave dish 60. The bolt 58 depends from the center of the concave dish 60 through the oversize opening 56 and into the space defined beneath the convex curved dish 54. A locking nut 72 having a handle 73 is threaded onto the lower end 76 of bolt 58 and supports a lock washer 74 in place beneath the inner surface of convex dish 54.
With reference now to FIG. 6 the relationship of some of the parts described above may be seen by the representation of these parts in phantom in FIG. 6. The bolt 58 is at the center of the lock washer 74 and at the center of the lock nut 72 having handle 73. A pair of aligned hand access holes 80 permit the user to access the handle of the lock nut by hand and to turn the handle 73, and thus the locknut 72, to either loosen or to tighten it. By tightening the locknut 72 the lockwasher 74 is urged up against the underside of the convex dish 54. This action presses the two curved dishes 54 and 60 together and prevents any sliding motion of one relative to the other. However when the locknut 72 is loosened relative sliding motion is feasible and the upper dish 60 may be moved in any direction to bring the appliance supported on platform 64 to true upright position. A lubricious surface such as a nylon layer 82 may be positioned on either of the confronting curved surfaces of the dishes 54 and 60 to assist smooth movement of one dish relative to the other. In this way platform 74 is brought to true level and the operation of the supported appliance is assisted. Once the platform is in the true level position and the supported appliance is in the true upright position the handle 73 may be turned to tighten the locknut 72 and the platform is thus anchored in place.
The appliances will remain upright just so long as the vehicle remains on the same inclined surface. Once the vehicle is moved to another location then the process of levelling the platform or platforms in the vehicle must be repeated to ensure proper operation of the appliances. Accordingly there is provided by the mechanism of this invention a simple and inexpensive means for ensuring proper operation of the appliances of a recreational or similar vehicle. The cost of the mechanism is substantially less than one tenth of the cost of the vehicle leveling devices of the prior art.
Some modification of the mechanisms of the present invention may be made without departing from the spirit and scope of the present invention. Some such modifications are now described.
One such modification involves larger appliances such as larger refrigerators and particularly those which are built into a vehicle. Such a built in refrigerator may be positioned flush with other appliances or cabinets. For an appliance to function in the manner described above, the appliance must be free to move in any direction around a 360 degree circle. For example, with reference to FIG. 1 it is evident that to overcome the front to back tilt of the appliance the appliance must be free to move in a direction parallel to the length of the vehicle. Conversely for an appliance in a vehicle as depicted in FIG. 2 the appliance must be free to move laterally of the vehicle to achieve a true upright orientation. But if the vehicle is parked on a slope which tilts the vehicle both longitudinally and laterally the appliance must be free to move in directions which include both longitudinal and lateral motion. It is apparent from the description given above that the apparatus as described with reference to the FIGS. 3 to 6 that such motion in any needed direction including longitudinal and lateral and any combination of these motions can be accomplished with ease.
Now with reference to an appliance which is a "built in" of a recreation vehicle it is evident that to permit the present invention to be carried out there must be a separation between an appliance which is individually subject to levelling in accordance with the present invention and adjoining appliances, cabinets, furniture or the like. In this connection one modification of the present invention provides a flush mount for appliances to be leveled. The flush mount modification can be described with reference to FIGS. 7 and 8.
Referring now first to FIG. 7 a flush mounted refrigerator is illustrated. From the figure the refrigerator 98 may be discerned to be a larger variety having a plurality of doors and in particular three doors 100, 102, and 104. The flush mounting is accomplished with the aid of an accordian apron 106 which extends fully around the entire front surface of the refrigerator 98. The accordian apron 106 is one which is adapted to enlarging or extending in any direction as the refrigerator is moved in that direction. The apron 106 can also shrink or collapse at one side in compensation for an expansion of the apron at the other side. The refrigerator can be moved from side to side or can be moved backward or forward to achieve a true upright position and the apron accomodates that movement and still maintains a flush mounting of the refrigerator relative to the other cabinets of appliances of the vehicle in which refrigerator is mounted. The refrigerator 98 of FIG. 8 is housed in a vehicle which is parked on an incline similar to the incline 34 of FIG. 4. However the refrigerator is able to achieve a true upright position in the vehicle and still retain its flush mount because of the combination of the accordian apron 106 with the leveling mechanism which is now described.
Referring now next to FIG. 9 a vertical sectional view of a positioning mechanism for use in connection with an overhead securing mechanisms is illustrated. In FIG. 9 parts are illustrated which resemble some of the parts illustrated in FIG. 5. For clarity of reference the reference numerals used in FIG. 5 are employed in FIG. 9 but they are increased by a value of 100. Thus a base plate 150 is illustrated as disposed on a support surface 152. A less than hemispherical dish 154 is attached to or formed with the base plate 150 to provide a convex support on which an upper concave plate 160 can rest. Braces 166 extend upward from concave plate 160 to support a platform 164 on which an appliance such as the refrigerator of FIGS. 7 and 8 can be mounted. A lip 170 may be formed along the perimeter of the platform 164 to facilitate retaining an appliance in a desired position on the platform. A nylon liner 182 may be disposed on or attached to the convex plate 154 or the concave plate 160 to facilitate pivoting motion of the platform and the supported appliance above the base plate 150. The mechanism thus described permits articulated movement of an appliance mounted on the platform to achieve any angle needed to attain true upright position.
To position a larger refrigerator as illustrated with reference to FIGS. 7 and 8 a mechanism is provided at the top of the refrigerator and this mechanism is particularly adapted to cooperate with the articulated pivot mechanism to provide both articulation of the pivot joint described below and also an unlocking of the mechanism prior to the positioning of the refrigerator and a locking of the refrigerator into place once the movement to a true upright position has taken place. In this sense the appliance itself becomes part of the mechanism to permit the proper positioning to take place.
Referring now next to FIG. 10 there is illustrated a top positioning and locking mechanism. This mechanism includes a top plate 210 having a downwardly extending lip 212. The plate and lip are of a size which nests securely over the top of the appliance to be secured and positioned and are initially held in place by gravity. The plate 210 holds the appliance and moves with the appliance as the appliance is positioned with the mechanism. There is a locking bolt 214 attached to and extending up from the plate 210. The bolt 214 is best seen in FIG. 11 in its relation to the plate 210.
FIG. 11 is an exploded view of the positioning mechanism. The mechanism includes the plate 210 and bolt 214 as one unit. It also includes an upper slotted disk 216 and a lock nut 218 with a handle 220 attached to the lock nut as a second unit. The edges of the disk 216 are supported in a fixed peripheral runway 222. The runway 222 is in turn supported by angle braces 224, 226, 228 and 230 which are fixedly mounted to the walls of a housing, not shown, within the vehicle 10. The runway 222 is of generally C shaped cross section and the edges 217 of the disk 216 fits snugly within the C form of the runway but can nevertheless be easily rotated therein.
The disk 216 is preferably made of nylon and is provided with an elongated slot opening 232 to permit the threaded bolt to slide therein as the bolt 214 and plate 210 are moved to position the appliance in a true upright position. Thus while the bolt 214 is permanently and fixidly attached to the plate 210 the bolt can both move along the slot 232 and the disk 216 can rotate to bring the bolt 218 to any position within a circle defined by the runway 222. By rotating the disk 216 and sliding the bolt 218 in the slot 232 the bolt can be brought to a position which leaves the appliance in a true upright position. It is only after the appliance is in the true upright position that the bolt is fixed in a single position. The bolt 214 is fixed in position when the nut 218 firmly grips the nylon disk 216. This tightening occurs when the nut 218 is tightened by handle 220 to clamp the edges of the disk 216 along slot 232 between two ribbed washers 234 and 236.
For an appliance having the advantages of the flush mounting depicted in and described with reference to FIGS. 7 and 8 the access to the upper portion of the alternative leveling mechanism described immediately above is through a hinged door 105 as illustrated in FIGS. 7 and 8. The access through this door permits the handle 220 to be gripped and turned to first loosen the nut 218. After the nut 218 is loosened the bolt 214 can be moved to any position needed to set the appliance to a true upright position and the nut can then be tightened to hold the appliance in that position.
To ascertain the true upright position a leveling indicator is incorporated into the mechanism. The leveling indicator may be for example a full round bubble level indicator which indicates the level of a plane. The bubble level indicator is preferred. Alternatively two bent tube level indicators positioned at right angles may be employed to determine true level or true upright positions for the appliance.
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A leveling device which utilizes joining convex and concave dishes. The concave dish is attachable to a support platform to hold an appliance or other item which requires leveling as is often the case when these items are in recreational vehicles. The dishes are joined together to be slideable with regard to each other permitting the concave dish and platform to be articulated to any position above the convex dish.
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INTRODUCTION AND BACKGROUND
[0001] The present invention relates to a wood particle mixture and also to a method for producing a wood particle mixture, especially from raw wood, for an extruded or injection-molded wood-plastic composite material, especially wood-plastic compound. In addition, the invention relates to a device for performing the method according to the invention.
[0002] It is known to include such wood particle mixtures in various plastics, especially in polypropylene, wherein each individual wood particle is encased by plastic. Such wood-plastic composite materials are known from WO 96/34045. Because their strength properties are largely dependent on the homogeneity of the compound, the individual wood particles of the wood particle mixture lie in a range of sizes featuring pre-defined limits. However, the shape of the individual particles and their alignment within the wood-plastic composite material also have a strong influence on the strength properties.
SUMMARY OF THE INVENTION
[0003] A wood particle mixture, a method, and a device of the class described in the introduction, which significantly improve the strength properties in a wood-plastic composite material are described herein.
[0004] According to the invention, there is described a wood particle mixture, especially made from raw wood for an extruded or injection-molded wood-plastic composite material, especially manufactured from wood-plastic compound, characterized in that each wood particle has two cut surfaces which define its thickness and which run approximately in the direction of its grain, and each wood particle has cut edges and/or fracture edges defining its length in the direction of the grain and also its width perpendicular to the direction of the grain. In a further aspect of the invention, there is described a method for producing a wood particle mixture, especially made from raw wood, for an extruded or injection-molded wood-plastic composite material, e.g., manufactured from wood-plastic compounds, especially for producing the herein described wood particle mixture, characterized in that flat chips are generated from the raw wood by means of at least one blade, the flat chips are cut up, the cut-up flat chips are broken up into flat splinters, and the flat splinters are filtered.
[0005] The wood particle mixture is distinguished in that each of its wood particles has two cut surfaces that define its thickness and run approximately in the direction of its grain, and in that each wood particle has cut and/or fracture edges that define its length in the grain direction and define its width perpendicular to the grain direction. Wood particles shaped in this way thus feature fewer, but elongated, fibers relative to its body volume. The use of such wood particle mixtures in a wood-plastic composite material has the advantage that the connections between the individual wood particles and the plastic run essentially along the grain, so that the individual fibers effectively increase the tensile strength and flexural strength of the wood-plastic composite material.
[0006] According to one refinement of the invention, at least 90 wt % of the wood particles have a thickness between 0.2 mm and 2.0 mm, preferably a thickness between 0.4 mm and 0.5 mm, and a length and width up to 8.0 mm. These details on size ranges are to be understood as preferred ranges, with which sufficient homogeneity in the wood composite material can be achieved. However, especially preferred is that at least 90 wt % of the wood particles have a thickness between 0.2 mm and 1.4 mm and a length and width up to 2.5 mm.
[0007] According to a next refinement of the invention, the cut surfaces running in the grain direction are arranged approximately parallel to each other. Thus, the individual wood particles each receive the shape of a flattened fiber strand section, which further improves the strength properties of the wood-plastic composite material.
[0008] It is proposed that each wood particle consist of spruce wood. Spruce wood satisfies the requirements for the wood composite material and is available in sufficient quantities particularly economically in Europe. It is further proposed that each wood particle consist of loblolly pine wood, which is available in the USA in sufficient quantities at economical prices. However, it is also conceivable to use other types of wood, e.g., if these can be obtained especially economically in one region or part of the world or if these exhibit a special suitability in the particular use for wood-plastic composite materials. Mixtures of different woods can also be used. Any suitable polymer, including thermoplastics and thermosetting resins can be used to make the extruded or injection molded articles.
[0009] It is further proposed that the wood particle mixture have a moisture content of less than 15% relative to the absolute dry mass. The low moisture content is primarily important to guarantee uniform operating conditions for the extrusion of wood plastic compounds. The extrusion process generates high temperatures, which lead to controlled evaporation of the moisture bound in the wood particle mixture. The same also applies for injection molded parts. Furthermore, with a moisture content of less than 15%, fungal attack is for the most part prevented, so that the final product made from the wood-plastic composite material is fit for storage.
[0010] According to another refinement of the invention, the wood particle mixture has an extract content of less than 5.5% relative to the absolute dry mass. This specification is based on measurements according to the ethanol-cyclohexane method or the hot-water method. A low extract content, especially a low resin content, is primarily important, so that the top surfaces of the extrusion molds do not stick and to be able to guarantee on the extrusion molds constant friction resistance that is not too high.
[0011] According to the method of the invention it is proposed that flat chips be generated from the raw wood by means of at least one blade, that the flat chips be cut up, that the cut-up flat chips be broken up into flat splinters, and that the flat splinters be sifted. An especially large-volume chip pocket is advantageously allocated to each blade, so that the flat chips feature an especially low curvature.
[0012] According to a refinement of the invention, the flat chips are generated by blades arranged parallel to the grain of the raw wood. This has the advantage that the flat chips in the chip pocket are bent only around a line running in the direction of the grain. The individual fibers are thus not bent.
[0013] In the following, the individual method steps are described in more detail:
[0014] The flat chips generated from the raw wood are led into a wet bunker, which represents intermediate storage for continuous removal of the flat chips. A stirring machine integrated in the wet bunker prevents sticking or bridging of the flat chips. Then the flat chips are supplied from the wet bunker via a vibrating flat channel at least to a cutting mill with a filter passage. The cutting mill advantageously features a cutting roll with V-shaped blades and also a counter blade corresponding to the blades. By means of air, the cut-up flat chips are suctioned from the cutting mill through the filter passage, led into a wet cyclone, and there separated from the air stream. Then the cut-up flat chips are led from the wet cyclone into a dosing bunker. From the dosing bunker, the cut-up flat chips are led by means of air into a dryer. The dosing bunker is used as intermediate storage for the dryer. This has a pressure generator and a cyclone, wherein the flat chips are led through the dryer with the air stream generated by the pressure generator and are separated again from the air stream in the cyclone. The cut-up and dried flat chips are then led from the dryer into a dryer bunker, which is used in turn as intermediate storage, and from which the cut-up and dried flat chips are supplied via a worm to a hammer mill, which also features a filter passage. Here, the cut-up and dried flat chips are broken up into flat splinters with beating tools and suctioned through the filter passage from the hammer mill. Then the flat splinters are led into a drying cyclone, where they are again separated from the air stream. From the drying cyclone, the flat chips are then led into a filtering device, in which the flat splinters lying within a certain range of sizes for the wood particle mixture are filtered out and flat splinters lying above the predetermined range of sizes are fed back into the drying bunker. The returned flat splinters are thus reduced in size again in the hammer mill.
[0015] In the filtering device, the flat splinters are sorted according to the size of their cut surfaces defining their thickness. The filtering device advantageously has a damping plate, on which the flat splinters are laid flat. By means of vibrating motion, the flat splinters then slide over the inclined damping plate onto the first flat sieve under which further flat sieves are arranged for filtering out predetermined ranges of sizes of the flat splinters.
[0016] According to an especially advantageous refinement of the invention, it is preferred that the flat splinters filtered from the filtering device and lying within a predetermined range of sizes be led to a wobble sieve, which separates out flat splinters lying below the predetermined range of sizes for the wood particle mixture. In this way, additional fine material, which could not be separated by the filtering device, is subsequently separated in an especially efficient way.
[0017] According to another refinement of the invention, the flat chips are cut up in undefined directions. This is realized especially in that the flat chips are supplied via the vibrating flat channel in an undefined alignment to the V-shaped blades of the cutting mill.
[0018] According to an especially advantageous refinement of the invention, extracts, especially resins, are washed out from the raw wood and/or the flat chips and/or the cut-up flat chips and/or the flat splinters and/or the wood particle mixture. This is realized, e.g., with the ethanol-cyclohexane method or the hot-water method.
[0019] The device according to the invention is used for performing the method according to the invention and is distinguished in that the filtering device has at least two flat sieves arranged one after the other with different mesh widths. The flat sieves are used to filter out the flat splinters lying in a predetermined range of sizes for the wood particle mixture. To be able to realize the size ratios of the individual wood particles mentioned for the wood particle mixture according to the invention, the first flat sieve has an open mesh width between 2 mm and 4 mm. In contrast, the second flat sieve has an open mesh width between 0.5 mm and 1.0 mm. The meshes of the flat sieves are shaped like squares.
[0020] In addition, it is provided that the cutting mill have at least one filter passage on the output side, which is formed as an elongated filter, whose elongated holes have a length between 40 mm and 70 mm and a width between 3 mm and 8 mm.
[0021] The hammer mill has at least two different alternating filter passages on the output side, which are formed as elongated filters, wherein the difference between the filter passages consists essentially in that the elongated holes of one of the filter passages has approximately twice the width of the elongated holes of the other filter passage. Such a configuration advantageously prevents the flat splinters from clogging or stopping up the filter passages. The elongated holes of the filter passages arranged in the hammer mill have a length between 10 mm and 50 mm and a width between 0.5 mm and 2.5 mm.
[0022] According to a refinement of the invention, the elongated holes of the filter passages arranged in the hammer mill and also the filter passages arranged in the cutting mill have a rotational spacing or a bridge width between 0.5 mm and 5.0 mm to each other.
[0023] The blade for generating the flat chips has a length between 15 mm and 25 mm. The blades are advantageously assembled from a plurality of cutting teeth, which are in turn distributed over the circumference of a cutting roll. In addition, it is proposed that the blade be set in the device such that the ratio of the cutting speed divided by the advancing speed is between 550 and 750, preferably 650. A cutting speed of 39 m/s thus produces a preferred advancing speed of approximately 0.06 m/s.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will be further understood with reference to the accompanying drawings, wherein:
[0025] FIG. 1 shows a plan view of a layout for a device for performing the method according to the invention;
[0026] FIG. 2 shows a perspective view of a flat chip for producing a wood particle mixture according to the invention at an enlarged scale;
[0027] FIG. 3 shows a perspective view of reduced size flat chips from the flat chip shown in FIG. 2 ; and
[0028] FIG. 4 shows a perspective view of flat splinters from the cut-up flat chips shown in FIG. 3 .
DETAILED DESCRIPTION OF INVENTION
[0029] FIG. 1 shows a plan view of a layout for a device, for which the method according to the invention for producing a wood particle mixture is to be described in the following:
[0030] Tree trunks are stripped by a bark peeling device 1 . The debarked tree trunks are then fed to a cutter shaft chipper 2 or to a cutter ring chipper, in which the stripped tree trunks are machined into flat chips. From the cutter shaft chipper 2 , the flat chips are transported via a worm 3 and an elevator 4 into a wet bunker 5 . The wet bunker 5 is configured as intermediate storage for continuous removal of the flat chips. From here, the flat chips are transported by means of two worms 6 , 6 โฒ and two vibrating flat channels 7 , 7 โฒ into two cutting mills 8 , 8 โฒ, in which the flat chips are cut up. By means of air, the cut-up flat chips are then suctioned from the cutting mills 8 , 8 โฒ and led into a wet cyclone 9 , which separates the cut-up flat chips from the air. From the wet cyclone 9 , the cut-up flat chips are led with a pressure chain conveyor 10 into a dosing bunker 11 . The dosing bunker 11 is formed as intermediate storage for a dryer 12 and is connected to the dryer 12 by means of a pressure chain conveyor 13 . In this dryer, the cut-up flat chips are dried, which is why the previously described system components are referred to with the term โwet sideโ and the system components described in the following are referred to with the term โdry side.โ
[0031] The cut-up flat chips are suctioned through the dryer 12 and led on the output side into a dryer bunker 15 via a pressure chain conveyor 14 . The dryer bunker 15 is formed as intermediate storage for two hammer mills 16 , 16 โฒ, which are each connected via a vibrating flat channel 17 , 17 โฒ and a common worm 18 to the dryer bunker 15 . In the hammer mills 16 , 16 โฒ, the cut-up and dried flat chips are broken up into flat splinters. The flat splinters are suctioned by means of air from the hammer mills 16 , 16 โฒ and led into a drying cyclone 19 . In this cyclone the flat splinters are separated from the air stream. From the drying cyclone 19 , the flat splinters are led by means of an inclined damping plate 20 into a filtering device 21 . In the filtering device, the flat splinters lying in a predetermined range of sizes for the wood particle mixture according to the invention are filtered out by means of flat sieves 22 arranged one above the other. Flat splinters lying above the predetermined range of sizes are fed back from the filtering device 21 via a pressure chain conveyor 23 into the dryer bunker 15 . The flat splinters lying in the predetermined range of sizes are led from the filtering device 21 via an elevator (not shown) into a finished goods silo (not shown).
[0032] FIG. 2 shows a flat chip for producing a wood particle mixture according to the invention. The flat chip has two cut surfaces 25 , 26 , which define its thickness and which run in the direction of its grain 24 . The width of the flat chip in the direction of its grain 24 is defined by cut edges 27 , 27 โฒ. The length of the flat chip perpendicular to the direction of its grain 24 is defined by fracture edges 28 , 28 โฒ.
[0033] FIG. 3 shows reduced size flat chips from the flat chip shown in FIG. 2 . The reduced size flat chips have cut edges 29 , which run in undefined directions relative to the grain 24 . Equivalent surfaces and edges are provided with the same reference numbers.
[0034] FIG. 4 shows flat splinters from the cut-up flat chips shown in FIG. 3 . The flat splinters have fracture edges 30 , which run approximately in the direction of the grain 24 . Equivalent surfaces and edges are provided with the same reference numbers.
[0035] Further variations and modifications of the foregoing will be apparent to those skilled in the art and are intended to be encompassed by the claims appended hereto.
[0036] German prior application 103 27 848.6 of Jun. 18, 2003, is relied on and incorporated herein by reference.
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A wood particle mixture is described especially made from raw wood for an extruded or injection-molded wood-plastic composite material, especially manufactured from wood-plastic compound, which significantly improve the strength properties in a wood plastic composite material. Each wood particle has certain dimensions and certain shaping.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to computer programming languages and more specifically to a mechanism implemented in the Java programming language for handling threads in a manner which avoids leaving the threads in unstable states when they are stopped.
2. Description of Related Art
Java is a high-level programming language which supports multi-threaded program execution. A thread is basically a separate stream of execution that can take place independently from and concurrently with other streams of execution. A thread is similar to a small program that performs particular tasks within a larger program. If, for some reason, there is a problem with the execution of the tasks performed by a particular thread, other threads may continue performing their own tasks despite this problem. For example, if one thread becomes stuck in an infinite loop, the other threads may continue and complete their processing without having to wait for the first thread to break out of the loop.
While threading is a similar to multitasking, it is typically more difficult to implement. This is due, in part, to the fact that multitasking involves individual programs that are executed in isolation from each other, while threading involves the performance of tasks which may be interrelated. For example, one thread may print the contents of certain memory locations, while another thread may write new data to those same memory locations. If the interaction between the threads is not handled properly, the results of the tasks performed by the two threads may be uncertain.
Threads can be implemented in Java by creating a subclass of java.lang.Thread, or by using the java.lang.Runnable interface. The java.lang.Thread class includes three methods which are the primary means for controlling threads: start( ), run( ) and stop( ). The start( ) method prepares the thread to be executed. The run( ) method performs the functions of the thread. The stop( ) method terminates the thread. The java.lang.Thread class also includes several other methods which are used to control the execution of instructions in a thread, including suspends, resumes, sleep( ) and yield( ).
Two of these methods are inherently problematic. It may be unsafe to use the stop( ) method because, when a thread is terminated, objects which may have been locked by the thread are all unlocked, regardless of whether or not they were in consistent states. These inconsistencies can lead to arbitrary behavior which make corrupt the functions of the thread and the program. The suspend( ) method may also cause problems because it is prone to deadlock. For example, if a thread holds a lock on the monitor for a particular resource when it is suspended, no other thread can access the resource until the thread holding the lock is resumed. If a second thread should cause the first thread to resume, but first attempts to access the resource, it may wait for access to the resource and consequently may never call the first thread's resume( ) method. Because these two methods are so problematic, their use is discouraged and they are being deprecated from the Java Developers Kit produced by Java's originator, Sun Microsystems Inc.
SUMMARY OF THE INVENTION
One or more of the problems outlined above may be solved by various embodiments of the present mechanism. The mechanism provides a means for controlling threads in a Java application while avoiding the unsafe conditions inherent in the use of existing java.lang.Thread methods. The present mechanism provides a simple and easy-to-use mechanism. for stopping threads without causing unnecessary waiting, without creating a need for exception handling, and without leaving the associated application in an unknown state.
In one embodiment, a class is defined for handling threads in an application. The class uses a target variable to indicate whether a thread should continue to run, or whether it should be stopped. This class provides a start( ) method to set up the target variable, a stop( ) method to set the target variable to indicate that the thread should be stopped, and an abstract run( ) method. An abstract method is one which is defined, but contains no functionalityโthe functionality of the method must be provided by subclasses which extend this class. At least one subclass is created to extend the class. The subclass overrides the abstract run( ) method and defines the tasks to be performed by threaded objects instantiated from this class.
When an object is instantiated from the subclass, the start( ) method inherited from the class is configured to create a thread having the object as its target. The start( ) method is also configured to set the target variable (which is local to the thread) is set to a value which indicates that the thread should be running. The stop( ) method of the class is also inherited by the subclass. When the stop( ) method is invoked, it is configured to set the target variable to a value which indicates that the thread should be stopped. The run( ) method provided by the subclass periodically checks the target variable within the thread. The checking of the target variable occurs in the normal course of execution of the run method. If the target variable indicates that the thread should be stopped, the run( ) method is configured to complete execution and exit normally, causing the thread to terminate. An exception is not required to stop the run( ) method, so exception handling is not necessary.
In one embodiment, a computer readable storage medium contains instructions defining the class and subclasses described above.
In one embodiment, a thread-handling method is provided for improved handling of threads in Java applications. Broadly speaking, the method comprises providing a class that includes methods for stopping threads based on the indication of a target variable. Instructions that are to be executed within threads are provided in the run( ) methods of subclasses that extend the first class. Rather than creating threads from the standard Thread class and individually configuring the threads to stop execution upon the occurrence of a particular condition, threads are created using the subclasses above. The safer methods which are inherited from these subclasses override the methods of the Thread class so that stopping threads is inherently safer. When a thread is created, the target variable is initialized to indicate that the thread should be running. The instructions being executed by the thread periodically check the target variable to determine whether it indicates that the thread should continue running, or should stop. If the target variable indicates that the thread should continue running, the thread executes normally until the target variable is checked again. If the target variable indicates that the thread should be stopped, the run( ) method completes execution and exits normally.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 is a diagram illustrating the life cycle of a Java thread.
FIG. 2 is a flow diagram illustrating the execution of instructions in a thread and the stopping of the thread using the java.lang.Thread.stop( ) method.
FIG. 3 is a flow diagram illustrating the execution of instructions in a thread and the stopping of the thread using the present mechanism.
FIG. 4 is a diagram illustrating the relationships between a Handler class, the java.lang.Runnable interface and the java.lang.Thread class
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawing and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the invention is described below. In this embodiment, a class is written to handle the threads which may be used in an application. (For the purposes of this disclosure, this class will be a referred to as the โHandlerโ class.) The threads are created using this class. When a thread needs to be stopped, a target variable defined in the class is set to indicate that the thread should be stopped. The thread periodically checks the target variable to determine whether or not it should stop. The target variable is checked by the thread when it is in a stable state so that, if the thread should be stopped, the run( ) method can complete execution and terminate normally rather than having to use the stop( ) method defined in the java.lang.Thread class.
Before describing the present mechanism, it may be helpful to describe the operation of a thread. As indicated above, a thread is a separate stream of execution that can take place independently from and concurrently with other streams of execution. A thread is created, then it runs, and then it dies. Execution of instructions within a thread may be suspended, or the thread may be put to sleep, blocked or made to yield to other threads, after which execution may continue. A thread may be terminated by completing its run( ) method, by another thread preempting it or by calling its stop( ) method.
Referring to FIG. 1, the life cycle of a Java thread is illustrated. While this figure is not a complete state diagram, it provides an overview of the life cycle of the thread. A thread can be created in either of two ways: it can extend the java.lang.Thread class; or it can implement the Runnable class. In the first instance, a class extends Thread:
class example1 extends Thread {
\\ overrides Thread.run( )
public void run( ) {
\\ example1 logic here
}
}
The example1 subclass extends the Thread class and inherits all of Thread's methods, except that example1 implements a run( ) metod that overrides the run( ) method of the Thread class. The examplel.start( ) method causes the Java virtual machine to execute examplel.run( ) in a new thread of execution. In the second instance, a class implements Runnable:
class example2 implements Runnable {
\\ implements a run method
public void run( ) {
\\ example2 logic here
}
}
In order to implement Runnable, the example2 class must provide a run( ) method. The example2 class must also implement start( ) and stop( ) methods, because there is no reference in this class to the Thread class, so these methods are not inherited from the Thread class.
The creation of the thread places the thread in the New Thread state. In this state, the thread is simply an empty Thread object. No resources have been allocated for the thread. Once the thread has been created, it can be started using the start( ) method. The start( ) method allocates the system resources which are necessary to run the thread and schedules the thread to be run. After the appropriate resources have been allocated and the thread has been scheduled, the start( ) method signals the virtual machine to schedule the thread to run (by being placed on the run queue). When cpu resource is available, the run( ) method is executed. (It should be noted that the run( ) method is never explicitly called by an application, but is instead called by the start( ) method.)
After the thread has been started, it can be considered to be running. A running thread can be in a โrunnableโ state, or in a โnot-runnableโ state. (The โrunnableโ state described here should not be confused with the java.lang.Runnable interface.) That is, the thread may be currently able to execute instructions (i.e., it may be runnable,) or it may not be currently able to execute instructions and (i.e., it may be not-runnable.) Because several threads may have been started on a computer having a single processor (which can only execute one thread at a time,) some of the threads which are runnable may not actually be executing. These threads many instead be waiting to be executed by the processor.
Threads which are in the โnot-runnableโ state, on the other hand, will not be executed even if a processor is available to execute them. Several events may cause the threads to be not-runnable. For example, if a thread's sleep( ) method is invoked, that thread will wait for a designated amount of time before continuing execution. In another instance, if a thread's suspend( ) method is invoked, execution of the thread will be discontinued until its resume( ) method is called. A thread may also be in the not-runnable. state if it is blocked while waiting for I/O. It should be noted that, when these threads are once again runnable, they may not actually begin execution if a processor is not available.
If a thread is stopped, it is in the โdeadโ state. A dead thread cannot resume execution in the same manner as a not-runnable thread, but it can be re-started. Execution of a thread may be stopped in several ways. Preferably, a thread stops when execution of its run( ) method has completed (i.e., if there are no more instructions to be executed.) There may also be instances in which it may be desirable to have a thread stop on demand. For example, it may be desirable to have a thread continue execution indefinitely and to stop when instructed to do so. The stop( ) method is provided for this purpose in the java.lang.Thread class. The Thread.stop( ) method, however, may cause the thread to be terminated when it is in an unstable state. This problem may be illustrated using FIG. 2 .
Referring to FIG. 2, a flow diagram illustrating the execution of instructions in a thread is shown. In this example, the thread is configured to execute instructions 1โN, then loop back and repeat these instructions. The thread will continue to execute instructions 1โN until the thread is stopped. If the Thread.stop( ) method is invoked to stop the thread, it will immediately cause an exception and terminate the thread's execution. The stop( ) method is not constrained to halt execution of the thread at any particular point, so there is no way to determine where among these instructions execution will be stopped. The thread may be stopped at point A, point B, point C, or any other point in the execution of the thread's run( ) method. If the instructions modify the state of the application, stopping the thread may leave the application in an unknown state. The thread will also unlock all of the monitors which had been locked by the thread, possibly leaving objects protected by these monitors in inconsistent states. Objects which are left in these inconsistent states are said to be damaged, and operations on these damaged objects may lead to arbitrary behavior. Errors that are caused by the behavior of damaged objects may be difficult to detect and a user may have no warning that the errors have occurred.
It is therefore preferable to stop a thread by allowing it to complete the run( ) method. The present mechanism employs a target variable associated with the thread to provide a way to instruct the thread to stop, while allowing the run( ) method to complete execution. Essentially, the target variable provides an indication of whether the thread should continue to run or to stop. The thread periodically checks the target variable. If the target variable indicates that the thread should continue to run, execution of the thread proceeds normally. If the target variable indicates that the thread should stop, execution of the thread proceeds to the point at which the target variable is checked, then exits normally (i.e., completes the run( ) method.)
Referring to FIG. 3, a flow diagram illustrating the execution of instructions in a thread using the present mechanism is shown. After the start( ) method is called, the body of the run( ) method is executed. The flow diagram on the left side of the figure represents body of the run( ) method. The thread is still configured to execute instructions 1โN, but it is further configured to periodically examine the target variable to determine its value (e.g., by using the isRunning( ) method described below.) If the target variable is set to indicate that the thread should continue running, instructions 1โN are repeated. If the target variable is set to indicate that the thread should be stopped (e.g., using the stop( ) method illustrated here as a different thread of execution,) the thread branches to point A, where it completes execution and exits normally. Because instructions 1โN are completed normally before the target variable is checked, the state of the application is easier to determine. Because the run( ) method executes to completion, no exception handling is required and no objects are damaged by abnormal termination of the thread. It should be noted that the target variable can be checked at different points in the code of the run( ) method. It should also be noted that the target variable can be set by other threads or by the run( ) method itself to indicate that the thread should be stopped.
The check of the target variable can easily be implemented in the run( ) method by enclosing the functionality of the run( ) method in a while loop:
public void run( ) {
while(target_variable !=null) {
\\ thread logic here
. . .
}
}
In one embodiment, the present mechanism comprises the Handler class shown below.
public class Handler implements Runnable {
private Thread thread=null;
public void start( ) {
if(thread==null) {
thread=new Thread(this);
thread.start( );
}
}
public void stop( ) {
thread=null;
}
public void run( ) {
}
public boolean isRunning( ) {
return thread !=null;
}
public void finalize( ) {
thread=null;
}
}
Referring to FIG. 4, a diagram illustrating the relationships between the Handler class above, the Runnable interface and the java.lang.Thread class are shown. It can be seen from the figure that the Handler class implements the Runnable interface. Because the Handler class implements the Runnable interface, any class that extends the Handler class is also Runnable. Objects instantiated from such a class can therefore be referenced using the Runnable interface. While the Handler class implements the Runnable interface instead of extending the java.lang.Thread class, it references this class to create the threads.
In the example above, it can be seen that the run( ) method is implemented, but is empty. When a thread is needed to perform a particular function, a subclass that extends the Handler class is written. This subclass implements a run( ) method that overrides the run( ) method of the Handler class and provides functional code to be executed by the thread.
The stop( ) method of the Handler class provides a means for gracefully terminating the thread and should not be overridden by the second class. By providing an indication that the thread should be stopped rather than simply stopping the thread using the stop( ) method of the thread class, the instability inherent in the Thread.stop( ) method is avoided. The thread does not immediately throw an exception (unlocking monitors as the exception propagates up the stack,) but instead allows the thread to terminate normally, leaving the system in a stable state.
The Handler class example above also defines an isRunning( ) method that enables the thread to determine locally whether the thread should continue to run. The isRunning( ) method returns โtrueโ if the thread should continue to run, and returns โfalseโ if it should be stopped. Because the isRunning( ) method references only the thread itself, there is no need to reference Thread.currentThread( ). (It should be noted that current.Thread is static, so it is implied that there is only one current thread at any point in time. In a multi-processor environment, several threads may be running at one time, so the result of current.Thread becomes uncertain. Current.Thread may therefore prevent scaling of applications and should not be used.)
The Handler class above further defines a finalizes method. This method is included in the class for the purpose of cleaning up. In a Java virtual machine, the garbage collector calls the finalize( ) method to set the thread equal to null before deallocating the thread's resources. It should be noted that the policy for each garbage collector may vary, so the point at which finalize( ) is called may vary from one to another.
The Handler class described above thereby provides the following advantages: first, it gracefully handles stopping a thread without exception handling; second, classes which extend the Handler class implement the Runnable interface and can be referenced as Runnable; third, it can be determined locally within a thread whether the thread should continue to run, or should be terminated, based on the result of the isRunning( ) method; and fourth, because this class has such a simple API, it provides a suitable core for Java servers, agents and socket handlers to handle asynchronous peer communications. The Handler class thereby provides a means for standardization in the handling of threads which is object oriented, which uses self-contained logic, and which allows developers to use programming techniques with which they are already familiar. (It should be noted that other embodiments may vary from the implementation described above and may therefore provide advantages which differ from those listed here.)
While the present invention has been described with reference to particular embodiments, it will be understood that the embodiments are illustrated and that the invention scope is not so limited. Any variations, modifications, additions and improvements to the embodiments described are possible. These variations, modifications, additions and improvements may fall within the scope of the invention as detailed within the following claims.
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A mechanism for controlling threads in a Java application while avoiding the unsafe conditions inherent in the use of existing java.lang.Thread methods. In one embodiment, a first class is defined for handling threads in an application. The first class uses a target variable to indicate whether a thread should continue to run, or whether it should be stopped. This first class provides a start( ) method to set up the target variable, a stop( ) method to set the target variable to indicate that the thread should be stopped, and an abstract run( ) method. The functionality of the run( ) method is provided by one or more additional classes which extend the first class. The additional classes override the abstract run( ) method and define the tasks to be performed by threaded objects instantiated from these classes. When a thread needs to be stopped, the corresponding target variable is set to indicate that it should be stopped. The thread periodically checks the target variable and, when the target variable is set to indicate that the thread should be stopped, the thread executes one or more instructions that cause execution of the thread to complete and to exit normally.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority as a non-provisional perfection of prior filed U.S. provisional application No. 61/876,378 and incorporates the same by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of construction and more particularly relates to a system for placing siding on a building and the components of said system.
BACKGROUND OF THE INVENTION
[0003] Siding is often used to provide a building with both an attractive and a protective finish. Typical siding systems involve panels of a weather-resistant material fastened directly to an exterior wall of a building. In the past, this has required nails or other fasteners to be thrust through the panel and into the exterior wall, inherently causing damage to both and providing a passage for water to seep into the space between the panel and the wall. Older systems were also limited in their ability to expand and contract with environmental changes affecting the building on which such systems were used. There have been some modifications in more recent times. Current siding and trim systems in the market include James Hardie trims and LP SmartSide trims. These trims are face nailed to the exterior of the building and provide some cosmetic enhancements and protection to the buildings. However, these trims are limited because they are still not sufficiently waterproof. In particular, these systems do not provide air gaps and water traps to protect the trim and building from moisture and different climates. Further, these trims are caulked, which causes tears in the trims when expanding and compressing due to environmental conditions such as different climates and air pressure changes. These tears allow water to seep in the trim and onto the structure underneath the trim, where water is being trapped between the backside of trim and the building causing structural damage to the trim and even more serious causing dry-rot and mold as well as structural damage to the building structure itself. As a result, these trims and the structure itself are subject to extensive dry-rot and mold and costly structural damage due to water entrapment, face nailing, nail pops and blemishes, caulk tarring, shrinking and drying out, lack of air movement, constant expansion and contraction ending in cosmetic damage such as, splitting trim and warping, dry rot and mold to the trims and potentially the building structure itself.
[0004] As such, there is a need in the industry for a cost effective siding and system for use on buildings that is pliable to expand and compress when in the presence of different environmental conditions. There is a further need in the industry for a waterproof siding and trim system that effectively prevents moisture buildup and damage to the siding and trim and more importantly the building structure itself. The present invention is such a system.
[0005] The present invention represents a departure from the prior art in that the siding system of the present invention is comprised of various interacting components, each being set off from the exterior walls of the buildings on which the system is used and having limited but secure attachment thereon. The components have limited attachment to each other, thereby allowing for expansion and contraction of the building. The components also feature water control structures and each component terminates with a transitional finish to at least one other component in the system.
SUMMARY OF THE INVENTION
[0006] In view of the foregoing disadvantages inherent in the known types of siding systems, this invention provides a siding system which is cost effective to manufacture and install with less damage to the building and the system components and provides more weather and water resistance to the structure on which it is installed. As such, the present invention's general purpose is to provide a new and improved siding system that is easily and efficiently installed and effective in weatherproofing a building.
[0007] To accomplish these objectives, the system comprises numerous components, each comprising at least one weather resistant panel and at least one bracket. Each bracket presents an attachment flange used to connect the component to the exterior wall of the building and also has water containment and control elements inherently manufactured thereon. The term โpanelโ is used liberally in this specification and the appended claims and include any finishing surface of the component. As such the term includes the obvious planks and siding boards and also corner pieces, door and window trim, and other finishing components that are not necessarily flat. The components are limited in their contact with the exterior wall to create air passageways therebetween. A limited number of types of interfaces are used so that the components of the system are readily and easily fitted together to enhance efficiency in the installation.
[0008] 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.
[0009] Many objects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
[0010] 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.
[0011] 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
[0012] FIG. 1 is a perspective view of a building utilizing embodiments of the method and apparatus, in a state of partial completion.
[0013] FIG. 2 is a sectional view of an outer corner component installed on an exterior wall.
[0014] FIG. 3 is a sectional view of an inner corner component installed on an exterior wall.
[0015] FIG. 4 is a perspective view of a customizable corner component.
[0016] FIG. 5 is a sectional view of the customizable corner component of FIG. 4 .
[0017] FIG. 6 is a perspective view of the corner support utilized in the customizable corner component of FIG. 4 .
[0018] FIG. 7 is a perspective view of a siding plank component.
[0019] FIG. 8 is a side elevation of the siding plank component of FIG. 7
[0020] FIG. 9 is an alternate embodiment of the siding plank component.
[0021] FIG. 10 is a rear perspective view of the siding plank component of FIG.
[0022] FIG. 11 is a front perspective view of the siding plank component of
[0023] FIG. 8 .
[0024] FIG. 12 is a sectional view detailing the assembly of siding plank components according to the present invention.
[0025] FIG. 13 is a side elevation of a finishing plank.
[0026] FIG. 14 is a perspective view of one embodiment of a base apron for use with the present invention.
[0027] FIG. 15 is a sectional view of the base apron of FIG. 14 .
[0028] FIG. 16 is a side elevation of anther embodiment of a base apron according to the present invention.
[0029] FIG. 17 is a perspective view of the base apron of FIG. 16 .
[0030] FIGS. 18-21 are side elevations of four different embodiments of mid-wall aprons for use with the present invention.
[0031] FIG. 22 is a sectional view of a cantilevered apron, installed, for use with the present invention.
[0032] FIG. 23 is a perspective view of a mullion for use in the present invention.
[0033] FIG. 24 is a sectional view of a board and batten assembly according to the present invention.
[0034] FIG. 25 is a board and batten plank used in the board and batten assembly of FIG. 24 .
[0035] FIG. 26 is a batten used in the board and batten assembly of FIG. 24 .
[0036] FIG. 27 is a board used in the board and batten assembly of FIG. 24 .
[0037] FIG. 28 is a sectional view of a fascia pice utilized with the present invention.
[0038] FIG. 29 is a sectional view of a frieze board utilized with the present invention.
[0039] FIG. 30 is a perspective view of an alternate frieze board utilized with the present invention.
[0040] FIG. 31 is a perspective view of a third alternate frieze board for use with the present invention.
[0041] FIG. 32 is a sectional view of an assembly of a frieze board and fascia utilized in the present invention.
[0042] FIG. 33 is a top plan view of a garage door extension jamb utilized with the present invention.
[0043] FIG. 34 is a sectional view of a door trim component for use with the present invention.
[0044] FIG. 35 is a perspective view of the door trim component of FIG. 34 installed about a door.
[0045] FIG. 36 is a perspective view of a window trim component for use with the present invention.
[0046] FIG. 37 is a perspective view of a left window bushing for use with the window rim of FIG. 36 .
[0047] FIG. 38 is a perspective view of a right window bushing for use with the window rim of FIG. 36 .
[0048] FIG. 39 is a side elevation of a shim for use with the present invention.
[0049] FIG. 40 is a partial perspective view of a building sided according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0050] With reference now to the drawings, the preferred embodiment of the siding system and its constituent components is herein described. It should be noted that the articles โaโ, โanโ, and โtheโ, as used in this specification, include plural referents unless the content clearly dictates otherwise.
[0051] With reference to FIG. 1 , the system itself is illustrated as being partially installed on a building, such as the depicted house. It should be noted that the primary intended use of the system is for dwellings, but the principles and teachings of the invention may be applied to any suitable structure and, as such, the use of a house in the figures and any reference to a โhomeโ or โdwellingโ should not be considered limiting. As can be seen in FIG. 1 , the system comprises a number of components; however these components are relatively easily categorized. First you have support structures such as outer corners 20 , inner corners 30 , adjustable corners 40 , mullions 10 and aprons 70 , 80 , 90 . Second you have covering components, which are meant to cover large areas of the building, such as shingle planks 50 and board and batten planks 60 . Finally, you have finishing or specialty pieces such as door trim 140 and window trim 130 , garage door trim 120 , frieze boards 110 and fascia 100 . Each piece may be vertically oriented, like the board and batten plank and corners, or horizontally oriented, like the siding planks and aprons. As such there is one interface for vertical pieces to mate with other pieces. There is one standard interface for horizontal pieces and one for the specialty siding plank pieces. Finishing components will also have special mounting and interface strategies. The system, as seen in FIGS. 1 and 40 , covers the entirety of a building exterior from roof single down to the foundation. The components of this system inherently contain their own flashing in the form of the flanges, thus cutting material cost and installation labor.
[0052] The construction of the components is simple. The panel is manufactured from any durable material of choice. The ideal material, as found by the inventor, is a polymer/wood composite which may be extruded to size and shape. Any shape may be utilized, including giving a staggered shingle or a Dutch single look to planks, using rounded or squared edges, etc. Panels and brackets may also be orthogonal or may be angled to accommodate gabled roofs. Brackets are ideally made of durable polymers with limited give so as to resist the effects of gravity and other forces. It is incumbent upon both these materials that they be relatively easily cut to size as buildings will rarely conform to standard lengths and widths of wall. Ultimately, each major component has at least one bracket that extends significantly beyond one edge of the panel and is utilized both for the attachment of the component to the exterior wall of the building and for waterproofing. In an effort to keep each component minimally adjacent the exterior wall, spacers, like the one underneath the attachment strip, are positioned at various places on the back of the panel and the bracket. These spacers, or โstandeesโ may be as simple as a thin strip or bead along an edge, a post, or may be more significant and be, in essence, a separate bracket.
[0053] In assembling the siding system, each component's bracket 26 has an attachment strip 28 , as shown with the outside corner piece 20 in FIG. 2 , located beyond the edge 23 of the component panel 22 . Ideally, this attachment strip 28 is provided for industrial staples 2 . The spacer 29 underneath the attachment strip may then be straddled by staples. Each bracket contains a trough 26 located in a position obscured by the panel 22 . For the standard interface, the trough serves two purposes: 1. interface for individual components to co-operate; and 2. water control and diversion. The trough in the standard interface is found running vertically in the corner pieces and horizontally in aprons and finishing pieces which interface with the narrow side of board and batten panels. Each trough 26 presents a trough spacer 25 so as to keep the individual pieces from tightly abutting each other while still maintaining a secure assembly. The trough spacer 25 , then, stands each piece off from each other so as to allow air and water to flow through the trough and in and around the component and the exterior wall 1 . In this way, horizontal troughs remain open to the vertical troughs and allow spillage of water in a controlled manner into the vertical troughs and away from the exterior wall. By joints being obscured by the panel, assembly of individual components into the troughs 26 will allow each piece to transition into a finished assembly with an appealing look.
[0054] Corner panels are provided in three types, outer corner panels 20 ( FIG. 2 ), inner corner panels 30 ( FIG. 3 ) and adjustable corner panels 40 ( FIGS. 4-6 ). Each uses the same trough construction. The outer corner panel 20 utilizes its brackets 26 to sand off from the wall. Inner corner 30 uses additional spacers 32 extending off of its support structure 34 to serve as standees. For non-orthogonal corners, a specialized corner component 40 is provided. The component features two panels 42 with detachable brackets 44 and a specialized, flexible corner brace 46 . The brackets 44 and panels 42 are mitered along their adjacent edges to the specified angle and attached to each other. Brace 46 is essentially two broad legs 48 joined at a hinge 49 . Brace 46 is then bent around the corner and joins the two halves of the corner component 40 together, usually held by screws 45 . This component is one where caulking and/or gluing is necessary to assure adequate weatherproofing and structural integrity. Each bracket 44 contains one trough 26 according to the designs already described.
[0055] The plank interface is different than the standard interface and is utilized for horizontal siding planks 50 and those aprons and trim components interfacing therewith. As the siding planks ( FIGS. 7-12 ) are used to create a sloping shingled appearance, the plank interface has an attachment spur 56 , which co-operates with the lower edge 52 of a plank to receive an upper edge 54 of a plank beneath it. The attachment spur 53 and panel are made to snap onto the top edge of the lower panel, thanks to lips provided on both the spur 53 and lower edge 52 , and recline rearwards to that the bracket of the upper siding plank may be attached to the exterior wall. The plank bracket 58 is of slightly different construction. Like the standard bracket, it has a flange 59 extending beyond the upper edge of the plank and a trough 57 disposed beneath that same edge (in fact, partially formed by the panel). A triangular spacer 55 is disposed on the flange 59 between the trough 57 and attachment strip and no spacer is in the trough. Ideally, the upper edge of the flange is hooked rearwardly to aid in the control of any water that may get behind the planks (as shown in FIG. 12 ). This feature may be used on any component with a horizontal flange, but is optional. When assembled, the narrow edges (as defined by being generally at a right angle to the bracket) of each plank are positioned in corresponding troughs of corner components or mullions. A finishing plank 50 a ( FIG. 13 ) is also provided which lacks the upper bracket and is designed to be cut to size and then the plank directly interfaces with finishing components, like frieze board, made to accept this piece. Since the plank interface has two distinct portions, an upper and a lower portion, any component made to interface with siding plank must have a portion of the interface dependent upon its location in relation to the siding plank (i.e. an apron underneath the plank will have the upper portion, essentially a connection spur, located on its upper edge while fascia finishing the wall will have a slot for receiving the upper edge of the finishing plank). Each plank 50 has a plurality of spacers 51 on its reverse side to help it stand off from the external wall 1 . The shape of the plank 50 may be any readily conceived and manufactured, such as the flat shape seen in FIGS. 7 , 8 , 12 and 18 or the Dutch lab board shape of FIGS. 9-10 .
[0056] Aprons are horizontal components of which there are three types. The base apron 70 , 71 ( FIGS. 14-17 ) runs along the bottom of the wall and provides support for the whole system. It is secured to the wall by the flange 74 and a support clip 72 . The support clip 72 is one of the few components that is secured to the wall by larger screws. The base apron has an edge 76 designed to fit over a lip in the support bracket 72 . There are two types of base aprons. One type 70 interfaces with board and batten panels with a trough 78 . The other type 71 presents a spur 73 to interface with planks, as can be seen in FIG. 12 . Both have a lower edge 75 that extends beneath the level of the bracket 72 .
[0057] The mid-wall apron 80 is used to break up the pattern established by the coverage planks. It must therefore have bottom 82 and top 84 interfaces for the coverage planks. As such, each mid-wall apron will have either a plank interface or a standard interface as either the top or bottom interface, for four possible configurations, as is illustrated in FIGS. 18-21 .
[0058] Cantilever aprons 90 , as shown in FIG. 22 , are used for areas on an exterior which project outward 96 from the general plane of the wall (such as for a bay window). Like the other aprons, it presents an upper flange 92 with one of the two horizontal connection interfaces. However, towards its bottom is a second flange 94 which extends rearward so as to allow the apron to fit around the corner of the projection 96 . Slightly beneath the rearward flange is a slot 98 for receiving soffit board 4 . The slot 98 is beneath the lower edge of the apron 90 .
[0059] Mullions 10 ( FIG. 23 ) are provided so as to allow tie-ins of planks or batten and boards. They contain the standard vertical interface on either side of the mullion. Mullions may be made in any shape, including a shape to match board and batten panels 15 ( FIG. 24 ).
[0060] Board and batten panels 70 ( FIGS. 24-27 ) have their extending flange 72 projecting on the batten side with a standard receiving trough. The board side of the panel terminates in a block 74 which rests in the standard receiving trough of a neighboring board and batten panel or a mullion or corner. For flexibility, a two-piece finishing panel construction is provided. The two piece panel is a board 76 which may be trimmed to size and a batten 78 which has a slot to receive the edge of the trimmed board and fits in the receiving trough of a corner or mullion. A flange 79 extends from the batten underneath the board 76 .
[0061] Finishing fascia 100 is provided to finish the area along the roof line of the building. Flashing 102 is provided to transition the top of the roof to the fascia 100 , thereby hiding the upper flange 104 , which contains a trough. Like the cantilevered apron, the fascia presents a rearward flange 106 and a slightly lower slot for soffit board 4 . Frieze board 110 finishes the top of the wall and may have a lower interface to either fit plank panels 111 ( FIG. 30 ) or board and batten panels 113 ( FIG. 29 ). It presents a corresponding slot 112 for soffit board 4 slightly underneath its upper flange 114 . Frieze board may be horizontal 110 or gabled 118 ( FIG. 31 ) with the lower edge 116 angled to accommodate the slope of the roof and the corresponding interface with coverage components. Soffit board 4 then fits between the frieze board 110 and the fascia 100 ( FIG. 32 ) or a cantilevered apron.
[0062] Finishing the siding system around doors windows and garage doors required specialized parts. The simplest of these parts is the garage door extension jamb shown in FIG. 33 . The jamb is simply a head 122 with a bracket 124 at a right angle thereto. The bracket 124 is fastened to the interior garage wall such that the head 122 proceeds outward, where it may be cut to size and interface with any corner. This arrangement keeps the siding flush with the garage door.
[0063] Similarly, a flashing bracket 152 is used to keep the door trim finishing components 150 flush with a door way ( FIGS. 34 and 35 ). When installed at the edge of the doorway, the flashing bracket 152 positions the door trim 150 slightly overlapping the door jamb 158 . With this arrangement, the trim stays evenly distributed down the door jamb. The door trim component 150 has a bracket 154 with the standard vertical trough interface 158 .
[0064] For window trim 160 , bushings 164 , 166 are used to secure the trim about a window ( FIGS. 36-38 ). Bushings may be for the right side of a window (right 164 ) or the left (left 166 ). Each bushing has a brace 168 that extends above the bushing and has a body that is an L-shaped block 167 with a divot 169 on the side of the bushing opposite its identification (the divot is on the left side of the right bushings body). Bushings 164 , 166 are attached to the exterior wall above the window such that the block 167 abuts the window frame, the divot 169 being proximate the frame. The window trim has the standard vertical interface trough 162 and a side the is made to interface with a hook 165 that mates with the corresponding divot 169 so that it resides in the divot next to the window frame. This structure keeps the trim 160 flush with the window frame and the trim itself is reversible for use on either side of the window. Siding may be installed to the very top and bottom edges of windows and doors. As such, headers and sills may be mounted directly on siding panels. In order for such sills and headers to be vertical on plank siding, shims 170 ( FIG. 39 ) are used to level the base on which the sills and headers are placed. Shims may be made of any shape to comport with the shape of the plank. They have an angled side 172 and a flat side with an adhesive 174 . Shims 170 are first secured to the plank, then the adhesive is used to secure the sill or header to the shim 170 .
[0065] Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.
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A system for providing siding to a building is disclosed. The system utilizes components which have their own brackets with attachment flanges in order to connect directly to an exterior wall of the building. The brackets contain their own integrated water control systems, which co-act with those of other components to control and direct water into vertical channels and out from behind the siding system. These flanges double as self-contained flashing. In all the system presents a roof-to-foundation siding system that is self-contained and fully transitional from one piece to another.
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CROSS REFERENCE
This application is a continuation application of U.S. patent application Ser. No. 09/876,022, filed Jun. 8, 2001 now U.S. Pat. No. 6,620,427 which claims benefit of 60/286,140 filed Apr. 24, 2001.
FIELD OF THE INVENTION
The present invention relates to a method for increasing bone mineralization in a pediatric population. Other aspects of the invention relate to methods for improving the nutritional status of infants and toddlers.
This application is related to a provisional patent application Ser. No. 60/286,140 filed Apr. 24, 2001, now abandoned.
BACKGROUND
Bone serves an important physiologic role. It provides mechanical strength. All of the bones collectively, need to be strong enough to support the entire weight of the body, and any additional mechanical burden. It is widely accepted that bone mineral content and density, are directly correlated with the mechanical strength of the bone.
Bone is composed primarily of matrix proteins and calcium salts. Bone growth involves not only an increase in bone size, but an increase in the amount of such components as well. Bone growth is controlled by osteoblasts. These osteoblasts adhere to the terminal portion of existing bone and secrete bone matrix proteins, which differentiate into bone cells (osteocytes) and become part of the tissue of the bone. These osteoid tissues are then mineralized, primarily by calcium and phosphorus. The mineralization gives the bone its mechanical strength and allows it to serve its physiologic role. Substantial bone growth continues for up to the first 20 years of life.
However, after age 35, bone mass and mineral content begin declining gradually reducing the strength of the bone tissue. Consequently, when mechanical strength declines to a certain level, the individual is at greater risk of bone fracture. This is often referred to as osteoporosis.
Medical research has focused on ways of preventing the occurrence of osteoporosis. This research has shown that one of the most effective means of preventing osteoporosis is the establishment of a high bone mass during the childhood years. The establishment of significant bone mass allows a greater loss of bone before osteoporosis becomes problematic. Investigators have started to study childhood diets and their impact on bone formation. Consumption of calcium is an important dietary variable in promoting the development of substantial bone mass in the individual.
Part of this research has examined what impact, if any, infant formula has on bone development. Nelson et al, Journal of the American College of Nutrition, Vol. 17, No. 4, 327-332 (1998), evaluated whether the fatty acid content of infant formula impacted calcium absorption. Nelson et al determined that oil blends did have an impact on calcium absorption. Nelson et al found that the presence of palm olein oil reduced calcium absorption by approximately 35%, when compared to formula which did not contain palm olein oil. The authors concluded that this reduced calcium absorption was unlikely to have any significant physiologic impact on the infant, including bone mineralization. The authors stated that the most likely adverse effect is constipation in the infant.
Nelson et al also evaluated the impact of palm olein on calcium absorption in a different group of infants Am J Clin Nutr 1996;64:291-6 (1996). The results obtained in this study were consistent with the results described by Nelson et al supra. Infants consuming formula containing palm olein oil had lower rates of calcium absorption. The authors emphasized that the clinical significance of such reduced absorption is unknown.
Motil commented on the work of Nelson et al supra, in the Journal of the American College of Nutrition, Vol. 17, No. 4, 303-305 (1998). Motil reiterated that Nelson et al had documented that infants consuming palm olein oil had lower relative calcium absorption, when compared to a group of infants consuming alternative fats. However, Motil emphasized that these findings were insignificant from a clinical standpoint. Motil emphasized that calcium homeostasis is a highly regulated process and is not dependent solely upon the amount of calcium that is absorbed. Further, infants in the palm olein group were receiving 100 mg/day of calcium, which is the established RDA. Thus, a fair reading of Motil is that the presence of palm olein is expected to have no impact upon the rate of bone mass development in an infant.
Kennedy et al evaluated an infant formula which contained a synthetic triglyceride (STG) Am J Clin Nutr 1999:70:920-7. This STG contained palmitic acid in the sn-2 position of the glycerol nucleus (i.e. the center carbon atom). This STG is structurally similar to the triglyceride contained in human breast milk. An infant formula containing this STG was compared against a formula containing triglycerides, in which the palmitic acid was contained primarily in the 1- and 3-positions of the glycerol nucleus. These triglycerides are typically contained in infant formula and are obtained from vegetable oils. Kennedy et al evaluated growth rates, fat absorption, and bone mineralization of the two groups. Similar parameters were observed in a group of infants consuming breast milk. Kennedy found that infants consuming the STG had rates of bone mineralization comparable to the breast fed group. Infants receiving the triglycerides obtained from vegetable oils had lower rates of bone mineralization than infants consuming the STG.
Kennedy noted that enhanced calcium absorption had previously been observed with formulae having reduced palmitate content. However, the fatty acid profile of such formula differs substantially from that of breast milk and therefore caution should exercised in its consumption. Kennedy emphasized that palmitic acid is the predominant fatty acid in human milk and the clinical significance of omitting this fatty acid needs further study.
Thus while the prior art clearly establishes that palmitic acid from bovine and vegetable sources negatively impacts the absorption of calcium, the clinical significance of this finding is unknown. Numerous authors agree that the impact of this finding on bone mass is unknown, but probably is clinically insignificant. Other authors suggest caution in the utilization of low palmitic acid formula since it's fatty acid profile differs so significantly from human milk.
SUMMARY OF THE INVENTION
In accordance with the present invention, it has been discovered that it is possible to enhance bone mass accretion in an infant or toddler. This increased bone mass can be accomplished by enterally feeding the juvenile a formula containing a source of calcium and a source of fat, in which the fatty acid profile is characterized by having a palmitic acid content of about 19 w/w %, or less. Such a feeding regimen will result in an enhanced rate of bone mineralization and ultimately enhanced skeletal strength.
The pediatric formula utilized in the method of the present invention will typically be an infant formula. It should contain sufficient nutrients to promote the growth and development of the juvenile. It typically will contain protein, carbohydrate, vitamins, and minerals, as is known in the art. The formula will contain calcium as is known in the art. The key to the invention is the utilization of a fat blend that is low in palmitic acid. While the prior art demonstrates that palmitic acid interferes with the absorption of calcium, the enclosed human clinical studies demonstrate that diminished absorption is associated with decreased levels of bone mass in a human infant. Such a finding contradicts the teachings of the prior art, which taught that this diminished calcium absorption had no clinical significance on bone mass accretion.
The fat blend utilized in the pediatric formula of the present invention must be low in palmitic acid, but yet contain sufficient fatty acids to support optimal infant growth and development. This may be accomplished by a blend having a fatty acid profile characterized by about 9.5-21 weight % lauric acid, about 19 weight %, or less, palmitic acid, and about 34-48 weight % oleic acid. In a further embodiment, palmitic acid content is maintained at about 15 weight %, or less, and often at about 10 weight %, or less. In an additional embodiment, the oil blend may additionally contain about 2.7-3.1 w/w % of stearic acid, about 17-29 w/w % of linoleic acid and about 1.7-3.2 w/w % of linolenic acid. A number of commercially available vegetable oils will produce this profile when blended as described in detail below.
It is believed that enhanced bone mass, continued throughout life, will make individuals less susceptible to osteoporosis when they reach their geriatric years. It is also believed infants consuming this formula will have the opportunity to achieve a greater peak bone mass.
DETAILED DESCRIPTION OF THE INVENTION
As used in this application, the following terms have the meanings defined below, unless otherwise specified. The plural and the singular should be treated as interchangeable:
1. โfatty acid profileโ as used herein means the total fatty acid content of the fat, oil, emulsifiers, and other components used to create a pediatric nutritional as determined by conventional analysis. Unless specified otherwise, all percentages are weight percents of total fatty acid content. Those skilled in the art will appreciate that sometimes the levels of fatty acids are reported as grams of fatty acid, per 100 grams of fat. 2. โincreasing bone mineralizationโ refers to the accumulation of minerals, including calcium and phosphorus, which are deposited in newly formed or remodeled bone matrix. 3. โinfantโ refers to a child under the age of 1 year. 4. โjuvenileโ refers to a child under the of age 6, and specifically includes infants, toddlers, etc. 5. Any reference to a numerical range in this application should be construed as an express disclosure of every number specifically contained within that range and of every subset of numbers contained within that range. Further, this range should be construed as providing support for a claim directed to any number, or subset of numbers in that range. For example, a disclosure of 1-10 should be construed as supporting a range of 2-8, 3-7, 5, 6, 1-9, 3.6-4.6, 3.5-9.9, 1.1-9.9, etc. 6. โpediatric formulaโ as used herein refers to a liquid nutritional designed for infants, toddlers, and juveniles which contains calcium, a fat blend, and optionally nutrients such as protein, vitamin, phosphorus, etc. that are required for growth and development.
The terms โbone mineralizationโ and โbone mass accretionโ are being used interchangeably within this application. Thus within the specification or claims, they should be considered as synonyms. โBone mineralizationโ should also be considered synonymous with increasing, enhancing or improving โbone strengthโ, โbone mineral densityโ, โbone mineral contentโ, โbone massโ, โbone accretionโ, etc. Likewise, the terms โpalm oilโ and โpalm olein oilโ are also being used as synonyms and should also be considered as interchangeable.
As noted above, the key to the present invention is the discovery that oil blends that inhibit the absorption of calcium produce statistically significant lower rates of bone mass accretion, when compared to oil blends which do not inhibit calcium absorption. Enhanced rates of bone mass accretion can be accomplished by limiting the quantity of palmitic acid contained within the infant formula. Based upon the overall fatty acid profile of the fat composition used in the formula, total palmitic acid content should not exceed about 19 w/w %. Such quantities of palmitic acid do not negatively impact bone mass accretion.
Limiting palmitic acid content in infant formulae goes against traditional wisdom in the field. Most infant formulae makers have attempted to utilize oil blends which create a fatty acid profile that mimics human milk. It is believed that such a profile produces superior growth and development. Palmitic acid typically makes up about 20-25 w/w % of the total fat content in human milk. A comparison of the fatty acid profile of human milk and one of the fatty acid profiles of the invention is listed below in Table I.
TABLE I
Fatty Acid Profiles of Infant Formulas, th Inv ntion and Human Milk
Fatty Acid
weight %
Invention 1
Human Milk*
12:0
9.5-21โ
1.4-6.5
lauric
14:0
3.8-8.4
โ3.8-10.2
myristic
16:0
up to about
19.8-24.0
palmitic
19
18:0
2.7-3.1
7.1-9.0
stearic
18:1n9
34-48
30.7-38.0
oleic
18:2n6
17-29
โ5.7-17.0
linoleic
18:3n3
1.7-3.2
0.1-1.8
linolenic
*as reported in literature
1 all quantities listed should be considered approximate and to be modified by the adjective โaboutโ, and to not specifically require the presence of all of the fatty acids listed therein, other than the express limitation upon palmitic acid content.
The fatty acid profile depicted above can be obtained with a number of vegetable oils that are routinely consumed by infants. These oils include soy, coconut, safflower, high oleic safflower (HOSO), high oleic sunflower (HOSUN), corn, medium chain triglyceride (MCT), palm kernel, palm, and palm olein. The fatty acid profile of each of these oils is listed below in Table II. One skilled in the art understands that a particular fatty acid profile can be obtained by blending different oils, based upon their individual fatty acid profiles, until the desired mix is obtained.
TABLE II
Fatty Acid Profile of Commodity Oils
High
Fatty Acid
Oleic
Palm
Palm
weight %
Soy
Coconut
Safflower
HOSO
Sunflower
Kernel
Olein
Palm
Corn
MCT
โ6:00
โ
โ
โ
โ
โ
โ
โ
โ
โ
2.0
caproic
โ8:00
โ
โ
โ
โ
โ
โ
โ
โ
โ
67.0
caprylic
10:00
โ
โ
โ
โ
โ
โ
โ
โ
โ
23
capric
12:0
โ
47.1
โ
0.1
โ
49.6
0.6
.1
โ
โ
lauric
14:0
0.1
18.5
0.1
0.1
โ
16
1.1
1.0
.1
โ
myristic
16:0
10.6
9.1
6.5
4.7
4.0
8.0
32.7
44.0
10.9
โ
palmitic
18:0
4.0
2.8
2.4
2.2
4.0
2.4
3.5
4.1
2.0
โ
stearic
18:1n9
23.2
6.8
13.1
74.5
80.0
13.7
48.1
39.3
25.4
โ
oleic
18:2n6
53.7
1.9
77.7
16.7
10.0
2.0
13.2
10
59.6
โ
linoleic
18:3n3
7.6
0.1
โ
0.4
0.1
โ
0.5
.4
1.2
โ
linolenic
1. as reported in the literature.
The invention is not limited to the fatty acid profile depicted above in Table I. Alternative fatty acid profiles depicted below in Table III will also produce enhanced rates of bone mass accretion in infants.
TABLE III
Fatty Acid
weight %
Embodiment 1 1
Embodiment 2 1
Embodiment 3 1
12:0
10.4-17.0
10.4-15.0
14.2
lauric
14:0
4.2-6.7
4.2-6.0
5.6
myristic
16:0
7.0-8.0
7.5-8.0
7.7
palmitic
18:0
2.8-3.1
2.9-3.1
2.9
stearic
18:1n9
37.0-45.2
37.6-43.0
40.0
oleic
18:2n6
21.0-28.2
22.0-28.0
22.6
linoleic
18:3n3
2.2-3.2
2.3-3.2
2.3
linolenic
1 all quantities listed should be considered approximate and to be modified by the adjective โaboutโ, and to not specifically require the presence of all of the fatty acids listed therein, other than the express limitation regarding the quantity of palmitic acid.
The fatty acid profile depicted as โEmbodiment 1โ as set out above can be accomplished through a blend of about 38-50 weight % high oleic safflower oil (HOSO/ or HOSUN), about 26-40 weight % soy oil (SO) and about 22-36 weight % coconut oil (CO). The fatty acid profile depicted as โEmbodiment 2โ can be accomplished through a blend of about 41-44 weight % HOSO/HOSUN, about 27-32 weight % SO, and about 27-32 weight % CO. The fatty acid profile depicted as โEmbodiment 3โ can be accomplished through a blend of about 42 weight % HOSO/HOSUN, about 28 weight % SO and about 30 weight % CO.
As is readily apparent to one skilled in the art, a number of alternative oil blends will provide fatty acid profiles meeting the criteria outlined above in Tables I and III. Examples of such oil blends include: those containing admixtures of corn oil, high oleic safflower oil or sunflower oil, MCT oil, safflower oil and coconut oil. More specifically the benefits of the invention can be obtained with an oil blend containing about 0-60 weight % of corn oil, about 20-45 weight % of coconut oil, about 25-60 weight % HOSO or HOSUN, about 0-40 weight % soy oil, about 0-40 weight % safflower oil, and about 0-35% MCT oil, with the proviso that the sum of said fatty acids does not exceed 100 weight %. Alternative blend include those containing from about 20-30 weight % coconut oil, about 45-60 weight % HOSO/HOSUN, and about 10-35% MCT oil. Other embodiments include blends containing 20-55 weight % corn oil, about 20-45 weight % of coconut oil and 25-60 weight % of HOSO/HOSUN. Numerous other variations will be readily apparent to those skilled in the art based upon the fatty acid profiles above and should be considered to be within the scope of the invention.
Other examples of suitable oil blends include: a) about 40% corn, about 20% coconut and about 40% HOSO or HOSUN; b) about 55% corn, about 20% coconut and about 25% HOSO/HOSUN; c) about 20% corn, about 45% coconut, and about 35% HOSO/HOSUN; d) about 40% coconut and about 60% HOSO/HOSUN, and; e) about 20-30% coconut, about 45-60% HOSO/HOSUN, and about 10-35% MCT. Other variations will be readily apparent to one skilled in the art.
High oleic safflower oil (HOSO) refers to oil derived from the seeds of a hybrid safflower plant, Carthamus tinctorus . Safflower oil is an edible oil which typically has a high content of linoleic acid. Hybrids of this plant have been developed which produce a seed oil which has an elevated level of oleic acid. It is the oil that is derived from the seeds of these hybrids which have been found useful in the present invention. Virtually interchangeable with HOSO is high oleic sunflower oil (HOSUN). Like HOSO, high oleic sunflower oil contains an elevated level of oleic acid. When used herein, the term โHOSOโ includes its sunflower relative.
Soy oil (SO) refers to the fat fraction obtained from the seeds of the legume, Soja max . Typically, the oil fraction of the soya seed undergoes a number of refining, bleaching and deodorization steps resulting in the commercial commodity. Soy oil generally contains relatively high levels of linoleic fatty acid and to a lesser extent, linolenic fatty acid.
Coconut oil (CO) refers to the oil obtained from copra, which is dried coconut meat. This oil is distinguished from HOSO and SO by its high content of saturated, short-chain and medium chain fatty acids. Palm kernel oil is very similar in fatty acid profile to CO. When used herein, the term โCOโ includes its palm kernel relative.
Medium chain triglyceride oil is often referred to as โfractionated coconut oilโ. As its name implies, it is obtained from coconut oil. Alternatively it may be obtained from palm kernel oil. The coconut oil or palm kernel oil is submitted to chemical purification in order to enrich its relative content of in saturated fatty acids in the C 8 -C 12 range, especially caprylic (C:8.0) and capric (C:10.0). Techniques for carrying out such enrichments are well known to those skilled in the art.
Numerous commercial sources for the fats listed above are readily available and known to one practicing the art. For example, soy oil is available from Archer Daniels Midland of Decatur, Ill. Corn, coconut, palm and palm kernel oils are available from Premier Edible Oils Corporation of Portland, Oreg. Fractionated coconut oil is available from Henkel Corporation of LaGrange, Ill. High oleic safflower and high oleic sunflower oils are available from SVO Specialty Products of Eastlake, Ohio.
In addition to the fat blend, the formula must contain calcium. Infants consuming human breast milk typically consume 250 mg to 330 mg of elemental calcium per day, with a net absorption of between 55-60%. By contrast, infants consuming formula typically consume 500 to 600 mg of elemental calcium per day. The amount of calcium that the infant absorbs is dependant upon the fat content of the formula. Calcium absorption is only about 40% if the formula contains levels of palmitic acid mimicking those of human breast milk. By contrast, the formula of this invention produce calcium absorption in the range of approximately 60%.
The infant formulae of this invention should contain from about 250 mg to about 2000 mg of elemental calcium per liter, and more typically from about 500 mg to about 1000 mg of elemental calcium per liter. Any source of calcium that is appropriate for use in a juvenile population may be utilized in the nutritionals of this invention. Examples of suitable sources of calcium include, but are not limited to, calcium carbonate, calcium chloride, calcium lactate, calcium gluconate, calcium sulfate, calcium phosphate, tricalcium phosphate, calcium citrate, tricalcium citrate, or calcium maleate.
In addition to the calcium and oil blends described above, the pediatric formula of this invention will typically contain protein, carbohydrate, vitamins, minerals, trace minerals, etc. as is known in the art. The specific sources of protein, carbohydrates, vitamins, etc., and their relative quantity, is not critical to the invention and will fit within guidelines typically used in the industry, which is described in greater detail below.
The pediatric formula of the invention may be provided in powdered, liquid concentrate or ready-to-feed forms. Before feeding, water is added to both the powdered and concentrate forms of the formula. In a first embodiment, a pediatric formula of the invention comprises, based on a 100 kcal basis, about 8 to about 16 grams carbohydrate (preferably about 9.4 to about 12.3 grams), about 3 to about 6 grams fat (preferably about 4.7 to about 5.6 grams), and about 1.8 to about 3.3 grams of protein (preferably about 2.0 to about 3.3 grams). If provided in a powder form, the formula comprises, based on 100 grams of powder, about 30 to about 90 grams carbohydrate (preferably about 48 to about 59 grams ), about 15 to about 30 grams fat (preferably about 22 to about 28), about 8 to about 17 grams protein (preferably about 9 to about 17 grams). A summary of the carbohydrate, fat, and protein ranges (on a per 100 kcal basis, per 100 grams powder basis and per liter basis (as fed concentration) for a formula according to the invention is provided in Table IV.
TABLE IV
RANGES OF CARBOHYDRATE, LIPID AND PROTEIN
PER 100 KCAL, PER 100 GRAMS POWDER AND
PER LITER (AS FED CONCENTRATION)
Per 100
Per 100
Per liter (as fed
Nutrient (g)
Range
kcal
grams powder
concentration)
Carbohydrate
Broadest
โ8-16
30-90
โ53-107
Preferred
โ9.4-12.3
48-59
64-83
Fat
Broadest
3-6
15-30
22-40
Preferred
4.7-5.6
22-28
32-38
Protein
Broadest
1.8-3.3
โ8-17
12-22
Preferred
2.4-3.3
10-17
14-22
Suitable carbohydrates, and proteins can vary widely and are well known to those skilled in the art of making pediatric formulas.
One component of the pediatric formulae is a source of carbohydrates. Carbohydrate is a major source of readily available energy that the infant needs for growth and that protects the infant from tissue catabolism. In human milk and most standard milk-based infant formulas, the carbohydrate is lactose.
The carbohydrates that may be used in the formula can vary widely. Examples of carbohydrates suitable for infants include hydrolyzed corn starch, maltodextrin, glucose polymers, sucrose, corn syrup, corn syrup solids, rice derived carbohydrate, glucose, fructose, lactose, high fructose corn syrup and indigestible oligosaccharides such as fructooligosaccharides (FOS). Any single carbohydrate listed above, or any combination thereof, as appropriate may be utilized.
Commercial sources for the carbohydrates listed above are readily available and known to one practicing the art. For example, corn syrup solids are available from Cerestar USA, Inc in Hammond, Ind. Glucose and rice based syrups are available from California Natural Products in Lathrop, Calif. Various corn syrups and high fructose corn syrups are available from Cargil in Minneapolis, Minn. Fructose is available from A. E. Staley in Decatur, Ill. Maltodextrin, glucose polymers, hydrolyzed corn starch are available from American Maize Products in Hammond, Ind. Sucrose is available from Domino Sugar Corp. in New York, N.Y. Lactose is available from Foremost in Baraboo, Wis. and indigestible oligosaccharides such as FOS are available from Golden Technologies Company of Golden, Colo.
The fats used in the formula have been described in detail above. In addition to these vegetable oils, the formula may also contain arachidonic acid, docosahexaneoic acid, and mixtures thereof. Such lipids have been shown to have beneficial effects in infants, including enhanced brain and vision development. U.S. Pat. No. 5,492,938 to Kyle et al. describes these effects in greater detail. Lipid sources of arachidonic acid and docosahexaneoic acid include, but are not limited to, marine oil, egg derived oils, and fungal oil. Marine oil is available from Mochida International of Tokyo, Japan. DHA is available from Martek Biosciences Corporation of Columbia, Md. Arachidonic acid is available from Genzyme Corporation of Cambridge, Mass.
The proteins that may be utilized in the pediatric formula of the invention include any proteins or nitrogen source suitable for human consumption. Such proteins are well known by those skilled in the art and can be readily selected when preparing such products. Examples of suitable protein sources include casein, whey, condensed skim milk, nonfat milk, soy, pea, rice, corn, hydrolyzed protein, free amino acids, and mixtures thereof.
Commercial protein sources are readily available and known to one practicing the art. For example, caseinates, whey, hydrolyzed caseinates, hydrolyzed whey and milk proteins are available from New Zealand Milk Products of Santa Rosa, Calif. Soy and hydrolyzed soy proteins are available from Protein Technologies International of Saint Louis, Mo. Pea protein is available from Feinkost Ingredients Company of Lodi, Ohio. Rice protein is available from California Natural Products of Lathrop, Calif. Corn protein is available from EnerGenetics Inc. of Keokuk, Iowa. Additionally, mineral enriched proteins are available from New Zealand Milk Products of Santa Rosa, Calif. and Protein Technologies International of Saint Louis, Mo.
A formula of the invention preferably also contains vitamins and minerals in an amount designed to supply the daily nutritional requirements of a pediatric population. The formula preferably includes, but is not limited to, the following vitamins and minerals: phosphorus, sodium, chloride, magnesium, manganese, iron, copper, zinc, selenium, iodine, and Vitamins A, E, C, D, K and the B complex. Further nutritional guidelines for infant formulas can be found in the Infant Formula Act, 21 U.S.C. section 350(a). The nutritional guidelines found in the Infant Formula Act continue to be refined as further research concerning infant nutritional requirements is completed. This invention is intended to encompass formulas containing vitamins and minerals that may not currently be listed in the Act.
The pediatric formulas of this invention can be manufactured using techniques well known to those skilled in the art. Various processing techniques exist for producing powdered, ready-to-feed and concentrate liquid formulas. Typically, these techniques include formation of a slurry from one or more solutions which may contain water and one or more of the following: carbohydrates, proteins, lipids, stabilizers, vitamins and minerals. This slurry is emulsified, homogenized and cooled. Various other solutions may be added to the slurry before processing, after processing or at both times. The processed formula is then sterilized and may be diluted to be utilized on a ready-to-feed basis or stored in a concentrated liquid or a powder. If the resulting formula is meant to be a ready-to-feed liquid or concentrated liquid, an appropriate amount of water would be added before sterilization. If the resulting formula is meant to be a powder, the slurry will be heated and dried to obtain a powder. The powder resulting from drying may be dry blended with further ingredients, if desired.
In actual use, the formula of this invention may be consumed by any human. More specifically, the specified fat composition of this invention may be incorporated into a formula which is in compliance with accepted levels of vitamins, minerals, micro-components and the like. The amount consumed does not differ from that associated with the normal consumption of commercially available infant formula. The caloric density (i.e., kcals/ml) and caloric distribution (i.e., the relative proportion of calories from fat, protein and carbohydrate) are not critical to this invention but are generally comparable to conventional formulas. As is well know to those skilled in the art, these factors can vary with the intended use of the formula. For example, pre-term, term and toddler infants have somewhat differing caloric density requirements. Also, formulas for specific disease states (e.g., diabetes, pulmonary deficiency, in-born errors of metabolism, and immuno-comprised) will have differing caloric distributions. Those skilled in the art are aware of these differences and will readily adapt the present invention to meet those special needs.
The invention has been described as a method of enhancing the bone mass of infants, juveniles, children, etc. It should be understood that any human being, regardless of their age, will experience enhanced calcium absorption, with the fat blends of this invention. As a practical matter however, typically only infants and toddlers consume such formula. The invention should be construed as covering any human being who consumes the nutritionals described above.
The following examples are illustrative of the methods and compositions of the invention for enhancing bone mass growth in pediatric patients. While the invention is described in terms of a ready-to-feed infant nutritional formula in the examples, below, it is not intended to be so limited, as it is intended to encompass both powdered and concentrate liquid infant formulas as well as formulas for children one year in age or older. The examples are not intended to be limiting as other carbohydrates, lipids, proteins, stabilizers, vitamins and minerals may be used without departing from the scope of the invention.
EXAMPLE I
The following Example illustrates the preparation of a ready-to-feed infant formula suitable for carrying out the method of the present invention. The components utilized in the formula are depicted Table V. The quantities outlined were used to prepare a 7711 Kg batch of formula.
TABLE V
INGREDIENT
AMOUNT
High Oleic Safflower Oil
โ120.2 Kg
Coconut Oil
โ85.7 Kg
Soy Oil
โ80.3 Kg
Lecithin
โ2.92 Kg
Mono-and diglyceride
โ2.92 Kg
Oil Soluble Vit, Premix
โ0.365 Kg
ฮฒ-carotene
0.0137 Kg
Carrageenan
โ1.43 Kg
Whey Protein Concentrate
โ61.2 Kg
Lactose
โ476.3 Kg
Potassium Citrate
โโ4.6 Kg
Magnesium Chloride
โ0.735 Kg
Low Heat Condensed Skim Milk
โโ821 Kg
Calcium Carbonate
โ3.36 Kg
Ferrous sulfate
โ0.450 Kg
Water Soluble Vitamin Premix
โ1.11 Kg
Trace Minerals/Taurine
Choline Chloride
โ0.600 Kg
Adenosine 5โฒmonophosphate
โ0.113 Kg
Guanosine 5โฒmonophosphate-
โ0.197 Kg
Na2
Cytidine 5โฒmonophosphate
โ0.259 Kg
Uridine 5โฒmonophosphate-Na2
โ0.216 Kg
Ascorbic Acid
โ1.78 Kg
45% KOH
โ2.36 Kg
Total Yield
โโ7711 Kg
The first step in the preparation of formulas is the preparation of the oil blend. To an appropriately sized blend tank with agitation and heating soy oil, coconut oil and high oleic safflower oil were added. The mixture was heated to 73.8-79.4ยฐ C. The lecithin and mono-and diglycerides (Myverol 18-06) were added to the blend tank with agitation. The oil soluble vitamin premix was added with agitation. The premix container was rinsed with the oil blend and transferred back to the blend tank to ensure complete delivery of the vitamin premix. The ฮฒ-carotene was added to the oil blend and the mixture agitated until the components were well dispersed. The ฮฒ-carotene container was rinsed with the oil blend and the contents returned to the blend tank to ensure complete delivery of the carotene solution. Lastly, the carrageenan was added to the oil blend and the mixture was agitated and held at 54.0-60ยฐ C. until used.
The carbohydrate, mineral and CSM (condensed skim milk) protein slurry was prepared next. To water heated to 68-73ยฐ C. the lactose was added and the mixture agitated until the lactose was well dissolved. Potassium citrate was then added followed by potassium chloride, sodium chloride and magnesium chloride. The condensed skim milk (CSM) and tri-calcium phosphate were then added and the mixture was agitated and held at 54-60ยฐ C. until used.
The protein-in-water (PIW) slurry was then prepared. The whey protein concentrate was added to water at 54-60ยฐ C. under mild agitation. The PIW slurry was held under mild agitation until needed. Also contemplated in this invention is the use of protein-in-fat (PIF) slurries, wherein an appropriate amount of protein is admixed with all or a portion of the oil (fat) component.
The PIW slurry was then added to the prepared oil blend. The required amount of the carbohydrate, mineral and CSM slurry was then added to the oil blend. The pH of the mixture was then determined and if below specification, it was adjusted using KOH to a pH of 6.75 to 6.85. The mixture was then held at 54-60ยฐ C. under agitation for at least 15 minutes.
The mixture was then heated to 68-74ยฐ C. and deaerated under vacuum. The mixture was then emulsified through a single stage homogenizer at 6.21 to 7.58 MPa. After emulsification, the mixture was heated to 120-122ยฐ C. for 10 seconds and then 149-150ยฐ C. for 5 seconds. The mixture was then passed through a flash cooler to reduce the temperature to 120-122ยฐ C. and then through a plate cooler to reduce the temperature to 71-79ยฐ C. The mixture was then passed through a two stage homogenizer at 26.89 to 28.27 MPa and 2.76 to 4.14 MPa. The mixture was held at 73 to 83ยฐ C. for 16 seconds and then cooled to 1 to 7ยฐ C. At this point, samples are taken for microbiological and analytical testing. The mixture was held under agitation.
A calcium carbonate solution may be prepared for use in adjusting the calcium level of the mixture if outside of specification.
A vitamin stock solution was prepared. To water heated at 37 to 66ยฐ C. was added potassium citrate and ferrous sulfate. The vitamin premix was then added and the mixture agitated. The choline chloride was added and then the required amount of this vitamin mixture was added to the batch.
The nucleotide solution was then prepared. The following nucleotides were added to water with mild agitation in the following order: AMP, GMP, CMP, UMP. Agitation was continued for about 10 minutes to dissolve the nucleotides. The nucleotide solution was then added to the batch.
Lastly, an ascorbic acid solution was prepared and added slowly to the batch with agitation for at least 10 minutes. Final dilution with water to meet specified levels of solids and caloric density was completed. The batch was then packaged in 0.9 Kg (32 ounce) metal cans and sterilized using conventional technology.
EXAMPLE II
Human Clinical Study
The study was undertaken to demonstrate that the reduced absorption of calcium does have clinical significance, despite the contrary teachings of the prior art. Two formula's that differed primarily based upon their palmitic acid content were evaluated in the study.
The study design was a controlled, masked (for investigator and subjects), randomized, parallel 6-month feeding in healthy, term infants comparing bone mineralization between two study formula groups.
The two study formulas were (1) a milk-based formula with palm-olein as a predominant oil, MFP (prior art) (Enfamil With Iron, Mead Johnson, Evansville, Ind.), and (2), a milk-based formula with no palm-olein, MF (invention) (Similac With Iron, Ross Products, Columbus, Ohio). Both study formulas were ready-to-feed (RTF) and contained cow's milk protein. They both provided 20 kcal per fl oz, and were packaged in clinically-labeled 32 fl oz cans for masking or blinding purpose. The two formulas are commercially available and meet or exceed the levels of nutrients recommended by the American Academy of Pediatrics Committee on Nutrition (AAP-CON) 4 and the Infant Formula Act of 1980 and subsequent amendments. Nutrient compositions of the 2 study formulas are presented in Table VI. The nutrient composition are generally comparable except for the fat blend. The MF had a fat blend of 42% high-oleic safflower, 30% coconut, and 28% soy oils. In contrast, the MFP had a fat blend of 45% palm-olein, 20% coconut, 20% soy, and 15% high-oleic safflower oils. As a result, the palmitic acid levels in MF and MFP were about 8.2% and 22.1%, respectively.
Methods
The study Procedures and Assessments involved identifying and enrolling subjects, obtaining written informed consents, and randomization into one of two formula groups and fed for 6 months. Total body bone mineral content (BMC) and density (BMD) were determined at enrollment time and at 12 and 26 weeks of age, using dual-energy x-ray absorptiometry (QDR, DXA instruments, Hologic Inc, Waltham, Mass.). Bone scans were done with Models QDR 2000 and/or 4500A using a standard procedure. 5 BMC was the primary outcome variable in the study. Weight, length, and head circumference were measured at enrollment and at 4, 12, and 26 weeks of age. Formula intake and frequency of feeding (number of feedings) by subjects were determined by recording dietary intake on appropriate intake forms. The forms were filled out by parents for 3 consecutive days prior to scheduled study visits at 4, 12, and 26 weeks of age. Total occurrence of serious or unexpected adverse events (SAEs) and the relationship of SAEs to study products were assessed and used to evaluate safety in this study. The study was approved by the ethic committee/institutional review board of the study research center (Wayne State University, Hutzel Hospital, Detroit, Mich.)
Key Statistical comparisons for this study focused on total body bone mineral content (BMC) as the primary outcome variable of interest. Statistical tests of hypotheses were two-tailed; p-values less than 0.05 were considered statistically significant. Analyses were reported on an โintent-to-treatโ basis, i.e. including all available data on all randomized infants. Infants who discontinued study feeding were asked to return for DXA scan measurements at the projected 3 month and 6 month visits. A confirmatory analysis was done on BMC, BMD, weight, length, head circumference, average number of feedings per day and average volume (in mls) of study formula fed per day on those infants who were fed the assigned study formula throughout the 6 month feeding period as required by the protocol. BMC, BMD, weight, length, and head circumference were analyzed using repeated measures analysis. With repeated measured analysis, comparison of study feedings at 3 months only were made using an ANOVA test if there was no significant feeding*visit interactions. Comparisons at both 3 and 6 months were made if feeding*visit interactions were significant. Weight at scan time and type of DXA scanner machine were included as a covariate for the analysis of BMC and BMD in this study. Birth weight, birth length and birth head circumference were included as covariates for their corresponding analysis of anthropometrics in this study. Ethnicity was included as a blocking factor in the analysis of variance for exit information continuous variables. For exit information categorical variables, ethnicity was incorporated into tests of association using Cochran-Mantel-Haenszel tests. All analyses were done using either SAS Release 6.09e or PC SAS Release 8.0.
TABLE VI Composition of Clinical Study Formulas (Per Liter) Nutrient MF (invention) MFP (prior art) Protein, g 14 14.2 Source nonfat milk, whey reduced minerals whey, protein concentrate nonfat milk Fat, g 36.5 35.8 Source High-oleic safflower palm olein (45%), (42%), coconut (30%), & coconut (20%), soy soy (28%) oils (20%), & high-oleic sunflower (15%) oils Carbohydrate, g 73.0 73.7 Source Lactose lactose Linoleic acid, g 7.4 5.8 Minerals Calcium, mg 527 527 Phosphorous, mg 284 358 Magnesium, mg 40.6 54.1 Iron, mg 12.2 12.2 Zinc, mg 5.1 6.8 Manganese, ฮผg 33.8 101 Copper, mg 0.61 0.51 Iodine, ฮผg 40.6 67.6 Sodium, mg 162 183 Potassium, mg 710 730 Chloride, mg 433 426 Selenium, ฮผg 14 18.9 Vitamins A, IU 2028 2028 D, IU 406 406 E, IU 20.3 13.5 K 1 , ฮผg 54.1 54.1 C, mg 60.8 81.1 Thiamine (B 1 ), ฮผg 676 541 Riboflavin (B 2 ), ฮผg 1014 946 B 6 , ฮผg 406 406 B 12 , ฮผg 1.7 2.03 Niacin, ฮผg 7098 6760 Folic acid, ฮผg 101 108 Pantothenic acid, ฮผg 3042 3380 Biotin, ฮผg 29.7 20.3 Choline, mg 108 81.1 m-Inositol, mg 31.8 40.6 ฮฒ-carotene, ฮผg 400 โ Values are label claim.
Results
Infants enrolled into this study were healthy, singleton and full term by birth (gestational age of 37 to 42 weeks). All subjects enrolled in the study had written informed consent forms voluntarily signed and dated by a parent or guardian. One hundred twenty-eight (128) infants were randomized and enrolled into this study; 102 infants completed the study through 6 months (79.7%); 26 infants (20.3%) discontinued the study post-randomization. Fifteen (15) infants (23%) in the MF feeding group and 10 infants (16%) in the MFP feeding group withdrew from the study by the 3 month visit and an additional infant (18205) in the MFP feeding group withdrew from the study by the 6 month visit. There were no significant differences between the feeding groups with respect to gender, ethnicity or study completion or withdrawal rate. The distribution of infants is summarized by gender, ethnicity and study termination Table VII.
TABLE VII Demographics and Study Exit Status of Enrolled Subjects Feeding Group MFP (prior MF (invention) art) Total (n = 65) (n = 63) (N = 128) p-value Sex Male, n (%) 30 (46.2) 27 (42.9) โ57 (44.5) 0.726 1 Female, n (%) 35 (53.9) 36 (57.1) โ71 (55.5) Ethnicity Black, n (%) 36 (55.4) 36 (57.1) โ72 (56.3) 0.860 1 Non-Black, n (%) 29 (44.6) 27 (42.9) โ56 (43.8) White 24 24 48 Hispanic 3 2 5 Asian 1 0 1 Other 1 1 2 Study Termination Withdrew from the 15 (23.1) 11 (17.5) โ26 (20.3) 0.398 2 Protocol, n (%) โ <3 months 15 10 25 3 < 6 months 0 1 1 Completed Study 50 (76.9) 52 (82.5) 102 (79.7) According to Protocol or with Acceptable Variations, n (%) 1 Fisher's Exact Test 2 Cochran-Mantel-Haenszel Test Controlling for Ethnicity - General Association
There were no significant differences between the feeding groups with respect to age at study day 1, birth head circumference, maternal age and gestational age. (Table VIII)
TABLE VIII Baseline Measurements (Age at Study Day 1, Birth Weight, Birth Length, Birth Head Circumference, Gestational Age) Feeding Group MF (invention) MFP (prior art) p-value Age at study day 1, days โ 5.6 ยฑ 0.5 (65) โ6.3 ยฑ 0.5 (63) ns Birth weight, g โ3372 ยฑ 42 (64) โ3329 ยฑ 42 (63) ns Birth length, cm โ50.9 ยฑ 0.3 (64) โ50.5 ยฑ 0.3 (62) ns Birth head โ34.0 ยฑ 0.2 (64) โ34.0 ยฑ 0.2 (61) ns circumference, cm Maternal Age, years โ25.7 ยฑ 0.7 (65) โ25.3 ยฑ 0.7 (63) ns Gestational Age, months โ39.4 ยฑ 0.2 (65) โ39.4 ยฑ 0.2 (63) ns Values are Means ยฑ SEM (N).
Primary Outcome Variable
For the adjusted analysis of the intent-to-treat population in which types of DXA instrument use were controlled for, BMC was significantly higher in infants fed MF compared to infants fed MFP at both 3 months (p=0.012) and 6 months (p=0.032). For the adjusted analysis of the evaluable subgroup, BMC was significantly higher in infants fed MF compared to infants fed MFP over the 6 month period (p=0.002) and also at 3 months only (p=0.004). For the unadjusted analysis of the intent-to-treat population, there was not a significant difference between MF and MFP for BMC over the 6 month period (p=0.056), however BMC was significantly higher in infants fed MF compared to infants fed MFP at 3 months only (p=0.015). For the unadjusted analysis of the evaluable subgroup, BMC was significantly higher in infants fed MF compared to infants fed MFP over the 6 month period (p=0.015) and at 3 months only (p=0.019). As seen in the results in Table IX, BMC was significantly higher for infants fed MF than for infants fed MFP at 3 months with the difference still present, although lessened, at 6 months for the intent-to-treat population. BMC was significantly higher for infants fed MF than for infants fed MFP over the entire 6 month period and at all visits for the evaluable subgroup.
TABLE IX
Bone Mineral Content (g)
p-value
Feeding Group
p-value
(adjusted for
MF (invention)
MFP (prior art)
(unadjusted)
machine)
Intent-to-Treat Population
0.056 1#
$
Enrollment
โ59.5 ยฑ 1.2 (64)
โ59.1 ยฑ 1.3 (63)
0.958 2
3 months
105.6 ยฑ 2.7 (50)
โ96.1 ยฑ 2.2 (53)
0.015 3
0.012 2
6 months
149.7 ยฑ 3.7 (50)
139.3 ยฑ 3.0 (52)
0.032 2
Evaluable Subgroup
0.015 1@
0.002 1&
Enrollment
โ60.2 ยฑ 1.3 (48)
โ57.9 ยฑ 1.4 (51)
3 months
105.2 ยฑ 2.8 (48)
โ96.0 ยฑ 2.3 (51)
0.019 3
0.004 3
6 months
149.1 ยฑ 3.7 (48)
139.1 ยฑ 3.0 (51)
Values are Means ยฑ SEM (N).
# Feeding Group*Visit interaction not significant (p = 0.085)->Feeding Group effect tested at 3 months only
$ Feeding Group*Visit interaction significant (p = 0.037)->Feeding Group effect tested by Visit
@ Feeding Group*Visit interaction not significant (p = 0.101)->Feeding Group effect also tested at 3 months only
& Feeding Group*Visit interaction not significant (p = 0.101)->Feeding Group effect also tested at 3 months only
1 Repeated measures ANOVA Type 3 Test of Feeding Group Fixed Effect (over all visits)
2 Repeated measures ANOVA Type 3 Test of Feeding Group*Visit Effect Slice - by Visit
3 ANOVA Type 3 Test of Feeding Group Effect at 3 months only
Secondary Variables
Bone Mineral Density (BMD) (g/cm 2 )
For the adjusted analysis of the intent-to-treat population, BMD was significantly higher in infants fed MF compared to infants fed MFP at 3 months (p=0.004) and at 6 months (p=0.0498) as seen in Table X. For the adjusted analysis of the evaluable subgroup, BMD was significantly higher in infants fed MF compared to infants fed MFP over the 6 month period (p<0.001) and also at 3 months only (p<0.001). For the unadjusted analysis of the intent-to-treat population, BMD was significantly higher in infants fed MF compared to infants fed MFP at 3 months (p=0.008). For the unadjusted analysis of the evaluable subgroup, BMD was significantly higher in infants fed MF compared to infants fed MFP over the 6 month period (p=0.007) and at 3 months only (p=0.003).
TABLE X Bone Mineral Density (g/cm 2 ) p-value Feeding Group p-value (adjusted for MF MFP (unadjusted) machine) Intent-to-Treat Population # $ Enrollment 0.203 ยฑ 0.002 0.203 ยฑ 0.002 (63) 0.999 2 0.865 2 (64) 3 months 0.230 ยฑ 0.003 0.216 ยฑ 0.003 (53) 0.008 2 0.004 2 (50) 6 months 0.262 ยฑ 0.004 0.249 ยฑ 0.003 (52) 0.097 2 0.0498 2 (50) Evaluable Subgroup 0.007 1@ <0.001 1& Enrollment 0.205 ยฑ 0.003 0.201 ยฑ 0.003 (51) (48) 3 months 0.230 ยฑ 0.003 0.216 ยฑ 0.003 (51) 0.003 3 <0.001 3 (48) 6 months 0.261 ยฑ 0.004 0.249 ยฑ 0.003 (51) (48) Values are Means ยฑ SEM (N). # Feeding Group*Visit interaction significant (p = 0.031)->Feeding Group effect tested by Visit $ Feeding Group*Visit interaction significant (p = 0.019)->Feeding Group effect tested by Visit @ Feeding Group*Visit interaction not significant (p = 0.105)->Feeding Group effect also tested at 3 months only & Feeding Group*Visit interaction not significant (p = 0.104)->Feeding Group effect also tested at 3 months only 1 Repeated measures ANOVA Type 3 Test of Feeding Group Fixed Effect (over all visits) 2 Repeated measures ANOVA Type 3 Test of Feeding Group*Visit Effect Slice - by Visit 3 ANOVA Type 3 Test of Feeding Group Effect at 3 months only
Anthropometrics
There was no significant difference between feeding groups with respect to weight, length, and head circumference over the course of this study. However, MF was found to be higher than MFP in Males only. (Table XI).
TABLES XI Weight, Length, and Head Circumference Measures of Study Subjects From Enrollment to 26 Weeks of Age. Variable MF MFP p-Value Weight, g Enrollment โ3357 ยฑ 47 (65) โ3363 ยฑ 45 (63) ns Week 4 โ4314 ยฑ 61 (53) โ4130 ยฑ 49 (55) ns Week 12 โ5911 ยฑ 97 (50) โ5730 ยฑ 79 (53) ns Week 26 โ7787 ยฑ 138 (50) โ7602 ยฑ 100 (52) ns Length, cm Enrollment โ48.8 ยฑ 0.3 (65) โ48.6 ยฑ 0.2 (63) ns Week 4 โ52.6 ยฑ 0.3 (53) โ51.6 ยฑ 0.2 (55) ns Week 12 โ58.7 ยฑ 0.3 (50) โ57.8 ยฑ 0.2 (53) ns Week 26 โ66.0 ยฑ 0.3 (50) โ65.5 ยฑ 0.3 (52) ns Head Circumference, cm Enrollment โ34.8 ยฑ 0.2 (65) โ34.9 ยฑ 0.1 (63) ns Week 4 โ37.4 ยฑ 0.2 (53) โ37.1 ยฑ 0.1 (55) ns Week 12 โ40.3 ยฑ 0.2 (50) โ40.1 ยฑ 0.1 (53) ns Week 26 โ43.4 ยฑ 0.2 (50) โ43.3 ยฑ 0.2 (52) ns Values are mean ยฑ SEM (n).
Volume of Intake (Avg. Volume (mls) of Study Formula Fed/day)
For the intent-to-treat population, formula intake was similar throughout the study except at 4 weeks and 6 weeks. Intake was significantly higher for infants fed MF compared to infants fed MFP at 4 weeks (p=0.037), while formula intake was significantly higher for infants fed MFP compared to infants fed MF at 26 weeks (p=0.043), Frequency of food intake was not different between the 2 formula groups. (Table XII).
TABLE XII Volume of Intake (Avg mis Study Formula Fed/day) - Intent-to-Treat Population Feeding Group p-value MF MFP # $ Week 3 โ832 ยฑ 47 (51) โ744 ยฑ 23 (51) 0.056 1 Week 4 โ913 ยฑ 56 (51) โ795 ยฑ 23 (53) 0.037 1 Week 8 โ972 ยฑ 31 (45) 1025 ยฑ 35 (51) 0.310 1 Week 12 (Month 3) 1072 ยฑ 41 (47) 1109 ยฑ 41 (51) 0.396 1 Week 16 1152 ยฑ 51 (49) 1210 ยฑ 44 (46) 0.388 1 Week 21 1181 ยฑ 47 (49) 1235 ยฑ 49 (47) 0.488 1 Week 26 (Month 6) 1097 ยฑ 58 (50) 1238 ยฑ 49 (46) 0.043 1 Values are Means ยฑ SEM (N) # Feeding Group*Gender interaction not significant (p = 0.701)->Feeding Group effect not tested by Gender $ Feeding Group*Visit interaction significant (p = 0.020)->Feeding Group effect tested by Visit 1 Repeated measures ANOVA Type 3 Test of Feeding Group*Visit Effect Slice - by Visit
Serious and/or Unexpected Adverse Events (SAE's)
The number of infants who had a Serious and/or Unexpected Adverse Event (SAE) and the total number of SAEs were compared by feeding group. There were no significant differences between feeding groups for either the number of infants who had an SAE of the total number of SAEs. There were 2 subjects in the MF group and 5 subjects with recorded SAEs during this study; and none were life threatening.
Conclusions
This study clearly demonstrates that high levels of palmitic acid not only diminish calcium absorption, but that they also lead to decreased bone mineralization and decreased bone mass in the infant. Formula that does not attempt to mimic the fatty acid profile of human milk leads to enhanced rates of bone mineralization.
References
1. Nelson S E, Frantz J A, Ziegler E E: Absorption of fat and calcium by infants fed a milk-based formula containing palm-olein J Am Coll Nutr 1998;17:327-332.
2. Nelson S E, Rogers R R, Frantz J A, Ziegler E E: Palm olein in infant formula: Absorption of fat and minerals by normal infants. J Am Clin Nutr 1996;64:291-296.
3. Specker B L, Beck A, Kalkwarf H, Ho M: Randomized trial of varying mineral intake on total body bone mineral accretion during the first year of life. Pediatrics 1997;99(6):e12.
4. American Academy of Pediatrics Committee on Nutrition: Pediatric Nutrition Handbook . Elk Grove Village, Ill.: American Academy of Pediatrics, 1993, pp 190, 360-361.
5. Koo W K, Bush A J, Walters J, Carlson S E: Postnatal development of bone mineral status during infancy. J Am Coll Nutr 1998;17:65-70.
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The present invention is directed to a method for increasing the bone mineralization of a human, and more preferably an infant or toddler. The method comprises administering to said human a source of calcium and a fat blend that is low in palmitic acid. The enhanced mineralization results in the production of a higher peak bone mass and correspondingly lowers the incidence of osteoporosis.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefits of and priority to U.S. Provisional Patent Application Serial No. 60/385,203 filed on Jun. 3, 2002, commonly owned herewith, the disclosures of which are hereby incorporated herein by reference in their entirety.
FILED OF THE INVENTION
[0002] The invention relates generally to the fields of textile manufacturing and visual displays and more specifically to the integration of visual displays into textiles.
BACKGROUND OF THE INVENTION
[0003] Ongoing efforts to integrate computing devices with common articles of clothingโfrequently termed โwearable computingโ applicationsโtypically have not involved changes to the clothing items themselves. Rather, for the most part, electronic devices have been mechanically attached to or fitted within clothing, or have been adapted to be directly worn by the user. More recently, textiles themselves have been modified to participate functionally in the design and operation of electronic devices (rather than serving merely as scaffolds). For example, U.S. Pat. No. 6,210,771 describes textiles having conductive fibers incorporated within the weave, facilitating direct application of electronic components to the textile itself. Still, the patterns, designs, and visual appearance of clothing involving wearable-computing capabilities have generally been fixed. For example, applications involving readouts typically utilize a conventional medium, like a LCD or LED display attached to the textile, rather than modifying the appearance of the textile itself.
[0004] This approach is limiting, since it separates the interactive component from the textile; the application is โwearableโ in the sense that it is borne by the user, but it is less a part of his or her clothing than an appendage thereto. Outside the context of textiles worn as clothing, conventional approaches uniting electronic circuitry with textiles do not alter visual characteristics of the textile itself, but rather merely add separate electronic functionality. A need therefore exists for textiles that are themselves capable of changing in appearance in coordination with computational components.
SUMMARY OF THE INVENTION
[0005] The invention provides dynamic, visual displays within and on a textile and techniques for manufacturing such a textile. This is accomplished by printing onto the textile thermoresponsive colorants, such as inks or dyes, which are selectively activated by heating a resistive fiber woven, embroidered, or otherwise integrated into the textile. In addition, the thermoresponsive colorant may be incorporated into conductive or resistive fibers used to fabricate the textile. The pattern and physical configuration of the colorants, resistive fibers, and conductive fibers then determine the visual properties of the textile, thereby creating an electronically controllable, visually dynamic textile with addressable display dynamics. Suitable textiles are not limited solely to wearable computing applications, but also will find utility in dynamic signs, paintings, or interior wall-coverings.
[0006] In one aspect, the textile includes a plurality of spaced-apart contacts for receiving electrical power. Additionally, at least one resistive fiber is connected to each of the contacts and is running along a first direction, while a thermoresponsive colorant is printed along at least a portion of the at least one resistive fiber. The thermoresponsive colorant changes color in response to heat generated by a voltage disposed across the contacts, which causes the at least one resistive fiber to produce heat and thereby change the color of the colorant.
[0007] The thermoresponsive colorant may be responsive within a temperature range of about 31ยฐ C. to about 45ยฐ C.; a preferred temperature range is about 31ยฐ C. to about 34ยฐ C. In one embodiment, the thermoresponsive colorant is in the form of ink applied to the textile in the region of the resistive fiber, whereas in another embodiment, the thermoresponsive colorant is in the form of a dye. In yet another embodiment, at least a portion of the thermoresponsive colorant is within the resistive fiber itself. The resistive fiber may have a resistance between about 15 to about 100 ฮฉ.
[0008] In one embodiment, each contact includes a series of conductive fibers running along a second direction distinct from the first direction. Alternatively, each contact may be (or include) a discrete electrical connector, e.g., a metal grommet or staple. In one embodiment, the textile is woven, and the conductive fibers run along a weft direction, while the resistive fibers run along a warp direction. In various embodiments, the at least one resistive fiber is either woven, sewn, embroidered, or otherwise adhered to the textile. In addition, the thermoresponsive colorant may be within the conductive fibers.
[0009] In another aspect, the invention relates to a method for manufacturing a textile. The method includes providing a plurality of spaced-apart contacts for receiving electrical power and electrically coupling the contacts to at least one resistive fiber running along a first direction. In addition, a thermoresponsive colorant, which is printed along at least a portion of the at least one resistive fiber, changes color in response to heat generated by applying a voltage across the at least one resistive fiber.
[0010] In one embodiment, the contacts and the at least one resistive fiber are coupled so as to minimize the resistance between them. The resistance may be less than about 10 ฮฉ. Each contact may include a series of conductive fibers running along a second direction distinct from the first direction, and in one embodiment, at least two of the plurality of spaced-apart contacts may be separated by cutting the series of conductive fibers. Alternatively or in addition, at least two of the plurality of contacts may be insulated by weaving a non-conductive fabric between them. In one embodiment, the method includes attaching at least one lead having at least one conductive fiber to at least one of the series of conductive fibers.
[0011] In another aspect, the invention provides a system including a textile with addressable color characteristics. This system includes a first set of spaced-apart resistive fibers extending along a first direction; interwoven therewith are a second set of spaced-apart resistive fibers extending along a second direction. A thermoresponsive colorant is printed at least at points of intersection between fibers of the first set and fibers of the second set. A power source is connectable to selected ones of the first set of fibers and the second set of fibers, and a voltage applied across intersecting fibers causes the thermoresponsive colorant to change color only in a region where the intersecting fibers cross.
[0012] The thermoresponsive colorant undergoes color change as a function of time and of a voltage applied through a resistive fiber in contact with the colorant. The color change exhibits hysteresis, and the system also includes a controller for operating the power source to vary, over time, the fibers to which power is applied in order to activate only selected points of intersection without interference by neighboring points of intersection.
[0013] Other aspects and advantages of the invention will become apparent from the following drawings, detailed description, and claims, all of which illustrate the principles of the invention, by way of example only.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing and other objects, features, and advantages of the invention described above will be more fully understood from the following description of various embodiments, when read together with the accompanying drawings. In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, and emphasis instead is generally placed upon illustrating the principles of the invention.
[0015] [0015]FIG. 1 is a schematic diagram of an electrical circuit, which is representative of a circuit made with fibers of a textile in accordance with the invention;
[0016] [0016]FIG. 2 is a plan view of a textile with color-changing striped regions;
[0017] [0017]FIG. 3 is a plan view of a textile embroidered with a resistive fiber to create a non-rectangular color-response region;
[0018] [0018]FIG. 4 is a plan view of a contact formed from a conductive fiber and a resistive fiber;
[0019] [0019]FIG. 5 depicts a plan view of a textile that illustrates ways of electrically isolating contacts and minimizing contact resistance; and
[0020] [0020]FIG. 6 is a plan view of a fully addressable matrix display constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] [0021]FIG. 1 illustrates a schematic diagram of an electrical circuit 100 , which is representative of a circuit made with fibers of a textile in accordance with the invention. As used herein, the term โfiberโ refers to any filament, group of filaments twisted together, yarn, thread, rope, cord, strand, or wire amenable to weaving, embroidering, stitching, felting, sewing, knitting, or otherwise incorporating into a textile as part of a textile manufacturing process or enhancing a textile manufactured by such a process. As used herein, the term โtextileโ refers to any pliable material including, but not limited to, a cloth, fabric, tapestry, or canvas made by weaving, embroidering, stitching, felting, sewing, knitting, or otherwise incorporating fibers into a pliable material. A battery or power source 110 supplies electricity. A series of conductive fibers 120 , 122 , 124 run in one direction, while a pair of resistive fibers 130 , 132 run along a second (e.g., perpendicular) direction. The resistors 140 , 142 , 144 , 146 represent contact resistances developed where the conductive fibers 120 , 122 , 124 join the resistive fibers 130 , 132 . The resistive fibers 130 , 132 are selected so that the resistance is larger in the fibers than at the contacts. The power source 110 may be connected to the conductive fibers 120 , 122 , 124 by conventional electrical wiring. Control electronics, including a switch 150 intervening between the power source 110 and the conductive fibers 120 , 122 , can activate specific resistive fibers, and therefore specific areas of the textile to create animation. Alternatively, the switch 150 , which includes an off position 152 , can be configured to activate and deactivate all of the conductive fibers. An off position 152 for the switch 150 is illustrated in FIG. 1.
[0022] The contacts need not be a series of conductive fibers. For example, a contact may be a discrete electrical connector, such as a metal grommet, metal staple, or other suitable connector. The discrete electrical connector may contact the resistive fiber independently or secure a running fiber contact, such as a series of conductive fibers, to a resistive fiber, as described in more detail below.
[0023] The resistances of the resistive fibers 130 , 132 are generally greater than about 10 ฮฉ, and preferably greater than about 20 ฮฉ. The resistances of the resistive fibers 130 , 132 may be as large as about 1000 ฮฉ or more. The resistance at the contact points 140 , 142 , 144 , 146 is generally less than about 10 ฮฉ, and preferably less than about 5 ฮฉ. The resistances of the conductive fibers 120 , 122 , 124 (e.g., less than about 1 ฮฉ per foot) are considerably less than the resistance of the contact points 140 , 142 , 144 , 146 . Techniques for reducing contact resistance are discussed below.
[0024] The source of electrical power will depend on the textile and its intended use. For example, a bench power supply or wall outlet may be preferable for a cubicle wall or interior design, whereas a battery or solar cell may work best for an article of clothing. The rapidity with which a color change is effected depends on how fast the resistive fiber heats up and, in turn, heats a thermoresponsive material. How fast the fiber heats up is determined by the voltage supplied and the resistance of the fiber 130 , 132 . To the extent that a slow response time can be tolerated, lower voltages can be utilized.
[0025] In a preferred embodiment, the source of electrical power uses pulse-width modulation (PWM) to heat resistive fibers at adjustable energizing levels with precise timing control. PWM permits the same power source to be used to drive textiles with resistive fibers that have different resistances by delivering different amounts of energy to individual resistive fibers or regions of the textile. The magnitude of the voltage, the resistance of the fiber, and the duration of the pulse may all determine the energy delivered to a particular resistive fiber. In addition, the current level and/or pulse width applied to a particular resistive fiber may be reduced after a color change is initially achieved in order to maintain the color change. In this way, the total energy delivered to a resistive fiber overtime can be minimized while maintaining the color change.
[0026] A wide variety of conductive and resistive fibers may be used to advantage. Suitable conductive fibers include, for example, the ARACON brand metal clad fibers available from DuPont and various stainless steel fibers available from Bekaert. These fibers may include a polymer core wrapped with a layer of either conductive or resistive metal, and then coated with a polymer for protection. In addition, the fiber may be metal fibers plated with the KEVLAR brand material available from DuPont, a metal foil or strand wrapped with polyester, or other composite material constructed from polyester and metal fibers.
[0027] A thermoresponsive, or thermochromic, material is a material that changes color as the temperature of the material increases over a predetermined thermal threshold. In various embodiments, the thermoresponsive material is in the form of an ink (e.g., DYNACOLOR screen inks available from Chromatic Technologies, Inc.), a dye (e.g., a leuco-dye product available from Color Changing, Corp.), or may be the resistive fiber itself (e.g., having a thermochromic ink or dye embedded into the structure); fabrication of suitable thermochromic fibers is described, for example, in U.S. Pat. No. 6,444,313, the entire disclosure of which is hereby incorporated by reference. When thermoresponsive inks and dyes are printed on the textile to represent a pattern or design of interest, the heat generated by the resistive fibers effects a color change in the ink or dye. For example, if the ink or dye is deposited (e.g., by a printing process such as screen printing, deposition (such as ink-jet) printing) in the region over and surrounding the resistive fiber, the areas closest to the fiber will undergo transition first, and the transition will then spread to more remote regions (to the extent that the surrounding material can conduct heat). As explained below, for this reason it is desirable to have the resistive fibers conform, to the extent practicable, to the thermochromic region. For example, in a region of the textile treated with a thermoresponsive ink or dye, four resistive fibers running in a first direction of a textile may be spaced about 0.25 inches apart. Within seconds of applying electrical power to the resistive fibers, the thermoresponsive ink or dye will change color, thereby creating a strip approximately one inch wide and running the length of the first direction.
[0028] If the thermoresponsive colorant is contained within the resistive fiber itself, mixing of colors is possible by printing a thermally unresponsive ink or dye on the textile. For example, a textile can be treated with yellow ink that is not thermoresponsive. A thermoresponsive, resistive fiber, which is blue in color but which becomes transparent when heated to its critical temperature, can be incorporated within the yellow textile. Yellow and blue are primary colors that subtractively mix to give the textile an appearance of green. When electricity is applied, the resistive fiber will heat up and change from blue to transparent. Thus, only the yellow, thermally unresponsive dye will be visible. Thus, the observed color depends on the current state of the thermoresponsive, resistive fiber and the thermally unresponsive ink printed on the textile.
[0029] Thermally responsive and unresponsive inks and dyes can be applied using conventional printing process, as noted above. In general, thermochromic materials have a critical temperature at which they undergo color transition and are hysteretic; that is, the color change persists until the material cools to a temperature below the critical temperature. In order to facilitate unassisted return to the initial color state in everyday environments, the critical temperature should be above room temperature. On the other hand, to avoid excessive response times, the critical temperature should be close enough to room temperature that a relatively small temperature shift is sufficient to bring about a color change. A preferred critical temperature range is about 31ยฐ C. to about 45ยฐ C.; a particularly preferred temperature range is from about 31ยฐ C. to about 34ยฐ C.
[0030] Thermochromic materials can change from one color to a second color, or from one color to transparent. Indeed, fibers can be fabricated to exhibit this behavior even if the thermochromic material itself only undergoes transition between colored and transparent. For example, a fiber can be treated with thermally unresponsive yellow ink and with blue thermoresponsive ink. The yellow and blue will mix to form green. When the fiber is heated, the blue will turn to transparent, and the yellow will be the dominant color. In this manner, shades of yellow and green are formed.
[0031] [0031]FIG. 2 illustrates an implementation suitable for creating color-changing stripes on a textile 200 . Resistive, conductive, and non-conductive fibers and yarns are woven together to form the textile. In FIG. 2, a plurality of conductive fibers 220 form a first contact woven along a first direction, and another set of conductive fibers 222 form a second, parallel contact spaced from fibers 220 . One or more resistive fibers representatively indicated at 230 , 232 , 234 are woven along a second direction (e.g., perpendicular to the first direction, as illustrated). In one embodiment, the conductive fibers 220 , 222 extend along the weft, and the resistive fibers 230 , 232 , 234 are woven along the warp. Contacts are formed where the conductive fibers 220 , 222 join the resistive fibers 230 , 232 , 234 . Adjacent contacts may be electrically isolated by cutting a notch 238 between them. A power source 240 supplies electrical power to a switch matrix 250 and a logic controller 260 , which direct the electricity to the resistive fiber or fibers of interest. In some instances, electricity will be supplied simultaneously to a plurality of resistive fibers along distinct electrical paths.
[0032] A thermoresponsive colorant 270 , 272 , 274 can be applied to the textile 200 in a variety of manners. With respect to resistive fiber 230 , the thermoresponsive colorant is in the form of non-conductive fibers 270 that have been treated with an ink or dye prior to being woven parallel or adjacent to the resistive fiber 230 . When electrical power is supplied to the resistive fiber 230 , the surrounding non-conductive fibers 270 warm up and change color.
[0033] With respect to resistive fiber 232 , an area 272 of the textile 200 is printed with a thermoresponsive ink or dye after weaving the textile 200 (including the fiber 232 ). As the resistive fiber 232 warms, the thermoresponsive colorant in the area 272 proximate to resistive fiber 232 will change color. Again, the farther the region 272 extends to each side of the fiber 232 , the longer it will take for the response to propagate to the edge. This delay can be exploited, if desired, as an animation effect.
[0034] With respect to resistive fiber 234 , an area 274 of the textile 200 is first printed with a thermoresponsive ink or dye. Then, the resistive fiber 234 is sewn or embroidered into the area 274 containing the thermoresponsive colorant. When electrical power is supplied and the resistive fiber 234 warms, the area 274 of the textile 200 printed with the thermoresponsive colorant will change color.
[0035] The thermoresponsive fiber can, if desired, incorporate a plurality of resistive fibers woven in close proximity. Therefore, a larger area will change color, or the color change may occur at a faster rate because a large area is heated. In another embodiment, a plurality of resistive fibers are woven along both the warp and the weft, thus forming contacts. When electrical power is supplied, intersecting lines are formed in an area printed with a thermoresponsive colorant.
[0036] Alternatively, a textile may be woven with both untreated fibers, which are subsequently treated with a thermoresponsive colorant. The textile is then treated with a resistive ink, and a power source is connected across the resistive region. When electrical power is supplied, the resistive region heats up, causing thermoresponsive color transition. The placement and pattern of the thermoresponsive fibers will determine the design of the dynamic visual pattern.
[0037] [0037]FIG. 3 illustrates an embodiment showing how embroidery can be used in a textile 300 to create a non-rectangular color-response region. A resistive fiber 330 is embroidered in a shape 370 of interest, in this case a circle. A thermoresponsive colorant 380 is applied around the embroidered shape 370 ; the embroidery effectively acts as a โskeletonโ within, and conforms as much as possible to, the printed region 380 . When electrical power is supplied, the circle 380 will appear on the textile 300 where the thermoresponsive colorant changes color.
[0038] [0038]FIG. 4 illustrates one approach to forming a contact, and minimizing resistance, when joining conductive and resistive fibers during the embroidery process. As illustrated, a contact 440 formed from a conductive fiber 420 and a resistive fiber 430 woven among a series of non-conductive fibers 490 and 492 , which compose the bulk of the textile. By placing the resistive fiber 430 in the bobbin and the conductive fiber 420 in the needle of the sewing machine, the conductive fiber 420 can be wound around the resistive fiber 430 as shown, thereby ensuring good mechanical contact extending over a length of the resistive fiber 430 .
[0039] [0039]FIG. 5 depicts approaches to separating contacts and minimizing contact resistance in a textile 500 . For example, adjacent contacts 504 , 508 may be separated by weaving an electrically insulating fiber or textile 512 between the contacts 504 , 508 . As described above, a notch 516 may be cut in the region of the conductive fibers 518 to electrically isolate the contacts 520 , 524 . FIG. 5 also illustrates various ways of connecting fibers to contacts. As illustrated, satisfactory mechanical and electrical connections may be achieved by means of a metal grommet 532 or a metal staple 536 . A conductive ink, paint, adhesive, or polymer 538 may instead or also be used to minimize contact resistance. According to the illustrated embodiment, a conductive fiber lead 540 is woven in the region of the conductive fibers 518 to connect the contact to a power source or an external load.
[0040] The invention is amenable to numerous applications. For example, a textile, printed with stripes of thermoresponsive colorant may be attached to a sneaker in order to form a pedometer. The individual stripes are selectively controlled, and the number of stripes activated represents a numerical quantity, e.g., steps taken, distance covered, calories burned, etc. For example, a counting circuit may include a piezoelectric device embedded in the sole of the sneaker that not only supplies the overall electrical power, as described in U.S. Pat. No. 5,930,026 (the entire disclosure of which is hereby incorporated by reference), but also serves as input to the step counter through flexion each time the user takes a step. As the distance covered by the user (as measured by sole flexions) increases, the counting circuit activates more stripes, thereby providing a visual read-out.
[0041] The present invention is amenable to a wide variety of applications involving virtually any type or use of textiles. These can include, for example, signage, decorative wall coverings, and paintings. Dynamic signage may, for example, be created by printing text in a thermoresponsive colorant. For example, a textile may be embroidered with resistive fibers, and printed with the letters โE-A-Tโ using thermoresponsive ink on a background of similarly colored non-responsive ink. When the resistive fibers are heated, the letters change color, and with suitable contrast, reveal the message. The letters may be activated simultaneously or in sequence to produce a dynamic image.
[0042] The hysteretic properties of thermoresponsive colorants can be used to facilitate fabrication of a fully addressable matrix display. A 2ร2 matrix is illustrated in FIG. 6 to explain the principle, it being understood that this principle is fully scalable to any desired matrix dimensionality. A textile, indicated generally at 600 , has a pair of vertical resistive fibers 602 1 , 602 2 , and a pair of horizontal resistive fibers 604 1 , 604 2 . These fibers, it should be emphasized, need not be directly adjacent as suggested in the figure; instead, they may be separated by one or more non-conductive fibers. Circular regions a, b, c, d of thermoresponsive colorant are applied at the intersections of the resistive fibers 602 1 , 602 2 , 604 1 , 604 2 . The circular regions a, b, c, d act as pixels of the matrix display.
[0043] In order to facilitate activation of a single pixel, logic controller 260 (see FIG. 2) causes the two fibers crossing the desired pixel to receive a voltage (via switch logic 250 ) having a selected magnitude, and for a chosen time period, such that thermochromic activation will occur only where the two fibers intersect. This is straightforwardly accomplished because the heat developed by a fiber is a predictable function of voltage magnitude and time. For example, if pixel c is to be activated, switch logic 250 energizes fibers 602 2 , 604 2 such that pixels b and d remain unaffected (because the heat developed at these regions is insufficient).
[0044] Without more, however, this scheme would not permit activation of arbitrary desired pixels due to the possibility of crosstalk. For example, suppose it is desired to activate pixels a and c. This requires energizing all four resistive fibers 602 1 , 602 2 , 604 1 , 604 2 , resulting in unwanted activation of all four pixels a, b, c, d. To avoid this, the hysteretic nature of the thermoresponsive colorant is exploited. The controller 260 causes switch logic 250 to cycle between energizing fibers 602 1 , 60 4 , (thereby activating pixel a) and fibers 602 2 , 604 2 (thereby activating pixel c). The time between cycles is sufficiently short to avoid deactivation of thermochromic material corresponding to pixels a and c, due to hysteresis, while also preventing spurious activation of pixels at other points of intersection (e.g., pixels b and d). Reliance on hysteresis is minimal for a 2ร2 matrix, as illustrated, but grows with the size of the matrix; the larger the matrix, the greater will be the number of other fiber pairs that must be energized between consecutive cycles energizing a particular fiber pair. On the other hand, multiple pixels involving non-interfering fibers can be simultaneously activated, reducing the time between successive activations of a given pixel.
[0045] It should also be noted that the thermoresponsive colorant need not be applied in the form of discrete circles. Timing, once again, and also the voltage level can be used to cause activation of colorant only in the immediate region of an intersection, allowing the colorant to be applied indiscriminately over the entire matrix. (Thus, the pixels shown in FIG. 6 would represent regions of influence rather than discrete patches of colorant.)
[0046] Although the invention has been described with reference to specific details, it is not intended that such details should be regarded as limitations upon the scope of the invention, except as and to the extent that they are included in the accompanying claims.
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A textile with dynamic, visual displays and a method for manufacturing such a textile are described. The textile is manufactured by weaving, embroidering, or otherwise integrating a series of conductive, resistive, and non-conductive fibers into the textile and printing a thermoresponsive colorant on or near the resistive fiber. The pattern and physical configuration of the materials composing the textile determine the visual properties of the textile. Electrical power is supplied to the resistive fiber(s) to change the visual properties of the textile. As the resistive fiber warms, the thermoresponsive colorant is warmed beyond a thermal threshold necessary to effect a color change in the thermoresponsive colorant, thereby creating an electronically controllable, visually dynamic textile.
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This is a division of application Ser. No. 333,314, filed Dec. 22, 1981, now U.S. Pat. No. 4,424,887, issued Jan. 10, 1984 which is a continuation of Ser. No. 080,456 filed Oct. 1, 1979 now abandoned.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to brake units and more particularly to brake units of the oil shear type having internal oil pump means operative to selectively circulate oil in response to rotation of the brake unit in a preselected direction.
Various types of brake units are used in conjunction with well drilling rigs such as those used in construction of oil and gas wells. In one manner of drilling oil and gas wells, a length or stand of pipe is connected to a drill bit which is then rotated thereby drilling deeper into the ground. As the well progresses, it is necessary to install a casing which usually consists of stands of larger diameter pipe connected together which operate to guide the drilling apparatus, support surrounding ground formations, seal the sides of the opening as well as other various purposes. The drilling apparatus generally comprises a drawworks assembly which includes a cable drum, driving apparatus for rotatably driving the cable drum, a main brake and a secondary brake often referred to as a mode absorber. The drawworks performs various functions including raising and lowering the drilling pipe and bit for bit replacement, and connection of additional stands of drill pipe as well as to control drilling pressure. Also, the drawworks may be used to assist in installation of the casing as well as replacement thereof should the casing become worn due to extended drilling operations. The main brake is commonly intimately associated with the cable drum of the drawworks operating to stop and hold the drilling apparatus, pipe stands or the like at any desired position whereas the mode absorber operates in the nature of a governor to limit lowering speeds. The mode absorber may be in the form of a water brake which utilizes the resistance of a turbine rotating through a fluid for example. While the mode absorber does reduce the rate of acceleration thereby increasing the available response time for an operator to effect corrective measures, it will constitute a significant drag during raising operations unless disconnected from the drawworks. If the mode absorber is allowed to remain connected to the drawworks, power consumption may be significantly increased as well as operating speeds reduced due to this drag. Thus, it is generally necessary to disconnect the mode absorber during raising. Not only does the disconnecting procedure require loss of valuable operating time but also the disconnection of the mode absorber eliminates the added safety factor due to the increased response time provided thereby within which the operator may actuate the brake should a power failure be encountered. Further, such absorbers constitute an additional piece of equipment requiring maintenance as well as additional controls to adjust the resistance for varying lowering speeds.
Accordingly, the present invention provides a brake unit for use in conjunction with such drawworks which combines in a single unit apparatus capable of performing the functions heretofore performed by both the main brake and mode absorber and further which is substantially more economical and efficient to operate as well as providing for fail-safe operation to protect associated drilling equipment from damage due to a power failure, brake through of the drilling bit into an underground cavern or any other such occurrences.
The present invention includes an input shaft operatively connected to the drawworks which drives an internal oil gear pump which is operative to circulate a large volume of oil through the brake unit along a first flowpath in response to rotation of the input shaft in one direction such as during lowering of pipe stands so as to cool and lubricate the brake discs and plates. During a raising operation, the gear pump operates to circulate oil through an alternative low resistance flowpath so as to reduce the drag due to pump operation. Thus, during lowering of pipe or other tooling or equipment into the well, the gravitational forces acting thereon also operate to drive this internal oil pump thereby circulating large quantities of oil through the brake unit. As this lowering operation represents the severest duty for the brake unit, the need for oil circulation for both cooling and lubricating is greatest during this mode of operation. However, during raising of pipe or equipment from the well, it is desirable to reduce drag on the driving equipment to an absolute minimum so as to allow such operations to be completed as rapidly as possible and with a minimum consumption of power. Heretofore, it has often been desirable to expend additional time and labor to disconnect the brake unit from the drawworks in order to reduce this drag. In the present invention, the oil flowpath within the brake unit is designed to minimize the drag resulting therefrom during such raising operations thereby eliminating the time consuming job of disconnecting the brake unit from the drawworks. This also enables the brake unit to act as a safety back-up during raising operations. Should an equipment failure be encountered during a raising operation, the internal oil pump will immediately be actuated in response to the descending tooling and will operate to override the control fluid pressure to actuate the brake unit thereby minimizing the possibility of equipment damage resulting therefrom.
Additional advantages and features of the present invention will become apparent from the following description of a preferred embodiment taken in conjunction with the drawings and claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a drilling rig having drawworks apparatus for raising and lowering stands of pipe to which a brake unit in accordance with the present invention is operatively connected;
FIG. 2 is a side elevational view of the brake unit of the present invention;
FIG. 3 is a front elevational view of the present invention;
FIG. 4 is a fragmentary longitudinal cross-sectional view of the upper portion of the present invention, the section being taken substantially along the line 4--4 of FIG. 3;
FIG. 5 is a fragmentary transverse cross-sectional view of the present invention, the section being taken along line 5--5 of FIG. 4;
FIG. 6 is a fragmentary transverse cross-sectional view of the present invention, the section being taken along line 6--6 of FIG. 4; and
FIG. 7 is an elevational view of the brake unit of FIG. 2 shown in operative relationship to associated primary and secondary fluid reservoirs.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and in particular to FIG. 1, there is illustrated a brake unit 10 in accordance with the present invention shown in operative relationship to a drilling rig assembly 12. Drilling rig assembly 12 may be of any conventional design such as those commonly utilized in oil and gas well constructions and will generally include a derrick 14, a conventional drawworks assembly 16 having cables 18 leading to derrick 14 and cooperable with blocks supported thereon for raising and lowering tooling, drill bits, or other equipment out of and into the well, and associated drive means 20 for driving drawworks 16. Drive means 20 may conventionally be of any type suitable for use in the particular locality of drilling such as an electric motor, gas or diesel engine or even steam engine if desired. In any event, an input shaft 22 of brake unit 10 will be operatively connected to drawworks assembly 16 either via drive means 20 or directly to the drawworks shaft 21 as illustrated so as to control rotation thereof during operation as is described in greater detail below.
Referring now to FIGS. 2 through 4, the construction of brake unit 10 will be described in detail. As shown, the brake unit 10 comprises a housing 24 of generally cylinrical cross-section having a pair of longitudinal spaced end plates 26 and 28 secured to opposite ends thereof by a plurality of suitable fasteners such as bolts 30 so as to define a cavity 31 therebetween. Housing 24 also has a plurality of depending mounting feet or flange portions 32 provided with suitable openings 34 therein so as to enable the brake unit to be secured to a work platform or other suitable foundation or supporting surface.
As best seen with reference to FIG. 4, end plate 26 has an opening 36 provided therein through which input shaft 22 extends into cavity 31. Similarly, end plate 28 also has an opening 38 within which the terminal end 40 of input shaft 22 is received. Input shaft 22 is provided with a pair of axially spaced annular grooves 42 and 44 adjacent opposite ends thereof within which are fitted dust seals 46 and 48 respectively so as to effectively seal shaft 22 within respective openings 36 and 38. Additional annular grooves 50, 52, and 54, 56 are disposed on shaft 22 interiorly from respective grooves 46 and 48 and are all adapted to receive suitable oil seals 57. Preferably, dust seals 46 and 48 as well as oil seals 50, 52, 54, and 56 will be in the form of piston rings.
An interiorly disposed portion 58 of input shaft 22 is provided with at least one end and preferably two circumferentially spaced axially extending slots or keyways 60 and 62 which are adapted to receive elongated keys 64 and 66.
A generally cylindrically shaped gear and brake disc carrier 68 is fixedly secured to portion 58 of input shaft 22 and has an axially extending radially outwardly spaced flange portion 70 designed to engage a bushing 72 mounted within end plate 26 so as to rotatably support the driven end portion 74 of input shaft 22. Bushing 72 is secured to end plate 26 by suitable fastening means in the form of radially inwardly extending bushing screws 76. Immediately adjacent and axially outwardly of bushing 72, end plate 26 is provided with an annular labyrinth comprising a plurality of grooves 78 provided in end plate 26 and surrounding flange portion 70 in close proximity thereto so as to control or limit oil leakage through bushing 72 into area 73 surrounding input shaft 22. Gear and brake disc carrier 68 will preferably be shrink fitted to input shaft 22 with keys 64 and 66 being operative to prevent relative rotation therebetween.
Gear and brake disc carrier 68 has an enlarged diameter splined center portion 82 upon which an annular or ring gear 84 having a correspondingly splined center bore is supported for rotation therewith. Gear 84 is supported upon gear carrier 68 in such a manner as to enable relative axial movement therebetween, gear 84 being axially restrained between axially spaced opposed wall portions 86 and 88 of housing 24.
As best seen in FIG. 5, housing 24 is provided with three circumferentially spaced interconnected chambers 90, 92, and 94 disposed radially outward from gear 84. Center chamber 92 has a gear pump 96 rotatably supported upon a fixed shaft 98. Opposite end portions of shaft 98 are received within openings 100 and 102 provided in wall portions 86 and 88 respectively. A bushing 103 is secured to gear pump 96 by a plurality of screws 104 extending radially inward from the circumference thereof. In order to prevent screws 104 from backing out during operation, a dowel 105 is installed in an axially extending passage 106 in a position so as to overlie the radial outer portion of screws 104. Dowel 105 may be retained within passage 106 in any suitable manner such as by a plug 108. In order to supply lubricant to bushing 103, shaft 98 is provided with an axially extending passage 109 opening into space 110 and having a radially extending passage 112 communicating with the inner end thereof. As shown, radial passage 112 is positioned so as to be approximately aligned with the axial center of bushing 103. Shaft 98 is also provided with an oil seal 113 disposed within groove 115 provided on the outer or left end thereof as seen in FIG. 4 which operates to prevent oil leakage therefrom.
Preferably both bushings 72 and 103 will be circumferentially segmented with slight clearances being provided between each of the segments so as to allow for thermal expansion thereof during operation of the brake unit.
As best seen with reference to FIGS. 2 and 3, chamber 90 is provided with an outwardly opening fluid inlet connection 114 adapted to have a fluid conduit connected thereto so as to supply fluid to chamber 90. Chamber 90 then acts as a supply reservoir supplying such fluid to gear pump 96 which is driven by counterclockwise rotation of input shaft 22 via gear 84 and is operative to pump such fluid under pressure into the next circumferentially spaced adjacent chamber 94.
An enlarged diameter generally cylindrical center portion 116 of gear and brake disc carrier member 68 is provided with a plurality of circumferentially spaced axially extending relatively shallow slots 122 which operate to provide axial oil passages for conducting lubricant to the brake discs and plates. A second plurality of circumferentially spaced axially extending slots 124 are also provided on portion 116 interposed between slots 122, each of which is adapted to receive an axially extending elongated gib 126. Gibs 126 are of an irregular shape generally as shown in FIG. 6 having a base portion 128 which is received in slot 124, a circumferentially narrowed neck portion 130 extending generally radially outward therefrom and oppositely circumferentially outwardly extending arcuate shaped upper portions 132. Each of gibs 126 are preferably secured to portion 116 of gear carrier 68 by a plurality of axially spaced fasteners 134 threadedly engaging openings provided in the bottom portions of slots 124. Extending between and adapted to be retained by respective gibs 126 are a plurality of radially outwardly extending brake discs 136 which are axially movable therealong and rotatable with input shaft 22. Gibs 126 and brake discs 136 may be of the type disclosed in copending application Ser. No. 849,857 entitled Clutch Unit and assigned to the assignee of the present invention, the disclosure of which is hereby incorporated by reference. Alternatively, if desired brake discs 136 may be in the form of continuous annular rings as opposed to circumferentially segmented discs as shown.
Center portion 116 of gear carrier 68 also has an axially extending flange portion 164 extending to the right as viewed in FIG. 4 which engages a bushing 166 secured in a recess 168 provided in end wall 28 so as to thereby rotatably support terminal end portion 40 of input shaft 22. Bushing 166 is preferably circumferentially segmented so as to allow for thermal expansion thereof and each of the segments are secured in recess 168 by a suitable threaded fastener 170. Another labyrinth comprising a plurality of grooves 172 is also provided being disposed axially outwardly from bushing 166 which serves to control the amount of lubricating oil leakage therefrom into area 174 surrounding input shaft 22.
A brake plate support member 138 is fixedly secured to housing 24 and projects axially inward into cavity 31 in radially outwardly spaced relationship to brake discs 136. A plurality of brake plates 140 are axially movable mounted on member 138 and project radially inward therefrom, the same being interposed between respective brake discs 136. Brake plate support member 138 is also provided with a plurality of radially extending spaced restricted openings 162 which operate to allow oil supplied to the brake plates and discs to flow radially outward therefrom during a lowering operation into area 110.
Center portion 116 of gear carrier 68 is also provided with a plurality of axially extending spaced bores 176 having one end opening into area 174 and the other end opening into area 73. Bores 176 serve to place area 73 in fluid communication with area 174 so as to equalize the pressure therebetween and allow oil accumulating within area 73 to drain into area 174. End wall 178 is provided with an opening 180 to which a fluid conduit may be connected to return oil from areas 73 and 174 to a remote main reservoir or tank. Also, a relatively small quantity of oil will leak past seals 57 provided on opposite end portions of input shaft 22 thereby lubricating same and will accumulate in respective areas 182 and 184 provided adjacent to and surrounding terminal end portion 40 and driven end portion 74 of input shaft 22 respectively. To prevent excessive accumulation and loss of oil in areas 182 and 184, openings 186 and 188 respectively are provided to which fluid conduits may be connected to direct this leakage oil to a remote secondary reservoir or scavenger tank.
Actuating means are provided for selectively axially moving brake discs 136 and plates 140 into and out of braking relationship which include an axially movable piston assembly 142 having a brake plate engaging surface 144. Resilient biasing means in the form of a plurality of pairs of coaxially arranged helical compression springs 146, 147 are provided extending between surface 148 of piston 142 and recessed seating surfaces 150 of housing 24. Springs 146 and 147 are operative to cause piston 142 to exert a clamping force on brake discs 136 and plates 140 between surface 144 and an axially spaced opposed surface portion 152 of housing 24. A control pressure chamber 154 is also provided which receives pressurized control hydraulic fluid through passage 156 in housing 24 which fluid operates to move piston 142 axially to the right as seen in FIG. 4 overcoming the biasing force of springs 146 and 147 thereby releasing the clamping force. Pressure chamber 154 is sealed by axially spaced fluid seals 158 and 160 provided on piston assembly 142.
As shown in FIG. 7, brake unit 10 has inlet 114 and outlet 194 connected to a primary lubricant reservoir or tank 212 via conduits 214 and 216 respectively. As brake unit 10 is designed for cyclic and reversing operation, it is desirable to maintain cavity 31 in a lubricant flooded condition so as to prevent cavitation or pounding of gear pump 96. This may be easily accomplished by merely positioning tank 212 so as to place the oil level 217 therein above the top of brake unit 10. Another return conduit 218 is also connected to tank 212 extending from opening 180 of brake unit 10 and operative to return lubricant accumulating within areas 73 and 174 thereof.
A secondary tank 220 is also provided having fluid conduits 222 and 224 extending from openings 186 and 188 respectively connected thereto which operate to drain lubricant from areas 182 and 184 respectively. A float switch 226 is provided in tank 220 which controls a pump 228 so as to return lubricant accumulating within tank 220 to primary tank 212 via conduit 230. Preferably, tank 220 will be positioned relative to brake unit 10 so as to enable gravity draining of lubricant from areas 182 and 184. As only a relatively small amount of lubricant is anticipated to accumulate in areas 182 and 184 of brake unit 10, it is believed preferable to employ a cyclically operating system utilizing a level responsive pump means; however, if desired a continuously operating relatively low capacity pump could be utilized in place thereof.
The operation of brake unit 10 will now be described in conjunction with the operation of a drilling rig although it should be noted that the present invention may find application in conjunction with other varied apparatus.
As illustrated, brake unit 10 is constructed for rotation of input shaft 22 in a counterclockwise direction as indicated by arrow 190 during a lowering operation. In order to initiate a lowering operation, it is first necessary to release the braking force generated by the clamping action exerted by piston assembly 142 on interposed brake discs 136 and plates 140 due to springs 146 and 147. This is accomplished by admitting hydraulic fluid under controlled pressure through passage 156 into chamber 154 thereby causing piston assembly 142 to move axially to the right as viewed in FIG. 4 reducing the clamping pressure and allowing gravitational forces acting on the equipment to be lowered to impart counterclockwise rotation to inut shaft 22. This counterclockwise rotation of input shaft 22 and associated gear carrier 68 and gear 84 will operate to cause a clockwise rotation of gear pump 96 which will operate to pump oil under pressure from inlet 114 and chamber 90 through pumping chamber 92 into chamber 94. Wall portion 86 of chamber 94 is provided with an arcuate shaped slot 191 which places chamber 94 in fluid communication with area 192 adjacent gear carrier 68. Oil will thus be applied under pressure to provide lubrication to splines 82 and therethrough to bushing 72 and a controlled leakage amount through labyrinth 78 to seals 57. The majority of this pressurized oil will be forced from area 192 through axially extending slots 122 and thence radially outwardly between interposed brake discs 136 and brake plates 140 thereby providing a continuous film between these opposed surfaces as well as serving to lubricate and cool same. This oil will then flow into area 110 via passages 162 provided in brake plate support member 138. Both the number and size of passages 162 will be selected relative to the volume of oil flow so as to generate a substantial pressure drop thereacross. Thus, during a lowering operation area 192 will experience a relatively high pressure substantially above that experienced by area 110. This pressure differential will, of course, be dependent upon the speed of rotation of input shaft 22 and associated gear pump 96.
A portion of the oil flowing into area 110 will be diverted to axially extending passage 109 and radially extending passage 112 so as to lubricate bushing 103 of gear pump 96. The remaining oil will accumulate in the lower portion of cavity 31 and be returned to a remote reservoir or supply tank via a return opening 194 provided in a lower sidewall portion of housing 24.
As best seen in FIG. 4, and as described above, the braking force generated by piston 142 is released by the application of a controlled hydraulic pressure to chamber 154 so as to overcome the biasing action of springs 146, 147. However, as the rotational speed of input shaft 22 increases, gear pump 96 will attempt to increase the oil flow through the brake unit which increased oil flow will be resisted by the controlled orifice passages 162 thereby resulting in an increased pressure within areas 192 and 196. As shown, piston 142 has a surface area 198 within another area or chamber 200 which is axially opposed to surface area 202 thereof disposed within chamber 154. Therefore as chamber 200 is in relatively unrestricted fluid communication with area 196, any increased fluid pressure therein will be exerted on surface 198 of piston 142. Thus, as the speed of rotation of input shaft 22 increases, pressure within area 196 and correspondingly within area 200 will increase to the point where the pressure differential between surfaces 202 and 198 will cause piston 142 to move axially to the left as illustrated thereby applying a braking force so as to decrease the rotational speed of shaft 22. As the speed decreases, the pressure within areas 196 and 200 will also decrease until a constant speed is achieved. Thus, the brake unit of the present invention provides internal self-governing speed regulation. This represents an important safety feature of the present invention in that should a sudden increase in lowering speed be encountered such as may occur should a drill break through into an underground cavern, a power failure during a raising operation or the like, the increased speed of rotation of gear pump 96 will increase the pressurization of the oil being circulated which increased oil pressure will overcome the control pressure exerted on piston assembly 142 so as to create a clamping force on brake discs 136 and plates 140 thereby preventing complete loss of control and possible equipment damage.
During a raising operation, input shaft 22 will be caused to rotate in a clockwise direction thereby imparting counterclockwise rotation to gear pump 96 causing the pumping action thereof to reverse or pump oil from chamber 94 to chamber 90.
As it is desirable to conduct the raising operations at as high a speed as possible within safe operating limits, restricted passage 162 will not be sufficient to allow enough oil flow therethrough to prevent starvation of gear pump 96. Further, in order to minimize the power required to effect raising of the drill stands, it is desirable to provide a free flowing supply of lubricant to gear pump 96 so as to reduce drag resulting therefrom. Accordingly, housing 24 is provided with an opening 204 communicating with area 110 to which a fluid conduit 206 is connected. Fluid conduit 206 extends through a check valve 208 to another opening 210 provided in end plate 28 which opens into area 196 of brake unit 16. Thus, as area 110 is maintained in an oil flooded condition due to the head pressure generated by the elevation of main supply tank oil level relative to the elevation of the brake unit, oil will be caused to flow through conduit 206, check valve 208 and into area 196. Thence, oil will be drawn through slots 122 into area 192, chamber 94 and through gear pump 96 being returned to the main supply tank via inlet chamber 90. Thus, starvation of gear pump 96 will effectively be prevented thereby eliminating the possibility of cavitation or pounding occurring. Further, this reduced drag feature eliminates the need for disconnecting the brake unit in order to achieve rapid raising of equipment from the drill hole with a minimum of power consumption. Thus, as the brake is continuously connected, it remains in standby condition providing an added safety factor should a power failure or other raising equipment faulter.
It should be noted that check valve 208 is designed to allow oil flow from area 110 to area 196 but prevent oil flow from 196 to area 110 thereby assuring pressurization of area 196 during lowering operations.
As previously mentioned, bushings 72 and 166 along with labyrinth grooves 78 and 172 operate to at least partially seal cavity 31 of brake unit 16. However, due to the relatively high pressure as well as the need to provide lubrication to bushings 72 and 166, some oil leakage will occur. Accordingly, areas 73 and 174 will both be subjected to some pressurized oil flow which oil is returned to the main tank via passages 176 and fluid conduit 218 connected to opening 180. Additionally, some oil leakage will occur past seals 57 at each end of shaft 22 into respective areas 182 and 184 to which fluid conduits 222 and 224 are connected which operate to drain fluid therefrom. However, the oil presence within areas 182 and 184 will be at or very near atmospheric pressure and because the oil level in tank 212 is above the level of areas 182 and 184 it is not possible to return this oil directly to the main tank due to the head produced thereby. Accordingly, fluid conduits 222 and 224 drain lubricant to secondary tank 220 thereby raising float switch 226 to a level sufficient to actuate pump 228. Pump 228 will then operate to return the oil from tank 220 to tank 212 via conduit 230 thereby reducing the oil level in tank 220 until float switch 226 de-actuates pump 228.
While brake unit 10 has been illustrated as constructed with input shaft 22 designed to rotate in a counterclockwise direction during lowering operations, this may be easily modified for clockwise rotation during lowering by moving inlet connection 114 to communicate with chamber 94 and moving slot 191 to the corresponding location in communication with chamber 90. The operation and oil circulation pattern within brake unit 10 will otherwise be substantially identical to that described above.
While it will be apparent that the preferred embodiment of the invention disclosed is well calculated to provide the advantages and features above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.
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There is disclosed herein a brake unit of the oil shear type which is specifically designed for use in controlling the drawworks of drilling rigs or the like. The drawworks brake unit comprises an input shaft driven by the drawworks which operates to drive a gear pump for circulating high volumes of oil under pressure over interposed brake discs and plates and through adjacent restricted orifices during a first direction of rotation such as during lowering of the pipe stands so as to both cool and lubricate the discs and plates. During an opposite rotation of the input shaft, such as during raising of the pipe stands, an alternate flowpath is provided by-passing the restricted orifices so as to reduce the drag placed on the drawworks during raising of the pipe stands. During the first direction of rotation or lowering, the gear pump also operates to provide self-actuating overspeed safety protection as well. A unique stepped oil sealing arrangement is also provided to prevent oil leakage between the input shaft and housing due to the high pressure generated therein.
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This application is a divisional of application Ser. No. 09/441,006, filed Nov. 16, 1999, now abandoned which is a CIP of application Ser. No. 09/211,551, filed Dec. 15, 1998 now abandoned which application(s) are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to an alkoxylation catalyst and a method for producing the same, and a method for producing an alkylene oxide adduct using the catalyst. More particularly, the invention relates to an alkoxylation solid catalyst comprising a metal oxide, and to a method for producing an alkylene oxide adduct that is useful as a chemical material for a surfactant or the like.
BACKGROUND OF THE INVENTION
A compound in which an alkylene oxide is added to an organic compound having an active hydrogen or to an ester is widely used as a chemical material for surfactants, solvents, or the like. Particularly, those obtained by polyalkoxylating alcohol, fatty acid, fatty acid ester, amine, alkylphenol, or the like with an alkylene oxide such as ethylene oxide or propylene oxide have been utilized as nonionic surfactants in a wide range of application.
As such an alkylene oxide adduct, one having a narrow adduct distribution has many advantages, e.g. high foamability, as compared with one having a wide adduct distribution. As a method for obtaining an alkylene oxide adduct having a narrow adduct distribution, those using a halide catalyst such as a halide of boron, tin, antimony, iron, or aluminum, or an acid catalyst such as phosphoric acid or sulfuric acid are well known. However, in such a method using an acid catalyst, sufficiently narrow adduct distribution cannot be obtained, and a large amount of by-product such as dioxane, dioxolane, or polyethylene glycol is produced. In addition, such an acid catalyst strongly corrodes materials of equipment.
Accordingly, as a solid catalyst for producing an alkylene oxide adduct having a narrow adduct distribution, the following composite oxides have been proposed.
1) Japanese Published Unexamined Patent Application No. (Ibkkai hei) 1-164437: A method for producing an alkylene oxide adduct having a narrow adduct distribution uses as a catalyst a magnesium oxide in which a metal ion such as aluminum is added. It discloses, for example, a magnesium oxide catalyst containing 3 wt. % of aluminum.
2) Japanese Published Unexamined Patent Application No. (Ibkkai hei) 2-71841: A method for producing an alkylene oxide adduct having a narrow adduct distribution with a calcined hydrotalcite as a catalyst is disclosed. The calcined hydrotalcite can be obtained by cacining a natural or synthetic hydrotalcite.
3) Japanese Published Unexamined Patent Application No. (Ibkkai hei) 7-227540: A method for producing an alkylene oxide adduct with a magnesium oxide containing zinc, antimony, tin, or the like as a catalyst, in which generation of a by-product (polyethylene glycol) is inhibited, is disclosed. By using the MgโZn, MgโSb or MgโSn composite oxide catalyst, the amount of polyethylene glycol formed as a by-product can be reduced, although the catalytic activity may be decreased as compared with a case using a magnesium oxide catalyst in which aluminum is added. However, the effect of inhibiting polyethylene glycol formation is still insufficient.
4) Japanese Published Unexamined Patent Application No. (Tokkai hei) 8-268919: A method for producing an alkylene oxide adduct having a narrow adduct distribution uses as a catalyst an AlโMg composite oxide which is obtained by cacining aluminum magnesium hydroxide.
An alkylene oxide adduct obtained using each of the above-mentioned catalysts has a narrower adduct distribution than that obtained with an acid catalyst. Moreover, generation of a by-product such as dioxane can be inhibited. Particularly, a composite oxide of magnesium and aluminum has a high activity. However, the composite oxide catalyst cannot inhibit formation of polyalkylene glycol as a by-product. Japanese Published Unexamined Patent Application No. Tokkai hei) 7-227540 discloses a catalyst capable of reducing the amount of polyalkylene glycol formed as a by-product. However, the effect of inhibiting polyethylene glycol formation is still insufficient. Moreover, it is a high molecular weight polyalkylene glycol with a molecular weight of several tens of thousands that causes particularly difficult problems. Even a trace of high molecular weight polyalkylene glycol can cause problems in polyalkoxylating. For example, removing catalysts may become difficult, and the stability of a product containing the alkylene oxide adduct may be reduced. Moreover, a catalyst for producing an alkylene oxide adduct is required to have a sufficient catalytic activity in practical use.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a catalyst with which an alkylene oxide adduct having a narrow adduct distribution can be produced more advantageously from an industrial standpoint and a method for producing the same, and a method for producing an alkylene oxide adduct using the catalyst. Particularly, it is an object of the present invention to provide a catalyst with which an alkylene oxide adduct having a narrow adduct distribution can be produced efficiently while inhibiting formation of high molecular weight polyalkylene glycol.
As a result of earnest research with respect to an alkoxylation catalyst suitable for production of an alkylene oxide adduct having a narrow adduct distribution, the inventors have found that it is possible to achieve both high catalytic activity and inhibition of high molecular weight polyalkylene glycol formation with a catalyst prepared by adding a particular metal to a MgโAl composite oxide.
Thus, a first alkoxylation catalyst of the present invention comprises a metal oxide containing magnesium, aluminum, and at least one metal selected from the metals that belong to group VIA, group VIIA, and group VIII.
The above-mentioned metal added to the MgโAl composite oxide is selected from those elements that belong to group VIA (chromium, molybdenum, and tungsten), group VIIA (manganese, technetium, and rhenium), and group VIII (iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, and platinum) in the periodic table according to a subgroup system.
The alkoxylation catalyst of the present invention is obtained by adding the metal as a third component to MgโAl composite oxide containing simultaneously a basic site of an oxygen atom adjacent to a magnesium atom for activating an organic compound having an active hydrogen, and an acidic site of an aluminum atom for activating an alkylene oxide. MgโAl composite oxide has been conventionally utilized, and it is a highly active catalyst with which an alkylene oxide adduct having a narrow adduct distribution can be produced. Moreover, according to the present invention, formation of high molecular weight polyalkylene oxide glycol as a by-product can be inhibited by the third component. This is because the addition of the metal as a third component causes a structural change in the active site of the side reaction. The structure of the active site in the catalyst is changed, for example, by forming a spinel-type structure that includes the third component metal and aluminum.
A second alkoxylation catalyst of the present invention comprises a metal oxide containing magnesium, aluminum, and M (M is at least one selected from the metal elements other than magnesium and aluminum). The metal oxide includes a spinel-type structure that contains aluminum and M.
The metal oxide having the spinel-type structure is represented, for example, by a chemical formula MAl 2 O 4 . The metals belonging to groups VIA, VIIA, or VIII can be employed as M, but it is not particularly limited. Two or more types of elements also may be used as M.
The presence of the above-mentioned spinel-type structure can be confirmed by X-ray diffraction analysis. It is preferable that the catalyst includes an oxide in which an X-ray diffraction peak resulting from a rock-salt structure of a magnesium oxide is observed as well as an X-ray diffraction peak resulting from a spinel structure.
Thus, by using at least one of the catalysts of the present invention, it is possible to produce an alkylene oxide adduct having a narrow adduct distribution efficiently, while inhibiting formation of high molecular weight polyalkylene glycol as a by-product. Furthermore, the method for producing an alkylene oxide adduct according to the present invention comprises adding an alkylene oxide to an organic compound in the presence of the alkoxylation catalyst of the present invention.
Furthermore, the method for producing an alkoxylation catalyst comprising a metal oxide according to the present invention comprises: forming a precipitate containing elements of magnesium, aluminum, and at least one element selected from the metal elements belonging to groups VIA, VIIA, and VIII from a mixed aqueous solution containing the elements; and burning the precipitate at a temperature of 300 to 1000ยฐ C. so as to obtain the metal oxide.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the adduct distribution of an EO adduct obtained according to Reaction Example 1 using a catalyst of the present invention.
FIG. 2 is a graph showing the adduct distribution of an EO adduct obtained according to Reaction Example 2 using a catalyst of the present invention.
FIG. 3 is a graph showing the adduct distribution of an EO adduct obtained according to Reaction Example 3 using a catalyst of the present invention.
FIG. 4 is a graph showing the adduct distribution of an EO adduct obtained according to Reaction Example 4 using a catalyst of the present invention.
FIG. 5 is a graph showing the adduct distribution of an EO adduct obtained according to Reaction Example 5 using a catalyst of the present invention.
FIG. 6 is a graph showing the adduct distribution of an EO adduct obtained according to Reaction Example 6 using a catalyst of the present invention.
FIG. 7 is a graph showing the adduct distribution of an EO adduct obtained according to Comparative Reaction Example 1.
FIG. 8 is a graph showing the adduct distribution of an EO adduct obtained according to Comparative Reaction Example 2.
FIG. 9 is a graph showing the adduct distribution of an EO adduct obtained according to Comparative Reaction Example 3.
FIG. 10 is a graph showing the adduct distribution of an EO adduct obtained according to Reaction Example 11 using a catalyst of the present invention.
FIG. 11 is a graph showing the adduct distribution of an EO adduct obtained according to Comparative Reaction Example 4.
FIG. 12 is a graph showing the adduct distribution of an EO adduct obtained according to a reaction example using a KOH catalyst.
FIG. 13 shows X-ray diffraction patterns of catalysts obtained in Examples 1, 3 and 4.
FIG. 14 shows an X-ray diffraction pattern of a conventional catalyst obtained in Comparative Example 1.
DETAILED DESCRIPTION OF THE INVENTION
The catalyst of the present invention will be described in detail as follows.
As the metal of the third component in the catalyst of the present invention, chromium, molybdenum, manganese, technetium, iron, cobalt, nickel, or ruthenium is preferably used. More preferably, chromium, manganese or iron is used, and particularly preferably manganese is used. A combination of at least two of the above-mentioned metals may be also used as the third component.
In the catalyst of the present invention, it is preferable that the ratio of each metal is within a range suitable for inhibiting formation of high molecular weight polyalkylene glycol as a by-product, while maintaining high catalytic activity of MgโAl composite oxide. A preferable ratio of each metal is described below.
The atomic ratio between magnesium and aluminum as shown by Al/(Mg+Al) is preferably in the range of 0.1 to 0.7, more preferably 0.3 to 0.6.
The atomic ratio of the metal added as a third component with respect to the total metals is preferably in the range of 0.05 to 0.4, more preferably 0.1 to 0.25. If the amount of the third component is too small, the effect of inhibiting formation of high molecular weight polyalkylene glycol cannot be obtained sufficiently. On the other hand, if the amount of the third component is excessively large, the catalytic activity may be decreased.
The catalyst of the present invention can be obtained by a known method for preparing a multi-element composite oxide, for example, by the impregnation method or coprecipitation method. A process of preparing the catalyst of the present invention by the coprecipitation method is herein described.
According to the coprecipitation method, first a mixed aqueous solution containing a metal compound such as nitrate, sulfate, carbonate, acetate, or chloride of each metal is prepared, and a precipitant is added to the aqueous solution. The precipitate obtained by the addition of the precipitant is treated by washing with water, drying, calcining, or the like so as to form a catalyst comprising a composite oxide.
A particular example applying the coprecipitation method to the present invention is a method of forming a precipitate by dropping a mixed aqueous solution containing metal compounds of magnesium, aluminum and a metal as a third component with a precipitant, while adjusting the flow so that the pH of the mixture solution falls in a predetermined range. In this example, it is preferable that the pH of the mixture solution is adjusted within the range of 7 to 11, particularly 8 to 10. If the coprecipitation is carried out at a pH not within the above-mentioned range, metals may be eluted. Thus, an oxide catalyst having desired composition and crystal structure may not be obtained. Preferable examples of the precipitant are alkaline aqueous solutions, particularly alkaline aqueous solutions containing a carbonate such as sodium carbonate. Furthermore, in order to maintain the pH within the above-mentioned range, it is preferable that the precipitant contains a hydroxide of alkali metal such as sodium hydroxide.
From the composite hydroxide obtained as a precipitate, water soluble salts are removed by washing with water, and then it is dried. Thereafter, it is calcined by heating at 300 to 1000ยฐ C., preferably at 600 to 900ยฐ C., more preferably at 700 to 900ยฐ C. Thus, a catalyst of the present invention comprising a composite oxide can be obtained. The heating temperature has an influence on the change of the structure of the active site in the catalyst. When the heating temperature is too low, the third component and aluminum may not form a spinel structure, so that the active site in the catalyst may not be changed adequately. On the other hand, when the heating temperature is too high, sintering is facilitated and surface area is decreased, so that catalytic activity may be decreased.
Next, an organic compound to which alkylene oxide is added using a catalyst of the present invention will be described. Such an organic compound is not particularly limited, as long as it can be alkoxylated, but particularly used is an organic compound having an active hydrogen or an ester. More particularly, alcohols, phenols, fatty acids, fatty acid esters, fatty amines, fatty acid amides, polyols, or a mixture thereof are suitably used. Typical examples of them are illustrated in the following.
As alcohols, it is preferable to use a saturated or unsaturated primary or secondary alcohol having 2 to 30 carbon atoms, more preferably a primary alcohol having 4 to 24 carbon atoms, particularly preferably a primary alcohol having 6 to 24 carbon atoms. Furthermore, as phenols, it is preferable to use mono-, di-, or trialkylphenol, particularly a compound having 4 to 12 carbon atoms in an alkyl group.
As fatty acids, a fatty acid having 8 to 22 carbon atoms, for example, a saturated or unsaturated straight-chain fatty acid obtainable by fat decomposition of coconut oil, palm oil palm kernel oil, soybean oil, sunflower oil, rapeseed oil, fish fat, or the like (e.g. caprylic acid, n-capric acid, lauric acid, myristic acid, oleic acid, or stearic acid), or a mixture thereof preferably can be used. Furthermore, as fatty acid esters, it is preferable to use those produced by esterifying the above-mentioned fatty acids with an alcohol of alkyl group having 1 to 4 carbon atoms (an alkanol having 1 to 4 carbon atoms).
As fatty amines, it is preferable to use a primary fatty amine obtainable from a saturated or unsaturated straight-chain fatty acid or a compound in which nitrile is introduced into corresponding aliphatic alcohol. Furthermore, as the fatty acid amides, it is preferable to use a derivative obtainable by reaction between a saturated or unsaturated straight-chain fatty acid and ammonia or primary fatty amine.
As the polyols, it is preferable to use polyethylene glycol or polypropylene glycol having an average degree of polymerization of 2 to 2,000, or glycerol, sorbitol, or the like.
On the other hand, in the present invention, it is preferable to use an alkylene oxide having 2 to 8 carbon atoms, particularly preferably ethylene oxide, propylene oxide, or butylene oxide having 2 to 4 carbon atoms.
In the following, preferable conditions of reaction in the method for producing an alkylene oxide adduct according to the present invention will be described. The reaction temperature is preferably 80 to 230ยฐ C., more preferably 120 to 200ยฐ C., most preferably 160 to 180ยฐ C. Although the reaction pressure also depends on the reaction temperature, it is preferably 0 to 20 atm, more preferably 2 to 8 atm. Although it also depends on the molar ratio of the alkylene oxide and the starting material provided in the reaction, usually the amount of the catalyst used is preferably 0.01 to 20 wt. %, more preferably 0.05 to 5 wt. %, of the starting material such as alcohol.
The reaction operation is as follows. For example, starting material such as alcohol and a catalyst are put in an autoclave. After the substitution of nitrogen gas for the air in the autoclave, an alkylene oxide is introduced into the autoclave to cause reaction under predetermined temperature and pressure conditions. The catalyst may be present in the reaction product depending on its use, however, it is usually separated from the reaction product by filtering, which is performed after adding water or a filter aid to decrease viscosity.
According to the present invention, in a method for producing an alkylene oxide adduct using the catalyst of the present invention, an alkylene oxide adduct having a very narrow adduct distribution can be produced more efficiently with high catalytic activity, with a very small amount of high molecular weight polyethylene glycol formed as a by-product. Particularly, because formation of high molecular weight polyalkylene glycol as a by-product is inhibited, the efficiency of filtering catalyst can be improved, and also the properties (e.g. stability in low temperature) of a chemical product using the obtained alkylene oxide adduct as a material are improved.
The present invention will be described below in more detail by way of examples and comparative examples. These examples are illustrative in nature and should not be considered as limiting the present invention.
EXAMPLE 1
To prepare a solution A, 68.03 g (0.265 mol) of magnesium nitrate hexahydrate, 47.69 g (0.127 mol) of aluminum nitrate nonahydrate, and 24.33 g (0.085 mol) of manganese nitrate hexahydrate were dissolved in 450 g of deionized water. On the other hand, 13.47 g (0.127 mol) of sodium carbonate was dissolved in 450 g of deionized water to prepare a solution B.
The solutions A and B were dropped into a catalyst preparation vessel previously supplied with 1,800 g of deionized water over a period of 1 hour, while maintaining the pH of 9 with 2N-NaOH and the temperature of 40ยฐ C. After completing the dropping, the mixed solution was aged for 1 hour. The mother liquor was removed by filtration, and the precipitate was washed with 6 liters of deionized water and spray-dried, and 30 g of a composite hydroxide was obtained. The composite hydroxide was calcined for 3 hours at 800ยฐ C. in a nitrogen atmosphere to obtain 19 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.26:0.18).
EXAMPLE 2
To prepare a solution A, 68.03 g (0.265 mol) of magnesium nitrate hexahydrate, 47.69 g (0.127 mol) of aluminum nitrate nonahydrate, and 20.83 g (0.085 mol) of manganese acetate tetrahydrate were dissolved in 450 g of deionized water. On the other hand, 13.47 g (0.127 mol) of sodium carbonate was dissolved in 450 g of deionized water to prepare a solution B.
After that, according to the same procedure as in Example 1, 19 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.26:0.18) was obtained.
EXAMPLE 3
To prepare a solution A, 69.68 g (0.272 mol) of magnesium nitrate hexahydrate, 61.06 g (0.163 mol) of aluminum nitrate nonahydrate, and 14.60 g (0.051 mol) of manganese nitrate hexahydrate were dissolved in 450 g of deionized water. On the other hand, 17.26 g (0.163 mol) of sodium carbonate was dissolved in 450 g of deionized water to prepare a solution B.
After that, according to the same procedure as in Example 1, 21 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.34:0.10) was obtained.
EXAMPLE 4
To prepare a solution A, 66.72 g (0.260 mol) of magnesium nitrate hexahydrate, 38.98 g (0.104 mol) of aluminum nitrate nonahydrate, and 29.82 g (0.104 mol) of manganese nitrate hexahydrate were dissolved in 450 g of deionized water. On the other hand, 11.01 g (0.104 mol) of sodium carbonate was dissolved in 450 g of deionized water to prepare a solution B.
After that, according to the same procedure as in Example 1, 18 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.22:0.22) was obtained.
EXAMPLE 5
To prepare a solution A, 57.26 g (0.223 mol) of magnesium nitrate hexahydrate, 50.06 g (0.133 mol) of aluminum nitrate nonahydrate, and 35.60 g (0.089 mol) of chromium nitrate nonahydrate were dissolved in 450 g of deionized water. On the other hand, 23.57 g (0.222 mol) of sodium carbonate was dissolved in 450 g of deionized water to prepare a solution B.
After that, according to the same procedure as in Example 1, 23 g of a MgโAlโCr composite oxide catalyst (Mg:Al:Cr (by atomic ratio)=0.50:0.30:0.20) was obtained.
EXAMPLE 6
To prepare a solution A, 68.03 g (0.265 mol) of magnesium nitrate hexahydrate, 47.69 g (0.127 mol) of aluminum nitrate nonahydrate, and 21.35 g (0.085 mol) of ferrous chloride tetrahydrate were dissolved in 450 g of deionized water. On the other hand, 13.47 g (0.127 mol) of sodium carbonate was dissolved in 450 g of deionized water to prepare a solution B.
After that, according to the same procedure as in Example 1, 18 g of a MgโAlโFe composite oxide catalyst (Mg:Al:Fe (by atomic ratio)=0.56:0.26:0.18) was obtained.
EXAMPLE 7
Following the same procedure as in Example 1 except that 16.82 g (0.085 mol) of manganese chloride tetrahydrate was used as the manganese salt, 19 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.26:0.18) was obtained.
EXAMPLE 8
Following the same procedure as in Example 1 except that 20.49 g (0.085 mol) of manganese sulfate pentahydrate was used as the manganese salt, 19 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.26:0.18) was obtained.
EXAMPLE 9
Following the same procedure as in Example 1 except that 9.77 g (0.085 mol) of manganese carbonate was used as the manganese salt, 19 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.26:0.18) was obtained.
EXAMPLE 10
To prepare a solution A, 317.48 g (1.24 mol) of magnesium nitrate hexahydrate, 222.55 g (0.593 mol) of aluminum nitrate nonahydrate, and 96.9 g (0.396 mol) of manganese acetate tetrahydrate were dissolved in 600 g of deionized water. On the other hand, 62.88 g (0.593 mol) of sodium carbonate was dissolved in 500 g of deionized water to prepare a solution B.
The solutions A and B were dropped into a catalyst preparation vessel previously supplied with 480 g of deionized water over a period of 1 hour, while maintaining the pH of 9 with 10N-NaOH and the temperature of 70ยฐ C. After completing the dropping step, the mixture solution was aged for 1 hour. The mother liquor was removed by filtration, and the precipitate was washed with 9.6 liters of deionized water and spray-dried, and 92 g of a composite hydroxide was obtained. The composite hydroxide was calcined for 3 hours at 800ยฐ C. in a nitrogen atmosphere to obtain 60 g of a MgโAlโMn composite oxide catalyst (Mg:Al:Mn (by atomic ratio)=0.56:0.26:0.18).
COMPARATIVE EXAMPLE 1
To prepare a solution A, 57.26 g (0.223 mol) of magnesium nitrate hexahydrate and 66.80 g (0.178 mol) of aluminum nitrate nonahydrate were dissolved in 450 g of deionized water. On the other hand, 18.87 g (0.178 mol) of sodium carbonate was dissolved in 450 g of deionized water to prepare a solution B.
After that, following the same procedure as in Example 1, 17 g of a MgโAl composite oxide catalyst (Mg:Al (by atomic ratio)=0.556:0.444) was obtained.
COMPARATIVE EXAMPLE 2
25 g of aluminum magnesium hydroxide with a chemical composition of 2.5MgOยทAl 2 O 3 ยทmH 2 O (KYOWAAD (registered trademark) 300 manufactured by Kyowa Chemical Industry) was calcined in a nitrogen atmosphere at 800ยฐ C. for 3 hours, and 16 g of MgโAl composite oxide catalyst was obtained.
COMPARATIVE EXAMPLE 3
25 g of hydrotalcite with a chemical composition of Mg 6 Al 2 (OH) 16 CO 3 ยท4H 2 O (KYOWAAD (registered trademark) 500 manufactured by Kyowa Chemical Industry) was calcined in a nitrogen atmosphere at 500ยฐ C. for 3 hours, and 18 g of MgโAl composite oxide catalyst was obtained.
Using each catalyst obtained in Examples 1 to 10 and Comparative Examples 1 to 3, alkylene oxide addition reactions were carried out according to the reaction evaluation method I as described below. The reactions are referred to as Reaction Examples 1 to 10 and Comparative Reaction Example 1 to 3, respectively. Furthermore, the catalytic activity and the amount of high molecular weight polyethylene glycol (PEG) formed as a by-product in each reaction example were evaluated according to the respective methods as described below. The evaluation results are shown in Table 1.
Furthermore, using each catalyst obtained in Example 1 and Comparative Example 1, alkylene oxide addition reactions were carried out according to the reaction evaluation method II as described below. The reactions are referred to as Reaction Example 11 and Comparative Reaction Example 4, respectively. The evaluation results of the reactions are shown in Table 2.
REACTION EVALUATION METHOD I
400 g of lauryl alcohol and 0.4 g of a catalyst were put in a 4-liter capacity autoclave. The air in the autoclave was replaced with nitrogen gas, and the temperature was increased while stirring. Then, while maintaining the temperature of 180ยฐ C. and the pressure of 3 atm, 663 g of ethylene oxide (EO) (average adduct molar number: 7) was introduced to cause reaction between the lauryl alcohol and the EO.
REACTION EVALUATION METHOD II
400 g of methyl laurate, 1.2 g of catalyst, and 0.12 g of 40% KOH aqueous solution were put in a 4 liter capacity autoclave. The air in the autoclave was replaced with nitrogen gas, and the temperature was increased while stirring. Then, while maintaining the temperature of 180ยฐ C. and the pressure of 3 atm, 494 g of EO (average adduct molar number: 6) was introduced to cause reaction between the methyl laurate and the EO.
CATALYTIC ACTIVITY
In each of the above-mentioned reaction evaluation methods, the EO supplying rate (g-EO/min) was converted into a value per unit amount of catalyst after a point when the temperature and the pressure reached the predetermined values (180ยฐ C. and 3 atm, respectively). The obtained value was used as an evaluation measure of the catalytic activity (the unit: [g-EO/(minยทg-catalyst)]). The EO supplying rate corresponds to the amount of EO consumed per unit time under the above-mentioned predetermined temperature and pressure conditions. During this measurement, the catalyst concentration was adjusted to a low level so that catalytic activity under the control of chemical reaction rate can be evaluated accurately.
THE AMOUNT OF HIGH MOLECULAR WEIGHT PEG FORMED AS BY-PRODUCT
In each of the above reaction evaluation methods, the content of high molecular weight polyethylene glycol having a molecular weight of at least 20,000 in the reaction product was analyzed quantitatively according to the HPLC method, and the comparison was made based on weight %.
TABLE 1
Reaction Examples 1 to 10 and Comparative Reaction Examples 1 to 3.
Amount
of High
Molecular
Catalytic
Weight PEG
Activity
Formed as
Composite Oxide
(g โ EO/
By-product
Catalyst
(min . g โ cat))
(wt. %)
Reaction
Example
1
Catalyst of Ex. 1
6.0
0.06
2
Catalyst of Ex. 2
11.1โ
0.04
3
Catalyst of Ex. 3
8.6
0.09
4
Catalyst of Ex. 4
3.4
0.05
5
Catalyst of Ex. 5
3.6
0.16
6
Catalyst of Ex. 6
3.0
0.20
7
Catalyst of Ex. 7
6.1
0.05
8
Catalyst of Ex. 8
4.5
0.02
9
Catalyst of Ex. 9
4.7
0.05
10โ
Catalyst of Ex. 10
9.2
0.04
Comparative
Reaction
Example
1
Catalyst of
5.7
0.53
Comp. Ex. 1
2
Catalyst of
4.8
0.60
Comp. Ex. 2
3
Catalyst of
6.7
1.10
Comp. Ex. 3
TABLE 2
Reaction Example 11 and Comparative Reaction Example 4.
Amount of
Catalytic
High Molecular
Activity
Weight PEG
Composite Oxide
(g โ EO/
Formed as
Catalyst
(min . g โ cat))
By-product (wt. %)
Reaction
Example 11
Catalyst of Ex. 1
2.7
0.06
Comparative
Reaction
Catalyst of
1.9
0.58
Example 4
Comp. Ex. 1
As is apparent from the results in Tables 1 and 2, formation of high molecular weight polyethylene glycol as a by-product is inhibited when using the catalyst of the present invention. Particularly, when using the catalyst of Example 1 containing Mn, the amount of high molecular weight polyethylene glycol formed as a by-product is decreased to about one tenth the amount of that formed with the catalyst of Comparative Example 1, which was prepared according to the same procedure but not containing Mn.
Furthermore, it was confirmed that the ability of catalyst is influenced depending on the type of the starting manganese salt. For example, the acetate is preferable with respect to catalytic activity, and the sulfate is preferable for inhibiting formation of high molecular weight polyethylene glycol as a by-product.
In a multi-layered hydroxide as a catalyst precursor before being calcined, anions are believed to be taken in the guest layer having a layered structure (while the host layer is metal hydroxide). As a result, the anions influence the crystal structure of the catalyst precursor.
With respect to the EO adducts obtained in Reaction Examples 1 to 6 and 11 and Comparative Reaction Examples 1 to 4, EO adduct distribution was measured by the HPLC method. The results are shown in FIGS. 1 to 11 . Furthermore, for the purpose of comparing the adduct distribution, alkylene oxide addition reaction was carried out using a KOH catalyst as an alkali catalyst according to the above-mentioned reaction evaluation method I. The adduct distribution of the EO adduct obtained by this reaction was measured in the same way as mentioned above. The result is shown in FIG. 12 .
Furthermore, crystal structure was investigated for each of the catalysts obtained in Examples 1, 3 and 4, and Comparative Example 1 by X-ray diffraction. The results are shown in FIGS. 13 and 14. As shown in FIG. 13, in each of the Examples, formation of a spinel-type oxide comprising aluminum and manganese (MnAl 2 O 4 ) was confirmed. Furthermore, a peak resulting from an oxide with a rock-salt structure (MgO) was confirmed as well as a peak resulting from a spinel-type structure. On the other hand, as shown in FIG. 14, only a peak resulting from a rock-salt structure of magnesium oxide was observed in the Comparative Example.
Finally, it is understood that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not restrictive, so that the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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The present invention provides an alkoxylation solid catalyst with which an alkylene oxide adduct having a narrow adduct distribution can be produced while inhibiting formation of high molecular weight polyalkylene glycol having a molecular weight of about tens of thousands as a by-product. The alkoxylation catalyst comprises a metal oxide containing magnesium, aluminum, and at least one metal selected from the metals that belong to group VIA, group VIIA, and group VIII as a third component. The third component metal changes the structure of the active site in the catalyst, for example, by forming a metal oxide having a spinel-type structure with aluminum (e.g. when the third component metal is Mn, MnAl 2 O 4 is formed), so that a side reaction of forming a high molecular weight polyalkylene glycol is inhibited.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 12/958,623, filed Dec. 2, 2010. Application Ser. No. 12/958,623 claims the benefit of U.S. provisional application 61/266,392, filed Dec. 3, 2009; and application Ser. No. 12/958,623 is also a continuation-in-part of U.S. patent application Ser. No. 12/146,918, filed Jun. 26, 2008, which (1) claims the benefit of U.S. provisional application 60/947,212, filed Jun. 29, 2007, and (2) is also a continuation-in-part of U.S. patent application Ser. No. 11/111,439, filed Apr. 21, 2005, which (a) claims the benefit of U.S. provisional application 60/565,065, filed Apr. 23, 2004, and U.S. provisional application 60/639,873, filed Dec. 27, 2004; (b) is a continuation-in-part of U.S. patent application Ser. No. 11/074,318, filed Mar. 7, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 10/315,576, filed Dec. 10, 2002, which is a continuation-in-part of U.S. patent application Ser. No. 10/285,313, filed Oct. 31, 2002, which is a continuation-in-part application of U.S. patent application Ser. No. 10/263,329, filed Oct. 2, 2002; (c) is a continuation-in-part of U.S. patent application Ser. No. 10/402,327, filed Mar. 28, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10/204,334, filed Oct. 16, 2002, which is the U.S. national phase of PCT/IB01/00202, filed Feb. 16, 2001, which claims the benefit of U.S. provisional application 60/183,295, filed Feb. 17, 2000; and (d) is a continuation-in-part of U.S. patent application Ser. No. 10/288,562, filed Nov. 5, 2002, which claims the benefit of U.S. provisional application 60/338,632, filed Nov. 6, 2001. Each of the above-referenced applications is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This invention concerns selective destruction of rapidly dividing cells in a localized area, and more particularly, selectively destroying target cells without destroying nearby non-target cells by applying an electric field with specific characteristics in vitro or to a region in a living patient.
BACKGROUND
[0003] All living organisms proliferate by cell division, including cell cultures, microorganisms (such as bacteria, mycoplasma, yeast, protozoa, and other single-celled organisms), fungi, algae, plant cells, etc. Dividing cells of organisms can be destroyed, or their proliferation controlled, by methods that are based on the sensitivity of the dividing cells of these organisms to certain agents. For example, certain antibiotics stop the multiplication process of bacteria.
[0004] The process of eukaryotic cell division is called โmitosisโ, which involves nice distinct phases (see Darnell et al., Molecular Cell Biology, New York: Scientific American Books, 1986, p. 149). During interphase, the cell replicates chromosomal DNA, which begins condensing in early prophase. At this point, centrioles (each cell contains 2) begin moving towards opposite poles of the cell. In middle prophase, each chromosome is composed of duplicate chromatids. Microtubular spindles radiate from regions adjacent to the centrioles, which are closer to their poles. By late prophase, the centrioles have reached the poles, and some spindle fibers extend to the center of the cell, while others extend from the poles to the chromatids. The cells then move into metaphase, when the chromosomes move toward the equator of the cell and align in the equatorial plane. Next is early anaphase, during which time daughter chromatids separate from each other at the equator by moving along the spindle fibers toward a centromere at opposite poles. The cell begins to elongate along the axis of the pole; the pole-to-pole spindles also elongate. Late anaphase occurs when the daughter chromosomes (as they are now called) each reach their respective opposite poles. At this point, cytokinesis begins as the cleavage furrow begins to form at the equator of the cell. In other words, late anaphase is the point at which pinching the cell membrane begins. During telophase, cytokinesis is nearly complete and spindles disappear. Only a relatively narrow membrane connection joins the two cytoplasms. Finally, the membranes separate fully, cytokinesis is complete and the cell returns to interphase.
[0005] In meiosis, the cell undergoes a second division, involving separation of sister chromosomes to opposite poles of the cell along spindle fibers, followed by formation of a cleavage furrow and cell division. However, this division is not preceded by chromosome replication, yielding a haploid germ cell. Bacteria also divide by chromosome replication, followed by cell separation. However, since the daughter chromosomes separate by attachment to membrane components; there is no visible apparatus that contributes to cell division as in eukaryotic cells.
[0006] It is well known that tumors, particularly malignant or cancerous tumors, grow uncontrollably compared to normal tissue. Such expedited growth enables tumors to occupy an ever-increasing space and to damage or destroy tissue adjacent thereto. Furthermore, certain cancers are characterized by an ability to transmit cancerous โseedsโ, including single cells or small cell clusters (metastases), to new locations where the metastatic cancer cells grow into additional tumors.
[0007] The rapid growth of tumors, in general, and malignant tumors in particular, as described above, is the result of relatively frequent cell division or multiplication of these cells compared to normal tissue cells. The distinguishably frequent cell division of cancer cells is the basis for the effectiveness of existing cancer treatments, e.g., irradiation therapy and the use of various chemo-therapeutic agents. Such treatments are based on the fact that cells undergoing division are more sensitive to radiation and chemo-therapeutic agents than non-dividing cells. Because tumors cells divide much more frequently than normal cells, it is possible, to a certain extent, to selectively damage or destroy tumor cells by radiation therapy and/or chemotherapy. The actual sensitivity of cells to radiation, therapeutic agents, etc., is also dependent on specific characteristics of different types of normal or malignant cell types. Thus, unfortunately, the sensitivity of tumor cells is not sufficiently higher than that many types of normal tissues. This diminishes the ability to distinguish between tumor cells and normal cells, and therefore, existing cancer treatments typically cause significant damage to normal tissues, thus limiting the therapeutic effectiveness of such treatments. Furthermore, the inevitable damage to other tissue renders treatments very traumatic to the patients and, often, patients are unable to recover from a seemingly successful treatment. Also, certain types of tumors are not sensitive at all to existing methods of treatment.
[0008] There are also other methods for destroying cells that do not rely on radiation therapy or chemotherapy alone. For example, ultrasonic and electrical methods for destroying tumor cells can be used in addition to or instead of conventional treatments. Electric fields and currents have been used for medical purposes for many years. The most common is the generation of electric currents in a human or animal body by application of an electric field by means of a pair of conductive electrodes between which a potential difference is maintained. These electric currents are used either to exert their specific effects, i.e., to stimulate excitable tissue, or to generate heat by flowing in the body since it acts as a resistor. Examples of the first type of application include the following: cardiac defibrillators, peripheral nerve and muscle stimulators, brain stimulators, etc. Currents are used for heating, for example, in devices for tumor ablation, ablation of malfunctioning cardiac or brain tissue, cauterization, relaxation of muscle rheumatic pain and other pain, etc.
[0009] Another use of electric fields for medical purposes involves the utilization of high frequency oscillating fields transmitted from a source that emits an electric wave, such as an RF wave or a microwave source that is directed at the part of the body that is of interest (i.e., target). In these instances, there is no electric energy conduction between the source and the body; but rather, the energy is transmitted to the body by radiation or induction. More specifically, the electric energy generated by the source reaches the vicinity of the body via a conductor and is transmitted from it through air or some other electric insulating material to the human body.
[0010] In a conventional electrical method, electrical current is delivered to a region of the target tissue using electrodes that are placed in contact with the body of the patient. The applied electrical current destroys substantially all cells in the vicinity of the target tissue. Thus, this type of electrical method does not discriminate between different types of cells within the target tissue and results in the destruction of both tumor cells and normal cells.
[0011] Electric fields that can be used in medical applications can thus be separated generally into two different modes. In the first mode, the electric fields are applied to the body or tissues by means of conducting electrodes. These electric fields can be separated into two types, namely (1) steady fields or fields that change at relatively slow rates, and alternating fields of low frequencies that induce corresponding electric currents in the body or tissues, and (2) high frequency alternating fields (above 1 MHz) applied to the body by means of the conducting electrodes. In the second mode, the electric fields are high frequency alternating fields applied to the body by means of insulated electrodes.
[0012] The first type of electric field is used, for example, to stimulate nerves and muscles, pace the heart, etc. In fact, such fields are used in nature to propagate signals in nerve and muscle fibers, central nervous system (CNS), heart, etc. The recording of such natural fields is the basis for the ECG, EEG, EMG, ERG, etc. The field strength in these applications, assuming a medium of homogenous electric properties, is simply the voltage applied to the stimulating/recording electrodes divided by the distance between them. These currents can be calculated by Ohm's law and can have dangerous stimulatory effects on the heart and CNS and can result in potentially harmful ion concentration changes. Also, if the currents are strong enough, they can cause excessive heating in the tissues. This heating can be calculated by the power dissipated in the tissue (the product of the voltage and the current).
[0013] When such electric fields and currents are alternating, their stimulatory power, on nerve, muscle, etc., is an inverse function of the frequency. At frequencies above 1-10 KHz, the stimulation power of the fields approaches zero. This limitation is due to the fact that excitation induced by electric stimulation is normally mediated by membrane potential changes, the rate of which is limited by the RC properties (time constants on the order of 1 ms) of the membrane.
[0014] Regardless of the frequency, when such current inducing fields are applied, they are associated with harmful side effects caused by currents. For example, one negative effect is the changes in ionic concentration in the various โcompartmentsโ within the system, and the harmful products of the electrolysis taking place at the electrodes, or the medium in which the tissues are imbedded. The changes in ion concentrations occur whenever the system includes two or more compartments between which the organism maintains ion concentration differences. For example, for most tissues, [Ca ++ ] in the extracellular fluid is about 2ร10 โ3 M, while in the cytoplasm of typical cells its concentration can be as low as 10 โ7 M. A current induced in such a system by a pair of electrodes, flows in part from the extracellular fluid into the cells and out again into the extracellular medium. About 2% of the current flowing into the cells is carried by the Ca ++ ions. In contrast, because the concentration of intracellular Ca ++ is much smaller, only a negligible fraction of the currents that exits the cells is carried by these ions. Thus, Ca ++ ions accumulate in the cells such that their concentrations in the cells increases, while the concentration in the extracellular compartment may decrease. These effects are observed for both DC and alternating currents (AC). The rate of accumulation of the ions depends on the current intensity ion mobilities, membrane ion conductance, etc. An increase in [Ca ++ ] is harmful to most cells and if sufficiently high will lead to the destruction of the cells. Similar considerations apply to other ions. In view of the above observations, long term current application to living organisms or tissues can result in significant damage. Another major problem that is associated with such electric fields, is due to the electrolysis process that takes place at the electrode surfaces. Here charges are transferred between the metal (electrons) and the electrolytic solution (ions) such that charged active radicals are formed. These can cause significant damage to organic molecules, especially macromolecules and thus damage the living cells and tissues.
[0015] In contrast, when high frequency electric fields, above 1 MHz and usually in practice in the range of GHz, are induced in tissues by means of insulated electrodes, the situation is quite different. These type of fields generate only capacitive or displacement currents, rather than the conventional charge conducting currents. Under the effect of this type of field, living tissues behave mostly according to their dielectric properties rather than their electric conductive properties. Therefore, the dominant field effect is that due to dielectric losses and heating. Thus, it is widely accepted that in practice, the meaningful effects of such fields on living organisms, are only those due to their heating effects, i.e., due to dielectric losses.
[0016] In U.S. Pat. No. 6,043,066 ('066) to Mangano, a method and device are presented which enable discrete objects having a conducting inner core, surrounded by a dielectric membrane to be selectively inactivated by electric fields via irreversible breakdown of their dielectric membrane. One potential application for this is in the selection and purging of certain biological cells in a suspension. According to the '066 patent, an electric field is applied for targeting selected cells to cause breakdown of the dielectric membranes of these tumor cells, while purportedly not adversely affecting other desired subpopulations of cells. The cells are selected on the basis of intrinsic or induced differences in a characteristic electroporation threshold. The differences in this threshold can depend upon a number of parameters, including the difference in cell size.
[0017] The method of the '066 patent is therefore based on the assumption that the electroporation threshold of tumor cells is sufficiently distinguishable from that of normal cells because of differences in cell size and differences in the dielectric properties of the cell membranes. Based upon this assumption, the larger size of many types of tumor cells makes these cells more susceptible to electroporation and thus, it may be possible to selectively damage only the larger tumor cell membranes by applying an appropriate electric field. One disadvantage of this method is that the ability to discriminate is highly dependent upon cell type, for example, the size difference between normal cells and tumor cells is significant only in certain types of cells. Another drawback of this method is that the voltages which are applied can damage some of the normal cells and may not damage all of the tumor cells because the differences in size and membrane dielectric properties are largely statistical and the actual cell geometries and dielectric properties can vary significantly.
[0018] What is needed in the art and has heretofore not been available is an apparatus for destroying dividing cells, wherein the apparatus better discriminates between dividing cells, including single-celled organisms, and non-dividing cells and is capable of selectively destroying the dividing cells or organisms with substantially no effect on the non-dividing cells or organisms.
SUMMARY
[0019] While they are dividing, cells are vulnerable to damage by AC electric fields that have specific frequency and field strength characteristics. The selective destruction of rapidly dividing cells can therefore be accomplished by imposing an AC electric field in a target region for extended periods of time. Some of the cells that divide while the field is applied will be damaged, but the cells that do not divide will not be harmed. This selectively damages rapidly dividing cells like tumor cells, but does not harm normal cells that are not dividing. Since the vulnerability of the dividing cells is strongly related to the alignment between the long axis of the dividing cells and the lines of force of the electric field, improved results are obtained by sequentially imposing the field in different directions.
[0020] A major use of the present apparatus is in the treatment of tumors by selective destruction of tumor cells with substantially no effect on normal tissue cells, and thus, the exemplary apparatus is described below in the context of selective destruction of tumor cells. It should be appreciated however, that for purpose of the following description, the term โcellโ may also refer to a single-celled organism (eubacteria, bacteria, yeast, protozoa), multi-celled organisms (fungi, algae, mold), and plants as or parts thereof that are not normally classified as โcellsโ. The exemplary apparatus enables selective destruction of cells undergoing division in a way that is more effective and more accurate (e.g., more adaptable to be aimed at specific targets) than existing methods. Further, the present apparatus causes minimal damage, if any, to normal tissue and, thus, reduces or eliminates many side-effects associated with existing selective destruction methods, such as radiation therapy and chemotherapy. The selective destruction of dividing cells using the present apparatus does not depend on the sensitivity of the cells to chemical agents or radiation. Instead, the selective destruction of dividing cells is based on distinguishable geometrical characteristics of cells undergoing division, in comparison to non-dividing cells, regardless of the cell geometry of the type of cells being treated.
[0021] According to one exemplary embodiment, cell geometry-dependent selective destruction of living tissue is performed by inducing a non-homogenous electric field in the cells using an electronic apparatus.
[0022] It has been observed by the present inventor that, while different cells in their non-dividing state may have different shapes, e.g., spherical, ellipsoidal, cylindrical, โpancake-likeโ, etc., the division process of practically all cells is characterized by development of a โcleavage furrowโ in late anaphase and telophase. This cleavage furrow is a slow constriction of the cell membrane (between the two sets of daughter chromosomes) which appears microscopically as a growing cleft (e.g., a groove or notch) that gradually separates the cell into two new cells. During the division process, there is a transient period (telophase) during which the cell structure is basically that of two sub-cells interconnected by a narrow โbridgeโ formed of the cell material. The division process is completed when the โbridgeโ between the two sub-cells is broken. The selective destruction of tumor cells using the present electronic apparatus utilizes this unique geometrical feature of dividing cells.
[0023] When a cell or a group of cells are under natural conditions or environment, i.e., part of a living tissue, they are disposed surrounded by a conductive environment consisting mostly of an electrolytic inter-cellular fluid and other cells that are composed mostly of an electrolytic intra-cellular liquid. When an electric field is induced in the living tissue, by applying an electric potential across the tissue, an electric field is formed in the tissue and the specific distribution and configuration of the electric field lines defines the direction of charge displacement, or paths of electric currents in the tissue, if currents are in fact induced in the tissue. The distribution and configuration of the electric field is dependent on various parameters of the tissue, including the geometry and the electric properties of the different tissue components, and the relative conductivities, capacities and dielectric constants (that may be frequency dependent) of the tissue components.
[0024] The electric current flow pattern for cells undergoing division is very different and unique as compared to non-dividing cells. Such cells including first and second sub-cells, namely an โoriginalโ cell and a newly formed cell, that are connected by a cytoplasm โbridgeโ or โneckโ. The currents penetrate the first sub-cell through part of the membrane (โthe current source poleโ); however, they do not exit the first sub-cell through a portion of its membrane closer to the opposite pole (โthe current sink poleโ). Instead, the lines of current flow converge at the neck or cytoplasm bridge, whereby the density of the current flow lines is greatly increased. A corresponding, โmirror imageโ, process that takes place in the second sub-cell, whereby the current flow lines diverge to a lower density configuration as they depart from the bridge, and finally exit the second sub-cell from a part of its membrane closes to the current sink.
[0025] When a polarizable object is placed in a non-uniform converging or diverging field, electric forces act on it and pull it towards the higher density electric field lines. In the case of dividing cell, electric forces are exerted in the direction of the cytoplasm bridge between the two cells. Since all intercellular organelles and macromolecules are polarizable, they are all force towards the bridge between the two cells. The field polarity is irrelevant to the direction of the force and, therefore, an alternating electric having specific properties can be used to produce substantially the same effect. It will also be appreciated that the concentrated and inhomogeneous electric field present in or near the bridge or neck portion in itself exerts strong forces on charges and natural dipoles and can lead to the disruption of structures associated with these members.
[0026] The movement of the cellular organelles towards the bridge disrupts the cell structure and results in increased pressure in the vicinity of the connecting bridge membrane. This pressure of the organelles on the bridge membrane is expected to break the bridge membrane and, thus, it is expected that the dividing cell will โexplodeโ in response to this pressure. The ability to break the membrane and disrupt other cell structures can be enhanced by applying a pulsating alternating electric field that has a frequency from about 50 KHz to about 500 KHz. When this type of electric field is applied to the tissue, the forces exerted on the intercellular organelles have a โhammeringโ effect, whereby force pulses (or beats) are applied to the organelles numerous times per second, enhancing the movement of organelles of different sizes and masses towards the bridge (or neck) portion from both of the sub-cells, thereby increasing the probability of breaking the cell membrane at the bridge portion. The forces exerted on the intracellular organelles also affect the organelles themselves and may collapse or break the organelles.
[0027] Advantageously, when non-dividing cells are subjected to these electric fields, there is no effect on the cells; however, the situation is much different when dividing cells are subjected to the present electric fields. Thus, the present electronic apparatus and the generated electric fields target dividing cells, such as tumors or the like, and do not target non-dividing cells that is found around in healthy tissue surrounding the target area. Furthermore, since the present apparatus utilizes insulated electrodes, the above mentioned negative effects, obtained when conductive electrodes are used, i.e., ion concentration changes in the cells and the formation of harmful agents by electrolysis, do not occur with the present apparatus. This is because, in general, no actual transfer of charges takes place between the electrodes and the medium, and there is no charge flow in the medium where the currents are capacitive.
[0028] It should be appreciated that the present electronic apparatus can also be used in applications other than treatment of tumors in the living body. In fact, the selective destruction utilizing the present apparatus can be used in conjunction with any organism that proliferates by division, for example, tissue cultures, microorganisms, such as bacteria, mycoplasma, protozoa, fungi, algae, plant cells, etc. Such organisms divide by the formation of a groove or cleft as described above. As the groove or cleft deepens, a narrow bridge is formed between the two parts of the organism, similar to the bridge formed between the sub-cells of dividing animal cells. Since such organisms are covered by a membrane having a relatively low electric conductivity, similar to an animal cell membrane described above, the electric field lines in a dividing organism converge at the bridge connecting the two parts of the dividing organism. The converging field lines result in electric forces that displace polarizable elements and charges within the dividing organism.
[0029] One aspect of the invention relates to a method of selectively destroying or inhibiting the growth of bacteria located within a target region of a patient. This method includes the steps of administering an antibiotic against the bacteria, so that a therapeutically effective dose arrives in the target region and capacitively coupling an AC electric field into the target region of the patient while the therapeutically effective dose is present at the target region, wherein the electric field has frequency characteristics that correspond to a vulnerability of the bacteria, and wherein the electric field is strong enough to damage, during cell division, a significant portion of the bacteria whose long axis is generally aligned with the lines of force of the electric field. The strength of the electric field in at least a portion of the target region is between 2 V/cm and 100 V/cm, and the electric field leaves non-dividing cells located within the target region substantially unharmed. The coupling step is repeated until a therapeutically significant portion of the bacteria die.
[0030] Another aspect of the invention relates to a method of selectively destroying or inhibiting the growth of bacteria located within a target region. This method includes the steps of capacitively coupling an AC electric field into the target region. The frequency of the electric field is between 5 MHz and 20 MHz, and the strength of the electric field in at least a portion of the target region is between 2 V/cm and 100 V/cm. The electric field has frequency characteristics that correspond to a vulnerability of the bacteria and the electric field is strong enough to damage, during cell division, a significant portion of the bacteria whose long axis is generally aligned with the lines of force of the electric field, and leave non-dividing cells located within the target region substantially unharmed. The coupling step is repeated until a therapeutically significant portion of the bacteria die.
[0031] Another aspect of the invention relates to an apparatus for selectively destroying or inhibiting the growth of bacteria located within a target region of a patient. This apparatus includes a first pair of insulated electrodes, and each of the electrodes has a surface configured to facilitate capacitive coupling of an electric field into the patient's body. The apparatus also includes an AC voltage source operatively connected to the electrodes. The AC voltage source and the electrodes are configured so that, when the electrodes are placed against the patient's body and the AC voltage source is activated, an AC electric field is capacitively coupled into the target region of the patient via the electrodes. The frequency of the electric field is between 5 MHz and 20 MHz, and the strength of the electric field in at least a portion of the target region is between 2 V/cm and 100 V/cm. The imposed electric field has frequency characteristics that correspond to a vulnerability of the bacteria, and is strong enough to damage, during cell division, a significant portion of the bacteria whose long axis is generally aligned with the lines of force of the electric field. The electric field also leaves non-dividing cells located within the target region substantially unharmed.
[0032] The above, and other objects, features and advantages of the present apparatus will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIGS. 1A-1E are simplified, schematic, cross-sectional, illustrations of various stages of a cell division process;
[0034] FIGS. 2A and 2B are schematic illustrations of a non-dividing cell being subjected to an electric field;
[0035] FIGS. 3A , 3 B and 3 C are schematic illustrations of a dividing cell being subjected to an electric field according to one exemplary embodiment, resulting in destruction of the cell ( FIG. 3C ) in accordance with one exemplary embodiment;
[0036] FIG. 4 is a schematic illustration of a dividing cell at one stage being subject to an electric field;
[0037] FIG. 5 is a schematic block diagram of an apparatus for applying an electric according to one exemplary embodiment for selectively destroying cells;
[0038] FIG. 6 is a simplified schematic diagram of an equivalent electric circuit of insulated electrodes of the apparatus of FIG. 5 ;
[0039] FIG. 7 is a cross-sectional illustration of a skin patch incorporating the apparatus of FIG. 5 and for placement on a skin surface for treating a tumor or the like;
[0040] FIG. 8 is a cross-sectional illustration of the insulated electrodes implanted within the body for treating a tumor or the like;
[0041] FIG. 9 is a cross-sectional illustration of the insulated electrodes implanted within the body for treating a tumor or the like;
[0042] FIGS. 10A-10D are cross-sectional illustrations of various constructions of the insulated electrodes of the apparatus of FIG. 5 ;
[0043] FIG. 11 is a front elevational view in partial cross-section of two insulated electrodes being arranged about a human torso for treatment of a tumor container within the body, e.g., a tumor associated with lung cancer;
[0044] FIGS. 12A-12C are cross-sectional illustrations of various insulated electrodes with and without protective members formed as a part of the construction thereof;
[0045] FIG. 13 is a schematic diagram of insulated electrodes that are arranged for focusing the electric field at a desired target while leaving other areas in low field density (i.e., protected areas);
[0046] FIG. 14 is a cross-sectional view of insulated electrodes incorporated into a hat according to a first embodiment for placement on a head for treating an intra-cranial tumor or the like;
[0047] FIG. 15 is a partial section of a hat according to an exemplary embodiment having a recessed section for receiving one or more insulated electrodes;
[0048] FIG. 16 is a cross-sectional view of the hat of FIG. 15 placed on a head and illustrating a biasing mechanism for applying a force to the insulated electrode to ensure the insulated electrode remains in contact against the head;
[0049] FIG. 17 is a cross-sectional top view of an article of clothing having the insulated electrodes incorporated therein for treating a tumor or the like;
[0050] FIG. 18 is a cross-sectional view of a section of the article of clothing of FIG. 17 illustrating a biasing mechanism for biasing the insulated electrode in direction to ensure the insulated electrode is placed proximate to a skin surface where treatment is desired;
[0051] FIG. 19 is a cross-sectional view of a probe according to one embodiment for being disposed internally within the body for treating a tumor or the like;
[0052] FIG. 20 is an elevational view of an unwrapped collar according to one exemplary embodiment for placement around a neck for treating a tumor or the like in this area when the collar is wrapped around the neck;
[0053] FIG. 21 is a cross-sectional view of two insulated electrodes with conductive gel members being arranged about a body, with the electric field lines being shown;
[0054] FIG. 22 is a cross-sectional view of the arrangement of FIG. 21 illustrating a point of insulation breakdown in one insulated electrode;
[0055] FIG. 23 is a cross-sectional view of an arrangement of at least two insulated electrodes with conductive gel members being arranged about a body for treatment of a tumor or the like, wherein each conductive gel member has a feature for minimizing the effects of an insulation breakdown in the insulated electrode;
[0056] FIG. 24 is a cross-sectional view of another arrangement of at least two insulated electrodes with conductive gel members being arranged about a body for treatment of a tumor or the like, wherein a conductive member is disposed within the body near the tumor to create a region of increased field density;
[0057] FIG. 25 is a cross-sectional view of an arrangement of two insulated electrodes of varying sizes disposed relative to a body; and
[0058] FIG. 26 is a cross-sectional view of an arrangement of at least two insulated electrodes with conductive gel members being arranged about a body for treatment of a tumor or the like, wherein each conductive gel member has a feature for minimizing the effects of an insulation breakdown in the insulated electrode.
[0059] FIGS. 27A-C show a configuration of electrodes that facilitates the application of an electric field in different directions.
[0060] FIG. 28 shows a three-dimensional arrangement of electrodes about a body part that facilitates the application of an electric field in different directions.
[0061] FIGS. 29A and 29B are graphs of the efficiency of the cell destruction process as a function of field strength for melanoma and glioma cells, respectively.
[0062] FIGS. 30A and 30B are graphs that show how the cell destruction efficiency is a function of the frequency of the applied field for melanoma and glioma cells, respectively.
[0063] FIG. 31A is a graphical representation of the sequential application of a plurality of frequencies in a plurality of directions.
[0064] FIG. 31B is a graphical representation of the sequential application of a sweeping frequency in a plurality of directions.
[0065] FIG. 32A depicts the construction of the electrodes used in an experiment on bacteria.
[0066] FIG. 32B depicts a test chamber used in an experiment on bacteria.
[0067] FIG. 32C depicts a setup that was used to induce fields in the test chamber.
[0068] FIGS. 33A and 33B show the effect of treating bacteria with electric fields at different frequencies.
[0069] FIG. 34 shows the effect of treating bacteria with electric fields at different field strengths.
[0070] FIGS. 35A and 35B show the effect of treating bacteria with electric fields at different switching rates.
[0071] FIG. 36 shows the results of this repeated exposure test of P. aeruginosa to electric fields.
[0072] FIG. 37 shows the electric field distribution in and around a bacteria.
[0073] FIGS. 38A and 38B show the magnitude of the forces acting on dipoles inside dividing bacteria.
[0074] FIG. 39 shows the results of an in vivo experiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0075] Reference is made to FIGS. 1A-1E which schematically illustrate various stages of a cell division process. FIG. 1A illustrates a cell 10 at its normal geometry, which can be generally spherical (as illustrated in the drawings), ellipsoidal, cylindrical, โpancake-likeโ or any other cell geometry, as is known in the art. FIGS. 1B-1D illustrate cell 10 during different stages of its division process, which results in the formation of two new cells 18 and 20 , shown in FIG. 1E .
[0076] As shown in FIGS. 1B-1D , the division process of cell 10 is characterized by a slowly growing cleft 12 which gradually separates cell 10 into two units, namely sub-cells 14 and 16 , which eventually evolve into new cells 18 and 20 ( FIG. 1E ). A shown specifically in FIG. 1D , the division process is characterized by a transient period during which the structure of cell 10 is basically that of the two sub-cells 14 and 16 interconnected by a narrow โbridgeโ 22 containing cell material (cytoplasm surrounded by cell membrane).
[0077] Reference is now made to FIGS. 2A and 2B , which schematically illustrate non-dividing cell 10 being subjected to an electric field produced by applying an alternating electric potential, at a relatively low frequency and at a relatively high frequency, respectively. Cell 10 includes intracellular organelles, e.g., a nucleus 30 . Alternating electric potential is applied across electrodes 28 and 32 that can be attached externally to a patient at a predetermined region, e.g., in the vicinity of the tumor being treated. When cell 10 is under natural conditions, i.e., part of a living tissue, it is disposed in a conductive environment (hereinafter referred to as a โvolume conductorโ) consisting mostly of electrolytic inter-cellular liquid. When an electric potential is applied across electrodes 28 and 32 , some of the field lines of the resultant electric field (or the current induced in the tissue in response to the electric field) penetrate the cell 10 , while the rest of the field lines (or induced current) flow in the surrounding medium. The specific distribution of the electric field lines, which is substantially consistent with the direction of current flow in this instance, depends on the geometry and the electric properties of the system components, e.g., the relative conductivities and dielectric constants of the system components, that can be frequency dependent. For low frequencies, e.g., frequencies lower than 10 KHz, the conductance properties of the components completely dominate the current flow and the field distribution, and the field distribution is generally as depicted in FIG. 2A . At higher frequencies, e.g., at frequencies of between 10 KHz and 1 MHz, the dielectric properties of the components becomes more significant and eventually dominate the field distribution, resulting in field distribution lines as depicted generally in FIG. 2B .
[0078] For constant (i.e., DC) electric fields or relatively low frequency alternating electric fields, for example, frequencies under 10 KHz, the dielectric properties of the various components are not significant in determining and computing the field distribution. Therefore, as a first approximation, with regard to the electric field distribution, the system can be reasonably represented by the relative impedances of its various components. Using this approximation, the intercellular (i.e., extracellular) fluid and the intracellular fluid each has a relatively low impedance, while the cell membrane 11 has a relatively high impedance. Thus, under low frequency conditions, only a fraction of the electric field lines (or currents induced by the electric field) penetrate membrane 11 of the cell 10 . At relatively high frequencies (e.g., 10 KHz-1 MHz), in contrast, the impedance of membrane 11 relative to the intercellular and intracellular fluids decreases, and thus, the fraction of currents penetrating the cells increases significantly. It should be noted that at very high frequencies, i.e., above 1 MHz, the membrane capacitance can short the membrane resistance and, therefore, the total membrane resistance can become negligible.
[0079] In any of the embodiments described above, the electric field lines (or induced currents) penetrate cell 10 from a portion of the membrane 11 closest to one of the electrodes generating the current, e.g., closest to positive electrode 28 (also referred to herein as โsourceโ). The current flow pattern across cell 10 is generally uniform because, under the above approximation, the field induced inside the cell is substantially homogeneous. The currents exit cell 10 through a portion of membrane 11 closest to the opposite electrode, e.g., negative electrode 32 (also referred to herein as โsinkโ).
[0080] The distinction between field lines and current flow can depend on a number of factors, for example, on the frequency of the applied electric potential and on whether electrodes 28 and 32 are electrically insulated. For insulated electrodes applying a DC or low frequency alternating voltage, there is practically no current flow along the lines of the electric field. At higher frequencies, the displacement currents are induced in the tissue due to charging and discharging of the electrode insulation and the cell membranes (which act as capacitors to a certain extent), and such currents follow the lines of the electric field. Fields generated by non-insulated electrodes, in contrast, always generate some form of current flow, specifically, DC or low frequency alternating fields generate conductive current flow along the field lines, and high frequency alternating fields generate both conduction and displacement currents along the field lines. It should be appreciated, however, that movement of polarizable intracellular organelles according to the present invention (as described below) is not dependent on actual flow of current and, therefore, both insulated and non-insulated electrodes can be used efficiently. Advantages of insulated electrodes include lower power consumption, less heating of the treated regions, and improved patient safety.
[0081] According to one exemplary embodiment of the present invention, the electric fields that are used are alternating fields having frequencies that are in the range from about 50 KHz to about 500 KHz, and preferably from about 100 KHz to about 300 KHz. For ease of discussion, these type of electric fields are also referred to below as โTC fieldsโ, which is an abbreviation of โTumor Curing electric fieldsโ, since these electric fields fall into an intermediate category (between high and low frequency ranges) that have bio-effective field properties while having no meaningful stimulatory and thermal effects. These frequencies are sufficiently low so that the system behavior is determined by the system's Ohmic (conductive) properties but sufficiently high enough not to have any stimulation effect on excitable tissues. Such a system consists of two types of elements, namely, the intercellular, or extracellular fluid, or medium and the individual cells. The intercellular fluid is mostly an electrolyte with a specific resistance of about 40-100 Ohm*cm. As mentioned above, the cells are characterized by three elements, namely (1) a thin, highly electric resistive membrane that coats the cell; (2) internal cytoplasm that is mostly an electrolyte that contains numerous macromolecules and micro-organelles, including the nucleus; and (3) membranes, similar in their electric properties to the cell membrane, cover the micro-organelles.
[0082] When this type of system is subjected to the present TC fields (e.g., alternating electric fields in the frequency range of 100 KHz-300 KHz) most of the lines of the electric field and currents tend away from the cells because of the high resistive cell membrane and therefore the lines remain in the extracellular conductive medium. In the above recited frequency range, the actual fraction of electric field or currents that penetrates the cells is a strong function of the frequency.
[0083] FIG. 2 schematically depicts the resulting field distribution in the system. As illustrated, the lines of force, which also depict the lines of potential current flow across the cell volume mostly in parallel with the undistorted lines of force (the main direction of the electric field). In other words, the field inside the cells is mostly homogeneous. In practice, the fraction of the field or current that penetrates the cells is determined by the cell membrane impedance value relative to that of the extracellular fluid. Since the equivalent electric circuit of the cell membrane is that of a resistor and capacitor in parallel, the impedance is a function of the frequency. The higher the frequency, the lower the impedance, the larger the fraction of penetrating current and the smaller the field distortion (Rotshenker S. & Y. Palti, Changes in fraction of current penetrating an axon as a function of duration of stimulating pulse , J. Theor. Biol. 41; 401-407 (1973).
[0084] As previously mentioned, when cells are subjected to relatively weak electric fields and currents that alternate at high frequencies, such as the present TC fields having a frequency in the range of 50 KHz-500 KHz, they have no effect on the non-dividing cells. While the present TC fields have no detectable effect on such systems, the situation becomes different in the presence of dividing cells.
[0085] Reference is now made to FIGS. 3A-3C which schematically illustrate the electric current flow pattern in cell 10 during its division process, under the influence of alternating fields (TC fields) in the frequency range from about 100 KHz to about 300 KHz in accordance with one exemplary embodiment. The field lines or induced currents penetrate cell 10 through a part of the membrane of sub-cell 16 closer to electrode 28 . However, they do not exit through the cytoplasm bridge 22 that connects sub-cell 16 with the newly formed yet still attached sub-cell 14 , or through a part of the membrane in the vicinity of the bridge 22 . Instead, the electric field or current flow linesโthat are relatively widely separated in sub-cell 16 โconverge as they approach bridge 22 (also referred to as โneckโ 22 ) and, thus, the current/field line density within neck 22 is increased dramatically. A โmirror imageโ process takes place in sub-cell 14 , whereby the converging field lines in bridge 22 diverge as they approach the exit region of sub-cell 14 .
[0086] It should be appreciated by persons skilled in the art that homogeneous electric fields do not exert a force on electrically neutral objects, i.e., objects having substantially zero net charge, although such objects can become polarized. However, under a non-uniform, converging electric field, as shown in FIGS. 3A-3C , electric forces are exerted on polarized objects, moving them in the direction of the higher density electric field lines. It will be appreciated that the concentrated electric field that is present in the neck or bridge area in itself exerts strong forces on charges and natural dipoles and can disrupt structures that are associated therewith. One will understand that similar net forces act on charges in an alternating field, again in the direction of the field of higher intensity.
[0087] In the configuration of FIGS. 3A and 3B , the direction of movement of polarized and charged objects is towards the higher density electric field lines, i.e., towards the cytoplasm bridge 22 between sub-cells 14 and 16 . It is known in the art that all intracellular organelles, for example, nuclei 24 and 26 of sub-cells 14 and 16 , respectively, are polarizable and, thus, such intracellular organelles are electrically forced in the direction of the bridge 22 . Since the movement is always from lower density currents to the higher density currents, regardless of the field polarity, the forces applied by the alternating electric field to organelles, such as nuclei 24 and 26 , are always in the direction of bridge 22 . A comprehensive description of such forces and the resulting movement of macromolecules of intracellular organelles, a phenomenon referred to as โdielectrophoresisโ is described extensively in literature, e.g., in C. L. Asbury & G. van den Engh, Biophys. J. 74, 1024-1030, 1998, the disclosure of which is hereby incorporated by reference in its entirety.
[0088] The movement of the organelles 24 and 26 towards the bridge 22 disrupts the structure of the dividing cell, change the concentration of the various cell constituents and, eventually, the pressure of the converging organelles on bridge membrane 22 results in the breakage of cell membrane 11 at the vicinity of the bridge 22 , as shown schematically in FIG. 3C . The ability to break membrane 11 at bridge 22 and to otherwise disrupt the cell structure and organization can be enhanced by applying a pulsating AC electric field, rather than a steady AC field. When a pulsating field is applied, the forces acting on organelles 24 and 26 have a โhammeringโ effect, whereby pulsed forces beat on the intracellular organelles towards the neck 22 from both sub-cells 14 and 16 , thereby increasing the probability of breaking cell membrane 11 in the vicinity of neck 22 .
[0089] A very important element, which is very susceptible to the special fields that develop within the dividing cells is the microtubule spindle that plays a major role in the division process. In FIG. 4 , a dividing cell 10 is illustrated, at an earlier stage as compared to FIGS. 3A and 3B , under the influence of external TC fields (e.g., alternating fields in the frequency range of about 100 KHz to about 300 KHz), generally indicated as lines 100 , with a corresponding spindle mechanism generally indicated at 120 . The lines 120 are microtubules that are known to have a very strong dipole moment. This strong polarization makes the tubules, as well as other polar macromolecules and especially those that have a specific orientation within the cells or its surrounding, susceptible to electric fields. Their positive charges are located at the two centrioles while two sets of negative poles are at the center of the dividing cell and the other pair is at the points of attachment of the microtubules to the cell membrane, generally indicated at 130 . This structure forms sets of double dipoles and therefore they are susceptible to fields of different directions. It will be understood that the effect of the TC fields on the dipoles does not depend on the formation of the bridge (neck) and thus, the dipoles are influenced by the TC fields prior to the formation of the bridge (neck).
[0090] Since the present apparatus (as will be described in greater detail below) utilizes insulated electrodes, the above-mentioned negative effects obtained when conductive electrodes are used, i.e., ion concentration changes in the cells and the formation of harmful agents by electrolysis, do not occur when the present apparatus is used. This is because, in general, no actual transfer of charges takes place between the electrodes and the medium and there is no charge flow in the medium where the currents are capacitive, i.e., are expressed only as rotation of charges, etc.
[0091] Turning now to FIG. 5 , the TC fields described above that have been found to advantageously destroy tumor cells are generated by an electronic apparatus 200 . FIG. 5 is a simple schematic diagram of the electronic apparatus 200 illustrating the major components thereof. The electronic apparatus 200 generates the desired electric signals (TC signals) in the shape of waveforms or trains of pulses. The apparatus 200 includes a generator 210 and a pair of conductive leads 220 that are attached at one end thereof to the generator 210 . The opposite ends of the leads 220 are connected to insulated conductors 230 that are activated by the electric signals (e.g., waveforms). The insulated conductors 230 are also referred to hereinafter as isolects 230 . Optionally and according to another exemplary embodiment, the apparatus 200 includes a temperature sensor 240 and a control box 250 which are both added to control the amplitude of the electric field generated so as not to generate excessive heating in the area that is treated.
[0092] The generator 210 generates an alternating voltage waveform at frequencies in the range from about 50 KHz to about 500 KHz (preferably from about 100 KHz to about 300 KHz) (i.e., the TC fields). The required voltages are such that the electric field intensity in the tissue to be treated is in the range of about 0.1 V/cm to about 10 V/cm. To achieve this field, the actual potential difference between the two conductors in the isolects 230 is determined by the relative impedances of the system components, as described below.
[0093] When the control box 250 is included, it controls the output of the generator 210 so that it will remain constant at the value preset by the user or the control box 250 sets the output at the maximal value that does not cause excessive heating, or the control box 250 issues a warning or the like when the temperature (sensed by temperature sensor 240 ) exceeds a preset limit.
[0094] The leads 220 are standard isolated conductors with a flexible metal shield, preferably grounded so that it prevents the spread of the electric field generated by the leads 220 . The isolects 230 have specific shapes and positioning so as to generate an electric field of the desired configuration, direction, and intensity at the target volume and only there so as to focus the treatment.
[0095] The specifications of the apparatus 200 as a whole and its individual components are largely influenced by the fact that at the frequency of the present TC fields (50 KHz-500 KHz), living systems behave according to their โOhmicโ, rather than their dielectric properties. The only elements in the apparatus 200 that behave differently are the insulators of the isolects 230 (see FIGS. 7-9 ). The isolects 200 consist of a conductor in contact with a dielectric that is in contact with the conductive tissue thus forming a capacitor.
[0096] The details of the construction of the isolects 230 is based on their electric behavior that can be understood from their simplified electric circuit when in contact with tissue as generally illustrated in FIG. 6 . In the illustrated arrangement, the potential drop or the electric field distribution between the different components is determined by their relative electric impedance, i.e., the fraction of the field on each component is given by the value of its impedance divided by the total circuit impedance. For example, the potential drop on element ฮV A =A/(A+B+C+D+E). Thus, for DC or low frequency AC, practically all the potential drop is on the capacitor (that acts as an insulator). For relatively very high frequencies, the capacitor practically is a short and therefore, practically all the field is distributed in the tissues. At the frequencies of the present TC fields (e.g., 50 KHz to 500 KHz), which are intermediate frequencies, the impedance of the capacitance of the capacitors is dominant and determines the field distribution. Therefore, in order to increase the effective voltage drop across the tissues (field intensity), the impedance of the capacitors is to be decreased (i.e., increase their capacitance). This can be achieved by increasing the effective area of the โplatesโ of the capacitor, decrease the thickness of the dielectric or use a dielectric with high dielectric constant.
[0097] In order to optimize the field distribution, the isolects 230 are configured differently depending upon the application in which the isolects 230 are to be used. There are two principle modes for applying the present electric fields (TC fields). First, the TC fields can be applied by external isolects and second, the TC fields can be applied by internal isolects.
[0098] Electric fields (TC fields) that are applied by external isolects can be of a local type or widely distributed type. The first type includes, for example, the treatment of skin tumors and treatment of lesions close to the skin surface. FIG. 7 illustrates an exemplary embodiment where the isolects 230 are incorporated in a skin patch 300 . The skin patch 300 can be a self-adhesive flexible patch with one or more pairs of isolects 230 . The patch 300 includes internal insulation 310 (formed of a dielectric material) and the external insulation 260 and is applied to skin surface 301 that contains a tumor 303 either on the skin surface 301 or slightly below the skin surface 301 . Tissue is generally indicated at 305 . To prevent the potential drop across the internal insulation 310 to dominate the system, the internal insulation 310 must have a relatively high capacity. This can be achieved by a large surface area; however, this may not be desired as it will result in the spread of the field over a large area (e.g., an area larger than required to treat the tumor). Alternatively, the internal insulation 310 can be made very thin and/or the internal insulation 310 can be of a high dielectric constant. As the skin resistance between the electrodes (labeled as A and E in FIG. 6 ) is normally significantly higher than that of the tissue (labeled as C in FIG. 6 ) underneath it (1-10 Kฮฉ vs. 0.1-1 Kฮฉ), most of the potential drop beyond the isolects occurs there. To accommodate for these impedances (Z), the characteristics of the internal insulation 310 (labeled as B and D in FIG. 6 ) should be such that they have impedance preferably under 100 Kฮฉ at the frequencies of the present TC fields (e.g., 50 KHz to 500 KHz). For example, if it is desired for the impedance to be about 10 K Ohms or less, such that over 1% of the applied voltage falls on the tissues, for isolects with a surface area of 10 mm 2 , at frequencies of 200 KHz, the capacity should be on the order of 10 โ10 F., which means that using standard insulations with a dielectric constant of 2-3, the thickness of the insulating layer 310 should be about 50-100 microns. An internal field 10 times stronger would be obtained with insulators with a dielectric constant of about 20-50.
[0099] Using an insulating material with a high dielectric constant increases the capacitance of the electrodes, which results in a reduction of the electrodes' impedance to the AC signal that is applied by the generator 1 (shown in FIG. 5 ). Because the electrodes A, E are wired in series with the target tissue C, as shown in FIG. 6 , this reduction in impedance reduces the voltage drop in the electrodes, so that a larger portion of the applied AC voltage appears across the tissue C. Since a larger portion of the voltage appears across the tissue, the voltage that is being applied by the generator 1 can be advantageously lowered for a given field strength in the tissue.
[0100] The desired field strength in the tissue being treated is preferably between about 0.1 V/cm and about 10 V/cm, and more preferably between about 2 V/cm and 3 V/cm or between about 1 V/cm and about 5 V/cm. If the dielectric constant used in the electrode is sufficiently high, the impedance of the electrodes A, E drops down to the same order of magnitude as the series combination of the skin and tissue B, C, D. One example of a suitable material with an extremely high dielectric constant is CaCu 3 Ti 4 O 12 , which has a dielectric constant of about 11,000 (measured at 100 kHz). When the dielectric constant is this high, useful fields can be obtained using a generator voltage that is on the order of a few tens of Volts.
[0101] Since the thin insulating layer can be very vulnerable, etc., the insulation can be replaced by very high dielectric constant insulating materials, such as titanium dioxide (e.g., rutile), the dielectric constant can reach values of about 200. There a number of different materials that are suitable for use in the intended application and have high dielectric constants. For example, some materials include: lithium niobate (LiNbO 3 ), which is a ferroelectric crystal and has a number of applications in optical, pyroelectric and piezoelectric devices; yttrium iron garnet (YIG) is a ferromagnetic crystal and magneto-optical devices, e.g., optical isolator can be realized from this material; barium titanate (BaTiO 3 ) is a ferromagnetic crystal with a large electro-optic effect; potassium tantalate (KTaO 3 ) which is a dielectric crystal (ferroelectric at low temperature) and has very low microwave loss and tunability of dielectric constant at low temperature; and lithium tantalate (LiTaO 3 ) which is a ferroelectric crystal with similar properties as lithium niobate and has utility in electro-optical, pyroelectric and piezoelectric devices. Insulator ceramics with high dielectric constants may also be used, such as a ceramic made of a combination of Lead Magnesium Niobate and Lead Titanate. It will be understood that the aforementioned exemplary materials can be used in combination with the present device where it is desired to use a material having a high dielectric constant.
[0102] One must also consider another factor that affects the effective capacity of the isolects 230 , namely the presence of air between the isolects 230 and the skin. Such presence, which is not easy to prevent, introduces a layer of an insulator with a dielectric constant of 1.0, a factor that significantly lowers the effective capacity of the isolects 230 and neutralizes the advantages of the titanium dioxide (rutile), etc. To overcome this problem, the isolects 230 can be shaped so as to conform with the body structure and/or (2) an intervening filler 270 (as illustrated in FIG. 10C ), such as a gel, that has high conductance and a high effective dielectric constant, can be added to the structure. The shaping can be pre-structured (see FIG. 10A ) or the system can be made sufficiently flexible so that shaping of the isolects 230 is readily achievable. The gel can be contained in place by having an elevated rim as depicted in FIGS. 10 C and 10 Cโฒ. The gel can be made of hydrogels, gelatins, agar, etc., and can have salts dissolved in it to increase its conductivity. FIGS. 10 A- 10 Cโฒ illustrate various exemplary configurations for the isolects 230 . The exact thickness of the gel is not important so long as it is of sufficient thickness that the gel layer does not dry out during the treatment. In one exemplary embodiment, the thickness of the gel is about 0.5 mm to about 2 mm. Preferably, the gel has high conductivity, is tacky, and is biocompatible for extended periods of time. One suitable gel is AG603 Hydrogel, which is available from AmGel Technologies, 1667 S. Mission Road, Fallbrook, Calif. 92028-4115, USA.
[0103] In order to achieve the desirable features of the isolects 230 , the dielectric coating of each should be very thin, for example from between 1-50 microns. Since the coating is so thin, the isolects 230 can easily be damaged mechanically or undergo dielectric breakdown. This problem can be overcome by adding a protective feature to the isolect's structure so as to provide desired protection from such damage. For example, the isolect 230 can be coated, for example, with a relatively loose net 340 that prevents access to the surface but has only a minor effect on the effective surface area of the isolect 230 (i.e., the capacity of the isolects 230 (cross section presented in FIG. 12B ). The loose net 340 does not affect the capacity and ensures good contact with the skin, etc. The loose net 340 can be formed of a number of different materials; however, in one exemplary embodiment, the net 340 is formed of nylon, polyester, cotton, etc. Alternatively, a very thin conductive coating 350 can be applied to the dielectric portion (insulating layer) of the isolect 230 . One exemplary conductive coating is formed of a metal and more particularly of gold. The thickness of the coating 350 depends upon the particular application and also on the type of material used to form the coating 350 ; however, when gold is used, the coating has a thickness from about 0.1 micron to about 0.1 mm. Furthermore, the rim illustrated in FIG. 10 can also provide some mechanical protection.
[0104] However, the capacity is not the only factor to be considered. The following two factors also influence how the isolects 230 are constructed. The dielectric strength of the internal insulating layer 310 and the dielectric losses that occur when it is subjected to the TC field, i.e., the amount of heat generated. The dielectric strength of the internal insulation 310 determines at what field intensity the insulation will be โshortedโ and cease to act as an intact insulation. Typically, insulators, such as plastics, have dielectric strength values of about 100V per micron or more. As a high dielectric constant reduces the field within the internal insulator 310 , a combination of a high dielectric constant and a high dielectric strength gives a significant advantage. This can be achieved by using a single material that has the desired properties or it can be achieved by a double layer with the correct parameters and thickness. In addition, to further decreasing the possibility that the insulating layer 310 will fail, all sharp edges of the insulating layer 310 should be eliminated as by rounding the corners, etc., as illustrated in FIG. 10D using conventional techniques.
[0105] FIGS. 8 and 9 illustrate a second type of treatment using the isolects 230 , namely electric field generation by internal isolects 230 . A body to which the isolects 230 are implanted is generally indicated at 311 and includes a skin surface 313 and a tumor 315 . In this embodiment, the isolects 230 can have the shape of plates, wires or other shapes that can be inserted subcutaneously or a deeper location within the body 311 so as to generate an appropriate field at the target area (tumor 315 ).
[0106] It will also be appreciated that the mode of isolects application is not restricted to the above descriptions. In the case of tumors in internal organs, for example, liver, lung, etc., the distance between each member of the pair of isolects 230 can be large. The pairs can even by positioned opposite sides of a torso 410 , as illustrated in FIG. 11 . The arrangement of the isolects 230 in FIG. 11 is particularly useful for treating a tumor 415 associated with lung cancer or gastro-intestinal tumors. In this embodiment, the electric fields (TC fields) spread in a wide fraction of the body.
[0107] In order to avoid overheating of the treated tissues, a selection of materials and field parameters is needed. The isolects insulating material should have minimal dielectric losses at the frequency ranges to be used during the treatment process. This factor can be taken into consideration when choosing the particular frequencies for the treatment. The direct heating of the tissues will most likely be dominated by the heating due to current flow (given by the I*R product). In addition, the isolect (insulated electrode) 230 and its surroundings should be made of materials that facilitate heat losses and its general structure should also facilitate head losses, i.e., minimal structures that block heat dissipation to the surroundings (air) as well as high heat conductivity. Using larger electrodes also minimizes the local sensation of heating, since it spreads the energy that is being transferred into the patient over a larger surface area. Preferably, the heating is minimized to the point where the patient's skin temperature never exceeds about 39ยฐ C.
[0108] Another way to reduce heating is to apply the field to the tissue being treated intermittently, by applying a field with a duty cycle between about 20% and about 50% instead of using a continuous field. For example, to achieve a duty cycle of 33%, the field would be repetitively switched on for one second, then switched off for two seconds. Preliminary experiments have shown that the efficacy of treatment using a field with a 33% duty cycle is roughly the same as for a field with a duty cycle of 100%. In alternative embodiments, the field could be switched on for one hour then switched off for one hour to achieve a duty cycle of 50%. Of course, switching at a rate of once per hour would not help minimize short-term heating. On the other hand, it could provide the patient with a welcome break from treatment.
[0109] The effectiveness of the treatment can be enhanced by an arrangement of isolects 230 that focuses the field at the desired target while leaving other sensitive areas in low field density (i.e., protected areas). The proper placement of the isolects 230 over the body can be maintained using any number of different techniques, including using a suitable piece of clothing that keeps the isolects at the appropriate positions. FIG. 13 illustrates such an arrangement in which an area labeled as โPโ represents a protected area. The lines of field force do not penetrate this protected area and the field there is much smaller than near the isolects 230 where target areas can be located and treated well. In contrast, the field intensity near the four poles is very high.
[0110] The following Example serves to illustrate an exemplary application of the present apparatus and application of TC fields; however, this Example is not limiting and does not limit the scope of the present invention in any way.
Example 1
[0111] To demonstrate the effectiveness of electric fields having the above described properties (e.g., frequencies between 50 KHz and 500 KHz) in destroying tumor cells, the electric fields were applied to treat mice with malignant melanoma tumors. Two pairs of isolects 230 were positioned over a corresponding pair of malignant melanomas. Only one pair was connected to the generator 210 and 200 KHz alternating electric fields (TC fields) were applied to the tumor for a period of 6 days. One melanoma tumor was not treated so as to permit a comparison between the treated tumor and the non-treated tumor. After treatment for 6 days, the pigmented melanoma tumor remained clearly visible in the non-treated side of the mouse, while, in contrast, no tumor is seen on the treated side of the mouse. The only areas that were visible discernable on the skin were the marks that represented the points of insertion of the isolects 230 . The fact that the tumor was eliminated at the treated side was further demonstrated by cutting and inversing the skin so that its inside face was exposed. Such a procedure indicated that the tumor has been substantially, if not completely, eliminated on the treated side of the mouse. The success of the treatment was also further verified by histopathological examination.
[0112] The present inventor has thus uncovered that electric fields having particular properties can be used to destroy dividing cells or tumors when the electric fields are applied to using an electronic device. More specifically, these electric fields fall into a special intermediate category, namely bio-effective fields that have no meaningful stimulatory and no thermal effects, and therefore overcome the disadvantages that were associated with the application of conventional electric fields to a body. It will also be appreciated that the present apparatus can further include a device for rotating the TC field relative to the living tissue. For example and according to one embodiment, the alternating electric potential applies to the tissue being treated is rotated relative to the tissue using conventional devices, such as a mechanical device that upon activation, rotates various components of the present system.
[0113] Moreover and according to yet another embodiment, the TC fields are applied to different pairs of the insulated electrodes 230 in a consecutive manner. In other words, the generator 210 and the control system thereof can be arranged so that signals are sent at periodic intervals to select pairs of insulated electrodes 230 , thereby causing the generation of the TC fields of different directions by these insulated electrodes 230 . Because the signals are sent at select times from the generator to the insulated electrodes 230 , the TC fields of changing directions are generated consecutively by different insulated electrodes 230 . This arrangement has a number of advantages and is provided in view of the fact that the TC fields have maximal effect when they are parallel to the axis of cell division. Since the orientation of cell division is in most cases random, only a fraction of the dividing cells are affected by any given field. Thus, using fields of two or more orientations increases the effectiveness since it increases the chances that more dividing cells are affected by a given TC field.
[0114] In vitro experiments have shown that the electric field has the maximum killing effect when the lines of force of the field are oriented generally parallel to the long axis of the hourglass-shaped cell during mitosis (as shown in FIGS. 3A-3C ). In one experiment, a much higher proportion of the damaged cells had their axis of division oriented along the field: 56% of the cells oriented at or near 0ยฐ with respect to the field were damaged, versus an average of 15% of cells damaged for cells with their long axis oriented at more than 22ยฐ with respect to the field.
[0115] The inventor has recognized that applying the field in different directions sequentially will increase the overall killing power, because the field orientation that is most effectively in killing dividing cells will be applied to a larger population of the dividing cells. A number of examples for applying the field in different directions are discussed below.
[0116] FIGS. 27A , 27 B, and 27 C show a set of 6 electrodes E 1 -E 6 , and how the direction of the field through the target tissue 1510 can be changed by applying the AC signal from the generator 1 (shown in FIG. 1 ) across different pairs of electrodes. For example, if the AC signal is applied across electrodes E 1 and E 4 , the field lines F would be vertical (as shown in FIG. 27A ), and if the signal is applied across electrodes E 2 and E 5 , or across electrodes E 3 and E 6 , the field lines F would be diagonal (as shown in FIGS. 27B and 27C , respectively). Additional field directions can be obtained by applying the AC signal across other pairs of electrodes. For example, a roughly horizontal field could be obtained by applying the signal across electrodes E 2 and E 6 .
[0117] In one embodiment, the AC signal is applied between the various pairs of electrodes sequentially. An example of this arrangement is to apply the AC signal across electrodes E 1 and E 4 for one second, then apply the AC signal across electrodes E 2 and E 5 for one second, and then apply the AC signal across electrodes E 3 and E 6 for one second. This three-part sequence is then repeated for the desired period of treatment. Because the efficacy in cell-destruction is strongly dependant on the cell's orientation, cycling the field between the different directions increases the chance that the field will be oriented in a direction that favors cell destruction at least part of the time.
[0118] Of course, the 6 electrode configuration shown in FIGS. 27A-C is just one of many possible arrangements of multiple electrodes, and many other configurations of three or more electrodes could be used based on the same principles.
[0119] Application of the field in different directions sequentially is not limited to two dimensional embodiments, and FIG. 28 shows how the sequential application of signals across different sets of electrodes can be extended to three dimensions. A first array of electrodes A 1 -A 9 is arranged around body part 1500 , and a last array of electrodes N 1 -N 9 is arranged around the body part 1500 a distance W away from the first array. Additional arrays of electrodes may optionally be added between the first array and the last array, but these additional arrays are not illustrated for clarity (so as not to obscure the electrodes A 5 -A 9 and B 5 -B 8 on the back of the body part 1500 ).
[0120] As in the FIG. 27 embodiment, the direction of the field through the target tissue can be changed by applying the AC signal from the generator 1 (shown in FIG. 1 ) across different pairs of electrodes. For example, applying the AC signal between electrodes A 2 and A 7 would result in a field in a front-to-back direction between those two electrodes, and applying the AC signal between electrodes A 5 and A 9 would result in a roughly vertical field between those two electrodes. Similarly, applying the AC signal across electrodes A 2 and N 7 would generate diagonal field lines in one direction through the body part 1500 , and applying the AC signal across electrodes A 2 and B 7 would generate diagonal field lines in another direction through the body part.
[0121] Using a three-dimensional array of electrodes also makes it possible to energize multiple pairs of electrodes simultaneously to induce fields in the desired directions. For example, if suitable switching is provided so that electrodes A 2 through N 2 are all connected to one terminal of the generator, and so that electrodes A 7 through N 7 are all connected to the other terminal of the generator, the resulting field would be a sheet that extends in a front-to-back direction for the entire width W. After the front-to-back field is maintained for a suitable duration (e.g., one second), the switching system (not shown) is reconfigured to connect electrodes A 3 through N 3 to one terminal of the generator, and electrodes A 8 through N 8 to the other terminal of the generator. This results in a sheet-shaped field that is rotated about the Z axis by about 40ยฐ with respect to the initial field direction. After the field is maintained in this direction for a suitable duration (e.g., one second), the next set of electrodes is activated to rotate the field an additional 40ยฐ to its next position. This continues until the field returns to its initial position, at which point the whole process is repeated.
[0122] Optionally, the rotating sheet-shaped field may be added (sequentially in time) to the diagonal fields described above, to better target cells that are oriented along those diagonal axes.
[0123] Because the electric field is a vector, the signals may optionally be applied to combinations of electrodes simultaneously in order to form a desired resultant vector. For example, a field that is rotated about the X axis by 20ยฐ with respect to the initial position can be obtained by switching electrodes A 2 through N 2 and A 3 through N 3 all to one terminal of the generator, and switching electrodes A 7 through N 7 and A 8 through N 8 all to the other terminal of the generator. Applying the signals to other combinations of electrodes will result in fields in other directions, as will be appreciated by persons skilled in the relevant arts. If appropriate computer control of the voltages is implemented, the field's direction can even be swept through space in a continuous (i.e., smooth) manner, as opposed to the stepwise manner described above.
[0124] FIGS. 29A and 29B depict the results of in vitro experiments that show how the killing power of the applied field against dividing cells is a function of the field strength. In the FIG. 29A experiment, B16F1 melanoma cells were subjected to a 100 kHz AC field at different field strengths, for a period of 24 hours at each strength. In the FIG. 29B experiment, F-98 glioma cells were subjected to a 200 kHz AC field at different field strengths, for a period of 24 hours at each strength. In both of these figures, the strength of the field (EF) is measured in Volts per cm. The magnitude of the killing effect is expressed in terms of TER, which is which is the ratio of the decrease in the growth rate of treated cells (GR T ) compared with the growth rate of control cells (GR C ).
[0000]
TER
=
GR
C
-
GR
T
GR
C
[0000] The experimental results show that the inhibitory effect of the applied field on proliferation increases with intensity in both the melanoma and the glioma cells. Complete proliferation arrest (TER=1) is seen at 1.35 and 2.25 V/cm in melanoma and glioma cells, respectively.
[0125] FIGS. 30A and 30B depict the results of in vitro experiments that show how the killing power of the applied field is a function of the frequency of the field. In the experiments, B16F1 melanoma cells ( FIG. 30A ) and F-98 glioma cells ( FIG. 30B ) were subjected to fields with different frequencies, for a period of 24 hours at each frequency. FIGS. 30A and 30B show the change in the growth rate, normalized to the field intensity (TER/EF). Data are shown as meanยฑSE. In FIG. 30A , a window effect is seen with maximal inhibition at 120 kHz in melanoma cells. In FIG. 30B , two peaks are seen at 170 and 250 kHz. Thus, if only one frequency is available during an entire course of treatment, a field with a frequency of about 120 kHz would be appropriate for destroying melanoma cells, and a field with a frequency on the order of 200 kHz would be appropriate for destroying glioma cells.
[0126] Not all the cells of any given type will have the exact same size. Instead, the cells will have a distribution of sizes, with some cells being smaller and some cells being larger. It is believed that the best frequency for damaging a particular cell is related to the physical characteristics (e.g., the size) of that particular cell. Thus, to best damage a population of cells with a distribution of sizes, it can be advantageous to apply a distribution of different frequencies to the population, where the selection of frequencies is optimized based on the expected size distribution of the target cells. For example, the data on FIG. 30B indicates that using two frequencies of 170 kHz and 250 kHz to destroy a population of glioma cells would be more effective than using a single frequency of 200 kHz.
[0127] Note that the optimal field strengths and frequencies discussed herein were obtained based on in vitro experiments, and that the corresponding parameters for in vivo applications may be obtained by performing similar experiments in vivo. It is possible that relevant characteristics of the cell itself (such as size and/or shape) or interactions with the cell's surroundings may result in a different set of optimal frequencies and/or field strengths for in vivo applications.
[0128] When more than one frequency is used, the various frequencies may be applied sequentially in time. For example, in the case of glioma, field frequencies of 100, 150, 170, 200, 250, and 300 kHz may be applied during the first, second, third, fourth, fifth, and sixth minutes of treatment, respectively. That cycle of frequencies would then repeat during each successive six minutes of treatment. Alternatively, the frequency of the field may be swept in a stepless manner from 100 to 300 kHz.
[0129] Optionally, this frequency cycling may be combined with the directional cycling described above. FIG. 31A is an example of such a combination using three directions (D 1 , D 2 , and D 3 ) and three frequencies (F 1 , F 2 , and F 3 ). Of course, the same scheme can be extended to any other number of directions and/or frequencies. FIG. 31B is an example of such a combination using three directions (D 1 , D 2 , and D 3 ), sweeping the frequency from 100 kHz to 300 kHz. Note that the break in the time axis between t 1 and t 2 provides the needed time for the sweeping frequency to rise to just under 300 kHz. The frequency sweeping (or stepping) may be synchronized with directional changes, as shown in FIG. 31A . Alternatively, the frequency sweeping (or stepping) may be asynchronous with respect to the directional changes, as shown in FIG. 31B .
[0130] In an alternative embodiment, a signal that contains two or more frequencies components simultaneously (e.g., 170 kHz and 250 kHz) is applied to the electrodes to treat a populations of cells that have a distribution of sizes. The various signals will add by superposition to create a field that includes all of the applied frequency components.
[0131] Turning now to FIG. 14 in which an article of clothing 500 according to one exemplary embodiment is illustrated. More specifically, the article of clothing 500 is in the form of a hat or cap or other type of clothing designed for placement on a head of a person. For purposes of illustration, a head 502 is shown with the hat 500 being placed thereon and against a skin surface 504 of the head 502 . An intra-cranial tumor or the like 510 is shown as being formed within the head 502 underneath the skin surface 504 thereof. The hat 500 is therefore intended for placement on the head 502 of a person who has a tumor 510 or the like.
[0132] Unlike the various embodiments illustrated in FIGS. 1-13 where the insulated electrodes 230 are arranged in a more or less planar arrangement since they are placed either on a skin surface or embedded within the body underneath it, the insulated electrodes 230 in this embodiment are specifically contoured and arranged for a specific application. The treatment of intra-cranial tumors or other lesions or the like typically requires a treatment that is of a relatively long duration, e.g., days to weeks, and therefore, it is desirable to provide as much comfort as possible to the patient. The hat 500 is specifically designed to provide comfort during the lengthy treatment process while not jeopardizing the effectiveness of the treatment.
[0133] According to one exemplary embodiment, the hat 500 includes a predetermined number of insulated electrodes 230 that are preferably positioned so as to produce the optimal TC fields at the location of the tumor 510 . The lines of force of the TC field are generally indicated at 520 . As can be seen in FIG. 14 , the tumor 510 is positioned within these lines of force 520 . As will be described in greater detail hereinafter, the insulated electrodes 230 are positioned within the hat 500 such that a portion or surface thereof is free to contact the skin surface 504 of the head 502 . In other words, when the patient wears the hat 500 , the insulated electrodes 230 are placed in contact with the skin surface 504 of the head 502 in positions that are selected so that the TC fields generated thereby are focused at the tumor 510 while leaving surrounding areas in low density. Typically, hair on the head 502 is shaved in selected areas to permit better contact between the insulated electrodes 230 and the skin surface 504 ; however, this is not critical.
[0134] The hat 500 preferably includes a mechanism 530 that applies a force to the insulated electrodes 230 so that they are pressed against the skin surface 502 . For example, the mechanism 530 can be of a biasing type that applies a biasing force to the insulated electrodes 230 to cause the insulated electrodes 230 to be directed outwardly away from the hat 500 . Thus, when the patient places the hat 500 on his/her head 502 , the insulated electrodes 230 are pressed against the skin surface 504 by the mechanism 530 . The mechanism 530 can slightly recoil to provide a comfortable fit between the insulated electrodes 230 and the head 502 . In one exemplary embodiment, the mechanism 530 is a spring based device that is disposed within the hat 500 and has one section that is coupled to and applies a force against the insulated electrodes 230 .
[0135] As with the prior embodiments, the insulated electrodes 230 are coupled to the generator 210 by means of conductors 220 . The generator 210 can be either disposed within the hat 500 itself so as to provide a compact, self-sufficient, independent system or the generator 210 can be disposed external to the hat 500 with the conductors 220 exiting the hat 500 through openings or the like and then running to the generator 210 . When the generator 210 is disposed external to the hat 500 , it will be appreciated that the generator 210 can be located in any number of different locations, some of which are in close proximity to the hat 500 itself, while others can be further away from the hat 500 . For example, the generator 210 can be disposed within a carrying bag or the like (e.g., a bag that extends around the patient's waist) which is worn by the patient or it can be strapped to an extremity or around the torso of the patient. The generator 210 can also be disposed in a protective case that is secured to or carried by another article of clothing that is worn by the patient. For example, the protective case can be inserted into a pocket of a sweater, etc. FIG. 14 illustrates an embodiment where the generator 210 is incorporated directly into the hat 500 .
[0136] Turning now to FIGS. 15 and 16 , in one exemplary embodiment, a number of insulated electrodes 230 along with the mechanism 530 are preferably formed as an independent unit, generally indicated at 540 , that can be inserted into the hat 500 and electrically connected to the generator (not shown) via the conductors (not shown). By providing these members in the form of an independent unit, the patient can easily insert and/or remove the units 540 from the hat 500 when they may need cleaning, servicing and/or replacement.
[0137] In this embodiment, the hat 500 is constructed to include select areas 550 that are formed in the hat 500 to receive and hold the units 540 . For example and as illustrated in FIG. 15 , each area 550 is in the form of an opening (pore) that is formed within the hat 500 . The unit 540 has a body 542 and includes the mechanism 530 and one or more insulated electrodes 230 . The mechanism 530 is arranged within the unit 540 so that a portion thereof (e.g., one end thereof) is in contact with a face of each insulated electrode 230 such that the mechanism 530 applies a biasing force against the face of the insulated electrode 230 . Once the unit 540 is received within the opening 550 , it can be securely retained therein using any number of conventional techniques, including the use of an adhesive material or by using mechanical means. For example, the hat 500 can include pivotable clip members that pivot between an open position in which the opening 550 is free and a closed position in which the pivotable clip members engage portions (e.g., peripheral edges) of the insulated electrodes to retain and hold the insulated electrodes 230 in place. To remove the insulated electrodes 230 , the pivotable clip members are moved to the open position. In the embodiment illustrated in FIG. 16 , the insulated electrodes 230 are retained within the openings 550 by an adhesive element 560 which in one embodiment is a two sided self-adhesive rim member that extends around the periphery of the insulated electrode 230 . In other words, a protective cover of one side of the adhesive rim 560 is removed and it is applied around the periphery of the exposed face of the insulated electrode 230 , thereby securely attaching the adhesive rim 560 to the hat 500 and then the other side of the adhesive rim 560 is removed for application to the skin surface 504 in desired locations for positioning and securing the insulated electrode 230 to the head 502 with the tumor being positioned relative thereto for optimization of the TC fields. Since one side of the adhesive rim 560 is in contact with and secured to the skin surface 540 , this is why it is desirable for the head 502 to be shaved so that the adhesive rim 560 can be placed flushly against the skin surface 540 .
[0138] The adhesive rim 560 is designed to securely attach the unit 540 within the opening 550 in a manner that permits the unit 540 to be easily removed from the hat 500 when necessary and then replaced with another unit 540 or with the same unit 540 . As previously mentioned, the unit 540 includes the biasing mechanism 530 for pressing the insulated electrode 230 against the skin surface 504 when the hat 500 is worn. The unit 540 can be constructed so that side opposite the insulated electrode 230 is a support surface formed of a rigid material, such as plastic, so that the biasing mechanism 530 (e.g., a spring) can be compressed therewith under the application of force and when the spring 530 is in a relaxed state, the spring 530 remains in contact with the support surface and the applies a biasing force at its other end against the insulated electrode 230 . The biasing mechanism 530 (e.g., spring) preferably has a contour corresponding to the skin surface 504 so that the insulated electrode 230 has a force applied thereto to permit the insulated electrode 230 to have a contour complementary to the skin surface 504 , thereby permitting the two to seat flushly against one another. While the mechanism 530 can be a spring, there are a number of other embodiments that can be used instead of a spring. For example, the mechanism 530 can be in the form of an elastic material, such as a foam rubber, a foam plastic, or a layer containing air bubbles, etc.
[0139] The unit 540 has an electric connector 570 that can be hooked up to a corresponding electric connector, such as a conductor 220 , that is disposed within the hat 500 . The conductor 220 connects at one end to the unit 540 and at the other end is connected to the generator 210 . The generator 210 can be incorporated directly into the hat 500 or the generator 210 can be positioned separately (remotely) on the patient or on a bedside support, etc.
[0140] As previously discussed, a coupling agent, such as a conductive gel, is preferably used to ensure that an effective conductive environment is provided between the insulated electrode 230 and the skin surface 504 . Suitable gel materials have been disclosed hereinbefore in the discussion of earlier embodiments. The coupling agent is disposed on the insulated electrode 230 and preferably, a uniform layer of the agent is provided along the surface of the electrode 230 . One of the reasons that the units 540 need replacement at periodic times is that the coupling agent needs to be replaced and/or replenished. In other words, after a predetermined time period or after a number of uses, the patient removes the units 540 so that the coupling agent can be applied again to the electrode 230 .
[0141] FIGS. 17 and 18 illustrate another article of clothing which has the insulated electrodes 230 incorporated as part thereof. More specifically, a bra or the like 700 is illustrated and includes a body that is formed of a traditional bra material, generally indicated at 705 , to provide shape, support, and comfort to the wearer. The bra 700 also includes a fabric support layer 710 on one side thereof. The support layer 710 is preferably formed of a suitable fabric material that is constructed to provide necessary and desired support to the bra 700 .
[0142] Similar to the other embodiments, the bra 700 includes one or more insulated electrodes 230 disposed within the bra material 705 . The one or more insulated electrodes are disposed along an inner surface of the bra 700 opposite the support 710 and are intended to be placed proximate to a tumor or the like that is located within one breast or in the immediately surrounding area. As with the previous embodiment, the insulated electrodes 230 in this embodiment are specifically constructed and configured for application to a breast or the immediate area. Thus, the insulated electrodes 230 used in this application do not have a planar surface construction but rather have an arcuate shape that is complementary to the general curvature found in a typical breast.
[0143] A lining 720 is disposed across the insulated electrodes 230 so as to assist in retaining the insulated electrodes in their desired locations along the inner surface for placement against the breast itself. The lining 720 can be formed of any number of thin materials that are comfortable to wear against one's skin and in one exemplary embodiment, the lining 720 is formed of a fabric material.
[0144] The bra 700 also preferably includes a biasing mechanism 800 as in some of the earlier embodiments. The biasing mechanism 800 is disposed within the bra material 705 and extends from the support 710 to the insulated electrode 230 and applies a biasing force to the insulated electrode 230 so that the electrode 230 is pressed against the breast. This ensures that the insulated electrode 230 remains in contact with the skin surface as opposed to lifting away from the skin surface, thereby creating a gap that results in a less effective treatment since the gap diminishes the efficiency of the TC fields. The biasing mechanism 800 can be in the form of a spring arrangement or it can be an elastic material that applies the desired biasing force to the insulated electrodes 230 so as to press the insulated electrodes 230 into the breast. In the relaxed position, the biasing mechanism 800 applies a force against the insulated electrodes 230 and when the patient places the bra 700 on their body, the insulated electrodes 230 are placed against the breast which itself applies a force that counters the biasing force, thereby resulting in the insulated electrodes 230 being pressed against the patient's breast. In the exemplary embodiment that is illustrated, the biasing mechanism 800 is in the form of springs that are disposed within the bra material 705 .
[0145] A conductive gel 810 can be provided on the insulated electrode 230 between the electrode and the lining 720 . The conductive gel layer 810 is formed of materials that have been previously described herein for performing the functions described above.
[0146] An electric connector 820 is provided as part of the insulated electrode 230 and electrically connects to the conductor 220 at one end thereof, with the other end of the conductor 220 being electrically connected to the generator 210 . In this embodiment, the conductor 220 runs within the bra material 705 to a location where an opening is formed in the bra 700 . The conductor 220 extends through this opening and is routed to the generator 210 , which in this embodiment is disposed in a location remote from the bra 700 . It will also be appreciated that the generator 210 can be disposed within the bra 700 itself in another embodiment. For example, the bra 700 can have a compartment formed therein which is configured to receive and hold the generator 210 in place as the patient wears the bra 700 . In this arrangement, the compartment can be covered with a releasable strap that can open and close to permit the generator 210 to be inserted therein or removed therefrom. The strap can be formed of the same material that is used to construct the bra 700 or it can be formed of some other type of material. The strap can be releasably attached to the surrounding bra body by fastening means, such as a hook and loop material, thereby permitting the patient to easily open the compartment by separating the hook and loop elements to gain access to the compartment for either inserting or removing the generator 210 .
[0147] The generator 210 also has a connector 211 for electrical connection to the conductor 220 and this permits the generator 210 to be electrically connected to the insulated electrodes 230 .
[0148] As with the other embodiments, the insulated electrodes 230 are arranged in the bra 700 to focus the electric field (TC fields) on the desired target (e.g., a tumor). It will be appreciated that the location of the insulated electrodes 230 within the bra 700 will vary depending upon the location of the tumor. In other words, after the tumor has been located, the physician will then devise an arrangement of insulated electrodes 230 and the bra 700 is constructed in view of this arrangement so as to optimize the effects of the TC fields on the target area (tumor). The number and position of the insulated electrodes 230 will therefore depend upon the precise location of the tumor or other target area that is being treated. Because the location of the insulated electrodes 230 on the bra 700 can vary depending upon the precise application, the exact size and shape of the insulated electrodes 230 can likewise vary. For example, if the insulated electrodes 230 are placed on the bottom section of the bra 700 as opposed to a more central location, the insulated electrodes 230 will have different shapes since the shape of the breast (as well as the bra) differs in these areas.
[0149] FIG. 19 illustrates yet another embodiment in which the insulated electrodes 230 are in the form of internal electrodes that are incorporated into in the form of a probe or catheter 600 that is configured to enter the body through a natural pathway, such as the urethra, vagina, etc. In this embodiment, the insulated electrodes 230 are disposed on an outer surface of the probe 600 and along a length thereof. The conductors 220 are electrically connected to the electrodes 230 and run within the body of the probe 600 to the generator 210 which can be disposed within the probe body or the generator 210 can be disposed independent of the probe 600 in a remote location, such as on the patient or at some other location close to the patient.
[0150] Alternatively, the probe 600 can be configured to penetrate the skin surface or other tissues to reach an internal target that lies within the body. For example, the probe 600 can penetrate the skin surface and then be positioned adjacent to or proximate to a tumor that is located within the body.
[0151] In these embodiments, the probe 600 is inserted through the natural pathway and then is positioned in a desired location so that the insulated electrodes 230 are disposed near the target area (i.e., the tumor). The generator 210 is then activated to cause the insulated electrodes 230 to generate the TC fields which are applied to the tumor for a predetermined length of time. It will be appreciated that the illustrated probe 600 is merely exemplary in nature and that the probe 600 can have other shapes and configurations so long as they can perform the intended function. Preferably, the conductors (e.g., wires) leading from the insulated electrodes 230 to the generator 210 are twisted or shielded so as not to generate a field along the shaft.
[0152] It will further be appreciated that the probes can contain only one insulated electrode while the other can be positioned on the body surface. This external electrode should be larger or consist of numerous electrodes so as to result in low lines of force-current density so as not to affect the untreated areas. In fact, the placing of electrodes should be designed to minimize the field at potentially sensitive areas. Optionally, the external electrodes may be held against the skin surface by a vacuum force (e.g., suction).
[0153] FIG. 20 illustrates yet another embodiment in which a high standing collar member 900 (or necklace type structure) can be used to treat thyroid, parathyroid, laryngeal lesions, etc. FIG. 20 illustrates the collar member 900 in an unwrapped, substantially flat condition. In this embodiment, the insulated electrodes 230 are incorporated into a body 910 of the collar member 900 and are configured for placement against a neck area of the wearer. The insulated electrodes 230 are coupled to the generator 210 according to any of the manner described hereinbefore and it will be appreciated that the generator 210 can be disposed within the body 910 or it can be disposed in a location external to the body 910 . The collar body 910 can be formed of any number of materials that are traditionally used to form collars 900 that are disposed around a person's neck. As such, the collar 900 preferably includes a means 920 for adjusting the collar 900 relative to the neck. For example, complementary fasteners (hook and loop fasteners, buttons, etc.) can be disposed on ends of the collar 900 to permit adjustment of the collar diameter.
[0154] Thus, the construction of the present devices are particularly well suited for applications where the devices are incorporated into articles of clothing to permit the patient to easily wear a traditional article of clothing while at the same time the patient undergoes treatment. In other words, an extra level of comfort can be provided to the patient and the effectiveness of the treatment can be increased by incorporating some or all of the device components into the article of clothing. The precise article of clothing that the components are incorporated into will obviously vary depending upon the target area of the living tissue where tumor, lesion or the like exists. For example, if the target area is in the testicle area of a male patient, then an article of clothing in the form of a sock-like structure or wrap can be provided and is configured to be worn around the testicle area of the patient in such a manner that the insulated electrodes thereof are positioned relative to the tumor such that the TC fields are directed at the target tissue. The precise nature or form of the article of clothing can vary greatly since the device components can be incorporated into most types of articles of clothing and therefore, can be used to treat any number of different areas of the patient's body where a condition may be present.
[0155] Now turning to FIGS. 21-22 in which another aspect of the present device is shown. In FIG. 21 , a body 1000 , such as any number of parts of a human or animal body, is illustrated. As in the previous embodiments, two or more insulated electrodes 230 are disposed in proximity to the body 1000 for treatment of a tumor or the like (not shown) using TC fields, as has been previously described in great detail in the above discussion of other embodiments. The insulated electrode 230 has a conductive component and has external insulation 260 that surrounds the conductive component thereof. Each insulated electrode 230 is preferably connected to a generator (not shown) by the lead 220 . Between each insulated electrode 220 and the body 1000 , a conductive filler material (e.g., conductive gel member 270 ) is disposed. The insulated electrodes 230 are spaced apart from one another and when the generator is actuated, the insulated electrodes 230 generate the TC fields that have been previously described in great detail. The lines of the electric field (TC field) are generally illustrated at 1010 . As shown, the electric field lines 1010 extend between the insulated electrodes 230 and through the conductive gel member 270 .
[0156] Over time or as a result of some type of event, the external insulation 260 of the insulated electrode 230 can begin to breakdown at any given location thereof. For purpose of illustration only, FIG. 22 illustrates that the external insulation 260 of one of the insulated electrodes 230 has experienced a breakdown 1020 at a face thereof which is adjacent the conductive gel member 270 . It will be appreciated that the breakdown 1020 of the external insulation 260 results in the formation of a strong current flow-current density at this point (i.e., at the breakdown 1020 ). The increased current density is depicted by the increased number of electric field lines 1010 and the relative positioning and distance between adjacent electric field lines 1010 . One of the side effects of the occurrence of breakdown 1020 is that current exists at this point which will generate heat and may burn the tissues/skin which have a resistance. In FIG. 22 , an overheated area 1030 is illustrated and is a region or area of the tissues/skin where an increased current density exits due to the breakdown 1020 in the external insulation 260 . A patient can experience discomfort and pain in this area 1030 due to the strong current that exists in the area and the increased heat and possible burning sensation that exist in area 1030 .
[0157] FIG. 23 illustrates yet another embodiment in which a further application of the insulated electrodes 230 is shown. In this embodiment, the conductive gel member 270 that is disposed between the insulated electrode 230 and the body 1000 includes a conductor 1100 that is floating in that the gel material forming the member 270 completely surrounds the conductor 1100 . In one exemplary embodiment, the conductor 1100 is a thin metal sheet plate that is disposed within the conductor 1100 . As will be appreciated, if a conductor, such as the plate 1100 , is placed in a homogeneous electric field, normal to the lines of the electric field, the conductor 1100 practically has no effect on the field (except that the two opposing faces of the conductor 1100 are equipotential and the corresponding equipotentials are slightly shifted). Conversely, if the conductor 1100 is disposed parallel to the electric field, there is a significant distortion of the electric field. The area in the immediate proximity of the conductor 1100 is not equipotential, in contrast to the situation where there is no conductor 1100 present. When the conductor 1100 is disposed within the gel member 270 , the conductor 1100 will typically not effect the electric field (TC field) for the reasons discussed above, namely that the conductor 1100 is normal to the lines of the electric field.
[0158] If there is a breakdown of the external insulation 260 of the insulated electrode 230 , there is a strong current flow-current density at the point of breakdown as previously discussed; however, the presence of the conductor 1100 causes the current to spread throughout the conductor 1100 and then exit from the whole surface of the conductor 1100 so that the current reaches the body 1000 with a current density that is neither high nor low. Thus, the current that reaches the skin will not cause discomfort to the patient even when there has been a breakdown in the insulation 260 of the insulated electrode 230 . It is important that the conductor 1100 is not grounded as this would cause it to abolish the electric field beyond it. Thus, the conductor 1100 is โfloatingโ within the gel member 270 .
[0159] If the conductor 1100 is introduced into the body tissues 1000 and is not disposed parallel to the electric field, the conductor 1100 will cause distortion of the electric field. The distortion can cause spreading of the lines of force (low field density-intensity) or concentration of the lines of field (higher density) of the electric field, according to the particular geometries of the insert and its surroundings, and thus, the conductor 1100 can exhibit, for example, a screening effect. Thus, for example, if the conductor 1100 completely encircles an organ 1101 , the electric field in the organ itself will be zero since this type of arrangement is a Faraday cage. However, because it is impractical for a conductor to be disposed completely around an organ, a conductive net or similar structure can be used to cover, completely or partially, the organ, thereby resulting in the electric field in the organ itself being zero or about zero. For example, a net can be made of a number of conductive wires that are arranged relative to one another to form the net or a set of wires can be arranged to substantially encircle or otherwise cover the organ 1101 . Conversely, an organ 1103 to be treated (the target organ) is not covered with a member having a Faraday cage effect but rather is disposed in the electric field 1010 (TC fields).
[0160] FIG. 24 illustrates an embodiment where the conductor 1100 is disposed within the body (i.e., under the skin) and it is located near a target (e.g., a target organ). By placing the conductor 1100 near the target, high field density (of the TC fields) is realized at the target. At the same time, another nearby organ can be protected by disposing the above described protective conductive net or the like around this nearby organ so as to protect this organ from the fields. By positioning the conductor 1100 in close proximity to the target, a high field density condition can be provided near or at the target. In other words, the conductor 1100 permits the TC fields to be focused at a particular area (i.e., a target).
[0161] It will also be appreciated that in the embodiment of FIG. 24 , the gel members 260 can each include a conductor as described with reference to FIG. 23 . In such an arrangement, the conductor in the gel member 260 protects the skin surface (tissues) from any side effects that may be realized if a breakdown in the insulation of the insulated electrode 230 occurs. At the same time, the conductor 1100 creates a high field density near the target.
[0162] There are a number of different ways to tailor the field density of the electric field by constructing the electrodes differently and/or by strategically placing the electrodes relative to one another. For example, in FIG. 25 , a first insulated electrode 1200 and a second insulated electrode 1210 are provided and are disposed about a body 1300 . Each insulated electrode includes a conductor that is preferably surrounded by an insulating material, thus the term โinsulated electrodeโ. Between each of the first and second electrodes 1200 , 1210 and the body 1300 , the conductive gel member 270 is provided. Electric field lines are generally indicated at 1220 for this type of arrangement. In this embodiment, the first insulated electrode 1200 has dimensions that are significantly greater than the dimensions of the second insulated electrode 1210 (the conductive gel member for the second insulated electrode 1210 will likewise be smaller).
[0163] By varying the dimensions of the insulated electrodes, the pattern of the electric field lines 1220 is varied. More specifically, the electric field tapers inwardly toward the second insulated electrode 1210 due to the smaller dimensions of the second insulated electrode 1210 . An area of high field density, generally indicated at 1230 , forms near the interface between the gel member 270 associated with the second insulated electrode 1210 and the skin surface. The various components of the system are manipulated so that the tumor within the skin or on the skin is within this high field density so that the area to be treated (the target) is exposed to electric field lines of a higher field density.
[0164] FIG. 26 also illustrates a tapering TC field when a conductor 1400 (e.g., a conductive plate) is disposed in each of the conductive gel members 270 . In this embodiment, the size of the gel members 270 and the size of the conductors 1400 are the same or about the same despite the differences in the sizes of the insulated electrodes 1200 , 1210 . The conductors 1400 again can be characterized as โfloating platesโ since each conductor 1400 is surrounded by the material that forms the gel member 270 . As shown in FIG. 26 , the placement of one conductor 1400 near the insulated electrode 1210 that is smaller than the other insulated electrode 1200 and is also smaller than the conductor 1400 itself and the other insulated electrode 1200 is disposed at a distance therefrom, the one conductor 1400 causes a decrease in the field density in the tissues disposed between the one conductor 1400 and the other insulated electrode 1200 . The decrease in the field density is generally indicated at 1410 . At the same time, a very inhomogeneous tapering field, generally indicated at 1420 , changing from very low density to very high density is formed between the one conductor 1400 and the insulated electrode 1210 . One benefit of this exemplary configuration is that it permits the size of the insulated electrode to be reduced without causing an increase in the nearby field density. This can be important since electrodes that having very high dielectric constant insulation can be very expensive. Some insulated electrodes, for example, can cost $500.00 or more; and further, the price is sensitive to the particular area of treatment. Thus, a reduction in the size of the insulated electrodes directly leads to a reduction in cost.
[0165] As used herein, the term โtumorโ refers to a malignant tissue comprising transformed cells that grow uncontrollably. Tumors include leukemias, lymphomas, myelomas, plasmacytomas, and the like; and solid tumors. Examples of solid tumors that can be treated according to the invention include sarcomas and carcinomas such as, but not limited to: fibrosarcoma, myxosarcoma, liposarcoma, chondrosarcoma, osteogenic sarcoma, chordoma, angiosarcoma, endotheliosarcoma, lymphangiosarcoma, lymphangioendotheliosarcoma, synovioma, mesothelioma, Ewing's tumor, leiomyosarcoma, rhabdomyosarcoma, colon carcinoma, pancreatic cancer, breast cancer, ovarian cancer, prostate cancer, squamous cell carcinoma, basal cell carcinoma, adenocarcinoma, sweat gland carcinoma, sebaceous gland carcinoma, papillary carcinoma, papillary adenocarcinomas, cystadenocarcinoma, medullary carcinoma, bronchogenic carcinoma, renal cell carcinoma, hepatoma, bile duct carcinoma, choriocarcinoma, seminoma, embryonal carcinoma, Wilms' tumor, cervical cancer, testicular tumor, lung carcinoma, small cell lung carcinoma, bladder carcinoma, epithelial carcinoma, glioma, astrocytoma, medulloblastoma, craniopharyngioma, ependymoma, pinealoma, hemangioblastoma, acoustic neuroma, oligodendroglioma, meningioma, melanoma, neuroblastoma, and retinoblastoma. Because each of these tumors undergoes rapid growth, any one can be treated in accordance with the invention. The invention is particularly advantageous for treating brain tumors, which are difficult to treat with surgery and radiation, and often inaccessible to chemotherapy or gene therapies. In addition, the present invention is suitable for use in treating skin and breast tumors because of the ease of localized treatment provided by the present invention.
[0166] In addition, the present invention can control uncontrolled growth associated with non-malignant or pre-malignant conditions, and other disorders involving inappropriate cell or tissue growth by application of an electric field in accordance with the invention to the tissue undergoing inappropriate growth. For example, it is contemplated that the invention is useful for the treatment of arteriovenous (AV) malformations, particularly in intracranial sites. The invention may also be used to treat psoriasis, a dermatologic condition that is characterized by inflammation and vascular proliferation; and benign prostatic hypertrophy, a condition associated with inflammation and possibly vascular proliferation. Treatment of other hyperproliferative disorders is also contemplated.
[0167] Furthermore, undesirable fibroblast and endothelial cell proliferation associated with wound healing, leading to scar and keloid formation after surgery or injury, and restenosis after angioplasty or placement of coronary stents can be inhibited by application of an electric field in accordance with the present invention. The non-invasive nature of this invention makes it particularly desirable for these types of conditions, particularly to prevent development of internal scars and adhesions, or to inhibit restenosis of coronary, carotid, and other important arteries.
[0168] In addition to treating tumors that have already been detected, the above-described embodiments may also be used prophylactically to prevent tumors from ever reaching a detectable size in the first place. For example, the bra embodiment described above in connection with FIGS. 17 and 18 may be worn by a woman for an 8 hour session every day for a week, with the week-long course of treatment being repeated every few months to kill any cells that have become cancerous and started to proliferate. This mode of usage is particularly appropriate for people who are at high risk for a particular type of cancer (e.g., women with a strong history of breast cancer in their families, or people who have survived a bout of cancer and are at risk of a relapse). The course of prophylactic treatment may be tailored based on the type of cancer being targeted and/or to suit the convenience of the patient. For example, undergoing a four 16 hour sessions during the week of treatment may be more convenient for some patients than seven 8 hour session, and may be equally effective.
Example 2
[0169] Experiments were also performed on two different types of bacteriaโ Pseudomonas aeruginosa strain PAO1 and Staphylococcus aureus strain SH1000. All strains were grown in LB media (1.0% Bacto tryptone, 0.5% Yeast extract, 1% NaCl). Broth cultures of freshly plated bacteria strains were grown in 3 ml of liquid medium at 37ยฐ C. for 15 hours in an orbital shaker (220 RPM) and diluted in fresh LB broth to a predetermined absorbance at 595 nm which yielded the desired CFU per ml.
[0170] FIG. 32A depicts the construction of the electrodes 1610 used in the experiment. Each electrode is 15 mm long and 5 mm high. It include an electrical conductor 1611 with its outer face coated with a thin layer of lead magnesium niobate-lead titanate (PMN-PT) ceramic insulation 1612 , which has a high dielectric constant (โ>5000) such that their capacitance was about 10 nF each. The rear of the conductor 1611 was insulated using a 5 mm layer 1614 of 353ND medical grade epoxy (Epoxy Technology, Billerica, Mass., USA) and a wire 1613 is connected to the conductor 1611 . Of course, it may be appropriate to vary the dimensions of the electrodes depending on the intended application.
[0171] FIG. 32B depicts a test chamber that includes four electrodes 1610 , arranged in pairs and positioned in a 50 mm Petri dish 1626 . The electrodes were held in place by a polycarbonate holder 1624 . Electric fields were generated in the test chamber by applying an AC voltage across one pair of opposing electrodes, then applying an AC voltage across the other pair of opposing electrodes, in an alternating sequence to produce electric fields in the medium that are oriented at 90ยฐ with respect to each other. The electrodes were placed 23 mm apart. The electrodes were completely insulated from the medium in the Petri dish by the ceramic insulation 1614 on the face of the electrode 1610 , so the field is capacitively coupled through the layer 1614 into the target region.
[0172] FIG. 32C depicts a setup that was used to induce fields in the test chamber 1620 . The output of a sinewave generator 1632 (Model 662, OR-X, Israel) is routed to an RF amplifier 1634 (75A250, AR worldwide, Souderton, Pa., USA), and the output of the RF amplifier 1634 is routed to a field direction switching relay 1636 that either imposes the amplified sine wave between the upper and lower electrodes or between the right and left electrodes. The switching relay is configured to switch back and forth between those two states periodically, thereby switching the direction of the field at the desired interval. The entire field generating system was placed inside a Faraday cage 1644 in order to meet the guidelines for limiting exposure to time-varying electric, magnetic, and electromagnetic fields of the International Non-Ionizing Radiation Committee (INIRC).
[0173] Temperature was measured continuously using insulated T type thermocouple (Omega, Stamford, Conn.) with its tip positioned at the center of the chamber 1620 . The thermocouples were connected to a TC-08 Thermocouple Data Logger (Pico Technologies, UK) the output of which was connected to computer 1630 . When high field frequencies (30-50 MHz) were used, the fields interfered with the temperatures measurements. So to measure the temperature, the field was temporarily turned off for two seconds during each temperature measurement.
[0174] As electric fields are associated with heat production, the chamber temperature was held at the desired value by computer feedback control of the amplitude of the waveform at the input of the power amplifier. The electric field intensities in the culture medium were measured using a shielded coaxial probe having two exposed tips fixed at a distance of 1 cm. The probe was connected, through a coaxial cable, to a 190B floating scope meter (Fluke, The Netherlands). Field intensities were measured at the end of each treatment by dipping the probe in the culture media, such that the two measuring points were in parallel with the lines of the electric field. Field intensities are expressed as peak-to-peak voltage per centimeter distance (V/cm).
[0175] Overnight bacterial cultures were diluted in fresh LB broth to an OD that corresponds to bacterial counts of 1ร10 7 Colony Forming Units (CFU)/ml. Petri plates containing the electric fields chamber 1620 were filled with 7 ml of the diluted cultures, and placed inside a pre-cooled incubator (FOC 225I, Velp Scientifica). Fields were applied for 2 hours for S. aureus and 2.5 hours for P. aeruginosa with the field direction alternating every 300 ms (i.e., 300 ms in one direction followed by 300 ms in the other direction). Preliminary experiments indicated that these durations were sufficient to allow for approximately one order of magnitude growth of the control (unexposed to electric fields) group.
[0176] Temperature within the chamber 1620 was controlled by modifying the field strength within a predetermined range since the field causes heating. The electric fields chamber temperature reached 37ยฑ0.2ยฐ C. within the first 5 minutes of the experiment in both the treated group and in the control group. (The control bacteria groups were not exposed to the electric fields, but were temperature-controlled to match the temperature in the test groups.)
[0177] At the end of treatment, the cultures were stirred several times by up and down pipetting. Four aliquots of 250 ฮผl were dispensed into a 96 MicroWells plate (Nunclonโขฮ, Nunc, Denmark) and the OD was determined spectrophotometrically with a microplate reader (Infinite 200, Tecan, Austria) at 750 nm. The optical densities (ODs) of the blanks, which consisted of uninoculated LB, were subtracted from the ODs of the inoculated plates. The percentage of growth for each well was calculated by dividing the OD of the wells by that of the control: (OD 750 nm of treated wells/ OD750 nm of the control well)ร100.
[0178] The effect of the electric fields' frequency was tested by applying fields between 100 kHz and 50 MHz. The results, depicted in FIGS. 33A and 33B , show that 2-4V/cm electric fields inhibit the growth of the S. aureus (after 2 hours treatment) and P. aeruginosa (after 2.5 hours treatment), respectively. The calculated effect, expressed in % (using the scale on the left side of the graphs), is based on OD measurements. Averages of at least two independent experimentsยฑstandard errors are presented. The corresponding average field intensitiesยฑstandard errors are indicated by the solid line (using the scale on the right side of the graphs).
[0179] The results show that the growth inhibition is frequency dependent, having a maximum growth inhibition at 10 MHz fields for both S. aureus and P. aeruginosa . Note that as the electric fields generating system was designed to maintain a constant temperature in the chamber by adjustment of the field intensity, and therefore the fields' intensities vary between the different frequency tests. The field intensity variations in the tests was limited to a range of ยฑ1 V/cm. The results presented are meansยฑstandard errors (SE) of at least 2 independent experiments, each consisting of 6-8 plates. Higher field frequencies were not tested due to equipment limitations.
[0180] The effect of the electric fields' intensity was tested by applying 10 MHz fields to S. aureus at different intensities for 6 hours. The relative growth, based on CFU counts, is expressed as a percentage of the heat controlยฑstandard errors. The initial S. aureus concentration in this set of experiments was 0.5-1ร10 5 CFU/ml. As seen in FIG. 34 , the growth inhibition is field intensity dependent reaches a plateau of just above an 80% inhibition, at field intensities of about 2-2.5 V/cm. Note that although this intensity worked best for treating S. aureus at 10 MHz, field strengths between 0.5 and 10 V/cm may be used.
[0181] The effect of the switching rate of the electric fields between the two perpendicular directions was tested by applying 10 MHz, 3.5 V/cm fields and varying the switching rate (i.e., the time the field was applied in each direction). The dependency of the fields' inhibitory effect is illustrated in FIGS. 35A and 35B for S. aureus and P. aeruginosa , respectively (after treatment for 2 hours for S. aureus or 2.5 hours for P. aeruginosa ). The results indicate that for S. aureus , durations of 100 mSec, 1 Sec, and 30 Sec resulted in a significantly higher inhibition than the other durations tested. In the case of P. aeruginosa the maximal inhibition was observed when the duration of each field direction was 30 Sec.
[0182] The combined effect of the electric fields and antibiotics was also tested. Chloramphenicol was obtained as powder and dissolved in EtOH (99%, Frutarom). All the stock solutions were filter sterilized and held at โ20ยฐ C. until use. Serial twofold dilutions of each antibiotic agent were prepared following NCCLS guidelines. The MIC of an antibiotic was defined as the lowest concentration that completely inhibited growth of the organism, as determined by the unaided eye. These results were in agreement with over 95% inhibition compared with that of drug-free wells, as determined using the microplate reader at 750 nm. The MIC of electric fields was defined as the lowest intensity that inhibits growth by 80% or more compared with control, as determined using the microplate reader.
[0183] Drug interactions with the electric fields were assessed according to the checkerboard method, with the following modifications: S. aureus inocula were diluted in LB medium containing the antibiotic to final concentration of 0.5 to 1.0ร10 5 CFU/ml. The final concentrations of the chloramphenicol ranged from 0.125 to 16 ng/ml. Petri dishes containing the electric fields chamber were filled with 7 ml of the diluted cultures, and placed inside a pre cooled incubator. Fields were applied for 6 hours with the field direction alternating every 300 ms and the field intensities were varied by changing the incubator ambient temperature. Thus, lower ambient temperatures allowed for higher field intensities while maintaining the proper culture temperature of 37ยฐ C. Control plates containing the same electric fields chambers were placed in a pre-warmed incubator set at 37ยฐ C. At the end of the treatment, the cultures were stirred by pipetting the plate content up and down. Quadruplicates of 250 ฮผl each were transferred to a 96 MicroWells plate (Nunc) and the OD was determined using Tecan microplate reader. Cultures were subjected to serial 10-fold dilution (up to 1/10,000) by adding 20 ฮผl of sample to 180 ฮผl of saline solution (0.85% NaCl), from which 80 ฮผl aliquots were plated on LB agar plates (1.5% agar, 1.0% Bacto tryptone, 1% NaCl, 0.5% Yeast extract). CFU counts were performed after overnight incubation at 37ยฐ C. The results were grouped and the effect was calculated by dividing the OD or CFU of the experiments plates with those of the control plates.
[0184] To evaluate the effect of the combinations, the fractional inhibitory concentration (FIC) was calculated for the electric fields and for each antibiotic. The following formulas were used to calculate the FIC index:
[0000] FIC of electric fields=MIC of electric fields in combination/MIC of electric fields alone,
[0000] FIC of drug B =MIC of drug B in combination/MIC of drug B alone,
[0000] and
[0000] FIC index=FIC of electric fields+FIC of drug B.
[0000] Synergy was defined as an FIC index of โฆ0.5. Indifference was defined as an FIC index of >0.5 but of โฆ4. Antagonism was defined as an FIC index of >4.
[0185] The MIC of chloramphenicol against S. aureus was found to be 4 ฮผg/ml, similar to the concentrations reported in the literature. The combined effect of electric fields and chloramphenicol on the growth of S. aureus is given in Table 1. The results demonstrate that there is an additive effect between electric fields and chloramphenicol. As seen, in the presence of 4 V/cm 10 MHz electric fields applied for 6 hours, with the field direction alternating every 300 ms, much lower concentrations of chloramphenicol (1 ฮผg/ml) are sufficient to produce complete inhibition of the growth of S. aureus . The FIC index was found to be 0.625, indicating that there is an additive effect for the combined exposure to electric fields and chloramphenicol. Note that these calculations are based on OD measurements.
[0000]
TABLE 1
0 V/cm
0.5-2.0 V/cm
2.0-2.5 V/cm
3.5-4.5 V/cm
0 ฮผg/ml
100%
62%
32%
19%
0.25 ฮผg/mlโโ
66%
39%
51%
13%
0.5 ฮผg/mlโโ
45%
16%
20%
21%
1 ฮผg/ml
30%
26%
6%
2%
4 ฮผg/ml
7%
13%
2%
0%
[0186] Note that while the examples above used an antibiotic, other therapeutic agents may be substituted for antibiotics in appropriate situations.
[0187] Tests were also performed to determine whether repeated exposure of P. aeruginosa to electric fields could select for bacteria that are resistant to the fields. For this test, overnight bacterial cultures were diluted in fresh LB broth to an OD that corresponds to bacterial counts of 1ร10 6 CFU/ml. Bacteria were exposed to 10 MHz electric fields of approximately 5 V/cm for 6 hours as described above, with the field direction alternating every 300 ms. Control bacteria groups, placed in inactivated electric fields chambers, were positioned in a pre-warmed incubator. The electric fields' effect was determined based on the OD measurements. After the initial electric fields inhibition experiment, the fields' effect was determined anew daily, for four passages as follows: samples from the plates treated with electric fields were pooled and used again for electric fields effect determination in the subsequent generation. In parallel, the fields' effect evolution during these subcultures was compared concomitantly with each new generation, using bacteria harvested from control wells (wells cultured in the pre-warmed incubator). The relative effect was calculated for each experiment from the ratio of inhibition obtained for a given subculture to that obtained for first-time exposure.
[0188] The results of this repeated exposure test of P. aeruginosa to electric fields are presented in FIG. 36 . As demonstrated, four passages of exposure to electric fields did not result in development of resistance, and the inhibition percentage remained around 70% in each iteration.
[0189] Numerical calculations, based on finite element mesh, were used in order to calculate the electric field distribution inside dividing P. aeruginosa and S. aureus , and the following geometries and parameters were used for the calculations: P. aeruginosa was assumed to be an ellipse with a large radius of 2.0 ฮผm and a small radius of 0.6 ฮผm having two membranes (external and internal) of 8 nm thickness. The two membranes were assumed to be separated by a periplasmic space of 50 nm. The dividing bacterium furrow diameter was assumed to be 0.2 ฮผm and the applied external field was 20 V/cm. Since no published data on the electric properties of P. aeruginosa was found, the following data for E. coli was substituted in the calculations: inner membrane conductivityโ1 ฮผS/m, outer membrane conductivityโ3 mS/m, medium conductivityโ0.5 S/m, cytoplasm conductivityโ0.5 S/m and the conductivity of the periplasmic spaceโ50 mS/m.
[0190] S. aureus was assumed to be a sphere with a radius of 0.6 ฮผm and a membrane thickness of 8 nm. The bacterial cell wall thickness was assumed to be 20 nm, and the dividing bacterium furrow diameter was assumed to be 0.2 ฮผm. The applied external field was 20 V/cm. In the simulation the membrane conductivity was assumed to be 1 ฮผS/m, and the cell wall conductivity 10 mS/m. The conductivity of the medium was 0.5 S/m and the conductivity of the cytoplasm was assumed to be 0.8 S/m.
[0191] The electric field distribution in and around P. aeruginosa and S. aureus was calculated using finite element mesh method, and the results are depicted in FIGS. 37 and 38 . In the simulation ( FIG. 37 ) it is seen that the inside dividing rod-like bacteria, close to the furrow, the electric field is strongest and is non uniform. This non uniformity generates dielectrophoresis forces. When the field intensity is 20 V/cm, the magnitude of the Force acting on a dipole of 3000 debyes inside dividing bacteria as a function of field frequency is depicted in FIG. 38A for P. aeruginosa , which peaks at about 2 MHz, and depicted in FIG. 38B for S. aureus , which peaks at about 7 MHz.
[0192] In vivo tests were also performed to test the ability of electric fields to inhibit the growth of bacterial pathogen in vivo. 2ร10 8 S. aureus bacteria were injected S.C. into the dorsum of 8 weeks old female ICR mice. Mice in which abscess was developed in the site of injection within 24 hours were anesthetized and 4 electrodes were placed on their back. The electrodes were similar to those described above but also contained a thermistor positioned inside the electrodes near the electrode surface. The electrodes were arranged in two electrode pairs positioned perpendicular to each other so as to generate electric fields in two different directions, spaced 90ยฐ apart, and the distance between each electrode within any given pair was 2 cm. Note, however, that alternative electrode configurations may be used, e.g., as discussed above in connection with FIGS. 27 and 28 .
[0193] Mice in the control group were identical to those in the electric fields group, but carrying heating electrodes. Mice were held in an IVC system (Techniplast, Italy) whose cages were modified in order to allow for electric fields application inside the cage. 10 MHz electric fields were applied for 48 hours at a nominal field strength of about 5 V/cm, with the field direction alternating every 300 ms, and the temperature at the electrode surface was monitored continuously. The electrodes temperature was held at the desired value by computer feedback control of the amplitude of the waveform at the input of the power amplifier. Sham control electrodes were heated to the same temperature as the electric fields electrodes. No adverse side effects were observed. After 48 hours the mice were anesthetized, sacrificed, and the electrodes were removed. A 2ร2 cm square of the skin surrounding the abscess was harvested, weighed and homogenized. The homogenate was serially diluted and plated in triplicates for CFU determination. The initial S. aureus concentration in these experiments was 2ร10 7 CFU/ml. The results of this experiment are depicted in FIG. 39 , which indicate that the electric fields can inhibit bacterial growth in mature abscesses.
[0194] Depending on the location of the target region within the body, the electrodes may be either placed on the patient's body or implanted in the patient's body. For example, in a patient with an infected cyst, the electrodes could be implanted near the cyst. Note that the Megahertz-range frequencies that were found to be effective against bacteria have virtually no impact on eukaryotic cells, so specificity is excellent, and adverse side effects are not a major concern. Optionally, different frequencies may be applied to the target region, either simultaneously or sequentially, to target one or more types of bacteria that may be present, as discussed above in connection with the other embodiments. The method may also be used in vitro, e.g., to combat bacteria in food, on media, cell cultures, etc.
Example 3
[0195] In vivo experiments were also performed on Pseudomonas aeruginosa strain PAO1 in lungs of infected mice. For this example, bacteria were grown in LB media (1.0% Bacto tryptone, 0.5% Yeast extract, 1.0% NaCl (Frutarom, Haifa, Israel). Broth cultures of freshly plated bacteria were grown in 250 ml of liquid medium at 37ยฐ C. in an orbital shaker at 220 RPM (New Brunswick Scientific, N.J., USA) up to logarithmic phase, centrifuged and resuspended in saline containing 15% glycerol. Stocks were divided into aliquots of 50 ฮผl each containing 2.17ร10 7 Colony Forming Units (CFU)/ml and kept at โ70ยฐ C. until use.
[0196] Experiments were conducted on 7- to 8-week-old (body weight 26-35 g) ICR female mice obtained from Harlan laboratories (Israel). Mice were housed under standard conditions of light and temperature, and were fed standard laboratory chow and water ad libitum. Electric fields were generated by 2 pairs of parallel metal electrodes, 15 mm-long; 3 mm-high. The front of the electrodes was completely insulated from the medium by a ceramic [(lead magnesium niobate-lead titanate (PMN-PT) (EDO, New York, N.Y.)] having a very high dielectric constant (โ>5000) such that their capacitance was about 10 nF each. The back of the electrodes was insulated by a 2.5 mm thick layer of 353ND medical grade epoxy (Epoxy Technology, Billerica, Mass., USA). Each electrode contained a thermistor placed within the epoxy directly on top of the ceramic in order to allow for constant monitoring of the electrodes' temperature.
[0197] The four insulated electrodes were attached to the skin using hydrogel after mouse depilation. The electrodes were wrapped with leucoplast and electrodes wires were connected to the Electric fields generating system or to the sham control system. The four electrodes were functionally divided into two pairs, identified by the red or blue wires. The electrode pairs were placed so as to create two perpendicular field directions at the center of the animal body.
[0198] In order to allow for electric fields generation in mice, while maintaining the strict isolation required when working with animal infected with pathogens, the mice were held in an Individually Ventilated Cage system (IVC) (TouchSLIMโข, Techniplast, Italy) that was modified as follows: Each cage (GR900, Techniplast, Italy) was split by a polycarbonate partition into two units, each housing one mouse. Each mouse was treated with a separate field generator consisting of an RF amplifier (75A250, AR worldwide, Souderton, Pa., USA) activated by a sine-wave generator (Model 662, OR-X, Israel). Six hermetically sealed, shielded electric connection sockets (SM3416 BNC, S.M. electronics, TX, USA) were positioned at the front panel of the cage. Each socket allowed for the connection (by means of coax cables) of a connection box placed inside the cage to an exterior device; an RF amplifier or a temperature measuring system. The connection box served for transferring the electric currents to the mice electrodes, and the mice temperature readout to the computer.
[0199] The entire IVC system, together with the electric fields generating system, were placed inside a Faraday cage in order to meet the guidelines for limiting personnel exposure to time-varying electric, magnetic, and electromagnetic (International Non-Ionizing Radiation CommitteeโINIRC). To avoid field interference with temperature measurements, temperatures were measured periodically while the field was briefly turned off.
[0200] As electric fields are associated with heat production, the electrodes surface temperature was kept constant at the desired level by computer feedback control of the field amplitude. The current source output was switched, every 300 ms, between the two electrodes pairs. This interval was found previously to be effective against P. aeruginosa while preventing the formation of temperature gradients that could affect bacterial growth rate (Giladi et al., 2008). The lung temperature was measured periodically by inserting a thermocouple connected to a temperature data logger (TC08 USB) (Pico technology, Cambridgeshire, UK) into the mouse trachea.
[0201] Two control groups were set in each experiment: sham heat control, and non treated control (referred to as โControlโ). Control electrodes of identical size and shape to the electric fields electrodes, were placed on mice of the two control groups. The Sham heat electrodes produced equal temperature changes to those produced by the field electrodes by means of a heating resistor incorporated within them, and the sham heat electrodes were placed in the same positions as the real electrodes. Except for the differences in the electrodes, the control mice and the sham heat treated mice were held in conditions identical to those of the electric fields treated mice.
[0202] The electric field intensity was measured using a shielded coaxial cable and probe having two exposed tips positioned at a distance of 1 cm from each other. The probe was connected to a floating input oscilloscope (190B Fluke, The Netherlands). Field intensities within lungs were measured by performing a 5 mm long incision in the thoracic skin of an anesthetized mouse and inserting the measurement probe at an intercostal space to a depth of 5 mm into the thorax. The probe was oriented such that the line connecting the two measuring points was parallel to the lines of the electric field. Field intensities are expressed as peak-to-peak volts per centimeter distance (V/cm).
[0203] Mice were rendered neutropenic (neutrophil counts, <100/mm 3 ), as described in Andes and Craig (1998), by two intraperitoneal injections of cyclophosphamide; four days before infection (150 mg/kg of body weight) and an additional injection one day before infection (100 mg/kg of body weight). The pulmonary infection model of Takeda et al., (2006) was used with minor modifications: Anesthetized ICR mice were challenged intra-nasally with 20 ฮผL of saline containing various concentrations (10 4 -10 7 CFU/ml) of P. aeruginosa strain PAO1. On the day of infection, immediately before use, frozen bacterial cultures were thawed and diluted in saline to the desired concentration. Anesthetized mice were challenged intra-nasally with the bacterial suspension. Mice were sacrificed at 0, 3, 6, 9, 24, and 48 hours after infection in order to determine CFU counts in their lungs. After skin disinfection with 70% alcohol, lungs from sacrificed mice were removed aseptically, photographed, weighted and their CFU content was determined.
[0204] Application of electric fields to the mouse torso was carried out as follows: 4 days before infection, the torso of anesthetized mice was shaved with electrical clippers and depilated using cold wax. Electric fields treatment was applied through four insulated electrodes placed around the mouse torso so as to generate fields of two perpendicular directions. Mice were placed inside the IVC cages and the electrodes were connected to the connection box. Application of electric fields began 3 hours after infection and was maintained for 48 h with two brief stops daily for monitoring the physical condition of the mice. After 48 h of treatment, the mice were sacrificed and bacterial numbers in lung were determined.
[0205] The combined effect of electric fields and antibiotics was tested using Ceftazidime, an agent recommended by the infectious disease society of America for the treatment of hospital acquired pneumonia.
[0206] Experiments were conducted as described above for electric fields treatment of P. aeruginosa pulmonary infection with the following modifications: mice were challenged intra-nasally with a predetermined bacterial titer. Ceftazidime (5 mg/kg body weight) was administered intra-peritoneally twice daily for 48 hours starting 3 h after infection. Antibiotic administration was stopped at least 12 h before experiment termination.
[0207] Cold sterile saline was added to each lung sample tube, saline:tissue weight ratio being 10:1. Tubes were placed in an ice bath and the suspensions were homogenized using Omni tissue homogenizer (Omni, Ga., USA) with Omni disaggregation tips. Appropriate suspension dilutions were plated on LB agar plates and kept at 37ยฐ C. for 24 h. Bacterial counts were expressed as number of P. aeruginosa CFU per lung.
[0208] Bacterial growth in the lungs of each mouse was expressed using the following formula: log(CFU T48 /CFU T0 ), where CFU T48 is the CFU counts in the mouse lungs at the end of treatment and CFU T0 is the initial number of bacteria used for inoculation in the specific experiment. The results of all mice that received the same treatment were pooled and the average bacterial growth was calculated for each group. T test with two tailed distribution and equal variance was used to compare the mean values.
[0209] Lungs were first inflated with formaldehyde to their normal volume and then underwent fixation. The specimens were processed and embedded in paraffin wax. Histological sections of 5 ฮผm were cut, stained with haematoxylin-eosin (HE) and examined using light microscopy by an independent expert who was blinded to the source of the sections. A semi-quantitative grading scheme was used to evaluate the extent of the lesions in the sections as follows: minimal (grade 1) lesions involving less than 10% of the lung section; mild (grade 2), 11%-40%; moderate (grade 3), 41%-80%; marked (grade 4), 81%-100%.
[0210] The results of the experiments are described below. Field intensities and temperature measurements were done during electric fields treatment and sham heat application. The average electric fields intensities in the lungs were 12ยฑ4 V/cm. Under these conditions lung temperature was identical to, or up to 1ยฐ C. lower than the electrode surface temperatures which were set to 37ยฐ C. for both the electric fields and the sham heat control.
[0211] Pulmonary infection was induced by intranasal administration of different amounts of P. aeruginosa strain PAO1 to neutropenic ICR mice. Bacteria concentrations that were found to induce a severe pulmonary infection which persisted for at least 48 h were around 5ร10 4 CFU/mouse. Higher concentrations (5ร10 5 CFU/mouse) resulted in a high mortality rate (100% within the first 24 h) while lower concentrations (5ร10 3 CFU/mouse) resulted in a complete recovery.
[0212] Table 2 shows the electric fields' effect on mice with P. aeruginosa lung infection, used alone and combined with ceftazidime. The log CFU at both the start of treatment (T0) and 48 hours later (T48) is listed in table 2. Table 3 shows the electric fields' effect on mice with P. aeruginosa lung infection, used alone and combined with ceftazidime. The growth listed in table 3 is relative to the inoculums after 48 hours of treatment. Table 4 shows the electric fields' effect on mice with P. aeruginosa lung infection, used alone and combined with ceftazidime. The lung weights listed in table 4 are the weights at the end of the 48 hour treatment.
[0000]
TABLE 2
Number of bacteria (CFU) in the lungs of infected mice
without ceftazidime
with ceftazidime
Log CFU
Log CFU
P values
Log CFU
Log CFU
P values
(T0) ยฑ
(T48) ยฑ
compared
# of
(T0) ยฑ
(T48) ยฑ
compared
# of
STDEV
STDEV
to control
mice
STDEV
STDEV
to control
mice
fields
3.6 ยฑ 0.2
4.1 ยฑ 1.5
<0.001
17
4.6 ยฑ 0.2
5.0 ยฑ 1.7
0.005
36
sham heat
3.6 ยฑ 0.2
5.0 ยฑ 2.5
0.009
20
4.6 ยฑ 0.2
6.0 ยฑ 2.3
0.398
27
control
3.6 ยฑ 0.2
7.5 ยฑ 2.7
24
4.6 ยฑ 0.2
6.5 ยฑ 2.5
40
[0000]
TABLE 3
P. aeruginosa growth in mice lungs
without ceftazidime
with ceftazidime
log CFU/lung
P values
log CFU/lung
P values
(T48/T0)
compared
(T48/T0)
compared
(ยฑSTDEV)
to Control
(ยฑSTDEV)
to Control
fields
0.5 ยฑ 1.6
<0.001
0.4 ยฑ 1.7
0.004
sham heat
1.6 ยฑ 2.5
<0.01
1.3 ยฑ 2.2
0.4
control
3.8 ยฑ 2.8
1.9 ยฑ 2.5
[0000]
TABLE 4
Average lungs weight in mice with
pulmonary infection after treatment
without ceftazidime
with ceftazidime
P values
P values
weight in mg
compared
weight in mg
compared
(ยฑSTDEV)
to Control
(ยฑSTDEV)
to Control
fields
257 ยฑ 32
<0.001
244 ยฑ 31
<0.001
sham heat
290 ยฑ 49
<0.001
275 ยฑ 60
0.047
control
377 ยฑ 97
310 ยฑ 77
[0213] 48 hours electric fields treatment of mice suffering from pulmonary infection resulted in 3.4 log reduction in the CFU content of the treated mice as compared to the untreated control mice (see Table 2). The sham heated control treatment resulted in 2.5 log reduction as compared to the control mice (see Table 2). The average bacterial growth [log(CFU T48 /CFU T0 )] of both electric fields treated mice and the sham heat treated mice was significantly lower than in the control mice (see Table 3). A significant reduction was also observed in the weight of lungs of electric fields treated mice as compared to both the sham heated control mice (P=0.02) and to the untreated control mice (P<0.001) (see Table 4). Finally, histopathology examination of the lung samples of the mice that were treated with electric fields were rated as normal to grade 1 with focal acute inflammation. In contrast, lungs of control mice or the sham heat group were rated as grade 2 to 3 associated with acute necrotizing pneumonia and the presence of numerous bacterial colonies.
[0214] Experiments were also performed to test the effects of combined treatment of pulmonary infection caused by P. aeruginosa by electric fields combined with ceftazidime. The inoculums that were found to induce a persistent pulmonary infection in the presence of ceftazidime (10 mg/kg BW/day) alone were around 5ร10 5 CFU per mouse. The results presented in Table 2 demonstrate that 48 h combined treatments of electric fields and ceftazidime resulted in a 1.5 log reduction in the lung CFU content compared to the antibiotic-only treated control. The combined treatment of sham heat and ceftazidime did not result in a significant count reduction compared to the control (see Table 2). Bacterial growth [log(CFU T48 /CFU TO )] in the lungs of mice treated with electric fields and ceftazidime was significantly lower than in the control mice (P=0.004) (see Table 3). The average lung weight was significantly lower in both the ceftazidime/electric fields combination treatment group (P<0.001) and in the ceftazidime/sham heat combination treatment group (P=0.047) as compared to the control group (see Table 4).
[0215] The results obtained demonstrate that electric fields, previously shown to be an effective in-vitro tool for combating bacterial pathogens (Giladi et al., 2008), are also effective in the in-vivo arena. Specifically, it was demonstrated that electric fields, applied by means of external insulated electrodes, have a significant inhibitory effect on the growth of a bacterial pathogen in-vivo. The inhibitory effect was observed when electric fields were applied either as a sole treatment or as an adjuvant to antibiotic therapy.
[0216] One striking outcome of the electric fields application was the fact that the number of bacteria in the lungs of electric fields treated mice was increased only by a fraction of an order of magnitude compared to the number in the inoculums used for infection, while at the same time the number of bacteria in the control group grew by 3.8 orders of magnitude. This observation could be the consequence of either an electric fields inhibitory effect or a bactericidal effect. Histopathology analysis demonstrated that in the electric fields treated mice, the lung morphology was normal with no evidence of a former massive infection. Thus it is reasonable to assume that the electric fields treatment led to cell proliferation arrest, rather than to the elimination of the bacteria after thriving in the lungs. Supportive evidence for this conclusion can be found in the results of the experiment in which combined electric fields/ceftazidime treatment was tested. Ceftazidime is a third-generation cephalosporin antibiotic with a broad bactericidal activity against Gram positive and Gram negative bacteria. Like other beta-lactam antibiotics, ceftazidime is most effective against dividing bacteria. Indeed, ceftazidime treatment of 10 mg/kg BW/day, alone, resulted in a growth reduction of close to 2 logs, compared to the non treated lungs (1.9 vs. 3.8 respectively, see Table 3). Yet, the combined treatment of electric fields and ceftazidime did not lead to a reduction in the bacterial growth compared to the electric fields treatment alone (0.4 vs. 0.5, respectively, see Table 3), nor did it reduce CFU counts in the lungs compared to the inoculums suggesting that bacterial growth was arrested.
[0217] Previously we demonstrated that application of electric fields in vitro led only to a 20% reduction in the number of treated bacteria compared to the control, which is considerably less than the inhibition that occurred in the in vivo study discussed herein. One possible explanation for the enhanced efficacy in the in vivo experiments could be derived from the fact that the electric Fields inhibitory effect is positively correlated with field intensity (Giladi et al., 2008). While the electric fields intensity in the in vitro experiments was limited to 4 V/cm, in order to avoid over heating of the culture, the electric fields intensity in the in vivo experiments was significantly higher (i.e., about 12 V/cm). The application of such electric fields with higher intensities was made possible in view of the active heat removal that occurs in the mouse's body.
[0218] Experimental data obtained for both microorganisms and proliferating living cells, such as cancer cells, indicates that higher field intensities result in higher efficacy. However, there is a practical limit on field intensity due to the heat generated under the electrodes and within the treated animal, and the relevant anatomy's ability to carry that heat away.
[0219] For example, in the case of a human brain, the blood can carry away the heat that is generated in the tissue, and the total blood flow is about 2000 cc/min. Assuming that we want to keep the temperature of the brain below 39ยฐ C., which is 2ยฐ above the normal body temperature, this blood flow should be able to carry away 4000 calories/min, which corresponds to about 280 W. We should therefore be able to apply 278 W safely to the brain. Since the side to side electric resistance of the human brain is about 100 Ohms, and power equals voltage squared divided by resistance, we should be able to use a voltage of 167 V safely. This voltage drops over a distance of about 10 cm, in which case the field strength will be about 17 V/cm. Thus, for the brain, it would be reasonable to operate at field strengths between 5 and 20 V/cm, and more preferably at field strengths between 10 and 17 V/cm.
[0220] In the case of resting skin, the blood flow is sufficient to handle fields of 5V/cm, and in the case of hyperemic heated skin the blood flow is sufficient to handle fields of 50 V/cm or even 80 V/cm. It is therefore expected that practical useful fields will range from 2 V/cm to 100V/cm, depending on the treated organ and its state. Note that the above calculations are for RMS Voltage, and not peak to peak voltage.
[0221] Another possible factor for the enhanced efficacy of the electric fields treatment in the in vivo arena could be related to the fact that the sham heat treatment also led to an inhibitory effect on bacterial growth. Though the sham heat control effect was smaller than the electric fields effect, it was nevertheless significant. Bacterial growth inhibition due to elevated temperatures may result from either a direct effect of the heat on bacterial growth or from local and systemic โhostโ reactions and responses to the heating. The former hypothesis was tested in vitro by comparing the growth rate of P. aeruginosa at various temperatures within the range of normal to febrile temperatures. Similar to the reports in the literature (Magnusson et al., 1995), we found that the growth rate of P. aeruginosa is positively correlated with increase in the temperature in the range of 34-38ยฐ C. Thus we can rule out the possibility of a direct effect of heat on bacterial growth. The alternative notion, i.e. that local and systemic host reactions to elevated temperatures negatively affect bacterial growth is not new. In fact, heat and fever were used as a tool against microbial pathogens for over a century (reviewed by Atkins, 1982 and Hasday et al., 2000). There are numerous reports regarding the effect of elevated host temperatures on the growth of bacterial pathogens demonstrating for example that: fever induced after Malaria inoculation can serve as a treatment against Treponema pallidum (Wagner-Jauregg, 1919), febrile core temperature is essential for optimal host defense against Klebsialla pneumonia peritonitis in mice (Jiang et al., 2000), fever in elderly patients with community-acquired pneumonia is positively correlated with high survival rates (Ahkee et. al, 1997) and maintaining a normal core body temperature (36.6ยฑ0.5ยฐ C.) after anesthesia decreases the incidence of infectious complications in patients undergoing colorectal resection (Kurz et al., 1996). Amongst the mechanisms suggested to play a role in the antibacterial effect of heat, augmentation of the innate immune function is probably the most intensively studied one (Hanson, 1993; Hasday et al., 2001; Mackowiak et al., 1983; Lederman et al., 1987; Rosenpire et al., 2002). Though our results demonstrate that electric fields and sham heat application did not cause an increase in the lung temperatures, they did raise the temperature of the peripheral organs of the treated mice, by at least 2 degrees (the normal skin temperature of mice is 34-35ยฐ C. while in the present study the electrodes temperature was set to 37ยฐ C.). Hanson (1993) demonstrated that mature primary T-cells response is strongly regulated by temperature changes in the range of 29ยฐ to 37ยฐ C., which corresponds to the peripheral tissue temperature elevation during febrile episodes. This finding provides a possible explanation for the sham heat inhibitory effect reported in the present study. Since application of electric fields is always associated with heat production it is reasonable to assume that the enhanced efficacy of the fields reported in the present study compared to our previous report (Giladi et al., 2008) is in part due to elevated temperatures of the peripheral tissue.
[0222] Thus, electric fields can be an effective and safe antibacterial treatment modality which could be applied in cases of both superficial and deep infections, either as a sole treatment or in combination with antibiotics, for both P. aeruginosa pathogens and other types of bacteria. Such treatments will involve placement of insulated electrodes on the skin surrounding the infected organs, and generating electric fields by applying the appropriate AC voltages to those electrodes.
[0223] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details can be made without departing from the spirit and scope of the invention.
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Cells that are in the process division are vulnerable to damage by AC electric fields that have specific frequency and field strength characteristics. The selective destruction of rapidly dividing cells can therefore be accomplished by imposing an AC electric field in a target region for extended periods of time at particular frequencies with particular filed strengths. Some of the cells that divide while the field is applied will be damaged, but the cells that do not divide will not be harmed. This selectively damages rapidly dividing cells like bacteria, but does not harm normal cells that are not dividing. Since the vulnerability of the dividing cells is strongly related to the alignment between the long axis of the dividing cells and the lines of force of the electric field, improved results can be obtained when the field is sequentially imposed in different directions.
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CROSS-REFRENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. patent application Ser. No. 13/672,725 filed Nov. 9, 2012, now U.S. Pat. No. 9,113,869, which is a Continuation of U.S. patent application Ser. No. 12/753,998 filed Apr. 5, 2010, now U.S. Pat. No. 8,328,064, which claims benefit of U.S. Provisional Application No.61/175,815, filed May 6, 2009, and the disclosures of each of the above-identified applications are hereby incorporated by reference in their entirety.
Technical Field
The present disclosure relates generally to a surgical instrument and, more specifically, to a surgical instrument for clamping, severing, and joining tissue.
Background of Related Art
Certain surgical stapling instruments are used for applying rows of staples through compressed living tissue. These surgical stapling instruments are employed, for example, for fastening tissue or organs prior to transection or resection or during anastomoses. In some cases, these surgical stapling instruments are utilized for occluding organs in thoracic and abdominal procedures.
Typically, such surgical stapling instruments include an anvil assembly, a cartridge assembly for supporting an array of surgical staples, an approximation mechanism for approximating the cartridge and anvil assemblies, an alignment or guide pin assembly for capturing tissue between the cartridge and anvil assemblies and for maintaining alignment between the cartridge and anvil assemblies during approximation and firing, and a firing mechanism for ejecting the surgical staples from the cartridge assembly.
In use, the alignment pin assembly is advanced and the anvil and cartridge assemblies are approximated. Next, the surgeon fires the instrument to place staples in tissue. Optionally, the surgeon may use the same instrument or a separate device to cut the tissue adjacent or between the row(s) of staples. The alignment pin in some instances is advanced automatically with approximation of the cartridge; in other instances it is advanced by a separate mechanism.
SUMMARY
The present disclosure provides a surgical instrument comprising a handle portion, an elongated portion defining a longitudinal axis and extending distally from the handle portion, and an end effector disposed adjacent a distal portion of the elongated portion including a first jaw member and a second jaw member dimensioned to clamp tissue therebetween.
A pin is disposed in mechanical cooperation with the first jaw member and includes an engagement section and is movable between a first position wherein the engagement section is spaced from the second jaw member and a second position wherein the engagement section engages the second jaw member. The pin has a non-circular cross-section.
Preferably, a knife is provided to move distally to cut the clamped tissue. Preferably, the knife has an upper edge terminating alongside the pin. In one embodiment, the pin has a gap dimensioned to accommodate the knife. The instrument can include rows of fasteners with the knife positioned between the rows.
In one embodiment, the pin is substantially semi-circular in cross-section. In another embodiment the pin is substantially L-shaped in cross-section.
The instrument can include a second non-circular pin. In one embodiment, the pins are spaced from each other and one pin is adjacent a top portion of a knife and the other pin is positioned adjacent a bottom portion of the knife. The pins can be positioned on opposite sides of a knife slot from which the knife extends.
In some embodiments, the instrument can further include a second pin having a substantially semi-circular cross section, each of the pins having a substantially planar surface, the substantially planar surface of the second pin facing a direction opposite the direction the substantially planar surface the other pin faces.
The pins in some embodiments can move in a distal direction automatically when the first and second jaw members move to a position to clamp tissue.
In another aspect, a surgical instrument is provided comprising a handle portion, an elongated portion defining a longitudinal axis and extending distally from the handle portion, and an end effector disposed adjacent a distal portion of the elongated portion. The end effector included a first jaw member and a second jaw member, the first and second jaw members dimensioned to clamp tissue therebetween. The first jaw member has at least one row of fasteners arranged in a row substantially transverse to the longitudinal axis. A pin is disposed in mechanical cooperation with the first jaw member and includes an engagement section, the pin movable between a first position wherein the engagement section is spaced from the second jaw member and a second position wherein the engagement section engages the second jaw member. A second pin is spaced from the first pin, the first pin and second pin each having a surface alongside the knife wherein the first surface of the first pin faces in a first direction and the second surface of the second pin faces in a second opposite direction.
In some embodiments, the first and second surfaces of the pins are substantially planar. The first pin can have a third surface facing toward a top surface of the knife and the second pin can have a fourth surface facing towards the bottom surface of the knife. In some embodiments, the pins move in a distal direction automatically when the first and second jaw members move to a position to clamp tissue.
BRIEF DESCRIPTION OF DRAWINGS
Various embodiments of the presently disclosed surgical stapling instrument are disclosed herein with reference to the drawings, wherein:
FIG. 1 is a perspective view of a surgical stapling instrument of the present disclosure;
FIG. 1A is a perspective view of an end effector of the instrument of FIG. 1 ;
FIG. 1B is a side cross-sectional view of the end effector of the instrument of FIG. 1 with the jaw members in the open position;
FIG. 1C is a side cross-sectional view of the end effector of FIG. 1 with the jaw members in the closed position;
FIG. 2 is a close up perspective view of one embodiment of the cartridge assembly having a pin with a semi-circular cross-section;
FIG. 3 is a perspective view of the area of detail designated in FIG. 2 ;
FIG. 4 a close up perspective view of another embodiment of the cartridge assembly having four rows of staples;
FIG. 5 is a close up perspective view of another embodiment of the cartridge assembly;
FIG. 6 is a close up perspective view of the area of detail designated in FIG. 5 ; and
FIG. 7 is a close up perspective view of another embodiment of the cartridge assembly having two pins with a semi-circular cross-section.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Embodiments of the presently disclosed surgical stapling instrument are described in detail with reference to the drawings, wherein like reference numerals designate corresponding elements in each of the several views. In the description that follows, the term โproximalโ refers to the end or portion of the surgical stapling instrument closer to the user, whereas the term โdistalโ refers to the end or portion of the surgical stapling instrument further from the user.
In the interest of brevity, the present disclosure focuses on the pin for a surgical stapling instrument designated in the drawings by reference numeral 100 . U.S. Pat. No. 7,407,076, the entire contents of which are incorporated by reference herein, describes in detail the structure and operation of an embodiment of surgical stapling instrument 100 .
FIG. 1 illustrates a surgical stapling instrument 100 designed for applying fasteners and cutting tissue. In brief, surgical stapling instrument 100 includes a handle portion 110 , an elongate portion 120 , and an end effector 130 extending from the distal portion of the elongate portion 120 . Handle portion 110 contains a trigger 140 for actuating end effector 130 . Elongate portion 120 extends distally from handle portion 110 and defines a longitudinal axis A-A therealong. End effector 130 is disposed adjacent to a distal portion of elongate portion 120 and includes a first jaw member or cartridge assembly 150 and a second jaw member or anvil assembly 160 . In this embodiment, cartridge assembly 150 is adapted to move longitudinally with respect to anvil assembly 160 upon actuation of trigger 140 to clamp tissue between the jaw members 150 , 160 . It is also contemplated that the anvil assembly can be moved (approximated) toward the cartridge assembly or that the cartridge and anvil assemblies can both be moved toward each other to clamp tissue.
Cartridge assembly 150 includes a plurality of slots 152 ( FIGS. 1B and 1C ) each capable of holding a staple or any other suitable fastener. Each slot 152 is operatively associated with a pusher thrust bar or plunger 122 . Pusher 122 extends along elongate portion 120 and partially into cartridge assembly 150 . Cartridge assembly 150 also includes a knife advanceable to cut tissue clamped between the cartridge and anvil assemblies 150 , 160 , respectively. In use, pusher 122 moves distally upon actuation of trigger 140 and causes the ejection of the staples disposed in slots 152 in a distal direction, substantially parallel to the longitudinal axis of the elongate portion 120 . In addition to slots 152 , cartridge assembly 150 includes a pin 154 operatively connected to pusher 122 and a bore 156 dimensioned to slidably receive pin 154 . Pin 154 is adapted to move longitudinally along bore 156 in response to a translation of pusher 122 . The pin 154 can alternatively be moved by a sliding knob 155 in the handle portion 110 . In the embodiment depicted in FIG. 1A-1C , anvil assembly 160 has a hole 162 designed to receive at least a portion of pin 154 . Anvil assembly 160 has staple-deforming pockets 164 for deforming the fasteners ejected from cartridge assembly 150 . An elongated slot can be provided between the pockets 164 in the anvil assembly to accommodate the knife described below.
While anvil assembly 160 remains stationary with respect to cartridge assembly 150 during operation, cartridge assembly 150 is movable longitudinally between a proximal position and a distal position upon actuation of trigger 140 . In the proximal position, cartridge assembly 150 is spaced apart from anvil assembly 160 , as seen in FIG. 1B in an approximated position. The actuation of trigger 140 causes clamp slides 170 , operatively connected thereto, to move distally which in turn causes thrust bar 122 to move distally due to pins 174 . In turn, the distal translation of thrust bar 122 causes the distal movement of cartridge assembly 150 toward anvil assembly 160 to an approximated position. While cartridge assembly 150 moves from the proximal position toward the distal position, end effector 130 clamps any tissue โTโ placed between cartridge assembly 150 and anvil assembly 160 as shown in FIG. 1C . In the distal position, cartridge assembly 150 is located closer to anvil assembly 160 and presses tissue โTโ against anvil assembly 160 .
Further actuation of trigger 140 , i.e. a second squeeze of the trigger 140 , once cartridge assembly 150 reaches its distal (approximated) position causes ejection of the fasteners from slots 152 . That is, the continued distal translation of pusher 122 , once cartridge assembly 150 is located in the distal position, causes the deployment of the fasteners positioned in slots 152 . During deployment, these fasteners exit slots 152 and advance through tissue and into contact with staple-deforming pockets 164 of anvil assembly 160 for formation thereof, e.g. bending of the staple legs into a โBโ configuration. Actuation of trigger 140 also advances the knife to sever tissue clamped between the cartridge and anvil jaw assemblies 150 , 160 .
Note the distal motion of clamp slides 170 causes alignment pin 154 to move distally along bore 156 due to the operative connection of the alignment pin pusher 172 to the clamp slides 170 via pins extending through elongated slots in pin pusher 172 as described in U.S. Pat. No. 7,407,076. (Pin pusher 172 includes a vertical portion having an abutment member configured to engage the proximal end of the pin 154 .) Upon sufficient distal movement of pin 154 , hole 162 of anvil assembly 160 receives a portion of pin 154 . The structural interaction between pin 154 and hole 162 (when cartridge assembly 150 is located in the distal position) assists in the alignment of slots 152 with staple-deforming pockets 164 . It should be appreciated that alignment pin 154 can alternatively be moved manually as pin pusher 172 is moved manually, e.g. by sliding knob 155 .
Turning now to embodiments of the alignment pins of the present disclosure illustrated in FIGS. 2-7 , these pins can be used with the stapler of FIG. 1 described above or with other suitable surgical staplers. They can be configured to move automatically with approximation of the cartridge, i.e. in response to actuation of the trigger, and/or moved by the user separate from approximation, e.g. by an independent slidable knob or other manual controls or knobs located at various portions of the instrument. Thus, it should be understood that it is contemplated that the pins disclosed herein can be moved in either way (automatic or manual) or in both ways.
FIGS. 2 and 3 illustrate a close up view of the cartridge assembly 150 of FIG. 1 . In this embodiment, cartridge assembly 150 includes a plurality of staple slots 132 and a knife slot 134 . Each staple slot 132 houses a staple or fastener 136 . Knife slot 134 is adapted to receive knife 138 . Knife 138 is configured to move longitudinally to cut tissue between the staple rows. Preferably, knife 138 is advanced distally when the staples are advanced from cartridge assembly 150 through tissue. In this embodiment, two rows of staples are provided, extending substantially linearly and substantially transverse to longitudinal axis A-A of the instrument 100 . A different number of staples and staple rows are also contemplated.
Cartridge assembly 150 further includes a bore 156 configured to receive a pin 154 . Pin 154 is adapted to move longitudinally between a proximal position and a distal position and has a substantially semi-circular cross-section to allow passage of knife 138 adjacent the pin 154 . That is, the knife 138 passes by (alongside) the substantially planar inner surface region of the pin 154 . The substantially semi-circular shape of pin 154 allows the knife 138 to extend up to the region of the pin 154 . As shown, the knife 134 extends past the bottom 154 a of the pin 154 and terminates adjacent an intermediate region 154 b of the pin 154 . Other knife heights are also contemplated. The staple slots 156 and staple line extend beyond the top edge 138 a of the knife 138 and beyond the bottom edge 138 b of the knife 138 .
FIG. 4 illustrates an alternate embodiment of the cartridge assembly, designated generally by reference numeral 250 . Cartridge assembly is substantially identical to cartridge assembly 150 of FIG. 2 , except that four rows of staples are provided. As shown, the four substantially linear rows of staples 236 are arranged substantially transverse to the longitudinal axis A-A of the instrument, with two staggered rows positioned on either side of knife 238 . As in the other embodiments herein, the staples 236 are fired in a direction substantially parallel to the longitudinal axis of the instrument. The knife 238 is movable from knife slot 234 to sever tissue clamped between the cartridge and anvil assemblies. Pin 254 is substantially semi-circular shaped, similar to pin 154 . The staples 236 extend beyond the upper and lower edges 238 a , 238 b , respectively, of knife 238 .
In the alternate embodiment of FIG. 5 , cartridge assembly, designated generally by reference numeral 350 , is substantially identical to cartridge assembly 150 of FIG. 2 , except for the configuration of pin 354 . As shown, two substantially linear rows of staples 236 are arranged substantially transverse to the longitudinal axis of the instrument, with one row positioned on either side of knife 338 . A different number of rows are also contemplated. The knife 338 is movable from knife slot 334 to sever tissue clamped between the cartridge and anvil assemblies. The staples 336 extend beyond the upper and lower edges 338 a , 338 b , respectively, of knife 338 . Pin 354 is substantially L-shaped in configuration to create a gap 357 to accommodate the knife. That is, portion 354 a extends downwardly alongside the knife 338 and portion 354 b extends transversely above the upper edge 338 a of knife 338 . Consequently, the pin 354 extends in an arc of about 270 degrees (although other arcs are also contemplated).
It should be appreciated that although one alignment pin is shown, it is also contemplated that two alignment pins can be provided, e.g. one on the upper portion of the cartridge and the other on the lower portion of the cartridge. This is shown for example in the embodiment of FIG. 7 , wherein upper pin 454 and lower pin 455 are provided in cartridge 450 . Each of the pins 454 , 455 are substantially semi-circular in configuration, similar to pin 254 of FIG. 2 , however the substantially L-shaped pins of FIG. 5 could also be provided (either one at the top or bottom utilized with the substantially semi-circular pin on the opposing end or on both the top and bottom.) Note that the pins 454 , 455 are preferably on opposing sides of the knife 438 . As in the other embodiments, the staple line extends beyond the upper edge 438 a and lower edge 438 b of knife 438 .
While the above description contains many specifics, these specifics should not be construed as limitations on the scope of the present disclosure, but merely as illustrations of various embodiments thereof. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
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A surgical instrument comprising a handle portion, an elongated portion defining a longitudinal axis and extending distally from the handle portion, and first and second jaw members dimensioned to clamp tissue therebetween. The first jaw member has at least one row of fasteners arranged in a row substantially transverse to the longitudinal axis. A pin is disposed in mechanical cooperation with the first jaw member and is movable between a first position where the engagement section is spaced from the second jaw member and a second position where the engagement section engages the second jaw member. The pin has a non-circular cross-section.
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This invention relates to an electrical connector and a method of manufacture utilizing a sheet of flexible insulation material having an ordered mesh containing discrete contacts operable to interconnect contact paths between components and circuits.
BACKGROUND OF THE INVENTION
The ever decreasing size of electronic components, such as integrated circuits, and the associated reduction in center line spacings of contacts of the components and of the circuits on which they are mounted raises substantial difficulties in the manufacture of connectors. It does because the traditional tolerances in metal and plastic parts for connectors, expressed in several thousandths of an inch, are now being achieved in the components and circuits themselves in terms of conductive path widths and spacings.
Because of this, a number of approaches have been taken which employ very small conductive particles held in a matrix of insulating material including adhesives. These materials are variously whisker-like particles, or slivers, or platelets and flakes which are either fabricated of precious metals or of inert ingredients coated with precious metals. These various elements can range in size from ten to twenty microns in width or diameter up to 25 or 30 microns in maximum dimension. The elements are held in various binders, including pressure sensitive or hot melt and polymerizable adhesives and in elastomeric materials. The resulting product may be termed to be a conductive elastomer or a conductive adhesive, and both operate to interconnect the conductive paths of components to the conductive paths of circuits when such elements are forced together against the conductive element. The forcing together forces the conductive particles to touch each other and to contact the paths being interconnected to form electrical interconnections. U.S. Pat. No. 4,729,809, granted Mar. 8, 1988, is drawn to anisotropically conductive adhesive composition and details a conductive adhesive composition which is, in essence conductive in one direction. It mentions that the conductive particles have a tendency to form clusters during the mixing of the composition and also that larger particles may be employed, which are of a sufficient size to provide single particles conduction through an adhesive layer which is on the order in thickness of the diameter of the particles.
The foregoing patent and numerous other patents and teachings relating to conductive elastomers and/or adhesives employ a random placement of conductive particles in an insulating medium and depend upon the mixture of the composition to result in their being at least sufficient particles to form an interconnection when the composition is compressed between conductive paths. This randomness causes no particular problems when the areas of the conductive paths to be joined are relatively large compared to the size and number of particles and the spacing thereof, making the provision of particles statistically such as to assure interconnection.
But as the dimensions between conductive paths to be interconnected shrink, the statistically based random disposition of particles can become less reliable. Moreover, the randomness almost assures discrepancies as between contact paths manifest in variations in conductivity or resistivity and occasionally, variations in capacitive and inductive effects of the differently dimensioned conductive pathways based on the orientation, number, and disposition of not only the conductive particles, but of the insulating medium and thus the dielectric values of the interconnection.
Another problem facing the foregoing connection devices and techniques relates to the dependence upon the characteristics of adhesion which are directly related to the chemistry of the adhesive, its mixture and handling, shelf life, and relative volatilization.
Accordingly, the present invention has as an object the provision of an electrical connector and a method of manufacture which features an ordered disposition of fine conductive particles in a preformed sheet of insulating and dielectric material to provide an array of discrete contact elements, each essentially identical to the other in electrical and mechanical characteristics. The invention has as a further object the provision of a sheet of thin insulating material containing fine conductive particles forming an area array connector for interconnecting contact paths on very close centers and with very small spacing of paths between components and circuits. Still a further object is to provide a method of manufacturing ordered electrical connectors having discrete contacts on very fine centers. The invention further contemplates an objective of providing a thin film-like ordered array of conductive particles wherein the particles and the insulating matrix can be preformed and assembled together utilizing adhesive substances for mechanical purposes.
SUMMARY OF THE INVENTION
The present invention connector and method relate to the use of a plastic sheet which, in a preferred embodiment, is defined by a fine web of insulating strands woven together to define a mesh made to contain conductive contacts held by an adhesive in the mesh. The resulting structure is an ordered anisotropic conductive medium which may be manufactured on a continuous basis and cut into areas which interconnect the multiple paths of components such as integrated circuits and circuits such as printed circuits, all compressed together by a housing or the equivalent. The invention alternatively contemplates a molded sheet having holes or apertures defining the mesh with the conductive particles forced in such holes to define a single layer of insulation and contact elements which is on the order of the thickness of the diameter of the conductive elements. In accordance with the invention concept, contact elements on the order of 50 microns in diameter may be employed with a sheet of similar dimension and thickness utilizing an adhesive to hold the contacts in position within the sheet. In the woven variety of the invention, the warp and woof of the woven strands is such as to define a mesh receiving the contact elements.
The invention method contemplates displacement of a sheet of insulating material, a spraying of the sheet with adhesive followed by an air jet removal of excess adhesive, a flooding of the adhesive coated sheet with contact elements with a suitable doctoring to load the sheet to a single thickness of contact elements and a curing of the adhesive to hold the contact elements in place. The sheet following curing can be cut into suitable lengths to form connectors.
The invention contemplates contact elements formed of metal or glass spheres coated with appropriate finishes such as gold over nickel as well as spheres formed of conductive gel and/or discrete metallic spring elements. In one embodiment utilized for area array interconnection of components to circuits, a housing is provided for the component and the invention connector sheet operable to press the component against the sheet and in turn press the sheet against the circuit to be interconnected with the contact elements providing the electrical path between the conductive paths of component and circuit. By virtue of the ordered arrangement of contact elements, electrical parameters can be calculated and relied upon from contact to contact and connector to connector, both in term of numbers of contacts, and the physical dimensions of plastic and metal elements.
IN THE DRAWINGS
FIG. 1 is an exploded perspective view of an assembly of circuit, connector, sheet, component, and a connector housing operable to hold, position, and interconnect the various elements.
FIG. 2 is an elevational view, substantially enlarged, of the contact paths of a component and a circuit prior to interconnection with the sheet connector of the invention.
FIG. 3 is an elevational view, in partial section, of the connector shown in FIG. 2.
FIG. 4 is a plan view of the connector shown in FIG. 3.
FIG. 5 is an elevational view, in partial section, of an alternative embodiment of contact element.
FIG. 6 is a schematic view of a preferred embodiment of the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, an assembly 10 is shown to include a circuit 12, a component 20, a sheet connector 30, and a housing 60 which fit together to provide an electrical and mechanical interconnection of component to circuit. The circuit 12 may be considered to be a printed circuit board having a number of layers of conductive paths defining a functioning circuit and interconnecting various components to provide electronic functions, memory and logic. These elements in turn may be utilized to form computers, business machines, communication systems and the like. The circuit 12 includes a series of surface-mounted contact pads 18 arranged in an array on the surface thereof corresponding with contact pads on component 20 shown as 24 mounted on the undersurface of the body of the component shown as 22. The pads 18 interconnect to the various circuits within circuit 12. The circuit 12 includes at the periphery mounting holes 14 which facilitate the mounting of the connector housing 60 in a manner to be described. Also included in circuit 12 are guide and alignment holes 16, one of which is shown, which serve to align the connector housing 60 and the component and connector contained therewithin. The component 20 may be thought of as an integrated circuit, a hybrid, or other functioning device which contains therewithin arrays of solid state components interconnected by the pads 24 in the body 22 of the component. A flat metal plate, forming a heat sink 26, is attached to the upper surface of component 20. The sheet connector 30, shown in FIGS. 1 and 2, includes a series of discrete contacts 36 distributed in an ordered fashion over the surface of 30. FIGS. 2-4 show, in enlarged detail, the contacts 36 in the ordered arrangement in a matrix formed in the embodiment of FIGS. 3 and 4 of a plurality of strands of insulating material woven into warp and woof strands 32 and 34 to define a mesh of cavities 35 into which are fitted the contacts 36. Shown also in FIGS. 3 and 4 is an adhesive 38 which holds the contacts 36 in position within the mesh and also holds the web forming the sheet together. As can be seen in FIGS. 3 and 4, the contacts 36 essentially fill the mesh and are of a diameter and dimension approximating that of the sheet formed by strands 32 and 34.
Connector sheet 30 thus formed has an area corresponding to the area of the contact pads 18 of circuit 12 and contact pads 24 of component 20 and as can be discerned, contains contacts 36 on centers of ordered or fixed spacing so that numerous contacts 36 will engage a given pad 18 or pad 24 to provide for a redundancy of interface for electrical connection. The connector sheet 30 is fitted within the housing 60 along with component 20.
Referring to FIG. 1, housing 60 includes an upstanding or vertical flange 62 defining interiorly a cavity 64 into which the component 20 and the connector sheet 30 are fitted. On the exterior vertical surface of the flange 62 are latch projections 66 extending around the four sides thereof. At the corners of the housing 60 are fasteners 70 which include beveled downwardly projecting portions 72 which fit into holes 14 of the circuit 12. Connected to and integral with the portions 72 are projections 74 which extend above the flange 68. A cap 78 is provided, including a center projecting portion 80 which is flat and intended to bear against the heat sink plate 26 of component 20. The center portion 80 is relieved at the edges to provide a limited spring action for improving compliance in application of forces to component 20. On the exterior of cap 78 are downwardly projecting flanges 82 which include apertures 84 intended to be engaged by latches 66 when the assembly is put together. In practice, the component 20 and connector sheet 30 are put together within housing 60 with the housing then guided onto the circuit 12, alignment pins 76, one of which is shown at one corner of the housing, fit into alignment holes 16 and align the connector, component, and housing with the circuit 12. Thereafter, the housing is forced downwardly by the application of the cap which serves to drive the posts 74 downwardly, driving the fasteners 72 within holes 14, such fasteners deforming inwardly in a radial sense to snap outwardly and latch the housing to the circuit. Further downward movement of cap 78 will result in the latches 66 engaging apertures 84 to latch the assembly together and to force the component downwardly bearing against the connector 30. FIG. 2 shows the connector 30 disposed between the pads 18 and 24 carried by the circuit and component, respectively, prior to closure of the component and circuit together. As can be discerned from FIG. 2, numerous contacts 36 will engage the pads 18 and 24 upon closure.
In a prototype embodiment wherein the contacts 36 were on the order of 70 microns in diameter, the overall thickness of the sheet from the connector 30 was on the order of 70 microns with the strands on the order of 30 microns in diameter. The invention contemplates the use of thicker strands and a greater mesh dimension as well as smaller strands and a smaller mesh dimension. The invention contemplates, for example, contacts on the order of 50 to 100 microns being used with a sheet having a mesh of similar dimension and strands on the order of 20 to 30 microns. The strands 32 and 34 may be made of a polyester fiber woven into the configuration shown. The invention also contemplates that the sheet forming connector 30 may be molded, thermoformed, extruded, or stamped and formed to have a mesh like that shown in FIGS. 3 and 4 with the contacts 36 inserted in the mesh thereformed.
The invention contemplates a variety of contact constructions, including solid brass spheres, suitably nickel and gold plated, to maintain a reduced bulk resistance and an enhanced contact surface. Alternatively, glass or other inert and insulating spheres or other shapes, suitably plated with conductive material, may be employed. FIG. 5 shows another alternative in the form of a "fuzz button" fabricated by fine wire formed into a sphere-like volume and inserted in the mesh of the sheet material. The contact 40 would provide a discrete resilience and compression to effect a multi-point contact with the pads 18 and 34. The invention also contemplates fabricating the contacts 36 out of spheres or other volumetric shapes utilizing a conductive gel to form the body of the contact. Conductive gels are taught in U.S. Pat. No. 4,770,641, granted Sep. 13, 1988. There, the gel should be sufficiently cured to be handled as a discrete body.
As can be discerned from the dimensions above given, the resulting connector provides an interconnection which is very short in terms of electrical resistance and physical dimension, very short in terms of the dielectric path, and one in which discrete contacts having discrete resistances and discrete dielectric properties may be employed.
Referring now to FIG. 6, a method for fabricating or manufacturing the invention is shown. The sheet forming connector 30, comprised of woven strands 32, 34 is guided by rollers 42, pulled by rollers similar to 42 but not shown to the left of the view in FIG. 6. Adjacent to rollers 42 is a nozzle 44 adapted to spray the strands with an adhesive to fill the mesh with such adhesive. Adjacent nozzle 44 is a drying and precure station 46 which precures the adhesive partially. An air jet may be provided to remove excess adhesive, leaving a film deposited within the mesh of the sheet. Adjacent to precure 46 is a station including a source of contacts and a vibrator 50 carrying the adhesive-coated sheet. The contacts 36 are flowed onto the sheet to fill the mesh thereof with a suitable doctor blade, not shown, positioned to remove excess contacts from the mesh. A roller, not shown, may be employed to seat the contacts within the mesh and a curing station 52 employed to cure the adhesive to produce a finished connector sheet 30 drawn therefrom. Controls, not shown, would be employed to regulate the method. Connector sheets 30 of discrete area would be formed by cutting the sheet 30 shown in FIG. 6 into appropriate lengths.
In practice, contacts formed of solid material would be used in applications requiring high normal forces and low contact resistance. Contacts of gel or metal springs would be employed in other appropriate applications of lower force and higher allowed electrical resistance and less planar tolerance.
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A connector assembly (10) and a method of manufacture include a connector sheet (30) formed of a fine web of insulating strands (32, 34) woven together to define a mesh of cavities (35) containing discrete contacts (36, 40) held by an adhesive (38) to define an ordered anisotropic area of discrete contact points useful in interconnecting contact pads (24) of a component (20) to contact pads (18) of a circuit (12). A connector housing (60) is provided to clamp the component (20) to the circuit (12) with the connector sheet (30) therebetween.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a gas analyzing apparatus for measuring by alternately feeding a sample gas and a reference gas, and more particularly to a gas analyzing apparatus capable of analyzing in one method of analysis or in plural combinations of different methods of analysis.
2. Description of the Prior Art
Explaining, for example, the ultraviolet gas analysis method (NDUV method) and infrared gas analysis method (NDIR method), the NDUV method makes use of the characteristic that the gas to be analyzed absorbs ultraviolet rays in an intrinsic wavelength region, and the NDIR method also makes use of the characteristic that the gas to be analyzed absorbs infrared rays in an intrinsic wavelength region.
That is, in the case of NDUV method, as shown in FIG. 4, a solenoid valve 12 is disposed in a line 1 for feeding sample gas, and a solenoid valve 14 is also disposed in a line 3 for feeding reference gas; therefore, the sample gas and reference gas are fed into an NDUV gas analyzer 6 including an ultraviolet ray source, a filter, and a detector. The ultraviolet absorption spectrum is analyzed, and qualitative analysis or quantitative analysis of the object gas is conducted. In the case of NDIR method, on the other hand, as shown in FIG. 3, a solenoid valve (three-way valve) 2 is disposed in a line 1 for feeding sample gas, and a solenoid valve (three-way valve) 4 is also disposed in a line 3 for feeding reference gas. Lines 5 and 7 are arranged so that the sample gas and reference gas may flow into other lines from these two solenoid valves 2 and 4; therefore, the sample gas and reference gas are fed alternately to an infrared gas analyzer 8 including an infrared ray source, a sample cell, a filter, and a detector. The infrared absorption spectrum is analyzed, and qualitative analysis or quantitative analysis of the object gas is conducted.
Thus, hitherto, when analyzing the sample gas, if the principle of measurement is different, individual sample gas lines are provided and separate units are built up, and one gas analyzer was used for each object gas. However, for example, when sulfurous acid (SO 2 ) is analyzed by the NDUV method and carbon monoxide (CO) is analyzed by the NDIR method, two gas analyzers are needed for analyzing stack flue gas which contains both SO 2 and CO gases, and they may be analyzed separately. It is also costly because the piping and parts in the unit of these gas analyzers must be composed and assembled for each gas to be measured. In actual measurement, moreover, a large space for the plurality of gas analyzers is needed for arranging the gas analyzers side by side.
SUMMARY OF THE INVENTION
In the light of the above problems, it is hence a primary object of the invention to present a gas analyzing apparatus capable of analyzing two or more types of gas by using analyzers differing in the principle of measurement in one sample gas line, curtailing the number of parts, reducing the cost, and further saving the space for installation.
That is, to solve the problems, the invention presents a gas analyzing apparatus in which a gas analyzer is disposed at either one or both of a sample gas line and a reference gas line. The sample gas line and reference gas line are connected to another gas analyzer. In the sample gas line and reference gas line, a valve is provided for feeding sample gas and reference gas alternately to the latter gas analyzer directly or through the former gas analyzer. The invention also presents a gas analyzing apparatus in which the gas analyzer disposed at either one or both of the sample gas line and reference gas line is provided in plurality.
This analyzing apparatus makes use of a physical measuring method which does not cause changes in the sample gas. Further, for either of the gas analyzing apparatus set forth above, plural gas analyzers of high sensitivity for multiple components can be composed in one sample gas line and reference gas line, so that two or more components of sample gas can be analyzed simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a constitution of a first embodiment of a gas analyzing apparatus of the invention;
FIG. 2 is a schematic diagram showing a constitution of a second embodiment of a gas analyzing apparatus of the invention;
FIG. 3 is a schematic diagram showing a constitutional example of a conventional infrared gas analyzing apparatus by NDIR method and according to prior art; and
FIG. 4 is a schematic diagram showing a constitutional example of a conventional ultraviolet gas analyzing apparatus by NDUV method according to prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, preferred embodiments of the invention are described in detail below. FIG. 1 is a diagram showing a constitution of a first embodiment of a gas analyzer of the invention. To avoid duplicated explanation, the same elements as explained in the prior art are identified with same reference numerals. This gas analyzer is an analyzer of a fluid modulation system for feeding sample gas and reference gas alternately. A gas changeover solenoid valve (three-way valve) 2 is disposed in a line 1 for sample gas. Line 1, moreover, is provided with a sample cell 6b of small volume of an ultraviolet analyzer (hereinafter NDUV gas analyzer) 6 and one sample cell 8b of a non-dispersion type infrared analyzer of high sensitivity (hereinafter NDIR gas analyzer) 8. In a line 3 for reference gas, a gas changeover solenoid valve (three-way valve) 4 is disposed, and also an other sample cell 8b of the NDIR gas analyzer 8 is disposed.
At a port 2a of the gas changeover solenoid valve 2, a line 5 connected to the reference gas line 3 is connected, and at a port 4a of the gas changeover solenoid valve 4, a line 7 connected to the sample gas line 1 is connected. Therefore, when the gas changeover solenoid valve 2 is operated, the sample gas is alternately supplied into the line 1 for sample gas and line 3 for reference gas. Similarly, when the gas changeover solenoid valve 4 is operated, the reference gas is alternately supplied into the line 3 for reference gas and line 1 for sample gas.
The NDUV gas analyzer 6 is composed of ultraviolet ray source 6a, sample cell 6b, and detector 6c (filters and other elements are not shown). By alternately feeding sample gas and reference gas into the sample cell 6b, ultraviolet ray absorption of the target component in the sample gas (for example, SO 2 ) is measured. The NDIR gas analyzer 8 is composed of infrared ray sources 8a, 8a', sample cells 8b, 8b', and detector 8c (filter and others are not shown). By alternately feeding sample gas and reference gas into the two sample cells 8b and 8b', infrared absorption of the target component in the sample gas (for example CO) is measured. Incidentally, instead of the gas changeover solenoid valves 2, 4, the gases may be supplied into the NDUV gas analyzer 6 and NDIR gas analyzer 8 by rotary-type valves.
In the gas analyzer of the invention thus constituted, by feeding sample gas from the line 1 for sample gas and feeding reference gas from the line 3 for reference gas, when the gas changeover solenoid valves 2 and 4 are put in operation, the gas having an absorption band in a specific wavelength region of ultraviolet rays can be analyzed in the NDUV gas analyzer 6, while, at the same time, using the sample gas and reference gas, the gas having an absorption band in a specific wavelength region of infrared rays can be measured in the NDIR gas analyzer 8.
FIG. 2 is a diagram showing a constitution of a second embodiment of a gas analyzer of the invention. In this embodiment of a gas analyzer, the NDUV gas analyzer 6 is disposed in the line 1 for sample gas, and one sample cell 8b of the NDIR gas analyzer 8 is also disposed. In the line 3 for reference gas, moreover, the NDUV gas analyzer 6 is disposed, and an other sample cell 8b of the NDIR gas analyzer 8 is also disposed. In this combination, different types of gas components having absorption and in the wavelength region of ultraviolet rays can be measured by two NDUV has analyzers 6, 6. Simultaneously, gas components having an absorption band in the wavelength region of infrared rays can be measured by the NDIR gas analyzer 8. Using two NDUV gas analyzers 6, 6, if one fails, the other can be used for analysis. Also, trouble can be discovered early if the numerical values are different when the same gas is measured by two NDUV gas analyzers 6, 6. Still further, in these two NDUV gas analyzers 6, 6, they can be calibrated with each other by using span gas, and the reliability of the analyzer is assured.
Thus, according to the gas analyzer of the invention, in either one or both of the line for sample gas and the line for reference gas, the NDUV gas analyzer(s) 6 (6) is disposed, and also the NDIR gas analyzer 8 is disposed. Moreover, in either one or both of the line 1 for sample gas and the line 3 for reference gas, three, four, or more NDUV gas analyzers 6 may be disposed. The infrared gas analyzer such as NDIR gas analyzer 8 may be also provided in plurality. Thus, by disposing plural NDUV gas analyzers and plural NDIR gas analyzers 8, multiple components can be analyzed simultaneously as analyzers of high sensitivity and multiple components.
Not only is the combination of NDIR and NDUV analyzers applicable, but also a chemical luminescence gas analyzer (CLD), a hydrogen ionization gas analyzer (FID), an ultraviolet fluorescent gas analyzer (UVF), a magnetic oxygen meter, and so on, are applicable to the gas analyzer for measuring by alternately feeding sample gas and reference gas in any combination. However, the analyzer initially disposed in the line and initially used for measurement is limited only to the measuring method without altering the sample gas or reference gas by chemical reaction or the like.
According to the gas analyzing apparatus of the invention as described herein, if using gas analyzers differing in the principle of measurement, multiple gas components can be analyzed simultaneously by one gas analyzing apparatus. Hitherto, in different methods of analysis, different gas analyzers were used, but by the gas analyzing apparatus of the invention, only one gas analyzing apparatus is enough, the number of parts is decreased, and the manufacturing cost is lowered. At the same time, the space for installation is saved for gas analysis. Moreover, plural gas analyzers of same type are used and if one is defective, analysis can continue, or a defective analyzer can be detected promptly.
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A gas analyzing apparatus includes a sample gas line with a sample line valve for providing a sample gas, and a reference gas line with a reference line valve for providing a reference gas. A first gas analyzer is connected to the sample line downstream of the sample line valve, and a second gas analyzer is connected to both the sample and reference gas lines downstream of the valves. The lines are configured such that sample gas and reference gas may be alternately provided to the second gas analyzer either directly or indirectly via the first gas analyzer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application of PCT/US2010/056160, filed Nov. 10, 2010 which claims priority to U.S. Patent Application No. 61/259,732 filed on Nov. 10, 2009, the disclosures of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure relates to tissue repair, and more specifically, to an anchor for securing tissue to bone.
2. Related Art
Arthroscopic procedures often require soft tissue to be reattached to bone. To achieve this, anchors are placed in the bone and sutures attached to the anchor are passed through the tissue to securely retain the tissue in place. When making a repair of soft tissue to bone, it is advantageous to have as large an area of contact between the bone and tissue as possible. Anchor points spaced from one another in rows result in a repair having a broader area of contact. A procedure, and components for use in such procedure, that securely attaches tissue to bone using a plurality of attachment points over a large area of contact is needed. Such procedure must be able to be done in a quick and efficient manner with a minimum of recovery time for the patient.
SUMMARY OF THE INVENTION
In an aspect, the present disclosure relates to an anchor assembly. The anchor assembly includes an anchor including a distal portion and a proximal portion, the anchor defining a cavity and an opening to the cavity; an insertion member disposed within the cavity of the anchor; and a sleeve coupled to the anchor, the sleeve disposed over the proximal portion of the anchor. In an embodiment, the distal portion of the anchor includes barbs. In another embodiment, the anchor includes a through hole. In yet another embodiment, the cavity includes threads. In a further embodiment, the insertion member includes a threaded proximal portion and a non-threaded distal portion. In yet a further embodiment, the insertion member includes a cannulation. In an embodiment, the sleeve includes a threaded proximal portion and a non-threaded distal portion. In another embodiment, the anchor includes protrusions.
In another aspect, the present disclosure relates to an anchor delivery device for tissue repair including a handle; a first knob coupled to the handle; a second knob coupled to the handle; and a shaft coupled to the handle, the shaft including an outer member, an inner member disposed within the outer member, and a driver disposed within the inner member. In an embodiment, a proximal portion of the driver is coupled to the first knob and a proximal portion of the outer member is coupled to the second knob. In another embodiment, the anchor delivery device further includes a sleeve coupled to the outer member, an anchor coupled to the inner member, and an insertion member disposed within a cavity of the anchor, the insertion member coupled to the driver.
Further features, aspects, and advantages of the present disclosure, as well as the structure and operation of various embodiments of the present disclosure, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 shows an exploded view of the anchor assembly of the present disclosure.
FIG. 2 shows a side view of the sleeve of the anchor assembly of FIG. 1 .
FIG. 3 shows a cross-sectional view of the sleeve of FIG. 2 .
FIG. 4 shows a side view of the anchor of the anchor assembly of FIG. 1 .
FIG. 5 shows a cross-sectional view of the anchor of the anchor of FIG. 4 .
FIG. 6 shows a cross-sectional view of the insertion member of the anchor assembly of FIG. 1 .
FIG. 7 shows an isometric view of the anchor delivery device of the present disclosure.
FIG. 8 shows a cross-sectional view of the anchor delivery device of FIG. 7 prior to insertion of the anchor assembly into bone.
FIG. 9 shows an expanded view of the distal end of the shaft of the anchor delivery device of FIG. 8 .
FIG. 10 shows a cross-sectional view of the anchor delivery device of FIG. 7 after insertion of the anchor assembly into bone.
FIG. 11 shows an expanded view of the distal end of the shaft of the anchor delivery device of FIG. 10 .
FIG. 12 shows a side view of the anchor assembly of the present disclosure after the anchor assembly is placed within bone.
FIG. 13 shows a cross-sectional view of the anchor assembly of FIG. 12 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
FIGS. 1-6 show the components of the anchor assembly 10 of the present disclosure. The assembly 10 includes an anchor 11 , an insertion member 12 , and a sleeve 13 . The anchor 11 includes a distal portion 11 a , a proximal portion 11 b , a cavity 11 c defined within the anchor 11 and an opening 11 c โฒ to the cavity 11 c , a through hole 11 d having two openings 11 d โฒ, protrusions 11 e located below each opening 11 d โฒ, and barbs 11 f located on an outer surface 11 a โฒ of the distal portion 11 a . The insertion member 12 includes a proximal portion 12 a having threads 12 a โฒ, a non-threaded distal portion 12 b , and a cannulation 12 c . The sleeve 13 includes a threaded proximal portion 13 a , a non-threaded distal portion 13 b , a cavity 13 c , and an opening 13 d to the cavity. The anchor cavity 11 c includes threads 11 c โณ that engage threads 12 a โฒ of the insertion member 12 upon insertion of the member 12 into the cavity 11 c
FIGS. 7-11 show the delivery device 20 for use with the anchor assembly of FIG. 1 . The device 20 includes a handle 21 , a first knob 22 coupled to the handle 21 , a second knob 23 coupled to the handle 21 , and a shaft 24 coupled to the handle 21 . The shaft 24 includes an outer member 24 a , an inner member 24 b disposed within the outer member 24 a , and a driver 25 disposed within the inner member 24 b.
As shown in FIGS. 8-11 , the proximal portion 25 a of the driver 25 is coupled to the first knob 23 and the proximal portion 26 a of the outer member 24 a is coupled to the second knob 22 via a movable member 27 . The movable member 27 includes a distal portion 27 a , a proximal portion 27 b , and a cannulation 27 c . The proximal portion 27 b includes threads 27 b โฒ on its outer surface 27 b โณ. The movable member 27 is located in a cavity 21 a of the handle 21 . The cavity 21 a includes a distal portion 21 a โฒ and a proximal portion 21 a โณ. The proximal portion 21 a โณ includes threads 21 b that engage the threads 27 b โฒ on the proximal portion outer surface 27 b โณ. As will be explained further below, due to the threaded engagement of the movable member 27 with the cavity proximal portion 21 a โณ, rotation of the knob 22 causes the outer member 24 a to move axially along the length of the shaft 24 . Rotation of the knob 22 is discontinued when an end 27 a โฒ of the movable member distal portion 27 a engages an end 21 c of the cavity distal portion 21 a โฒ, thereby preventing over-insertion of the sleeve 13 into the bone.
A proximal portion 25 a of the driver 25 includes threads 25 a โฒ that engage threads 29 on an inner surface 24 b โฒ of the inner member 24 b . Threaded engagement of the driver 25 and inner member 24 b allow for axial movement of the driver 25 along the shaft 24 via rotation of the knob 23 . Rotation of the knob 23 is discontinued when a depth stop 25 b engages an end 24 b โณ of the inner member 24 b , thereby preventing over-insertion of the insertion member 12 into the anchor 11 , as will be further explained below.
During tissue repair, suture is attached to a soft tissue, a hole is created in bone, ends of the suture are placed through the through hole 11 d of the anchor 11 , the anchor 11 is placed within the bone hole via axial advancement of the delivery device 20 , knob 23 is rotated to move the insertion member 12 axially and engage and fixate the suture to the anchor 11 , and knob 22 is then rotated to move the sleeve 13 axially and place the distal end 13 b of the sleeve 13 over the proximal end 11 b of the anchor 11 and further lock the suture between the sleeve 13 and the bone. FIGS. 12 and 13 show the assembled anchor assembly 10 without the suture. The suture may be tensioned prior to advancing the insertion member 12 to engage the suture. Optionally, a suture anchor may be placed within bone, ends of the suture placed through the soft tissue, and the ends then placed through the through hole 11 d of the anchor 11 . Repair would continue as described above. A similar type of repair is shown and described in U.S. Patent Application Publication Nos. 20090112270, 20100016869, and 20100016902, the disclosures of which are incorporated herein by reference in their entireties.
The components of the anchor assembly are made from a polymer material and via an injection molding process. However, other materials and processes may be used. The handle and knobs of the delivery device are manufactured from a polymer material and via an injection molding process. The handle and knobs are coupled via an interference fit. However, other materials, processes of making, and methods of coupling may be used. The components of the shaft are made from a metal material via an extrusion or drawings process. The components of the shaft are coupled to the handle and knobs via a threaded fit or an interference fit. However, other materials, processes of making, and methods of coupling may be used.
As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
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The present disclosure relates to an anchor assembly. The anchor assembly includes an anchor including a distal portion and a proximal portion, the anchor defining a cavity and an opening to the cavity; an insertion member disposed within the cavity of the anchor; and a sleeve coupled to the anchor, the sleeve disposed over the proximal portion of the anchor. A delivery device is also disclosed.
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TECHNICAL FIELD
This invention relates to data storage libraries of dismountable media, such as optical disks and tape cartridges, and in particular to an array of independent libraries using a data organization that improves write and read performance.
BACKGROUND OF THE INVENTION
An optical disk or a magnetic tape library (also called a "jukebox") is a mechanical device capable of mounting units of storage media (e.g., disks or tape cartridges) on a drive in response to access requests from a computer system. A library usually comprises a set of one or more drives, a storage area for unmounted media, recording media, and a robot picker mechanism (possibly more than one) that moves the recording media between the storage area and the drives. Libraries range in physical size from that of a small room containing 1,000 or more media units to a desk top unit containing as few as 8 media units. The storage capacity of the largest library systems is in the Terabyte range, while the smallest libraries may have capacities of only 1 Gigabyte.
Library systems are used in many applications and generally perform their function in a satisfactory manner. There is, however, much room for improvement in the reliability, performance, and flexibility of conventional systems. For instance, most libraries have only one picker mechanism for transporting media to and from its drives. This characteristic is a single mechanical point of failure and represents a major weakness in the reliability of a library. If and when a picker fails, all of the data stored in such a library--possibly Terabytes--is inaccessible until the picker is repaired. Another performance limitation of library systems is their data transfer rate. While individual drives found in optical and tape libraries are of the type that have good data transfer rates, it is generally not possible for the rate of any single data stream from the library to exceed that of a single drive. For some applications, this is a serious drawback. It is also difficult to configure libraries to match the differing needs of applications. Some libraries allow drives to be added in place of media storage space, but in general it is not possible to retrofit a library with additional pickers, higher data transfer rates, or greater capacity.
While some applications would benefit from higher data transfer rates, the major performance limitation of any library of dismountable media is the time required to mount and dismount media units. Separate media units in a library can only be accessed at the rate at which the picker can move the units to and from the drives. Optical disk libraries can require tens of seconds to complete a platter exchange, and tape libraries require even more time. This affects both the write and read performance of the library.
Schemes that provide flexibility in the physical placement of newly-written data have been devised for fixed media. Log-structured file (LSF) systems are described by Rosenblum et al., "The Design and Implementation of a Log-Structured File System", Association for Computing Machinery 13th Symposium on Operating System Principles, 1991. Log-structured arrays of fixed disks are described in PCT published patent applications WO 91/16711, WO 91/20025, and WO 91/20076, all assigned to Storage Technology Corporation. In a system having an LSF data architecture, new data is always written (appended) to logically blank areas of the storage media. The old version of the data, stored elsewhere, is simply marked as invalid in a directory. The current data and the blank space is called the log. When a read is performed, the directory is consulted to find the current location of the requested data. To ensure that there will always be blank areas for writes in the log, a "garbage collection" process is run in the background to scan the media for logically deleted data segments and collect them together. The key to these LSF systems for fixed media is the "indirection" provided by the directory. Indirection is the mapping of the logical address of a data set to its physical storage location. In a conventional file system, this mapping is fixed; in an LSF file system, it is regularly modified. This approach allows the address of a unit of data to be separated from its physical storage location and gives great flexibility when determining the physical placement of data in the system.
What is needed is a file system for a data storage library that takes advantage of the unique characteristic of dismountable media units and the flexibility of an LSF data architecture to minimize the number of media unit mounts and dismounts, and thereby improve both the write and read performance of the file system.
SUMMARY OF THE INVENTION
The present invention is a data storage library system, preferably arranged in an array of independent libraries, having an LSF data architecture. The log-structured library is similar to fixed media systems having log-structured architectures in that it employs a directory to provide indirection, but is different in that it divides the jobs of reading and writing (log accesses) and garbage collection among the different drives of the library. As required, the dismountable media storage units are moved from the storage area and mounted on a drive assigned the appropriate role. If the unit is to have data written on it, it is mounted on the log drive; if it is to be processed for garbage collection, it is mounted on the garbage collection drive. The roles assigned to the drives are flexible and can change as needed. The system allows both writes and reads to the log drive and garbage collection to occur simultaneously. In addition, the garbage collection process segregates the data into "hot" and "cold" segments, and ultimately into "hot" and "cold" media units, according to the age of the data from the last access by the host computer. In the library system, this allows all the cold data to be located on the same cold media units, which can then be exported from the library for off-line storage and replacement with new media units. Write performance of the library system is improved because the use of drives with assigned roles minimizes the number of mounts of media units. Read performance is improved because writes to the log drive do not generally require mounts of media units so the picker has more time available to handle read requests. Read performance is also improved because hot data becomes located on fewer hot media units, thereby decreasing the number of mounts required and increasing the likelihood that a media unit containing the data requested to be read will already be mounted.
For a fuller understanding of the nature and advantages of the present invention, reference should be made to the following detailed description taken together with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of a computer system attached to a library array.
FIG. 2 is a diagram illustrating an LSF system as applied to a library.
FIG. 3A is a diagram illustrating one type of drive assignment for segregating data in a log-structured library array having two drives in each independent library.
FIG. 3B is a diagram illustrating one type of drive assignment for segregating data in a log-structured library array having three drives in each independent library.
FIG. 4 is a block diagram of a preferred hardware and software environment illustrating an LSF system for an array of libraries, each library having drives with preassigned roles for specific LSF functions.
FIG. 5 is a diagram illustrating the drive assignment for segregating data in the system of FIG. 4, wherein the libraries in the array have four drives each.
FIG. 6 is a flow chart illustrating the read operation for the system of FIG. 4.
FIGS. 7A and 7B are a flow chart illustrating the write operation for the system of FIG. 4.
FIGS. 8A and 8B are a flow chart illustrating the garbage collection operation for the system of FIG. 4.
FIG. 9 is a flow chart illustrating the media export operation for the system of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
Redundant Arrays of Independent Libraries (RAIL)
An array of libraries comprises two or more libraries connected to a computer or controller and organized in such a manner that logical data sets are stored on more than one of the libraries. The diagram of FIG. 1 illustrates the system. The computer 100 of the array of libraries contains buffers 101 stored either in main memory or on nonvolatile secondary storage devices (e.g., fixed disks 400) and one or more interface controllers (one for each interface bus used in the array), suchas typical controller 102 attached to typical interface bus 200. The buffers 101 serve to store the results of recent library access requests so that some future requests can be resolved without accessing the libraries. Some buffers 101 are also used to reorganize data as it moves between the array of libraries and the computer 100. The computer 100 may be attached to a communications channel, such as a network 201, over whichit transmits and receives access requests and data.
Attached to each interface bus in the array, such as typical bus 200, are one or more libraries of dismountable storage media (optical disk or tape cartridges), such as the typical string of libraries 300. The array includes not just those individual libraries attached to one interface controller (such as libraries 300 on bus 200 attached to controller 102), but all other libraries on other buses in the system. Also attached to thecomputer 100 are a number of other secondary storage devices, such as typical optical or magnetic fixed disks 400 connected by interface bus 110to controller 112. A software routine 103 runs on the computer 100 and accepts access requests for a storage device and translates those requestsinto one or more access requests to one or more of the libraries in the array.
The manner in which access requests to the library storage device represented by the array are translated into requests to the individual libraries that make up the array depends upon the configuration of the array itself. The distinguishing features of the various types of array configurations are the manner in which data is spread across the librariesand the placement of redundant data. Different configurations or organizations of redundant arrays (RAID) are known for fixed disks, as described by Patterson et al., "A Case for Redundant Arrays of InexpensiveDisks (RAID)", Proceedings of ACM SIGMOD, Chicago, Ill., June 1-3, 1988, pp. 109-116.
The Log-structured Library Array
The present invention will be described in the context of a single library,although it will be understood that the invention is also applicable to arrays of independent libraries organized according to RAID architectures.
The data storage space in LSF architectures is organized into a number of equal-sized divisions called segments. Each segment is further subdivided into smaller storage units which are the units that can be logically addressed (i.e., sectors or tracks). The contents of the segments are indexed through two data structures: the log directory and the segment directory. The log directory performs the translation between logical and physical data addresses. It is a table that contains the storage media index, the segment number on that media unit, and the offset of the data from the start of the segment. The size of the log directory is generally quite small (.sup.ห 0.02%) relative to the size of the data being stored. The log directory typically resides on magnetic disk and is cachedin the main memory of the controlling computer for quick access. The segment directory is a small table stored in each segment. It contains a time stamp, a pointer to the segment directory of the segment written justprior to its own, and a list of the contents of the segment (duplication ofpart of the log directory). The time stamp and pointer are for crash recovery; in the event of a complete system failure, the segments can be scanned and the log directory reconstructed (i.e., find the segment with the latest time stamp and then scan backward filling in the log directory).
This organization is shown in the diagram in FIG. 2 in the form of four media units (units 1-4), each of which is logically divided into three segments (segments 1-3). In the example of FIG. 2, the logical sector or track address 45 is translated via the log directory into the physical address of media unit 3, segment 3, offset 315. If data were to be writtento that logical address 45 at a later date, the new data would be assigned to a different physical location (most likely a different segment) and theentry in the log directory would be updated to reflect the new physical location. The old physical storage location represented by segment 3 on media unit 3 will eventually be reclaimed by the garbage collection process and be made available again for the writing of new data.
The garbage collection process has the task of alleviating the segment fragmentation that occurs as new data is written and old versions of the data are abandoned. In practice, several complete segments will be read in, their contents compacted into as few segments as possible, and then new segments written out, after which the log directory is updated. According to the present invention, in a log-structured library array the tasks of log access and garbage collection are assigned to different drives. For example, in a simple library array consisting of libraries with two drives each, one drive in each library is the log drive while theother drive is the garbage collection drive. In this arrangement, the log drive keeps a media storage unit mounted collecting all write traffic, while the garbage collection drive systematically processes the rest of the media storage units in the storage area of the library. In the preferred implementation, the assignment of roles to the individual drivesis not fixed, but is adjustable to match the workload. For instance, if theworkload is read intensive, both drives can be used to satisfy read requests; if the workload is write intensive, both drives can perform writes (with the provision that some garbage collection must occur to freespace).
The selection of which segments to clean in the garbage collection process is a function of the dynamic nature of the data they contain. Cleaning segments that contain recently written and frequently changing data (called "hot" data) is not as efficient as cleaning segments that contain older and less volatile data (called "cold" data). The benefit of cleaningsegments with hot data is generally short lived. The contents of cold segments, however, tend not to change so the benefit of cleaning them to reduce fragmentation lasts longer.
The cleaning process can also separate the hot data in a segment from the cold to promote the formation of hot and cold segments. This segregation is of benefit because it reduces the number of times hot data is cleaned, as the garbage collection process tends to pay more attention to the cold segments. In the present invention, this segregation is extended in a log-structured library array to create hot and cold media storage units. The mounting of a media storage unit is an expensive operation that shouldnot be wasted on data that is not likely to be accessed. By creating hot and cold media units, the write and read performance of the library array is improved by increasing the amount of hot data that tends to be on each media unit that is mounted. This minimizes the number of mounts required to handle write requests, and the resulting reduced demand on the picker also frees the picker to handle additional read requests, which improves read performance. Cold media units are also excellent candidates for removal from the library array for replacement with newly-formatted media units.
Data Segregation and Access Characterization in Log-structured Library Array
The present invention using the above-described concepts of drives with assigned roles and hot and cold media can be understood with reference to FIGS. 3A and 3B.
In the log-structured library array, a data access, i.e., a read or a write, is characterized as either an external demand access (i.e., from anapplication) or an internal access (i.e., garbage collection). The types ofaccess are further characterized as being an access to either hot or cold data. For external accesses, the distinction between a demand hot and a demand cold write is passed by the particular application making the requests. For example, writes to a database log (not to be confused with the write log) and those of a database load utility are cold because the written data is likely to remain unaccessed for some time.
In the following description, acronyms are used to describe the different types of accesses. An external write request of hot data is labeled as a DWH (Demand Write Hot) access, a garbage collection write of hot data is labeled as CWH (Collection Write Hot), and a garbage collection write of cold data is labeled as CWC (Collection Write Cold). For both demand and collection reads, hot and cold data are not separately labeled so a demandread is labeled DR and a collection read CR.
Consider, for example, the assignment to an array with libraries having twodrives (log drive 50 and garbage collection drive 52), as illustrated in FIG. 3A. In that assignment, all demand writes (DWH and DWC) are handled by the log drive 50 and all collection accesses (CR, CWH and CWC) are handled by the garbage collection drive 52. Demand reads (DR) are handled by either of drives 50, 52, depending upon the workload and current activities, and when they have the data being requested. In this arrangement, called "a uniform platter temperature system", the garbage collection drive 52 is responsible for general clean up of the media storage units by recovering invalidated space, compacting and compressing segments, and possibly placing data on the media units to improve performance (e.g., by moving data to the middle tracks on an optical disk or to the middle of a tape so that seek distances are minimized).
In the assignment illustrated in FIG. 3B, there are three roles for the drives. There is a log drive 60, a garbage collection drive 62, and a "cold collection" drive 64. This arrangement is called the "hot platter/cold platter system" (or hot tape/cold tape system if the library array is an array of individual tape libraries). The log drive 60 has the job of writing all hot data (DWH and CWH), while the cold collection drive64 has the job of writing all cold data (CWC and DWC). The garbage collection drive 62 reads hot and cold data (CR) and sends it to the appropriate drive 60, 64 for writing. Demand reads (DR) are handled by anyof the drives 60, 62, 64 as workload and current activities dictate. Thus, the systems of FIGS. 3A and 3B are applicable for 1-, 2-, or 3-drive libraries, although multiple drives clearly offer the best performance when there is significant write activity. The hot/cold platter system of FIG. 3B has the feature that it tends to collect old (cold) data on specific media units. The advantage of this is that these media units can then be exported from the library array. This is a unique feature of the library array using the log-structured file system in that data can be reorganized by media storage units. Hot units remain mounted (which reduces mounts), and cold units containing obsolete data are exported fromthe array.
Preferred Embodiment
The preferred configuration of the present invention is illustrated in FIG.4 and comprises five main physical components: a host computer 500 in the form of an IBM PS/2 Model 80 with 16 Megabytes of semiconductor main memory, a 100 Megabyte magnetic disk drive 518 attached to the computer 500, and three IBM Model 3995 optical disk libraries 520, 540, 560. The host computer 500 may be a dedicated computer whose primary function is tomanage the data storage and retrieval on the libraries, such as would be the case in a network of other computers whose function is to run specificsoftware applications. Alternatively, computer 500 may run other software applications as well as manage the data storage on the libraries.
The libraries 520, 540, 560 are attached to the computer 500 by individual industry standard Small Computer System Interface (SCSI) buses that are attached to respective SCSI controllers/adapters 510, 512, 514. Other hardware and software subcomponents of the system reside inside the computer 500 and the libraries 520, 540, 560. The software in the computer500 includes file system controller software, Read and Write (R/W) logic 502, Garbage Collection logic 504, and Media Export logic 506. These logicmodules 502, 504, 506 are portions of a software program stored on the fixed-disk drive 518. In operation, a copy of the program or portions of the program are loaded into the main memory of the computer 500 when needed. In addition to SCSI bus controllers/adapters 510, 512, 514, the hardware in the computer also includes SCSI bus controller/adapter 516 attached to fixed-disk drive 518 and random access memory buffers 508.
Inside each of the libraries 520, 540, 560 are four optical disk drives: drives 521, 522, 523, 524 in the first library 520; drives 541, 542, 543, 544 in the second library 540, and drives 561, 562, 563, 564 in the third library 560. Each library 520, 540, 560 also includes a storage space for optical disks and a picker to mount and dismount disks from the drives.
There are four basic operations in the LSF system according to the present invention for the dismountable media located in each of the libraries 520,540, 560 of the array: read of data, write of data, garbage collection, andmedia export. Each of these operations of the system will be described within the context of the first library 520 illustrated in FIG. 4 and the assignment of roles to the drives 521, 522, 523, 524. The operation of thesystem within the context of the other libraries 540, 560 is the same as for library 520.
Referring to FIG. 5, the assigned roles for the drives in library 520 will be described. Drive 521 in the library 520 is assigned the role of being the log drive; it writes all of the data associated with hot data write requests, Demand Write Hot (DWH), and Collection Write Hot (CWH).
Drive 522 is assigned the role of being the garbage collection drive; it isused to periodically do Collection Reads (CR) of the contents of each optical disk in the library in order to reclaim abandoned storage space and reorganize the contents of the library. In relatively rare instances to be described, the garbage collection drive 522 will also do write requests for cold and hot data during the collection process (CWC and CWH).
Drive 523 is assigned the role of being the cold collection drive; its job is to write data that will not be accessed frequently. There are two sources of this type of data known to be cold: one is internal from the garbage collection drive 522, Collection Write Cold (CWC), as it reads data that has not been accessed for some user specified threshold; the other is external from applications that identify cold data to the log-structured file system, Demand Write Cold (DWC).
Drive 524 is assigned the role of being the read drive; it processes all external demand read requests, Demand Read (DR), that are for data that does not reside on disks in any of the other three drives, i.e., the otherdrives will also process DRs for data on disks that are already mounted on those drives.
For both read and write requests, the basic unit of data transfer is a logical sector. A logical sector consists of a fixed number of physical contiguous sectors stored on the disk. The size of a segment in the file system is chosen to be an integral multiple of the logical sector size.
The operation of the file system with respect to the assigned drive roles described above is illustrated in the flow charts in FIGS. 6-9 as described below.
1. READ Operation
The operation of the read component of the file system running on the computer 500 controlling the libraries 520, 540, 560 is illustrated in FIG. 6. When the R/W logic 502 receives a data read (DR) request, it firstconsults the log directory to determine the physical address of the requested data, given its logical address (602). It then determines if themedia unit specified in the physical address is mounted (604) on any of thefour drives 521, 522, 523, 524 in library 520. If it is, the R/W logic 502 reads the data (606) from the specified segment at the specified offset into a portion of the buffers 508 in the computer 500. It then updates thelast access time kept in the log directory for the requested logical address (608) and the last access time of the disk kept in the media directory (610).
If the media unit specified in the physical address is not mounted on any of the four drives in the library 520, then the R/W logic 502 determines if the read drive 524 is unmounted (612). If yes, it mounts the specified media (614) onto the read drive 524 and proceeds to read the specified data (606). If the read drive is not already mounted, the R/W logic 502 dismounts whatever media unit is currently mounted (616), and then proceeds to mount the specified media unit (614).
After the data has been retrieved and stored (606) in the file system buffers 508, it is transferred to the buffers of the requester and the reading is completed.
2. WRITE Operation
The operation of the write function of R/W logic 502 of the file system is illustrated in the flow chart of FIGS. 7A and 7B. When R/W logic 502 receives a write request, it first determines if the request is to write hot data (DWH) or cold data (DWC) (702). If the request is to write hot data, it then determines if a segment is available on the log drive 521 for writing hot data (704), as shown in FIG. 7B. If not, it checks if there is a media unit mounted (706) on the log drive 521, and if there is,it determines if there is currently a segment on that media unit that is empty (708). If yes, it selects an empty segment (710) and the data is written in that segment (712) on the log drive 521, the segment table on the media is updated (714), and the entry in the log directory for the logical address of the data being written is updated (716) to store the current media unit, segment index, offset in the segment, and the last access time for the data.
If after determining that there is not a segment selected for writing hot data (704) and determining that there is not a media unit mounted (706) onthe log drive 521, the write component of R/W logic 502 checks if there is a clean media unit, i.e., one with empty segments available to be mounted (718). If no, it requests that garbage collection be started and waits forone clean media unit to be made available (720). When a clean media unit isavailable, then the log drive 521 is again checked to see if it is unmounted (722). If no, then the media unit in log drive 521 is dismounted(724). If and when the log drive 521 is unmounted, a clean media unit is mounted (726) on the log drive 521 and the process of selecting an empty segment (710) and writing the data (712) continues.
Referring now to FIG. 7A, if the write request (702) is for cold data (DWC or CWC), the process is exactly as described above for a hot write, exceptthat instead of using the log drive 521, the cold collection drive 523 is used and checked to see if a segment is available (728) and if media is mounted (730).
3. GARBAGE COLLECTION Operation
The operation of the garbage collection logic 504 of the file system is illustrated in the flow chart of FIGS. 8A and 8B. After it is initiated, the garbage collection logic 504 first determines if there is a media unitthat is a candidate for cleaning (802). If there is one, it continues; however, if there is not, the garbage collection logic 504 pauses and waits for one to become a candidate.
Once the media unit to be cleaned is selected, the garbage collection drive522 is checked to see if it is unmounted (804) and if not, the media unit mounted on it is dismounted (806). The selected media unit is then mounted(808) and the processing of the segments is begun (810). When all segments have been processed on the media unit (812), the garbage collection drive 522 is dismounted (814) and the cycle continues with the selection of the next media unit for garbage collection (802).
The processing of the segments on the selected media unit to be cleaned is sequential and begins with the retrieval of the segment table (816). When all segment table entries have been processed (818), garbage collection logic 504 continues with the selection of the next segment (812). Each segment table entry is processed sequentially (820) and tested to see if the log directory for the data still points to the segment and offset stored in the segment table (822). If yes, the data is still valid; if no,then the data for the entry is no longer valid and the garbage collection logic 504 moves on to process the rest of the segment table entries (818).
For entries which are still valid, they are tested to see if the time difference between the current time and the time of the last access for the data is greater than or equal to the specified "cold" threshold (824),as shown in FIG. 8B. The cold threshold is a value corresponding to the ageof the cold data; it is a predetermined value but can be varied depending on the particular application. If the cold threshold is exceeded, then thedata for the entry is read into a "cold segment" buffer (826) located in the RAM buffers 508.
If the cold threshold is not exceeded, the data for the entry is read into a "hot segment" buffer (828) located in the RAM buffers 508. If the cold segment buffer is not yet full (830), the garbage collection logic 504 returns to processing the rest of the segment table entries (818). (This part of the process (832) occurs similarly for the hot segment buffer.) Ifthe cold segment buffer is full, then a check is made (834) for the abilityto write the contents of the buffer on the cold collection drive 523. If the contents of the cold buffer can be written on the cold collection drive 523, then a write request (CWC) is issued (836); however, if the write cannot be completed, then the cold segment buffer contents are written on the media unit in the garbage collection drive 522 in a previously cleaned segment (838) and the log directory is updated (839). If this is the first segment being cleaned, it is selected. This use of the garbage collection drive 522 for the role of doing CWCs and CWHs is not expected to occur except on the relatively rare occasions when writingcannot take place in the cold segment buffer or on the cold collection drive 523. This part of the process also occurs similarly for the hot segment buffer (840), but with respect to the log drive 521. If the hot segment buffer contents can be written on the log drive 521, a request is issued (842); if not, it is written (838) on the media unit in the garbagecollection drive 522 and the log directory is updated (839).
After the writes, the processing of the remaining segment table entries continues. When all of the segment table entries have been processed (818), the segment is marked as an empty segment (844) and its availability to be written on is recorded. If the first segment was overwritten with itself because a write was not possible on log drive 521 or the cold collection drive 523, then the segment would not be marked as empty.
4. MEDIA EXPORT Operation
The operation of the media export logic 506 of the file system is illustrated in FIG. 9. The media export logic 506 waits until a user requests that media units be exported (902). It then checks to see if all of the media units have been examined (904) to see if they should be exported, and if they have, then the media export logic 506 returns to waiting for the next media export request from the user.
If not all of the media units have been processed, the next media unit in turn is selected (906) and the last access time for the media unit is examined. If the elapsed time between the present time and the last accesstime is greater than or equal to a user-specified threshold (908), then themedia unit is exported (910) and a new blank media unit is imported (912) and formatted (914) to replace it.
Extension of Log-structured File Systems to Redundant Arrays of IndependentLibraries (RAIL)
The concept of dedicated drives for dismountable media in a log-structured file system can be extended to a system having more than a single library,e.g., a redundant array of library storage devices. A typical configurationwould be one that matched the corresponding drives in each of the independent libraries so that each library operates as described above forlibrary 520 and has a log drive, a garbage collection drive, a cold collection drive, and a read drive. Data is then striped across the drivesin such a way that part of a segment is stored on one media unit in one library and the next part of the segment is stored on another media unit in the next library, and so on across the number of libraries in the array. The last library is a "parity" library which stores the parity computed from each of the parts of the striped segment. For example, if the system illustrated in FIG. 4 were configured as a RAIL system, a fourth library would be the parity library, and each drive in that librarywould be a parity drive assigned to the corresponding group of drives from each of the other libraries 520, 540, 560, e.g., the first drive in the parity library would be the parity drive assigned to the log drives 521, 541, 561 so that when writing to the log drives, the segment is spread over the log drives 521, 541, 561 with parity being written to the parity drive in the parity library. The assigned parity library has the advantagethat none of the parity drives are located in a library that also contains data, so that in the event of a failed picker drive, media unit, etc. in one of the libraries, the data can still be reconstructed and made available to an application. The libraries and drives in the array operatesynchronously, each performing exactly the same operations.
More buffering of segments is used to collect entire segments before they are written to the array. This addition allows the parity of the segment to be computed once and eliminates the need to read, modify, and write thedata and read, modify, and write the parity of the segment, thus preservingthe fast write performance that is characteristic of log-structured file systems.
While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and improvements may be made to the invention without departing from the spirit and scope of the invention as described in the following claims.
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A data storage library system, preferably arranged in an array of independent libraries, uses a log-structured file (LSF) data architecture and assigned roles for the individual storage devices in the library. Each library includes a plurality of storage devices, such as optical disk drives, and a store of removable media units, such as optical disks, that are mounted and dismounted from the storage devices. The log-structured library is similar to fixed media systems having LSF data architectures in that it employs a directory to map the local address of a data set to its physical storage location, but is different in that it divides the jobs of reading and writing (log accesses) and garbage collection among the different storage devices of the library. As required, the dismountable media units are moved from the storage area and mounted on a device assigned the appropriate role. The roles assigned to the storage devices are flexible and can change as needed. The system allows both log accesses and garbage collection to occur simultaneously. The garbage collection process segregates the data into "hot" and "cold" segments, according to the age of the data. This allows all the cold data to be located on the same media units, which can then be exported from the library for off-line storage and replacement with new media units.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the manufacture of coke in slot-type coke oven batteries and more specifically to the clean-up of coke spilled during the pushing operations.
2. Description of the Prior Art
In the modern manufacture of coke it is conventional to use a battery, or series, of horizontal slot-type coke ovens to carbonize the coal in the production of either metallurgical or foundry grades of coke. The coal is loaded into these ovens from either an overhead larry car system or a pipeline charging system. Each of the ovens is generally in the form of a slot, for example, dimensions of 12 feet in height, 18 inches in width and 45 feet in length might be found. The coal is generally introduced through holes or ports in the top. The ends of the slots are covered with doors, including seals, to prevent the introduction of air and the leakage of gas during the coking cycle. After the coal is loaded in, it is leveled by conventional equipment, which will not be described, and heated at a substantially elevated temperature for a sustained period of time, for example 1,200ยฐ F. for 18 hours. Once this coking cycle has been completed, the doors on both ends of the slot are removed. A conventional pusher machine, which also will not be described, is positioned at the pusher side of the oven and a coke guide is positioned at the opposite, or coke side, of the oven slot. The coke guide is basically a slot extension having generally the same height and width as the coke oven. However, it is generally shorter in length, being for example about 8 feet long. The coke guide is made of steel and is mounted upon a movable carriage which travels along a pair of rails. The rails run parallel to the coke side of the battery, transverse to the length of the coke ovens. The rails are mounted on a shelf-like projection which extends from the coke side of the coke oven battery, running parallel to and the full length of the coke side of the coke oven battery. This shelf-like projection is the coke side bench and its upper horizontal surface is positioned somewhat below the floor of the coke ovens, for example, 3 feet.
At the end of the coke cycle, the doors are removed from both the coke side and pusher side of the oven. This is accomplished by door removers which are mounted on movable frames on door machines and pusher machines. The coke side door machine operates on the same rails as the coke guide. On the pusher side of the battery, the door machine is usually incorporated into the pusher.
In modern operations, the door machines not only serve to remove and replace the oven doors, but also include door seal, door plug, and door jamb cleaning apparatus which serves to scrape the tar and residue build-ups from these surfaces.
During the door removal, some hot coke spills from the ends of the ovens onto the benches (there is also usually a pusher side bench similar to the coke side bench but with no rails on it). In addition, the material that is scraped from the door seals, jambs and plugs falls onto the bench. This material all accumulates and builds up on the benches. Because of the track rails on the coke side bench and the need for clearance to move both the door machine and the cokeguide, the accumulation causes a problem.
In order to eliminate the accumulation of coke and scraped residue from the coke side bench, past practice has been to have one or more men shovel and broom the accumulation off.
Recent governmental regulations have dictated against the liberal use of manpower on or near the coke oven batteries except when absolutely necessary and then only with proper protective clothing and breathing apparatus. This clothing and breathing apparatus makes it difficult for its wearer to freely maneuver, diminishing the economy and effectiveness of utilizing manpower to clean the coke side bench. Thus there is a need for alternate procedures and tools to handle this job.
SUMMARY OF THE INVENTION
In a conventional door machine, which includes a door seal cleaner, a door plug cleaner and a door jamb cleaner, the operation is performed by first aligning the door removal mechanism with the particular door to be removed. The door removal mechanism is advanced toward the door, the door latches are released and the door is lifted away from the door jamb as the door removal mechanism is retracted to the cleaning position on the door machine. As the door is lifted away, some coke from within the oven spills out. This spillage falls into a spillage tray which is advanced upwardly in an inclined fashion toward the bottom of the door jamb before the door is lifted away. The spillage tumbles down the incline of the tray and into a catch pan at the base of the frame of the door machine.
Once the door has been lifted away from the jamb and withdrawn with the door removal mechanism to the retracted position, the door is vertically pivoted on the door removal mechanism about 90ยฐ to be engaged by the door seal and door plug cleaners. These cleaners scrape the built-up tar and other residue from the seal and plug allowing the scrapings to fall into the catch pan.
Concurrent with the pivotation of the door, the door machine is repositioned to align the door jamb cleaner with the door jamb. As the jamb cleaner advances to engage the door jamb, another spillage tray, substantially identical to the first, is advanced upwardly in an inclined fashion toward the bottom of the door jamb. The tar build-up and residue scraped off by the jamb cleaner falls onto the second spillage tray and gravitates down the inclined surface of that tray into the catch pan.
The material that accumulates in the catch pan is scraped, by a scraper means, to a position within the catch pan where it is picked up by an inclined conveyor means. The conveyor means carries the material to a collection bucket which stores the material until such time as the door machine becomes located adjacent to a quench car. As such time, the collection bucket is dumped into the quench car, thus disposing of the material.
In the present invention, the spillage and scrapings never actually get to the bench, thus greatly reducing the problem of build up on the track rails of the bench.
These and other features of the present invention will be more completely disclosed and described in the following specification, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a door machine, including the present invention, as seen from the coke side of a coke oven battery.
FIG. 2 is a sectional end view from II--II of FIG. 1.
FIG. 3 is a sectional view from III--III of FIG. 1.
FIG. 4 is a sectional plain view from IV--IV of FIG. 1.
FIG. 5 is an enlarged sectional view of the catch bin scraper.
DETAILED DESCRIPTION
Referring to FIG. 1 there is shown a typical door machine of modern design, generally designated by the numeral 11, with the improvements of the present invention included therein. The door machine 11 includes door extractor apparatus 13 which serves to extend toward the viewer, as shown in FIG. 1, to engage a selected door (not shown) of the coke oven to be pushed (also not shown). The door extractor apparatus 13 is complemented by a door seal and plug cleaning apparatus 15. In operation, once the door extractor apparatus 13 has disengaged the door from the coke oven, both are withdrawn into the framework 17 of the door machine 11 and the door extractor apparatus 13 pivots the door about 90ยฐ to the right, as viewed in FIG. 1. Then the door seal cleaner and plug cleaing apparatus 15 is advanced forward (from right to left as shown in FIG. 1) to engage the door to clean the door seals and the refractory plug surfaces.
Also included in the door machine 11 is a door jamb cleaning apparatus 19. Once the door has been removed from the oven, the door machine 11 is moved out of the way and the coke in the oven is pushed. After the push, the door machine 11 is repositioned to align the door jamb cleaning apparatus 19 with the door jamb (not shown). The moveable coke guide (not shown) is interposed in the operation in between the removal of the door and the cleaning of the door jamb, and the coke oven is pushed before the door jamb is cleaned.
In operation, the door jamb cleaning apparatus 19 is extended toward the viewer, as shown in FIG. 1 to engage the door jamb, which forms the end of the particular oven being pushed. The door jamp cleaning apparatus 19 then cleans the door jamb and is retracted within the framework 17. This operation takes place after the coke push, and the door machine 11 is first moved out of the way along the track rails 21 and the movable coke guide is positioned to align with the coke oven in question. The coke is pushed through the coke guide into quench car 23. Following the push, both the coke guide and quench car 23 are moved away, and the door machine is returned to the point of alignment of the door extractor apparatus 13 with the coke oven in question. The door extractor apparatus 13 then is operated to pivot the door about 90ยฐ back to its alignment with the door jamb, advance the door into contact with the door jamb, engage the door locks to secure the door in a closed and sealed position, and withdraw back into the framework 17.
During the initial operation of the door machine 11 as the door is removed from the selected oven, portions of the red hot coke spill out due to the fact that the coal charged into the oven and consequently the coke resulting from the coal carbonization is butressed against the inside of the door. Although most of the coke forms a solid cake, similar to a large cohesive block, within the oven, still, some end portions fall loose. These are the portions which spill out as the door is removed.
During the carbonization of the coal into coke, the volatiles are driven out of the coal by the heat. Significant portions of these volatiles are carbonaceous in composition, for example, coal tars. Theoretically, all of these gasified volatiles are evacuated through the stand pipes and gas mains at the top of the coke oven battery. However, in actuality, due to the heat warpage of the metal which forms the door seals and the door jambs, portions of these gases seep out through the doors. Because these metal portions are relatively cold compared to the interior of the coke oven, the gases condense and form residue build-ups on the surfaces. If the seal and jamb surfaces are not cleaned frequently, the mating seal surfaces on the doors and door jambs become less and less effective as the doors are removed and replaced during the normal coking cycle. These surfaces, as well as the refractory plug which forms most of the interior of the door surface which is exposed to the inside of the coke oven, are cleaned by mechanical metal scrapes which scrape off these residue build-ups.
Again referring to FIG. 1, the framework 17 is a superstructure, usually made up of conventional steel structural shapes such as I-Beams, channels, etc., all of which are mounted to base frame 25. Affixed to base frame 25 are preferably two pairs of bearings mounted wheeled axle assemblies 27 which serve to render the door machine 11 movable on track rails 21. The door machine may be pulled or pushed by a locomotive (not shown) which likewise travels on track rails 21. Alternately, the door machine is equipped with a traction motor drive unit 29 for self-propulsion, which is preferred.
Within the base frame 25 there is mounted, in a fixed position, a catch pan 31. The catch pan 31 is shaped and positioned to substantially enclose the lowermost portion of the base frame 25 between the two wheeled axle assemblies 27 as shown in FIG. 1. The catch pan 31 is composed of a horizontal button sheet 33, two longitudinal sides 35 disposed on the opposite side edges of the sheet 33 and an end shield 37 which serves to also protect the wheeled axle assembly 27, which is driven by the traction motor drive unit 29, from the scrapings falling from the door seal and plug cleaning apparatus 15. All of the scrapings from the door seal and plug cleaning apparatus 15 fall directly into the catch pan 31, as well as, indirectly, do the scrapings from the door jamb cleaning apparatus 19 and the spillage of portions of the red hot coke which results from the removal of the door.
Positioned directly beneath the door removal apparatus is a spillage acceptance tray 39 which is generally in the form of an inclined plane as best shown in FIG. 3. The spillage acceptance tray 39 has a bottom or slide 41 and two sides 43. It is reciprocally movable in the plane of the incline, as shown in phantom in FIG. 3, by a suitable reciprocating means, for example, a double acting hydraulic cylinder 45, the body 47 of which is stationarily fixed to the base frame, the extendable rod 49 being mounted to the underside of the slide 41 about as shown in FIG. 3.
In association with the spillage acceptance tray 39, a pair of channel guides 51 are mounted on the framework 17 one each of which is positioned adjacent to each of the sides 43 of the spillage acceptance tray 39 about as shown in FIG. 1. The channel guides 51 are aligned to parallel the plane of the incline of the spillage acceptance tray 39. A pair of rollers 53 is rotatably mounted to each side 43 of the spillage acceptance tray extending into each of the corresponding guide channels 51 so as to permit the spillage acceptance tray 39 to ride in the guide channels 51 as it is reciprocated and to support the spillage acceptance tray 39.
In operation, as the door removal apparatus 13 is extended to engage the selected coke oven door, the spillage acceptance tray 39 is concurrently extended toward that door, to a point on the coke oven battery which is adjacent to the battery, but just below the floor level of the ovens. As the door is removed, those portions of the coke that spill out, fall onto the spillage acceptance tray 39 and gravitate down its inclined plane into the catch pan 31. As the door removal apparatus 13 is retracted into the framework 17, with the door affixed thereto for cleaning, the spillage acceptance tray 39 is, likewise, retracted into the framework 17. Preferably, the retraction of the spillage acceptance tray 39, is delayed for a short time period, for example, 15 to 30 seconds, following the initiation of the retraction of the door removal apparatus 13, to enable the collection of any delayed coke spillage that may result from the door removal.
Following the push, the door machine 11 is repositioned to align the door jamb cleaning apparatus 19 with the subject coke oven, specifically with the door jamb of that coke oven. As detailed before, the door jamb cleaning apparatus 19 advances to engage the door jamb to clean it. The result of this cleaning apparatus is a varying quantity of scrapings of tar and other residue which have built up on the door jamb during the carbonizing cycle.
A second spillage acceptance tray 39a is arranged beneath the door jamb cleaning apparatus 19, identical in all respects to the spillage acceptance tray 39 beneath the door removal apparatus 13. The second spillage acceptance tray 39a includes a slide 41a and two sides 43a, and is, likewise, in the form of an inclined plane, being reciprocally movable in the plane of the incline by a similar reciprocation means as exemplified by hydraulic cylinder 45a. As explained above for spillage acceptance tray 41, channel guides 51a are fixed to framework 17, being located about where shown in FIG. 1. A pair of rollers 53a is rotatably mounted outboard of each side 43a of spillage acceptance tray 39a, the rollers 53a being engaged with the respective adjacent channel guides 51a to enable alignment and support of the spillage acceptance tray 39a and permit its freely reciprocating movement.
In operation, as the door jamb cleaning apparatus 19 is advanced toward the door jamb, the second spillage acceptance tray 39a is concurrently advanced to a point where it is positoned adjacent to the door jamb but just below the floor level of the ovens. The scrapings that result from the operation of the door jamb cleaing apparatus 19 fall onto the slide 41a and gravitate down the inclined plane thereof into the catch pan 31. The retraction of the door jamb cleaning apparatus 19 to within the framework 17 is followed closely by the retraction of the second spillage acceptance tray 39a.
As mentioned before, when the door removal apparatus 13 is retracted into the framework 17, the door is pivoted about 90ยฐ by the door removal apparatus 13. The door seal and plug cleaning apparatus 15 is advanced toward the pivoted door to engage so as to clean or scrape the seal on the door as well as the refractory door plug. The scrapings from this operation fall directly into the catch pan 31.
The catch pan 31 serves as a means to accumulate both the spillage and scrapings as described above so as to prevent their being deposited on the coke side bench 22 and the rails 21. The accumulations of these scrapings and the spillage, of course, need to be removed from time to time. To effect this operation a scraper means 55 is mounted to operate within the catch pan 31. Preferably the scraper means 55 includes a pair of continuous scraper chains 57, each of which is positioned to be longitudinally parallel to each other and the longitudinal sides 35 of the catch pan 31 the scraper chains 57 are each mounted outboard of, but adjacent to, the longitudinal sides 35 about as shown in FIGS. 3 and 4.
At both ends of the catch pan 31, rotably mounted axles 59, 59a are positioned. The mountings for the axles 59 are preferably bearings 61, as shown in FIG. 3, fixed to the base frame 25. Axle 59 is coupled to a gear reduced 63 which is, in turn, coupled to a reversing drive motor 65, both of which are mounted onto the base frame 25, all as shown best in FIG. 4.
On each of the axles 59, 59a are mounted matched pairs of sprockets 67, positioned to engage the scraper chains 57 respectively. Each of the scraper chains is reeved around a single sprocket 67 on each axle on a given longitudinal side 35 of the catch pan 31, as shown in FIG. 1, and thus is suspended by those sprockets 67 between the axles 59, 59a.
As will be noted, referring to FIG. 1, although each scraper chain 57 is continuous, as reeved around the sprockets 67 on axles 59, 59a respectively, each chain has a lower track 69 and an upper track 71, each of which extends substantially parallel to the other, allowing for slack, and both of which are positioned substantially horizontal, the upper track 71 remaining over the tops of the corresponding sprockets 67 while the lower track 69 runs between the bottoms of the corresponding sprockets 67. Referring to FIG. 5, an enlarged section of the lower track 69 of a scraper chain 57 is shown in relation to the horizontal bottom sheet 33 and a longitudinal side 35 of the catch pan 31. Secluded in the lower track 69 of each scraper chain 57 is a scraper link 73 which depends from the general plane of the lower track 69 about as shown in FIG. 5. Each of the scraper links 73 include a bushing 75. The scraper chains 57 and their respective sprockets 67 are arranged and positioned such that the longitudinal axes of the bushings 75 are axially aligned with each other. A scraper blade 77, having a pair of axially aligned trunions 79, a trunion 79 being disposed at each longitudinal end of the scraper blade 77, is pivotably mounted in the bushings 75. A pin stop 81 is fixed to extend from each of the scraper links 73 to prevent pivotation of the scraper blade 77 past the vertical in one direction, namely to the right as shown in FIG. 5. The uppermost section of the scraper blade 77 is canted away from the side of the scraper blade 77 which comes into contact with the pin stop 81 to provide a leading edge 83 in order to roll any coke that builds up in the direction of travel of the scraper blade 77.
In operation the scraping action of the scraper blade 77 is in the direction shown by arrow 85 in FIGS. 1 and 5. Reversing drive motor 65 and gear reducer 63 are activated to rotate axle 59 and sprockets 67 mounted thereon. This causes the two scraper chains 57 to concurrently move such that their respective lower tracks 69 advance in the direction of arrow 85. As the lower tracks 69 advance, the scraper blade 77 advances from one end to the other of catch pan 31 in the direction of arrow 85, pushing or scraping all of the spillage and scrapings in catch pan 31 to the discharge end 87 of catch pan 31. When the scraper blade 77 has reached the discharge end 87 of catch pan 31, the direction of rotation of axle 59 is reversed causing the motor of the scraper chains 57 to reverse, thus causing the direction of movement of the scraper blade 77 to reverse. This could be accomplished manually or by a system of limit switches 88. If any spillage or scrapings have been deposited in the catch pan 31 behind the scraper blade 77 during its movement toward the discharge end 87 of the catch pan 31, the scraper blade 77 pivots to the horizontal position when it makes contact that material and rides up over it rather than pushing it in the reverse direction away from the discharge end 87. During this operation, the leading edge 83 tends to prevent the scraper blade 77 from dragging into or becoming wedged against such material.
Adjacent to the discharge end 87 of the catch pan 31 is a chain link flight conveyor belt 89 reeved around an idler pulley 91 and a drive shaft 93. The flights 95 of the conveyor belt 89 extend outwardly therefrom as shown in FIG. 1. The idler pulley 91 is rotably mounted to the longitudinal sides 35 of the catch bin 31 adjacent to the discharge end 87 and is positioned such that the flights just clear the horizontal bottom sheet 33 of the catch bin 31 and the conveyor belt 89 moves. The plane of the conveyor belt 89 is inclined upwardly and away from the discharge end 87 of the catch pan about as shown in FIG. 1. The drive shaft 93 is rotably mounted to the framework 17 at one end by way of a bearing 97, and is coupled to a gear reducer 99 at the other end. The gear reducer 99 is driven by a motor 101 and both are mounted to the framework 17 about as shown in FIG. 4.
In operation, as the scraper blade 77 begins to move in the direction of arrow 85, the motor 101 is energized causing the gear reducer to rotate the drive shaft 93 in a counter-clockwise direction as showin in FIG. 1. This causes the conveyor belt 89 to move, thus rotating the idler pulley 91. As the material being pushed by scraper blade 77 comes into contact with the conveyor belt 89, the flights 95 engage that material causing it to be transported by the conveyor belt 89 movement toward the general location of the drive shaft 93. When the material on the conveyor belt 89 reaches the drive shaft 93 location, it falls off into a dump bucket 103.
Referring to FIG. 2, dump bucket 103 is pivotably mounted 105 to the framework 17. A tilting means 107, for example a torque actuator as is commonly known to those skilled in the art, is employed to pivot dump bucket 103 when it becomes full of material, permitting the material to gravitate from the dump bucket 103 into an adjacent quench car 23. Of course, the dump bucket 103 is only emptied after the movement of the conveyor belt 89 has been halted, following the return of the scraper blade 77 to its original position as shown in FIG. 1, thus preventing spillage of material onto the coke side bench and rails 21 from the conveyor belt 89 which could otherwise occur when the dump bucket 103 is in its pivoted position as shown in phantom in FIG. 2.
According to the provisions of the patent statutes, the principle, preferred construction and mode of operation of the present invention have been explained and its best presently known embodiment has been illustrated and described. However, it is to be understood that, within the scope of the appended claims, the present invention may be practical otherwise than as specifically illustrated and described hereinabove.
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In a coke oven coke side door machine, a bottom tray is mounted to collect spillage that results from the removal of coke oven doors as well as the residue buildup that is scraped from the door seals and bottom plugs during the door cleaning operation. Trays, in the form of inclined planes, are extended from the door machine to catch the coke spillage from the oven and to catch the residue buildup which is scraped from the door jambs during the jamb cleaning operations. This material gravitates down the trays into the catch pan. A scraper then pushes the material accumulated in the catch pan to one end of that catch pan where a conveyor carries it to a dump bucket. The dump bucket can be dumped when the door machine is positioned adjacent a quench car. All of the above apparatus is mounted onto and within the confines of the door machine.
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FIELD OF THE INVENTION
The present invention relates to a method for query and construction of a three-dimensional (3D) image database.
BACKGROUND OF THE INVENTION
Research in brain function may be roughly divided into various levels (from microscopic to macroscopic), e.g. gene expressions, protein biochemical reactions, neuronal functions, brain neural network organizations and animal behavior. Molecular biology, flourished since the 1960s, allows genetic manipulation to reflect biological functions at different scales. In such ways, researchers can now make use of technology to identify Drosophila memory genes of olfaction and memory and alter these genes to influence its behavior. Although scientists have a clear understanding of macro-scale biology such as animal behavior and micro-scale biology such as gene expression and perspectives of biology, micro-meso-scale biological research remains under-studied owing to technical limitations which including the difficulty to acquire the 3D structure of nerve cells and cerebral neural networks. Now, the integration of biofluorescent labeling and optical section scanning in confocal microscopy gives rise to the possibility of high-resolution digital images of the brain and its neural network.
Biologists often can not obtain images (information) of an organism's internal structure without damaging the organism itself. Furthermore, when acquiring biological images, physical limitations of laboratory equipment could only generate a serial of two-dimensional (2D) images instead of three dimensional images; as a result, the spatial information between organs is not immediately made available. While an invention in 2002, U.S. Pat. No. 6,472,216 presents a sample preparation solution which enables scientists to acquire images from a transparent whole mount samples.
Owing to the technological advances in the twentieth century, it is generally accepted that a completely modular brain model can depict its functional reality. Therefore, the interpretation of brain function can be analytically and anatomically described based on the interactions among different brain regions or even neurons. Accordingly, 3D image reconstruction technology can be exploited to build models of major compartments of the brain, and at the same time, merge the anatomy of neuropils or neurons with the function of neural networks in the brain.
Neuropil is a region between neuronal cell bodies in the gray matter of the brain and spinal cord (i.e. the central nervous system). It consists of a dense tangle of axon terminals, dendrites and glial cell processes. It is where synaptic connections are formed between branches of axons and dendrites.
Although the information processing and transmission of the human brain fascinates scientists the most, the fact that the human brain has 100 billion neurons, plus human's relatively longer life span and genes that cannot be manipulated at will, has limited neuroscience research on human brain structures at the cellular level. Scientists thus turn their investigation to other organisms, e.g. mice, zebrafish and Drosophila. For instance, the Drosophila brain only has about 135,000 neurons, but can still exhibit complex memory and learning behaviors; consequently, it has become one of the most popular and important research targets in neuroscience. In addition, Drosophila genes have been entirely sequenced, and its short life cycle (approximately 60 days) further makes it a valuable research target. The knowledge obtained from studies of neural networks in Drosophila may be extended to systems with much more complexities such as human brains (Armstrong, JD and Van Hemert JI, 2009 Towards a virtual fly brain Phil. Trans. R. Soc. A 367, 2387-2397).
SUMMARY OF THE INVENTION
The purpose of the present invention is to disclose methods for searching and constructing a 3D motif image database, wherein said 3D motif image database can be used to understand the connection relationship of a 3D network, e.g. a neural network.
Said motif image here indicates complicated 3D network configurations similar to a neural network; it may also be in open or closed spaces, ranging from ocean to micro-chip, and representing information communications and exchanges within 3D space.
The 3D image database, a proper computer-aided graphic platform, will not only facilitate the management of the huge amount of categorized data but also rationally excavate the hidden information cloaked within.
The โneural networkโ of the present invention indicates both biological neural networks and artificial neural networks.
Biological neural networks are made up of real biological neurons that are connected or functionally related in the peripheral nervous system or the central nervous system. In the present invention, they are identified as group of neurons or neuropils that perform specific physiological functions in 3D space. โNeuropilโ here indicates the region between neuronal cell bodies in the gray matter of the brain or spinal cord (i.e. the central nervous system). It consists of a dense tangle of axon terminals, dendrites and glial cell processes. It is where synaptic connections are formed between branches of axons and dendrites.
Artificial neural networks are made up of interconnecting artificial neurons (programming constructs that mimic the properties of biological neurons). Artificial neural networks may either be used to gain an understanding of biological neural networks, or for solving artificial intelligence problems without necessarily creating a model of a real biological system, i.e. artificial neuron networks can be applied to manipulate complicated geographical networks like traffic roots or electrical circuits, or further applied in manipulating relevant logical interconnections of nodes.
The present invention provides a method for constructing a 3D motif image database comprising the following steps:
1. Providing more than one 3D network motif image, e.g. different sets of Drosophila neuron images constructed from micro-imaging.
The aforementioned neuronal image is obtained from micro-imaging devices, comprising a charged particle scanning microscope, laser scanning microscope, confocal microscope or a fluorescent microscope. A neuronal image comprises at least one complete neuron, i.e. a neuron with a soma, axon, dendrites or a partial complete neuron. The source of the neuronal images comes from both male and female Drosophila of different maturity.
2. Aligning and correcting 3D images generated in the first step according to a 3D standardized coordinate, wherein each coordinate point registered to the 3D images is assigned a coordinate location (x, y, z) to indicate its position in the standardized space area.
3. Dividing 3D images in the second step with individual voxel or a self-defined brick consisting various voxels, wherein voxel is a volume element, representing 1ร1ร1 unit volume on a regular grid in the standardized space area.
4. Categorizing space information of each coordinate point registered to the 3D images within voxels. Space information comprises the location of said voxel and the ID number of motif images passing through that particular voxel unit.
Said 3D network motif images can be further processed using path tracing algorithm to present in skeletal form.
Path tracing algorithm refers to the selection of any given two points from said image and based on the image outline between these points to calculate the curve length s with the following formula:
E
โก
(
C
)
=
โซ
ฮฉ
โข
{
ฮฑ
โข
๏
C
โฒ
โก
(
S
)
๏
2
+
ฮฒ
โข
๏
C
โณ
โก
(
S
)
๏
+
ฮป
โข
โข
P
โก
(
C
โก
(
s
)
)
}
โข
โ
s
where ฮฑ, ฮฒ, ฮป denote constant positive real numbers; C (s) represents the curve outline of said image; L in ฮฉ=[0, L] denotes the length of the curve outline; P (C (s)) represents the potential used to capture the desirable image feature; E(c) indicates the optimal area of the image outline determined based on the brightness of image selected by best energy equation.
The best energy equation refers to a minimum energy action map which is built using the following function:
U Po โก ( P ) = โ APoP inf โข E โก ( C ) = โ APoP inf โข { โซ ฮฉ โข P ~ โก ( C โก ( s ) ) โข โ
s }
where U Po (P) is defined as the minimum energy of the path between a point Po and P in the image. Ap o p denotes the set of all paths between points Po and P. When the minimum energy action map is built, the shortest path between Po and P is obtained.
5. Storing processed 3D network motif images in the third step and space information in the forth step into a computer-readable recording medium, where the gray level intensity value of the voxel is above threshold. Said computer-readable recording medium comprises a magnetic storage device, an optical storage device, or an electronic storage device that can be on a PC or a remote device connected via a transmission system.
Said database comprises the spatial information and files of 3D neural images of Drosophila, information regarding neurons of Drosophila, the calculation results, the records of the calculation results and relevant files. Information regarding brain neuronal images of Drosophila, the calculation results, and the records are stored in a corresponding manner, i.e. storing the linkage of neuron names and their spatial points or the linkage of the spatial points and the neurons passing through those points.
The present invention also provides a query method for 3D motif image database comprising the following steps:
1. Providing a 3D network motif image database and constructing an interactive query interface for users. The database comprises 3D neuronal images of Drosophila and their spatial information.
The query interface provides at least one visualization interface and at least one search field which automatically identifies the database as demanded by the user for data search once the user initiates a search command; the resulting image information meeting the search criteria can be presented in dot-matrices, or 3D structure display together with texts on the visualization interface.
The visualization interface displays the neurons/neuropils in 3D and allows operations such as rotation and zooming from different angles to facilitate multi-angle observation. The visualization interface can also display the neural images using semi-transparent effect to illustrate numerous network motif images simultaneously on the visualization interface.
For real-time observation, the 3D images, e.g. nerve fibers of neuronal image, can be simplified into skeletal form using path tracing algorithm. Visualization interface comprises a computer screen, a 3D or non-3D multi-media display and an exhibition space or flat surface for 3D or non-3D projection.
2. Users may select, using the query interface, at least one spatial region or enter at least one search string to search for corresponding image information meeting the query criteria in database as follows:
I. Users select at least one spatial region or enter at least one search string in the query interface. Spatial region comprises at least one 3D rectangular object or at least one branch path or a Boolean combination of the aforementioned two regions. The path selection refers to the users' selecting at least one 3D network motif image with the query interface and from this image to connect at least two extends paths or network motif images.
In a preferred embodiment, the aforesaid network motif image refers to the neuronal image. The search string comprises at least one target neuron name or at least one neuronal image source or a Boolean operation combining the commands of the above.
II. The spatial region search allows the identification of spatial links between the target 3D network motifs and other 3D network motifs; or the detection of any 3D network motif, e.g. neurons passing through a target region.
III. Using the search criteria in the previous step together with binary Boolean (AND, OR, NOT) operations, users can perform more complicated conditional query, e.g. 3D network motif (e.g. neurons) passing through space A and B, but not space C. Boolean commands include AND, OR, NOT. For instance, โ(A AND B) NOT Cโ will search network motifs (e.g. neurons) passing only through spaces A and B, but not space C. Spatial relationship can be obtained using space intersection command (INTERSECT), e.g. โA INTERSCET BOX [1]โ finds the neurons passing through both of space A and spatial rectangle region [1].
3. The image information of the corresponding search criteria are presented in text lists, dot-matrices or 3D images on the query interface. The image information of the corresponding search criteria refers to network (e.g. neuron) name, characteristics of network (e.g. neuron) image and 3D network (e.g. neuron) images.
Network characteristic refers to the source of the network image and the dot-matrix density map. The dot-matrix density map represents the number of terminals of neuron path tracing graph in each unit space. Gray-scale dot-matrix can be used to represent the aforesaid level of density for the prediction of network (e.g. neural) hubs which indicate the aggregation of different nerve synapses. The image information of the corresponding query criteria refers to the network (e.g. neuron) name, characteristics of network (e.g. neuron) image and 3D network (e.g. neuron) images passing through a selected path.
The query method further refers to using image information of the corresponding search criteria to find similar image information in the database and display the results on the query interface. Similar image information comprises the information of network (e.g. neuronal) images from the same origin organisms or from proximate space point locations of the original image in the corresponding search criteria.
DETAILED DESCRIPTION OF THE INVENTION
Please refer to the following figures and descriptions for embodiment of the present invention. The invention may be embodied in a variety of forms and should not be inferred to be limited by the examples given in the text.
The present invention relates to a method for query and construction of a 3D image database. A preferred embodiment is a Drosophila 3D neuronal image database.
EXAMPLE 1
Generating 3D Images
The 3D image was generated by inputting Drosophila neuronal image obtained from micro-imaging device. Said image was acquired from a fluorescent-labeled specimen scanned by a laser scanning microscope. During the scanning process, at least part of the sample was scanned by laser. The cross-section of different depths of the sample was scanned in accordance with a predetermined order; the resulting scanned images were numerous plane images at different depths. Images from different slices of the same stack were combined to form a complete image; and then the resulting 3D image consisting of different cross-sections was generated by computer software such as AVIZO (Visualizaiton Science Group, Merignac Cedex, France).
EXAMPLE 2
Constructing 3D Image Database
1. Aligning 3D Images to a Standard Coordinate
The 3D images generated from image processor programs, such as AVIZO, were aligned to a standard coordinate. The alignment correction on 3D images made different image sets to have common space coordinates.
In a preferred embodiment, the standardized coordinate was generated by demarcating a standard Drosophila brain space according to Cartesian axis x, y and z. (Wu, C. C. et al. 2008 Algorithm for the creation of the standard Drosophila brain model and its coordinate system. 5th International Conference on Visual Information Engineering VIE, Xi'an, China, pp. 478-483).
After aligning to the standardized coordinate, each raw 3D image was corrected to fit the standardized coordinate. As a result, each voxel of the 3D image would designate a point location (X,Y,Z). The spatial and intensity information of the voxel (with gray level intensity value above threshold) of 3D images was then stored in a computerโreadable recording medium.
The sketch of neurons in the 3D image contained points within the range from (x1, y1, z1) to (x2,y2,z2), while the point locations indicated the space distribution of neurons in the Drosophila brain space.
The information of 3D images was stored in a table form. Referring to table 1 and FIG. 6 , the neuronal information table included the ID number of neurons (first column,โIโ), the type of neurons (second column, โTypeโ), location of start point of neurons (3 rd -5 th columns, โSx,Sy,Szโ), location of end point of neurons (6 th -8 th columns, โEx,Ey,Ezโ) and the filenames of the 3D image. The type of neurons included the gender of the origin organism that donated the neuron image (male or female), the function of neuron or any other biological characters which distinguish neuron images from one another.
TABLE 1 Neuronal information table I Type Sx Sy Sz Ex Ey Ez Filename 1 . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . . . . . . . . . 5 Np 10 10 10 20 20 20 Mb
2. Dividing 3D Images with Voxels
The 3D image was aligned and corrected by dividing with voxels or self-defined bricks, which contain more than one voxels. Each individual voxel was of 1ร1ร1 unit volume, representing a value of a spatial location in a regular grid of three-dimensional space.
After divided by voxels, all image data was searched to find neurons or neuropils which pass through each individual voxel, The ID number of passing neurons or neuropils was recorded, and the information was concluded in a 3D space table. Referring to table 2, wherein โXโ, โYโ and โZโ indicated the voxel locations (X,Y,Z) of 3D space, โVโ indicated the ID number of neurons or neuropils passing through this particular voxel. Table 2 illustrated a neuron of ID number 12 passing through voxel (0,0,0), a neuron of ID number 1 passing through voxel (0,0,1) and voxel (0,0,2), and a neuron of ID number 5 passing through voxel (0,0,3).
TABLE 2 3D space table X Y Z V 0 0 0 12 0 0 1 1 0 0 2 1 0 0 3 5 . . . . . . . . . . . .
3. Storing 3D Image into Database
The 3D images, neuronal information table and the 3D space table were stored in a computer-readable recording medium, e.g. magnetic storage devices such as disks, tapes, or optical storage devices such as CD-ROM or electronic storage devices such as flash drives. Such storage devices could be located in a local computer or a remote device connected via a transmission system.
In a preferred embodiment, the 3D images are neuronal images from different fruit flies. The source of the neuronal images comes from both male and female Drosophila of different maturity.
4. Simplifying Neuronal Images
Once the 3D neural images were loaded into computer, path tracing algorithm was utilized to obtain skeletal structures of the neural network (P. C. Lee, Y. T. Ching, H. M. Chang and A. S. Chiang. A Semi-automatic Method for Neuron Centerline Extraction in Confocal Microscopic Image Stack. IEEE 5 th International Symposium on Biomedical Imaging From Nano to Macro 2008:p 959-962). By transforming neuron images into skeleton structures, the time required for visualization and interaction was significantly reduced ( FIG. 1-4 ).
4.1 Path Tracing Algorithm
The minimal path technique captured the global minimum curve of a contour depending on the energy between two given points. The well-known snake model simultaneously considered the smoothness of curve and the potential term, which was determined by the image features in the energy function.
The function was shown below:
E โก ( C ) = โซ ฮฉ โข { ฮฑ โข ๏
C โฒ โก ( S ) ๏ 2 + ฮฒ โข ๏
C โณ โก ( S ) ๏ + ฮป โข โข P โก ( C โก ( s ) ) } โข โ
s
where ฮฑ, ฮฒ, ฮป were real positive constants, C(s) ฮต represented the curve outline of the neural image, ฮฉ=[0, L] is its domain of definition where L was the length of the curve, Cโฒ (s) and Cโณ(s) were the first and second derivatives with respect to s and P(C(s)) represented the optimal area of the neuron image outline determined based on the brightness of neural images selected using the best energy equation.
When the outline was simplified into a curve, s represented the curve length; w denoted a real positive constant that controlled the smoothness of the outline. The simplified formula was as follows:
E โก ( C ) = โซ ฮฉ โข { ฯ + ฮป โข โข P โก ( C โก ( s ) ) } โข โ
s = โซ ฮฉ โข P ~ โก ( C ) โข โ
s
or written as {tilde over (P)}=ฯ+ฮปP.
Given a potential P>0 that was defined to be small when the outline of the neural image was close to the optimal area.
The objective of minimal path technique was to look for a path connecting a given pair of points such that the integral of {tilde over (P)}=ฯ+ฮปP was minimum. Therefore, when selecting the shortest path of any two given points of the neural image, {tilde over (P)}=ฯ+ฮปP was the minimum.
4.2 Deciding the Shortest Path Between Two Given Points of the Neuronal Image
A minimum energy action map was built using the following function:
U Po โก ( P ) = โ APoP inf โข E โก ( C ) = โ APoP inf โข { โซ ฮฉ โข P ~ โก ( C โก ( s ) ) โข โ
s }
where U Po (P) was defined as the minimum energy of the path between a point Po and P in the image. Ap o p denoted the set of all paths between points Po and P. When the minimum energy action map was built (as aforementioned), the shortest path between Po and P was obtained.
EXAMPLE 3
Searching 3D Image Database
The present invention provided a method for query of neuronal image database. A preferred embodiment was an interactive method for searching a 3D brain neuronal image database of Drosophila.
The database in the present invention stored the information of connectivity relationships between the brain neuronal networks of Drosophila. Users can query the database through a 3D interactive interface. In this database, users could query the neuronal transmission paths of neuronal signal stimulated by the binding of olfactory receptors with certain molecules. The results showed the information regarding neural transmission paths to olfactory glomeruli, and users could further query which site of mushroom body was the recipient of the stimulated signal.
FIG. 5 illustrated system architecture for interactive search of the 3D image database. The said interactive search device 10 was linked via the internet 60 for data transmission, and automatically searched for information in the database 50 . The remote server 51 and query interface 20 were linked via the Internet 60 , which received the query commands from user interface 30 and visualization interface 40 . The user interface 30 comprised a search command field 31 , a 3D picking interface 32 and a file upload field 33 .
Visualization interface could display neuronal images in three-dimension form, while further provides users to rotate and zoom in and/or out the 3D images at any desire angles for panoramic view. To avoid nerves shadowing with one other, the neuronal images could be presented in a semi-transparent format for enhanced visualization. 3D images could also be presented in stereoscopic style, which users could perceive realistic depth perception through stereoscopic projection devices. ( FIG. 3 )
The 3D query interface provided users the capability to select the target neuron/neuropils directly from 3D scene instead of finding the desire target from a very long name list. Please refer to FIG. 4 , here presents an innervation-query interface, which enables users to build paths of neuron innervations step-by-step. Users may start from one neuron/neuropil and find out the connections of said neuron/neuropil with other neurons/neuropils. The figure illustrates two neurons (DVGLUT-F-000029, lemon yellow and DVGLUT-F-0000189, orange) innervating the mushroom body (MB_r, maroon). DVGLUT-F-000029 neuron is found to connect to a selected box, which occupies the space belonging to another neuropil-optic tubercle (OpTu โ 1, green). A third neuron (DVGLUT-F-000134, red) is found with its terminals innervating OpTu_l from the right side. A third neuropil (Lob_l, blue) is found to connect with DVGLUT-F-000134 neuron through its nerve terminals. A column on the left of the visualization interface shows part of neurons also innervating Lob โ 1.
To expedite the image display, 3D neuronal network images were all presented in skeletal forms. Interactive query referred to users inputting search commands through user interface, connecting to a remote server, and searching for information stored in a remote server database. Search results were then send back to user and presented on the visualization interface, and users could modify search commands according to the results presented on the interface to re-search the database for refined results. ( FIGS. 1 and 2 )
Query methods were divided into single query and combinational-query as follows:
1. Single query, i.e. using single command, comprised the following:
a. Query by name, which can be neuron's name or neuropil's name. b. Query by ROI Box: search particular neurons/neuropils passing through a certain rectangular space. c. Inside BOX Query: search particular neurons/neuropils within a certain rectangular space. d. Query by Data: users provide unknown novel neuron image for database search to find the most similar neuron.
2. Combinational-query: using single query coupled with combinations of Boolean operations (AND, OR, NOT) for more advanced search. Combinational-query contains following applications:
a. En Route Query: selecting two unlinked spatial locations or neurons, and trying to find a third party location or neuron to connect these two. For example: selecting areas A, B and C, and using query commands of A and C En Route B to make use of B as the connection hub between A and C. b. Spatial Query: selecting at least one adjustable spatial ROI box in the user interface to search neurons or neuropils passing through or within these spaces. c. Across Query: users could further filter the search results after Boolean or spatial search by selecting a particular spatial ROI box in a designated space to search for neurons passing through the target space and then displayed the results on screen. d. 3D Innervations Query: use 3D picking interface to select a neuron, neural terminal of a neuron, or neuropil as starting point to search for all connecting nerves in 3D space, in which the results can be presented on the visualization interface. Selecting another neuron, neural terminal of the neuron, or neuropil of interest from the previous query result as the next query target and the system would automatically display all innervations linking the second starting point (neuron, neural terminal, or neuropil); the information table of the innervations could also be displayed on the visualization interface. Repeating the above steps to find the information regarding a series of innervations, where the said information can be the names of neuron or terminals, or terminal of specific neuron.
EXAMPLE 4
Predicting the 3D Network Hub
FIG. 7 displayed the 3D neuron distribution in gray-scale dot matrix to represent the neural terminal density in 3D space. The spatial location with more gray-scale dots implied denser aggregation of nerve synapses, which infers the area is a neural network hub (neuropil), i.e. an area with more frequent neural signal transmissions. As displayed in this figure, the external outline of the Drosophila brain was observable, suggesting the dot matrix is indeed correlated with neural network functions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a visualization interface of the Drosophila 3D neural image database, which is able to visually present any compartments and details within Drosophila's brain, e.g. special structures like the mushroom body neuropils in mesh-form (brown color parts at the top of the brain), as well as drawing any geometric shapes (e.g. boxes). The small balls denote the nerve terminals, and the large balls represent the nerve soma (also known as the cell body of neuron).
FIG. 2 is a query interface and visualization interface of the Drosophila 3D neural image database. With the use of this interface, users can select neurons of interest from desired spatial regions in the 3D space. This figure selects parts of the female Drosophila brain neurons passing through boxes 1 and 2 . The outcome of the search in database is displayed in the Query Result panel at the bottom of the query interface. Users can move said boxes around or adjust their sizes (turned into cuboids) at their preference.
FIG. 3 shows the query interface of the Drosophila 3D neuronal image database and visualization interface. The objects in the scene can be rotated in 3D space at will by users for observation from different viewpoints. This figure is presented in semi-transparent form, permitting the view of numerous groups of neuronal paths/neuropils in need of investigation.
FIG. 4 shows the innervation-query interface, which enables users to build paths of neuron innervations step-by-step. Users can start from one neuron/neuropil and find out the connections of said neuron/neuropil with other neurons/neuropils. The figure illustrates two neurons (DVGLUT-F-000029, lemon yellow and DVGLUT-F-0000189, orange) innervating the mushroom body (MB_r, maroon). DVGLUT-F-000029 neuron is found to connect to a selected box, which occupies the space belonging to another neuropilโoptic tubercle (OpTu โ 1, green). A third neuron (DVGLUT-F-000134, red) is found with its terminals innervating OpTu_l from the right side. A third neuropil (Lob_l, blue) is found to connect with DVGLUT-F-000134 neuron through its nerve terminals. A column on the left of the visualization interface shows part of neurons also innervating Lob โ 1.
FIG. 5 shows system architecture of the system, which includes the interactive query interface, the visualization interface and the remote image database. Said interactive search device 10 is linked via the internet 60 for data transmission and to automatically search for information in the database 50 designated by the user using search commands. The remote server 51 and query interface 20 are linked via the internet 60 , receiving search commands from the user interface 30 and visualization interface 40 . The user interface 30 comprises search command field 30 , 3D picking interface 32 and file upload field 33 .
FIG. 6 shows the flow chart of database construction. In the neuronal information table, โIโ denotes neuron numbers, โTypeโ denotes neuron types (e.g. male, female and nerve function area), โSx, Sy, and Szโ represent the starting coordinates of a particular nerve, โEx, Ey, and Ezโ represent the ending coordinates of the aforesaid neuron, and โFilenameโ denotes the original file of this neuron. X, Y, Z in the 3D space table represent the coordinate of spatial unit (voxel or brick) in the 3D space, whereas V denotes the number of neuron passing through this particular space unit.
FIG. 7 displays the 3D nerve ending distribution map in gray-scale dot matrix to represent the nerve terminal density in a certain unit space. The spatial location with more gray-scale dots implies denser aggregation of nerve synapses, which infers the area is a neural network hub (neuropil), i.e. an area with more frequent neural signal transmissions. As displayed in this figure, the external outline of the Drosophila brain is observable, suggesting the dot matrix is indeed correlated with neural network functions.
DESCRIPTION OF MAJOR COMPONENT
10
Interactive query device for 3D Drosophila
neural image database
20
Query interface
30
User interface
31
Search command field
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3D picking interface
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File upload field
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Visualization interface
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3D Drosophila neural image database
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Remote server
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Internet connections
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The present invention relates to methods for searching and constructing a 3D motif image database, wherein said 3D motif image database can be used to understand the connection relationship of a 3D network, e.g. a neural network comprising biological neural networks or artificial neural networks. The searching and constructing methods are applied on the 3D motif image database, a proper computer-aided graphic platform. The database not only facilitates the management of the huge amount of categorized data but also rationally excavates the hidden information cloaked within.
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BACKGROUND OF THE INVENTION
It has been conventional for many years to delignify and bleach wood pulp by the use of various chlorination procedures. These are sometimes referred to in the paper industry as the C D E stages in the 5-stage C D EDED or 6-stage C D EHDED sequences. The use of chlorine gas is not inexpensive and the removal of unused chlorine gas and the chlorine-containing by-products from the effluent streams requires expensive chemical recovery systems so as to abate stream and environmental pollution problems.
Over the years suggestions have been advanced to replace the conventional chlorine delignification and bleaching treatments by replacing the use of chlorine with oxygen. A number of processes for bleaching and delignifying pulp with oxygen have been proposed, such as Richter U.S. Pat. Nos. 1,860,432, Grangaard et al. 2,926,114 and 3,024,158, Gaschke et al. 3,274,049, Meylan et al. 3,384,533, Watanabe 3,251,730, Rerolle et al. 3,423,282, Farley 3,661,699, French Pat. Nos. 1,310,248 and 1,387,853 and articles by Nikitin et al. in Trudy Leningradshoi Lesotekb. Nickeskoi Akad. i.S.M. Korova (Transactions of the Leningrad Academy of Forestry), Vol. 75, pp. 145-155 (1956), Vol. 80, pp. 65-75, 77-90 (1958) and Bumazh. Prom., Vol. 35, No. 12, pp. 5-7 (1960). However, these processes present certain disadvantages. Many of these processes require protective agents, such as magnesium carbonate disclosed in Meylan U.S. Pat. No. 3,384,533, to prevent depolymerization of the cellulose and preservation of pulp viscosity. In addition to the imparting of scale and encrustation problems on the process equipment, the use of such chemicals has a serious disadvantage in that they present pollution abatement problems. If pollution is to be avoided, expensive recovery treatments must be employed to remove such protective agents from the effluent streams.
Roymoulik and Brown U.S. Pat. No. 3,832,276, granted Aug. 27, 1974 marked an important advance in the art because it presented a commercially feasible process for delignification and bleaching of an alkaline, dilute slurry of pulp by means of oxygen. In that process there was employed an alkaline aqueous pulp slurry of a consistency of from about 2 to 10%, having a pH of between about 9 and 14, a reaction temperature of between about 70ยฐ and 120ยฐC., with the oxygen dissolved and intimately dispersed and subdivided into the slurry so that no agglomerated bubbles are formed and the oxygenated pulp slurry has substantially no bubbles exceeding about 1/16 inch in diameter. Conditions were employed so as to gradually decrease the pressure to which the slurry is subjected and continuously withdrawing treated slurry from the system. In an optional feature of said process, the slurry is pretreated with oxygen and alkali at an elevated temperature and pressure in a pretreatment vessel.
The aforesaid process of said U.S. Pat. No. 3,832,276, provided the paper industry with a new, efficient, continuous process which made excellent use of the chlorination towers with which conventional paper making plants were already equipped. In accordance with the present invention, I have provided an improvement over the process of said patent, making optimum use of the pressurized pretreatment stage of said process.
It is well established in the literature of oxygen bleaching that, all other variables held constant, an increase in reaction temperature will result in an increase in the extent of delignification. An article by Jan Gajdos in Papir a Celluloza, March, 1973, pp. 15-20, clearly demonstrates this point. When employing the conventional tower and passing the oxygenated pulp slurry upward through the tower, however, the maximum attainable temperature at the top of the tower is the boiling temperature of the alkaline pulp slurry. Since heat loss up the tower is small, the temperature at the base of the tower would also be near boiling. To use higher temperature would result in the highly undesirable consequence of flashing, and the belching of slugs of pulp slurry up the length of the tower, which cannot be tolerated.
It is, accordingly, an object of the present invention to provide a commercial low-cost continuous process for the delignification and bleaching of wood pulp, which is an improvement over the process of U.S. Pat. No. 3,832,276.
It is another object of the present invention to provide a low-cost continuous process for delignification and bleaching wood pulp which provides a practical method of achieving higher temperature in one portion of the process and, consequently, greater delignification.
It is a further object of the present invention to provide a process for delignification and bleaching of wood pulp which provides an additional benefit in the reduction of the amount of carbohydrate degradation, or viscosity loss, that accompanies delignification. This benefit is obtained as a result of the lower concentrations of NaOH that are utilized.
It is an additional object of the present invention to provide a low-cost continuous process for delignification and bleaching of wood pulp by the use of oxygen which provides an additional benefit of the invention in that, for a given retention time in the pre-retention reactor, use of the present invention allows the size of the reactor, and hence its cost, to be reduced.
Other objects will be apparent to those skilled in the art from the present specification, taken in conjunction with the appended drawings, in which:
FIG. 1 is a flow diagram illustrating one embodiment of the present invention;
FIG. 2 is a flow diagram illustrating another embodiment of the present invention.
GENERAL DESCRIPTION OF THE PROCESS
The present invention makes use of essentially the same apparatus and flow diagram as shown in said U.S. Pat. No. 3,832,276, with only slight modification. Thus, in the accompanying drawings, the features of difference (when compared to FIG. 2 of the patent drawings) are: alkali (NaOH) make up is provided by pipe 3b going into pipe 3, instead of optionally or through tank (1) as in said patent; pipe 3 introduces alkali and oxygen into pipe 2a, instead of tank 1. Oxygen sources 3a and the high pressure pre-retention vessel 6 are no longer merely optional, although the high speed pressure mixer 4 shown in attached FIG. 2 may serve the purpose of retention vessel 6 as will be described below.
Referring to FIG. 1 of the drawings, describing one form of apparatus and embodiment of the process, a pulp slurry of the desired consistency is produced by mixing in make-up tank 1. Pump 2 carries the pulp slurry of desired consistency into oxygenator or mixer 4, which is a chamber having a high-speed, high-shear mixing device, such as a Lightnin' Mixer, to incorporate and disperse oxygen along with alkali and recycled liquor from washer 10 into the alkaline pulp. Additional oxygen may be introduced into mixer 4 through inlet 4a. Alkali from make-up 3b and oxygen from 3a are incorporated along with wash liquor from washer 10 into pipe 3 which enters into pipe 2a and thence into mixer 4. The oxygenated pulp is then carried from mixer 4, through pipe 4b to heat exchanger 5 where steam is employed to elevate the temperature to the desired value. The heated alkaline oxygenated pulp is then passed through pipe 5a and subjected to pre-pressurizing chamber 6 where the pressure is momentarily elevated in that chamber, by means of oxygen pressure, for a brief period of time.
The pressure treated effluent from 6 is passed through pipe 6a where it is mixed with additional oxygen and alkali make-up from pipe 3c to reduce the pulp consistency to the desired value. The stream from pipe 6a is passed to vent 7 where any undissolved, undispersed oxygen is then removed from the liquid and thereafter the vented oxygenated alkaline pulp is introduced into the bottom of bleaching tower 8 by means of pipe 7a. At this stage care is taken that the temperature of the pulp slurry is below the boiling point. The flow of the alkaline oxygenated pulp is upward through the tower, as shown, with sufficient retention time to permit the desired bleaching and delignification to take place. Agitation of the pulp slurry in the tower is to be avoided. The initial pressure and differential in pressure during the bleaching treatment is determined by the height of the tower 8.
The effluent from the tower is then carried through pipe 9 to washer 10. The residual warm alkaline liquor recovered at the first washer is collected in container 11 and part of it is returned through pipe 3 to pipe 2a. Another part is returned to washer 10. The pulp from washer 10 is then carried through conduit 13 to second washer 14 where wash water is applied and the washed pulp is then carried to succeeding stages of bleaching, such as represented by chlorine dioxide treatments The effluent is collected in container 15 from which a portion is used for brown stock washing and the remainder carried through conduit 16 to be used in washing the pulp in first washer 10.
The embodiment of FIG. 2 and the apparatus described therein differs from that of FIG. 1 in that the pre-pressurizing chamber 6 of FIG. 1 is replaced with the high-speed mixer 4, which serves the same purpose as the pre-pressurizing chamber. The high-speed mixer 4 of FIG. 2 has an in-line high-shear mixer having the facility of readily dispersing oxygen throughout the pulp, and it is operated at elevated temperature and pressure to serve the purpose of the pre-retention chamber 6 of FIG. 1. To do this, the mixer must be equipped to withstand the pressures to which pre-retention chamber 6 will be subjected to. Upon leaving the mixer into line 6a, the pulp is diluted from line 3a with additional oxygenated alkali solution.
As can be seen from the foregoing, and the drawings, after the alkali stream has been replenished with alkali makeup 3b and oxygen 3a, it is split into two streams 3 and 3c. Stream 3, desirably constituting about one-half of the alkali stream, flows to dilute the incoming thick stock of pulp to a higher consistency than finally desired, such as about 4.5% consistency. The remainder of the alkali stream is introduced through pipe 3c to the effluent in pipe 6a from the high pressure pre-retention vessel 6. This will further reduce the pulp slurry consistency to a value of about 3% or any more desirable, more dilute value. This further dilution also serves to reduce the slurry temperature to below the boiling point. It is also believed to provide additional bleaching benefits in the tower. Since the volumetric flow rate of stock through the pre-retention system is diminished, the residence time is increased. Also, for the same quantity of heat used, a higher pre-retention temperature will be achieved. Also, for a given NaOH concentration in the filtrate, splitting the flow in the manner described will reduce the concentration of NaOH in the pre-retention reactor.
Desirably, the division of alkali make-up liquor flow should be regulated so that no less than about 1/3 of the total flow will be directed to the inlet thick stock, i.e., through pipe 3, with the remaining 2/3 flowing to the exit of the high pressure reactor, i.e., through pipe 3c. In this stage, the consistency of the pulp slurry in the high pressure pre-retention vessel 6 is desirably between about 3 and 11% by weight, preferably between about 4 and 8%. Desirably, no less than about 1/3 of the filtrate flow should be directed to the outlet of the high pressure reactor through pipe 3c.
In a commercial operation, it is contemplated that the temperature of the alkali make-up solution flowing into pipes 3 and 3c will reach an equilibrium at about 130ยฐ-140ยฐF.
In accordance with the process of the invention, an alkaline aqueous pulp of low consistency, such as less than about 10% by weight of wood pulp, preferably between about 2 to 6% and most desirably between 3 and 4%, is employed in the tower 8. Sufficient alkali is introduced to elevate the pH of the pulp to between about 9 and 14, and preferably between about 11.5 and 12.5. When sodium hydroxide is employed, it is usually desirable that about 1 to 10 grams per liter are employed, or to constitute between about 0.1% and 1.0% by weight of the pulp slurry.
The alkaline pulp is desirably mixed with oxygen in the high-shear mixing device 4 so that no large bubbles of oxygen remain in the aqueous pulp. Desirably no oxygen bubbles exceeding about 1/16 of an inch in diameter are present. Preferably, substantially no undissolved oxygen gas is present in the pulp. Ordinarily, oxygen is introduced in an amount of between about 0.1 and 4% by weight of aqueous pulp, with amounts of about 0.2 and 0.8% being preferred for softwood, and between about 0.2 and 0.4% by weight giving best results for hardwood pulp. Any undissolved bubbles of oxygen of substantial size are to be avoided, since they cause channeling to disrupt the upward flow of pulp through the bleaching tower, thereby causing non-uniform bleaching, which is highly undesirable. Also, larger bubbles tend to agglomerate and this is to be avoided. Any undissolved bubbles should be so finely dispersed as to avoid any substantial agglomeration.
Any undissolved oxygen, such as bubbles exceeding about 1/16 of an inch in diameter, are vented from the system, at vent 7 through pipe 7b, before the oxygenated pulp is introduced into the bleaching tower 8.
The distribution of oxygen through the pulp is desirably achieved through any high-speed, high-shear mixing device or gas absorber. Among such devices are the "Lightnin'" In-line mixer or the Line-Blender of Mixing Equipment Co., Inc. However, any high-shear mixer may be employed, as in 4 of FIG. 2 of the drawings.
In the pre-retention vessel 6 or high-speed mixer 4, momentary pressures of up to 300 p.s.i.g., or preferably 2 to 10 atmospheres, are desirable and temperatures of between about 160ยฐ and 300ยฐF., preferably between about 205ยฐ and 260ยฐF., for about 1 to 30 minutes.
During the treatment in tower 8, it is desirable that the reaction temperature of the aqueous pulp slurry be between about 160ยฐF. and its boiling point, with about 195ยฐ to 212ยฐF. preferred. Of course, where reaction temperatures substantially in excess of 212ยฐF. are employed, some means of providing pressure are required. For this reason, maximum reaction temperatures to be employed will be somewhat dependent on the height of the bleaching tower or initial pressure employed. The temperature should not exceed the boiling point of the pulp slurry at the pressure involved.
During the bleaching operation in tower 8, the pressure on the aqueous pulp is gradually reduced by a differential of at least about one atmosphere, with a maximum differential being about 10 atmospheres. This differential in pressure during the bleaching operation may be represented by the height of the bleaching tower, although any means for gradually and constantly reducing the pressure during treatment may be employed. Thus, a 300-foot bleaching tower provides an initial pressure of about 135 p.s.i.g. and a 40-foot bleaching tower provides an initial pressure of about 17 p.s.i.g. It is desirable that a bleaching tower be employed which is not higher than about 300 feet with the minimum height being about 40 feet.
The residence time of the aqueous pulp in the bleaching tower 8 may vary depending upon the pressure on the system and on the degree of bleaching required for the particular pulp employed. Some pulps require more drastic bleaching treatment than others. Generally speaking, from about 5 to 120 minutes is sufficient. With a higher initial pressure provided by a higher tower, the time can be reduced to a period of from about 2 minutes to 60 minutes. With a 40-foot tower, providing a pressure differential of roughly about one atmosphere, about 30 to 60 minutes, preferably about 40 minutes is satisfactory.
One of the important advantages of the process of the invention is that it permits enhancement of the viscosity of the pulp. Viscosity represents a measurement of the average degree of polymerization of the cellulose in the pulp sample, i.e., the average chain length of the cellulose. Thus, decreases in viscosity values represent the extent of depolymerization or degradation caused by the bleaching process. Excessive degradation is to be avoided since it provides undesirable physical properties in any paper made from the pulp.
Kappa No. is determined by the potassium permanganate consumed by a sample of pulp and represents a measurement of its retained lignin content. The higher the Kappa No., the less bleached and delignified is the pulp. By comparing Kappa Nos. of samples before and after bleaching treatment, one can obtain an evaluation of the extent of delignification which has taken place.
DETAILED DESCRIPTION OF THE INVENTION
In order to disclose more clearly the nature of the present invention, the following examples illustrating the invention are given. It should be understood, however, that this is done solely by way of example and is intended neither to delineate the scope of the invention nor limit the ambit of the appended claims. In the examples which follow, and throughout the specification, the quantities of material are expressed in terms of parts by weight, unless otherwise specified.
EXAMPLES I THROUGH X
Employing apparatus illustrated by FIG. 1 of the appended drawings, pilot plant studies were made and the conditions employed and the results obtained are set forth in Table I below. In these tests comparisons were made between conventional operation of the system in accordance with the process of U.S. Pat. No. 3,832,276, and the "split flow" features of the present invention. Thus, Examples I, II, VI, and VII employ the "full flow" technique, with all of the oxygenated alkaline solution going through the pre-retention pressure reactor 6 and are marked "conv" in said Table I. The remaining examples employ the split flow system of the present invention with some of the alkali and oxygen by-passing the pre-retention pressure reactor 6. These examples are marked "split" in said Table I.
In the Table, "UB" represents unbleached pulp. Oxygen flow is represented by the oxygen introduced by a Lightnin' mixer at 4 and by a high-shear mixer at 3a in the drawings.
Table I.__________________________________________________________________________Operating Data for Low Consistency OxygenBleaching Pilot Plant__________________________________________________________________________Example No. I II III IV V VI VII VIII IX X__________________________________________________________________________Type of Pulp DISSOLVING PULP PAPER GRADE PULPProduction Rate(Tons/Day) UB Pulp 1.27 1.21 0.95 1.03 1.11 0.86 0.86 0.80 1.15 0.86Type of Operation conv conv split split split conv conv split split splitPre-Retention Reactor(6)Consistency, % 3.8 3.5 4.4 4.7 4.7 2.9 2.9 4.8 4.9 4.1Temperature, ยฐF. 202 208 288 222 233 208 212 253 249 241Pressure, Psig. 102 101 100 100 99 100 101 102 97 101NaOH Conc., g/l. 1.6 1.8 1.6 1.2 1.0 4.5 4.9 1.4 2.2 3.4Bleaching Tower(8)Consistency, % 3.8 3.5 3.2 3.4 3.4 2.9 2.9 3.0 3.6 2.9Temperature, ยฐF. 202 196 198 193 199 202 209 201 213 199Make-up NaOHFlow, lb./Hr. 3.13 2.96 2.28 2.00 2.00 4.77 5.46 1.93 3.96 4.36% on UB Pulp 2.9 3.0 2.9 2.4 2.2 6.6 7.6 2.92 4.13 6.06Oxygen Flow, cc/min.Lightnin' Mixer 290 290 290 290 290 1000 1000 290 1000 1000High Shear Mixer 1360 1360 1360 1360 1360 1500 1500 1360 1360 1500Brightness, % ElrephoUnbleached 37.0 35.9 39.2 36.0 39.2 27.8 27.6 27.1 27.6 27.6Bleached 48.3 45.7 49.8 52.2 48.1 38.3 40.9 38.8 40.8 42.4A Brightness 11.3 9.8 10.6 16.2 8.9 10.5 13.3 11.7 13.2 14.8Permanganate No./KAPPAUnbleached 5.9 6.6 5.1 5.7 5.2 19.3 18.3 16.6 16.3 17.5Bleached 3.7 4.1 2.8 2.6 3.1 12.7 11.0 10.5 9.9 10.3% Reduction 37.3 37.9 45.1 54.4 40.4 34.2 40.0 36.7 39.3 41.1Viscosity, 1/2 % CEDUnbleached 32.0 33.4 22.7 33.4 32.1 46.7 46.2 38.1 36.2 41.2Bleached 12.4 13.1 10.4 12.7 19.7 26.3 23.5 25.5 23.0 24.2% Reduction 61.3 60.8 54.2 62.0 38.6 43.7 49.2 33.1 36.5 41.3__________________________________________________________________________
In the runs set forth in Table I, since it is natural that each method gives a range of levels of delignification, it is necessary to compare the methods at a given level of permanganate number or kappa number reduction. Thus, for dissolving pulp, Examples I and II show that, in total flow through the pressured pre-retention chamber 6, permanganate number reduction levels of 37-38% resulted in a reduction of viscosity of about 60-61%. By using split flow, Example V shows that a similar level of delignification (40.4% reduction in permanganate number), the viscosity was reduced by only 38.6%. Moreover, Examples III and IV show that, using split flow, the permanganate number can be reduced by 45-54% before the viscosity is reduced to the same extent noted in full flow through said chamber 6.
A similar trend, perhaps not as pronounced, is noted with the paper grade pulp. Examples VI and VII show that full flow gave kappa number reductions of 34.2% and 40.0%, with corresponding viscosity losses of 43.7% and 49.2%. Using split flow of the present invention, the lower level of delignification was achieved with only 33.1% loss of viscosity (Example VIII) while at the higher level of kappa reduction, Examples IX and X show the consistent superiority of the split flow method of the invention.
EXAMPLES XI THROUGH XIII
Table II below shows several additional examples of desirable operating conditions embodying the present invention. In these examples, the unbleached pulp initially was at 10% consistency, diluted to high pressure reactor 6 consistency with alkali a 4.8 g./l. and at a temperature of 140ยฐF. Outlet of the reactor was at a temperature of 203ยฐF. In these examples, Example XIII is a comparison example showing total flow through the pre-retention reactor 6 as in that process of U.S. Pat. No. 3,832,276.
Table II__________________________________________________________________________ Fraction of NaOH Conc. flow through in High- Tower (8)Consistency in Temp. (ยฐF) in Pressure not passingHigh-Pressure High-Pressure Pre-Retention throughExamplePre-Retention Pre-Retention Reactor (6) Pre-RetentionNo. Reactor (6) Reactor (6) (g./1.) Reactor (6)__________________________________________________________________________XI 5% 245 2.4 1/2XII 4% 220 3.1 1/3XIII 3% 203 4.0 0__________________________________________________________________________
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed.
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Cellulose pulp, in the form of an alkaline, dilute aqueous slurry, is continuously bleached and delignified by oxygen dissolved and intimately dispersed and subdivided into the slurry so that no agglomerated bubbles are formed. The alkaline, dilute slurry is prepared by adding not more than about 2/3 of an oxygenated, alkaline solution to the undiluted pulp entering the system, subjecting the resulting partially diluted alkaline pulp slurry to an elevated temperature and pressure, then further diluting said partially diluted alkaline pulp slurry with the remainder of oxygenated alkaline solution.
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This is a continuation of application Ser. No. 704,992, filed July 14, 1976 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a feedback color control system and, more particularly, to a system for controlling the simultaneous application of two dyes to a continuously formed material such as a web of paper.
Continuous process color control systems are known in the prior art. Generally, such systems use tristimulus colorimeters or similar instruments to measure the tristimulus values (red, green, and blue primary components) of the light reflected from a portion of the web or other material. Each of the red, green, and blue tristimulus signals is used to provide negative feedback individually to control an appropriate dye applicator located upstream from the measuring point. An example of such a system is shown in U.S. Pat. No. 3,389,265, issued to Schreckendgust.
Systems such as that described above are not universally applicable to any two dyes. If an attempt is made to control addition of a single dye by using a measured tristimulus variable, the variable chosen for control must be changed depending on the dye used. Direct use of the measured tristimulus variable for control of the addition of two dyes has proved impracticable.
I have provided a feedback color control system which overcomes the defects of color control systems pointed out hereinabove. My system may be used without change for one or two dye control. It can be used for any combination of two dyes regardless of color. It does not require detailed information about the optical properties of the component dyes. My system utilizes optical properties which correlate extremely well with visual color assessment.
SUMMARY OF THE INVENTION
One of the objects of my invention is to provide a feedback color control system which provides satisfactory color control.
Another object of my invention is to provide a feedback color control in a system which uses only two dyes.
A further object of my invention is to provide a feedback color control system which may be used over a broad range of dye values without reprogramming.
Other and further objects of my invention will appear from the following description.
In general, my invention contemplates the provision of a system for controlling the flows of two dyes used to color material including means for providing a first signal as a function of deviations in the color saturation of the material from a desired saturation, means for providing a second signal as a function of deviations in the hue of the material from a desired hue, means responsive to the first signal for varying the flows of the dyes in the same sense, and means responsive to the second signal for varying the flows of the dyes in opposite senses.
In its broad aspect, my invention takes advantage of the fact that the hue of a dyed material generally depends on the ratio of the concentrations of the various dyes used and is relatively insensitive to the total dye concentration, while the color saturation of a dyed material generally depends on the total dye concentration and is relatively insensitive to ratio changes. More particularly, my control system compares the measured color saturation of the dyed material with a predetermined desired color saturation to obtain a first error signal, and compares the measured hue of the dyed material with a predetermined hue to obtain a second error signal. My system includes readily programmed means, to be described, for deriving the first or color saturation error signal and second or hue error signals over a wide range of dye choices. In response to the first error signal, the flows of the two dyes used are varied in the same sense to change the total dye concentration to a corrected value. Similarly, in response to the second error signal, the flows of the two dyes are varied in opposite senses to change the ratio of the dye concentrations to a corrected value. The above system allows the hue and color saturation of a dyed material to be controlled independently in a system using only two dyes, thus permitting a simplicity of construction not found in the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of the International Commission on Illumination primary components of the wavelengths forming the visible spectrum.
FIG. 2 is an International Commission on Illumination chromaticity diagram illustrating the principle of operation of my system.
FIG. 3 is a schematic diagram of the preferred embodiment of my color control system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As is well known to those skilled in the art of colorimetry, the visual attributes of any light source may be characterized by expressing that light source as a linear combination of three primary light sources--that is, three light sources, no two of which can be combined to obtain the third. To facilitate the mathematical description of a light source in terms of such primary components, the International Commission on Illumination or ICI (also known by its French acronym CIE), has defined tristimulus values X, Y, and Z as follows:
(1) X=โซf(ฮป)x(ฮป)dฮป
(2) Y=โซf(ฮป)y(ฮป)dฮป
(3) Z=โซf(ฮป)z(ฮป)dฮป
where f(ฮป) is the spectral energy density of the light source and x(ฮป), y(ฮป), and z(ฮป) are previously defined weighting functions corresponding to the respective "red", "green", and "blue" ICI primary components of the wavelengths of the visible spectrum. These weighting functions, plotted with respect to wavelength ฮป, are shown in FIG. 1. The X, Y, and Z tristimulus values thus obtained correspond generally to the red, green, and blue components of the light source. The primaries, however, have been given a physically unobtainable "purity" for ease of mathematical description.
To further facilitate the quantitative description of the color of a light source, which is insensitive to proportionate changes in the X, Y, and Z tristimulus values, the ICI has defined a pair of chromaticity coordinates x and y by the equations: ##EQU1## The quantities x and y, which represent the fractional amount of the "red" and "green" primaries, respectively, are usually represented as the x and y coordinates of a standard x-y Cartesian coordinate plant commonly referred to as an ICI chromaticity diagram. FIG. 2 is such a diagram in which the spectrum locus, or locus of the chromaticity coordinates of pure spectral colors, is shown as a solid curved line RP. In FIG. 2, the pure "red" primary corresponds to the point (1,0), pure "green" to the point (0,1), and pure "blue" to the origin (0,0). "White" light, which is not precisely defined but implies an approximately equal mixture of red, green, and blue light, corresponds generally to the region around the point (1/3, 1/3). For the purposes of this disclosure, "white" light may be regarded as the light reflected from an undyed sample of the material being colored. As may be readily ascertained, additive mixtures of two light sources have x-y chromaticity representation that lies somewhere on the line segment joining the chromaticity points of the constituent light sources. The coordinate points R and P of the extremes (red and purple) of the visible spectrum have been joined by a solid straight line segment RP to form a closed curve whose border and interior region correspond to the set of physically realizable colors.
A more intuitive representation of a point (x, y) inside the spectrum locus may be obtained by drawing a line segment between the white light or source point (x w , y w ), as above defined, and the point (x, y) and extending the line segment past the point (x, y) to intersect the spectrum locus at a point (x.sub.ฮป, y.sub.ฮป). The wavelength ฮป corresponding to the point (x.sub.ฮป, y.sub.ฮป) is defined as the dominant wavelength. The "excitation purity" b of the point (x, y) is defined as the ratio of the distance between (x w , y w ) and (x, y) to the distance between (x w , y w ) and (x.sub.ฮป, y.sub.ฮป). Thus, a light source (x, y) having a dominant wavelength ฮป and an excitation purity of b could be formed by combining b units of pure spectral light of wavelength ฮป with (1-b) units of white light. The defined quantities of dominant wavelength and excitation purity correspond closely to the perceived hue and saturation of a light source. White light, for example, would have an undefined dominant wavelength and an excitation purity of zero. Pure spectral colors, on the other hand, would have an excitation purity of unity. All other colors have a dominant wavelength corresponding to some spectral wavelength (or some point on the red-purple line) and an excitation purity between zero and one.
It will be observed that the dominant wavelength of a light source (x, y) is a function only of the angular orientation ฮธ of the point (x, y) relative to the source point (x w , y w ). In other words, all points lying on a given line extending from the source point will have the same dominant wavelength. It will also be observed that the excitation purity of a point (x, y) may be considered as being the product of the distance of the point (x, y) from the source point (x w , y w ) and the reciprocal of the distance of the dominant wavelength point (x.sub.ฮป, y.sub.ฮป) from the source point (x w , y w ), the reciprocal being a slowly varying function of the dominant wavelength. From these relations it may be deduced that the color saturation of a light source (x, y) is generally determined by the distance of the point (x, y) from the source point (x w , y w ), and further that the hue of the light source (x, y) is generally determined by the angular orientation ฮธ of the point (x, y) relative to the source point (x w , y w ). One aspect of my invention, therefore, contemplates means for generating the chromaticity coordinates x and y of a reflected light beam from the dyed material, means for measuring the distance of the point (x, y) from the source point (x w , y w ) to obtain a measured saturation signal, means for measuring the angular orientation of the point (x, y) relative to the source point (x w , y w ) to obtain a measured hue signal, and means for comparing said signals respectively with a first or color saturation reference signal and a second or hue reference signal to produce respective first and second error signals. Since this system is generally operable over all possible color choices, it is unnecessary to reprogram the system when different dyes are used or different setpoints are selected. System flexibility is thus significantly increased.
Referring now to FIG. 3, my system includes first and second dye applicators, located at a dyeing station indicated generally by the reference character 12. A sensing station, indicated generally by the reference character 18, is located downstream from the dyeing station 12. A moving web 10 of paper pulp or the like moves past the stations in the direction indicated by the arrow. Electrically operated valves 24 and 26 connect respective dye supply lines 20 and 22 to applicators 14 and 16. Valve 24 increases the flow of the first dye in response to a positive ฮF1 signal on a line 28 and decreases the flow of the first dye in response to a negative ฮF1 signal. Similarly, valve 26 increases the flow of the second dye in response to a positive ฮF2 signal on a line 30 and decreases the flow of the second dye in response to a negative ฮF2 signal. Preferably, each of the valves 24 and 26 changes the dye flow at a rate proportional to the input signal F1 ฮF2 or F1, although this is not necessary where the valve actuating motors (not separately shown) are well damped. Flow meters 32 and 34 placed in respective dye lines 20 and 22 provide dye flow measurement signals F1 and F2 on lines 36 and 38.
At the sensing station 18, reference light sources 40 direct reference light beams on a portion of the paper web 10. The reflected light from this web portion is sensed by a tristimulus sensor 42 of any suitable type known in the art which produces X, Y, and Z signals representing, respectively, the red, green, and blue primary components of the reflected light beam. While the exact choice of primary colors used remains arbitrary, it is preferable for reasons of compatibility that the abovedefined primaries adopted by ICI be used. In a practical arrangement such as the one shown, the X, Y, and Z tristimulus values, may be derived by illuminating the sample with a standard light source having a prescribed spectral distribution, directing the reflected light through "red", "green", and "blue" filters having prescribed spectral responses, and measuring the light transmitted through the red, green, and blue filters. A detailed description of a tristimulus sensor capable of performing those steps is provided in my U.S. Pat. No. 3,936,189.
The analog X, Y, and Z tristimulus signals on lines 44, 46 and 48 are converted to digital form by respective analog-to-digital converters 50, 52 and 54 while the F1 and F2 flow measurement signals on lines 36 and 38 are changed to digital form by converters 120 and 122. Each of the remaining elements of my system to be described, unless otherwise stated, has a multibit parallel binary input and also has a multibit parallel binary output. While the input and output "lines" of these elements are shown as single conductors for clarity, it is to be understood that each such "line" actually comprises a plurality of conductors corresponding to the number of bits in the signal.
The digitalized signals X, Y, and Z from converters 50, 52 and 54 are fed to a chromaticity coordinate generator circuit indicated generally by the reference numberal 56. More particularly, a three-input parallel adder 58 supplied with the digitalized X, Y, and Z signals provides a sum signal X+Y+Z. This signal is fed to the divisor input of a first divider 60, the dividend input to which is the digitalized X signal to produce the x signal of Equation (4). The X+Y+Z signal is also fed to the divisor input of a second divider 52, the dividend input to which is the digitalized Y signal to produce the y signal of Equation (5).
I feed the x chromaticity signal to a subtractor 61 which also receives an x w signal representing the x chromaticity coordinate of the reflected light from a "white" or undyed sample of the material 10. As is explained more fully in U.S. Pat. No. 3,936,189, the tristimulus colorimeter 42 includes means for normalizing the measured X, Y, and Z tristimulus values relative to the tristimulus values of the light sources 40. As a result, it is unnecessary independently to measure the tristimulus values of the reflected light from an undyed sample, and the value x w need only be determined when the system is initially calibrated for a given material 10. Thus, the x w signal is obtained from an operator-actuated parallel binary signal source 62. In other systems which do not have a self-standardizing colorimeter, it may be necessary for best results to continuously derive x w from an on-line sensor or colorimeter.
Similarly, the y chromaticity signal is fed to a subtractor 63 which also receives a y w signal, representing the y chromaticity coordinate of the reflected light from an undyed sample, from a second operator-actuated parallel binary signal source 64. Subtractors 61 and 63 provide difference signals x d and y d indicated in FIG. 2 and which represent the difference between the measured chromaticity signals x and y and the respective reference or "white" chromaticity signals x w and y w .
Although it is desirable, from the standpoints of simplicity and standardization for monitoring or plotting, that the x and y chromaticity signals simply be the respective chromaticity coordinates, it is not essential to the practice of my invention. More generally, the chromaticity coordinate generator 56 may generate signals x' and y', where x'=aX+bY/(X+Y+Z) and y'=cX+dY/(X+Y+Z). By choosing appropriate coordinates x' and y', curves of equal "saturation" will appear on the x-y diagram as ellipses of various eccentricities and inclinations, rather than as circles. Such equal-saturation curves may be preferable in certain cases, depending on the particular operating point.
I apply the signals x d and y d to a polar coordinate generator indicated generally by the reference numeral 68 to obtain their polar coordinate equivalents. More particularly, the x d and y d signals are applied to respective squaring circuits 70 and 72, the outputs of which are fed to an adder 74. The adder 74 output is then fed to a square root extractor 76 to generate a Cl or r coordinate signal. I also apply the x d and y d signals to the dividend and divisor inputs, respectively, of a divider 78, the output of which is fed to an arc tangent generator 80 having an output range between -ฯ/2 and ฯ/2. A sign indicator 82 responsive to the x d signal has an output of zero whenever the input is zero or positive and an output of one whenever the input is negative. I pass the output of the sign indicator 82 through a multiplier 84, which multiplies the input by ฯ. I apply the output of multiplier 84 and the output of the arc tangent generator 80 to an adder 86 which provides a coordinate ฮธ or C2 signal which ranges between -ฯ/2 and (3ฯ)/2.
The C1 or measured saturation signal is applied to a subtractor 88 as a first input. A C1 set signal, derived from an operator-actuated parallel binary signal source 90 provides the second input for subtractor 88. Likewise, the C2 or measured hue signal is applied to a subtractor 92 as a first input. A C2 set signal derived from an operator-actuated parallel binary signal source 94 provides the second input to subtractor 92. Subtractors 88 and 92 provide error signals ฮC1 and ฮC2 representing deviations in the saturation and hue of the sample being monitored.
Means are provided for transforming the hue error signal ฮC2, which, assuming the signal generated by signal source 94 to range between -ฯ/2 and 3ฯ/2, may represent any angle between -2ฯ and 2ฯ, into a modified hue error signal representing an angle between -ฯ and ฯ. I feed the C2 signal to a first comparator 96 which produces a "one" output if C2 is greater than ฯ. A multiplier 98 multiplies the output of comparator 98 by -2ฯ to provide one input to an adder 100. The ฮC2 signal is also fed to a second comparator 102 which produces a "one" output if ฮC2 is less than -ฯ. A multiplier 104 multiplies the output of comparator 102 by 2ฯ to provide a second input to the adder 100. A third input to the adder 100 is provided by the ฮC2 signal directly. As is apparent from the above description, adder 100 provides a modified hue error signal ฮC2' ranging between -ฯ and ฯ and equal to ฮC2 plus or minus some multiple of 2ฯ.
Error signals ฮC1 and ฮC2' are fed to a circuit indicated generally by the reference character 106 which derives flow correction signals ฮF1 and ฮF2 to be applied to flow control lines 28 and 30. More specifically, I pass error signal ฮC1 through a multiplier 108 which multiplies the signal ฮC1 by a gain coefficient G1 derived from an operator-controlled parallel binary signal source 110. Likewise, hue error signal ฮC2' is passed through a multiplier 112 where it is multiplied by a second gain coefficient G2 derived from a second operator-controlled parallel binary signal source 114. The output of multiplier 108 is fed to one input of each of a pair of mutipliers 116 and 118 by feeding flow measurement signals F1 and F2 on lines 36 and 38 to respective analog-to-digital converters 120 and 122. Both digitalized signals are fed to an adder 124 and to the respective dividend inputs of dividers 124 and 128, each of the divisor input of which is the output of adder 124. The outputs of dividers 126 and 128, representing the respective fractional portions of the first and second dyes, are applied to the second inputs of multipliers 116 and 118. Multipliers 112 and 116 provide the inputs to adder 130 to produce the ฮF1 flow control signal. Multipliers 118 and 112 provide the inputs to produce the ฮF2 flow control signal. Finally, the ฮF1 and ฮF2 flow correction signals are passed to respective digital-to-analog converters 134 and 136 to provide analog signals on line 28 and 30 coupled to the respective control valves 24 and 26.
While the embodiment shown employs a special purpose digital circuit, it is to be understood that the signal processing functions of the system may also be performed by a suitably programmed general purpose computer in a manner familiar to those skilled in the art.
It will be seen that I have accomplished the objects of my invention. I have provided a feedback color control system which can be used for any combination of two dyes regardless of color. It can be used without change for one or two dye control. It utilizes optical properties which correlate extremely well with visual color assessment.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of my claims. It is further obvious that various changes may be made in details within the scope of my claims without departing from the spirit of my invention. It is, therefore, to be understood that my invention is not to be limited to the specific details shown and described.
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In a feedback color control system for controlling the flows of two colorants used to color an article, a first error signal is generated as a function of deviations in the color saturation of the article from a desired saturation, and a second error signal is generated as a function of deviations in the hue of the article from a desired hue. The flows of the dyes are varied in the same sense in response to the first error signal and are varied in opposite senses in response to the second error signal.
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FIELD OF THE INVENTION
[0001] The present disclosure relates to fault detection in encryption systems.
BRIEF SUMMARY
[0002] In accordance with one embodiment, a method is provided for improving the operation of a processor executing a cryptographic process by automatically detecting faults during both encryption and decryption operations by the cryptographic process. The method comprises segmenting the data to be encrypted and encrypting the data segments using a complex non-linear algorithm that can lead to faults; computing an output parity bit from a selected step of the algorithm for a selected data segment, based on the input value of that segment; comparing the actual output parity bit of the selected segment with the computed output parity bit for that segment; and determining whether a fault exists, based on whether the actual output parity bit matches the computed output parity bit for the selected segment. The data segments may be encrypted and decrypted, and the computing, comparing and determining operations are executed during both encrypting and decrypting. The data is preferably encrypted and decrypted using the Advanced Encryption Standard specification.
[0003] In one implementation, the method comprises computing an input parity bit for the selected data segment input to the selected step of the algorithm, based on the output value of that segment from the selected step of the algorithm; comparing the actual input parity bit of the selected segment input to the selected step of the algorithm, with the computed input parity bit for that data segment, and determining whether a fault exists, based on whether the actual input parity bit matches the computed input parity bit for the selected segment.
[0004] In a preferred implementation, the method computes an output parity bit from multiple steps of the algorithm; compares the actual output parity bit of each of the multiple steps with the computed output parity bit for that step; and determines whether a fault exists, based on whether the actual output parity bit matches the computed output parity bit for each of the multiple steps.
[0005] In another implementation, the method comprises segmenting the data to be encrypted and encrypting the data segments using a complex non-linear algorithm that can lead to faults; computing an output parity bit from a data segment processed by the algorithm, based on the input value of that segment before being processed by the algorithm; comparing the actual output parity bit of the data segment with the computed output parity bit for that segment, and determining whether a fault exists, based on whether the actual output parity bit matches the computed output parity bit for the selected segment. In one implementation, the data segments are encrypted and decrypted, and the computing, comparing and determining operations are executed for each data segment that is encrypted or decrypted.
[0006] The foregoing and additional aspects and embodiments of the present disclosure will be apparent to those of ordinary skill in the art in view of the detailed description of various embodiments and/or aspects, which is made with reference to the drawings, a brief description of which is provided next.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other advantages of the disclosure will become apparent upon reading the following detailed description and upon reference to the drawings.
[0008] FIG. 1 is a diagram of an embodiment of an encryption engine using two-way parity fault detection.
[0009] FIG. 2 is a diagram of an embodiment of the key expansion engine using two-way parity fault detection.
[0010] While the present disclosure is susceptible to various modifications and alternative forms, specific embodiments or implementations have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of an invention as defined by the appended claims.
REFERENCES
[0011] [1] Federal Information Processing Standards (FIPS). Advanced Encryption Standard ( AES ). Publication 197. November 2001.
DETAILED DESCRIPTION
[0012] The Advanced Encryption Standard (AES) [1] executes a complex non-linear algorithm which can lead to faults. In order to detect faults, the whole AES engine can be duplicated and executed twice in parallel. Results from both are compared to detect faults. However, this approach leads to more than 100% overhead, which for high-throughput engines is a large price to pay.
[0013] Using single parity to detect faults in AES engines can be considered as a solution to reduce the cost. In this case, the parity of the fault-free output is computed based on the input data and is compared with the parity generated from the output data. Only uneven bit errors can be detected. However, given the fact that errors in an AES engine spread quickly throughout the data and the control blocks, they are generally not detectable by single parity fault detection leading to unacceptable fault coverage.
[0014] There is a need for a low cost fault detection method with reliable fault coverage.
[0015] In this embodiment, checkpoints are incorporated throughout the data blocks to verify the parity and prevent the errors from spreading.
[0016] A two-way parity fault detector is applied to the AES datapath (in both encryption and decryption paths), while the control logic (e.g., finite state machine, multiplexors and registers) are optionally covered via duplication.
[0017] Referring to FIG. 1 , the round cipher module is protected using several fault detection steps. The S-box and inv S-box process 101 and the MixColumns and Inv MixColumns process 122 are each covered by a two-way parity fault detection with 1 parity bit per 8 bits. The output parity bit (1 parity bit per 8-bits of data) is computed based on the input value and compared with the actual output parity bit.
[0018] Data 100 of size 128-bits or 256-bits is segmented into 8-bit segments in step 102 . Prior to performing the S-box/inv S-box process 101 , a 1-bit parity of the fault-free output on w2 is computed based on the input w1 on the segments in step 106 . This computed parity is compared with the actual parity of the output of the S-box/inv S-box process 101 , and if the actual parity does not match the computed parity, a fault is detected at step 108 . At the same time, based on the segment output from the segment S-box/inv S-box process 101 , a 1-bit parity of the fault-free input packet is computed based on w2 at step 110 and compared with the input segment parity to detect a fault at step 112 .
[0019] The ShiftRows/inv ShiftRows process 114 is performed if no faults are detected, then the key 116 is segmented 117 and combined to perform the encrypt/decrypt process 118 .
[0020] Optionally, for higher fault coverage, parity for the encrypted/decrypted segments from the encrypt/decrypt process is computed at step 120 prior to input into the MixColumn/invMixColumn process 122 . Prior to performing the MixColumn/invMixColumn process 122 , a 1-bit parity of the fault-free output on w4 is computed based on the input w3 on the segments in step 120 . This computed parity is compared with the actual parity of the output of the MixColumn/invMixColumn process 122 , and if the actual parity does not match the computed parity, a fault is detected at step 124 . At the same time, based on the segment output from the MixColumn/invMixColumn process 122 , a 1-bit parity of the fault-free input packet is computed based on w4 at step 130 and compared with the input segment parity to detect a fault at step 132 .
[0021] Furthermore, based on the encrypted/decrypted segments from the encrypt/decrypt process, parity on the expected input segment can be computed at step 126 and compared with the original input segment for fault detection at step 128 .
[0022] Parity of the initial segment is compared with the output segments after the last round 134 for fault detection at step 136 prior to output of the data 150 .
[0023] An example of a protected key expansion module is shown in FIG. 2 . A 128-bit key is stored in registers 203 . The key is XORed at step 201 , and 4 segments of 32-bits 200 a . . . 200 d are re-circulated to the registers 203 for the next round. The round number 221 is input to the round constant process (RCON) 220 . Parity on the output of the RCON process based on the expected round number is compared to the parity of the RCON output for fault detection at step 224 .
[0024] A control function 205 selects either the first 32-bit segment of the new round key or the previous round key depending upon whether it is performing decryption or encryption. The bits of the selected segment are shifted by 8 to the left. Prior to performing the S_box process 210 , a 1-bit parity of the fault-free output on w7 is computed based on the input w6 on the segments in step 208 . This computed parity is compared with the actual parity of the output of S_box process 210 , and if the actual parity does not match the computed parity, a fault is detected at step 216 . At the same time, based on the segment output from the S_box process 210 , a 1-bit parity of the fault-free input packet is computed based on w7 at step 212 and compared with the input segment parity to detect a fault at step 214 .
[0025] A 1-bit parity check 222 can be optionally added to the RCON function 220 to detect faults in RCON block 224 .
[0026] The control logic and multiplexors can be optionally protected using duplication.
[0027] When a fault is detected 108 , 112 , 124 , 128 , 132 , 136 the process can be halted and the most recent encryption/decryption round restarted from the beginning to avoid wasting further cycles on ciphering segments with errors. Statistics on the frequency of detected faults and the step involved in the fault can be optionally gathered and used to manage the processor.
[0028] Conventional duplication method provides 100% fault coverage with greater than 100% area overhead. The two-way parity fault detection embodiment described provides for 99.9% fault detection coverage with 41% area overhead.
[0029] Although the algorithms described above including those with reference to the foregoing flow charts have been described separately, it should be understood that any two or more of the algorithms disclosed herein can be combined in any combination. Any of the methods, algorithms, implementations, or procedures described herein can include machine-readable instructions for execution by: (a) a processor, (b) a controller, and/or (c) any other suitable processing device. Any algorithm, software, or method disclosed herein can be embodied in software stored on a non-transitory tangible medium such as, for example, a flash memory, a CD-ROM, a floppy disk, a hard drive, a digital versatile disk (DVD), or other memory devices, but persons of ordinary skill in the art will readily appreciate that the entire algorithm and/or parts thereof could alternatively be executed by a device other than a controller and/or embodied in firmware or dedicated hardware in a well known manner (e.g., it may be implemented by an application specific integrated circuit (ASIC), a programmable logic device (PLD), a field programmable logic device (FPLD), discrete logic, etc.). Also, some or all of the machine-readable instructions represented in any flowchart depicted herein can be implemented manually as opposed to automatically by a controller, processor, or similar computing device or machine. Further, although specific algorithms are described with reference to flowcharts depicted herein, persons of ordinary skill in the art will readily appreciate that many other methods of implementing the example machine readable instructions may alternatively be used. For example, the order of execution of the blocks may be changed, and/or some of the blocks described may be changed, eliminated, or combined.
[0030] It should be noted that the algorithms illustrated and discussed herein as having various modules which perform particular functions and interact with one another. It should be understood that these modules are merely segregated based on their function for the sake of description and represent computer hardware and/or executable software code which is stored on a computer-readable medium for execution on appropriate computing hardware. The various functions of the different modules and units can be combined or segregated as hardware and/or software stored on a non-transitory computer-readable medium as above as modules in any manner, and can be used separately or in combination.
[0031] While particular implementations and applications of the present disclosure have been illustrated and described, it is to be understood that the present disclosure is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations can be apparent from the foregoing descriptions without departing from the spirit and scope of an invention as defined in the appended claims.
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A method of improving the operation of a processor executing a cryptographic process, by automatically detecting faults during both encryption and decryption operations by the cryptographic process, comprises segmenting the data to be encrypted and encrypting the data segments using a complex non-linear algorithm that can lead to faults; computing an output parity bit from a selected step of the algorithm for a selected data segment, based on the input value of that segment; comparing the actual output parity bit of the selected segment with the computed output parity bit for that segment; and determining whether a fault exists, based on whether the actual output parity bit matches the computed output parity bit for the selected segment.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of copending application Ser. No. 11/078,121 filed Mar. 11, 2005, Ser. No. 10/077,587 filed Mar. 11, 2005, and Ser. No. 10/366,173 filed Feb. 13, 2003 which is a continuation of application Ser. No. 09/657,018 filed Sep. 7, 2000, now U.S. Pat. No. 6,547,008, which is a continuation of application Ser. No. 09/092,549 filed Jun. 5, 1998 which is a divisional continuing application of Ser. No. 08/679,560 filed Jul. 12, 1996, now U.S. Pat. No. 6,039,119, which is a continuation of Ser. No. 08/204,397 filed Mar. 16, 1994, now U.S. Pat. No. 5,544,707, which claims the benefit of PCT application PCT/US93/05246 fled on May 28, 1993, which claims the priority of European Patent Office application 92305014 filed on Jun. 1, 1992, all of the above hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
FIELD OF THE INVENTION
[0003] Conventionally, wells in oil and gas fields are built up by establishing a wellhead housing, and with a drilling blow out preventer stack (BOP) installed, drilling down to produce the well hole whilst successively installing concentric casing strings, which are cemented at the lower ends and sealed with mechanical seal assemblies at their upper ends. In order to convert the cased well for production, a tubing string is run in through the BOP and a hanger at its upper end landed in the wellhead. Thereafter the drilling BOP stack is removed and replaced by a Christmas tree having one or more production bores containing actuated valves and extending vertically to respective lateral production fluid outlet ports in the wall of the Christmas tree.
[0004] This arrangement has involved problems which have, previously, been accepted as inevitable. Thus any operations down hole have been limited to tooling which can pass through the production bore, which is usually no more than five inch diameter, unless the Christmas tree is first removed and replaced by a BOP stack. However this involves setting plugs or valves, which may be unreliable by not having been used for a long time, down hole. The well is in a vulnerable condition whilst the Christmas tree and BOP stack are being exchanged and neither one is in position, which is a lengthy operation. Also, if it is necessary to pull the completion, consisting essentially of the tubing string on its hanger, the Christmas tree must first be removed and replaced by a BOP stack. This usually involves plugging and/or killing the well.
[0005] A further difficulty which exists, particularly with subsea wells, is in providing the proper angular alignment between the various functions, such as fluid flow bores, and electrical and hydraulic lines, when the wellhead equipment, including the tubing hanger, Christmas tree, BOP stack and emergency disconnect devices are stacked up. Exact alignment is necessary if clean connections are to be made without damage as the devices are lowered into engagement with one another. This problem is exacerbated in the case of subsea wells as the various devices which are to be stacked up are run down onto guide posts or a guide funnel projecting upwardly from a guide base. The post receptacles which ride down on to the guide posts or the entry guide into the funnel do so with appreciable clearance. This clearance inevitably introduces some uncertainty in alignment and the aggregate misalignment when multiple devices are stacked, can be unacceptably large. Also the exact orientation will depend upon the precise positions of the posts or keys on a particular guide base and the guides on a particular running tool or BOP stack and these will vary significantly from one to another. Consequently it is preferable to ensure that the same running tools or BOP stack are used for the same wellhead, or a new tool or stack may have to be specially modified for a particular wellhead. Further misalignmentโ can arise from the manner in which the guide base is bolted to the conductor casing of the wellhead.
[0006] In accordance with the present invention, a wellhead comprises a wellhead housing; a spool tree fixed and sealed to the housing, and having at least a lateral production fluid outlet port connected to an actuated valve; and a tubing hanger landed within the spool tree at a predetermined angular position at which a lateral production fluid outlet port in the tubing hanger is in alignment with that in the spool tree.
[0007] With this arrangement, the spool tree, takes the place of a conventional Christmas tree but differs therefrom in having a comparatively large vertical through bore without any internal valves and at least large enough to accommodate the tubing completion. The advantages which are derived from the use of such spool tree are remarkable, in respect to safety and operational benefits.
[0008] Thus, in workover situations the completion, consisting essentially of the tubing string, can be pulled through a BOP stack, without disturbing the spool tree and hence the pressure integrity of the well, whereafter full production casing drift access is provided to the well through the large bore in the spool tree. The BOP can be any appropriate workcover BOP or drilling BOP of opportunity and does not have to be one specially set up for that well
[0009] Preferably, there are complementary guide means on the tubing hanger and spool tree to rotate the tubing hanger into the predetermined angular position relatively to the spool tree as the tubing hanger is lowered on to its landing. With this feature the spool tree can be landed at any angular orientation onto the wellhead housing and the guide means ensures that the tubing string will rotate directly to exactly the correct angular orientation relatively to the spool tree quite independently of any outside influence. The guide means to control rotation of the tubing hanger into the predetermined angular orientation relatively to the spool tree may be provided by complementary oblique edge surfaces one facing downwardly on an orientation sleeve depending from the tubing hanger the other facing upwardly on an orientation sleeve carried by the spool tree
[0010] Whereas modern well technology provides continuous access to the tubing annulus around the tubing string, it has generally been accepted as being difficult, if not impossible, to provide continuous venting and/or monitoring of the pressure in the production casing annulus, that is the annulus around the innermost casing string. This has been because the production casing annulus must be securely sealed whist the Christmas tree is fitted in place of the drilling BOP, and the Christmas tree has only been fitted after the tubing string and hanger has been run in, necessarily inside the production casing hanger, so that the production casing hanger is no longer accessible for the opening of a passageway from the production casing annulus. However, the new arrangement, wherein the spool tree is fitted before the tubing string is run in provides adequate protected access through the BOP and spool tree to the production casing hanger for controlling a passage from the production casing annulus.
[0011] For this purpose, the wellhead may include a production casing hanger landed in the wellhead housing below the spool tree; an isolation sleeve which is sealed at its lower end to the production casing hanger and at its upper end to the spool tree to define an annular void between the isolation sleeve and the housing; and an adapter located in the annular space and providing part of a passage from the production casing annulus to a production casing annulus pressure monitoring port in the spool tree, the adapter having a valve for opening and closing the passage, and the valve being operable through the spool tree after withdrawal of the isolation sleeve up through the spool tree. The valve may be provided by a gland nut, which can be screwed up and down within a body of the adapter to bring parts of the passage formed in the gland nut and adapter body, respectively, into and out of alignment with one another. The orientation sleeve for the tubing hanger may be provided within the isolation sleeve.
[0012] Production casing annulus pressure monitoring can then be set up by method of completing a cased well in which a production casing hanger is fixed and sealed by a seal assembly to a wellhead housing, the method comprising, with BOP installed on the housing, removing the seal assembly and replacing it with an adapter which is manipulatable between configurations in which a passages from the production casing annulus up past the production casing hanger is open or closed; with the passage closed, removing the BOP and fitting to the housing above the production casing hanger a spool tree having an internal landing for a tubing hanger; installing a BOP on the spool tree; running a tool down through the BOP and spool tree to manipulate the valve and open the passage; inserting through the BOP and spool tree an isolation sleeve, which seals to both the production casing and spool tree and hence defines between the sleeve and casing an annular void through which the passage leads to a production caning annulus pressure monitoring port in the spool tree; and running a tubing string down through the BOP and spool tree until the tubing hanger lands in the spool tree with lateral outlet ports in the tubing hanger and spool tree for production fluid flow, in alignment with one another.
[0013] According to a further feature of the invention the spool tree has a downwardly depending location mandrel which is a close sliding fit within a bore of the wellhead housing. The close fit between the location mandrel of the spool tree and the wellhead housing provides a secure mounting which transmits inevitable bending stresses to the housing from the heavy equipment, such as a BOP, which projects upwardly from the top of the wellhead housing, without the need for excessively sturdy connections. The location mandrel may be formed as an integral part of the body of the spool tree, or may be a separate part which is securely fixed, oriented and sealed to the body
[0014] Pressure integrity between the wellhead housing and spool tree may be provided by two seals positioned in series one forming an environmental seal (such as an AX gasket) between the spool tree and the wellhead housing, and the other forming a production seal between the location mandrel and either the wellhead housing or the production casing hanger.
[0015] During workover operations, the production casing annulus can be resealed by reversing the above steps, if necessary after setting plugs or packers down hole.
[0016] When production casing pressure monitoring is unnecessary, so that no isolation sleeve is required, the orientation sleeve carried by the spool tree for guiding and rotating the tubing hanger down into the correct angular orientation may be part of the spool tree location mandrel itself.
[0017] Double barrier isolation, that is to say two barriers in series, are generally necessary for containing pressure in a well. If a spool tree is used instead of a conventional Christmas tree, there are no valves within the vertical production and annulus fluid flow bores within the tree, and alternative provision must be made for sealing the bore or bores through the top of the spool tree which provide for wire line or drill pipe access.
[0018] In accordance with a further feature of the invention, at least one vertical production fluid bore in the tubing hanger is sealed above the respective lateral production fluid outlet port by means of a removable plug, and the bore through the spool tree being sealed above the tubing hanger by means of a second removable plug.
[0019] With this arrangement, the first plug, takes the function of a conventional swab valve, and may be a wireline set plug. The second plug could be a stopper set in the spool tree above the tubing hanger by, e.g., a drill pipe running tool. The stopper could contain at least one wireline retrievable plug which would allow well access when only wire line operations are called for. The second plug should seal and be locked internally into the spool tree as it performs a barrier to the well when a BOP or intervention module is deployed. A particular advantage of this double plug arrangement is that, as is necessary to satisfy authorities in some jurisdictions, the two independent barriers are provided in mechanically separate parts, namely the tubing hanger and its plug and the second plug in the spool tree,
[0020] A further advantage arises if a workover port extends laterally through the wall of the spool tree from between the two plugs; a tubing annulus fluid port extends laterally through the wall of the spool tree from the tubing annulus; and these two ports through the spool tree are interconnected via an external flow line containing at least one actuated valve. The bore from the tubing annulus can then terminate at the port in the spool tree and no wireline access to the tubing annulus bore is necessary through the spool tree as the tubing annulus bore can be connected via the interplug void to choke or kill lines, i.e. a BOP annulus, so that downhole circulation is still available. It is then only necessary to provide wireline access at workover situations to the production bore or bores. This considerably simplifies workover BOP and/or riser construction. When used in conjunction with the plug at the top of the spool tree, the desirable double barrier isolation is provided by the spool tree plug over the tubing hanger, or workover valve from the production flow.
[0021] When the well is completed as a multi production bore well, in which the tubing hanger has at least two vertical production through bores each with a lateral production fluid flow port aligned with the corresponding port in the spool tree, at least two respective connectors may be provided for selective connection of a single bore wire line running tool to one or other of the production bores, each connector having a key for entering a complementary formation at the top of the spool tree to locate the connector in a predetermined angular orientation relatively to the spool tree. The same type of alternative connectors may be used for providing wireline or other running tool access to a selected one of a plurality of functional connections, e.g. electrical or hydraulic couplings, at the upper end of the tubing hanger
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The development and completion of a subsea wellhead in accordance with the present invention are illustrated in the accompanying drawings, in which:
[0023] FIGS. 1 to 8 are vertical axial sections showing successive steps in development and completion of the wellhead, the Figure numbers bearing the letter A being enlargements of part of the corresponding Figures of same number without the A:
[0024] FIG. 9 is a circuit diagram showing external connections to the spool 3 ;
[0025] FIG. 10 is a vertical axial section through a completed dual production bore well in production mode;
[0026] FIGS. 11 and 12 are vertical axial sections showing alternative connectors to the upper end of the dual production bore wellhead during work over; and,
[0027] FIG. 13 is a detail showing the seating of one of the connectors in the spool tree.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] FIG. 1 shows the upper end of a cased well having a wellhead housing 20 , in which casing hangers, including an uppermost production casing hanger 21 for, for example, 9โ
โณ or 10ยพโณ, production casing is mounted in conventional manner. FIG. 1 shows a conventional drilling BOP 22 having rams 23 and kill and choke lines 24 connected to the upper end of the housing 20 by a drilling connector 25
[0029] As seen in more detail in FIG. 1A , the usual mechanical seal assemblies between the production casing hanger 21 and the surrounding wellhead housing 20 have been removed and replaced through the BOP with an adapter 26 consisting of an outer annular body part 27 and an inner annular gland nut 28 which has a screw threaded connection to the body 27 so that it can be screwed between a lowered position shown on the right hand side of FIG. 1A , in which radial ducts 29 and 30 , respectively in the body 27 and nut 28 , are in communication with one another, and a raised position shown on the left hand side of FIG. 1A , in which the ducts are out of communication with one another. The duct 29 communicates through a conduit 31 between a depending portion of the body 27 and the housing 20 , and through a conduit 32 passing through the production casing hanger 21 , to the annulus surround the production casing. The duct 30 communicates through channels 33 formed in the radially inner surface of the nut 28 , and hence to a void to be described. The cooperation between the gland nut 28 and body 27 of the adapter therefore acts as a valve which can open and close a passage up past the production casing hanger from the production casing annulus. After appropriate testing, a tool is run in through the BOP and, by means by radially projecting spring lugs engaging in the channels 33 , rotates the gland nut 28 to the valve closed position shown on the right hand side on FIG. 1A . The well is thus resealed and the drilling BOP 22 can temporarily be removed.
[0030] As shown in FIGS. 2 and 2 A, the body of a tree spool 34 is then lowered on a tree installation tool 35 , using conventional guide post location, or a guide funnel in case of deep water, until a spool tree mandrel 36 is guided into alignment with and slides as a close machined fit, into the upper end of the wellhead housing 20 , to which the spool tree is then fixed via a production connector 37 and bolts 48 . The mandrel 36 is actually a separate part which is bolted and sealed to the rest of the spool tree body. As seen particularly in FIG. 2A a weight set AX gasket 39 , forming a metal to metal environmental seal is provided between the spool tree body and the wellhead housing 20 . In addition two sets of sealing rings 40 provide, in series with the environmental seal, a production fluid seal externally between the ends to the spool tree mandrel 36 to the spool tree body and to the wellhead housing 20 . The intervening cavity can be tested through a test part 40 A. The provision of the adapter 26 is actually optional, and in its absence the lower end of the spool tree mandrel 36 may form a production seal directly with the production casing hanger 21 . As is also apparent from reasons which will subsequently become apparent, the upper radially inner edge of the spool tree mandrel projects radially inwardly from the inner surface of the spool tree body above, to form a landing shoulder 42 and at least one machined key slot 43 is formed down through the landing shoulder.
[0031] As shown in FIG. 3 , the drilling BOP 22 is reinstalled on the spool tree 34 . The tool 44 used to set the adapter in FIG. 1 , having the spring dogs 45 , is again run in until it lands on the shoulder 42 , and the spring dogs 45 engage in the channels 33 . The tool is then turned to screw the gland nut 28 down within the body 27 of the adapter 26 to the valve open position shown on the right hand side in FIG. 1A . It is now safe to open the production casing annulus as the well is protected by the BOP.
[0032] The next stage, shown in FIGS. 4 and 4 A, is to run in through the BOP and spool tree on an appropriate tool 44 A a combined isolation and orientation sleeve 45 . This lands on the shoulder 42 at the top of the spool tree mandrel and is rotated until a key on the sleeve drops into the mandrel key slot 43 . This ensures precise angular orientation between the sleeve 45 and the spool tree 44 , which is necessary, and in contrast to the angular orientation between the spool tree 34 and the wellhead casing, which is arbitrary. The sleeve 45 consists of an external cylindrical portion, an upper external surface of which is sealed by ring seals 46 to the spool tree 34 , and the lower external surface of which is sealed by an annular seal 47 to the production casing hanger 21 . There is thus provided between the sleeve 45 and the surrounding wellhead casing 20 a void 48 with which the channels 33 , now defined radially inwardly by the sleeve 45 , communicate. The void 48 in turn communicates via a duct 49 through the mandrel and body of the spool tree 34 to a lateral port. It is thus possible to monitor and vent the pressure in the production casing annulus through the passage provided past the production casing hanger via the conduits 32 , 31 the ducts 29 and 30 , the channels 33 , shown in FIG. 1A , the void 48 , the duct 49 , and the lateral port in the spool tree. In the drawings, the radial portion of the duct 49 is shown apparently communicating with a tubing annulus, but this is draftsman's license and the ports from the two annuli are, in fact, angularly and radially spaced
[0033] Within the cylindrical portion of the sleeve 45 is a lining, which may be fixed in the cylindrical portion, or left after internal machining of the sleeve. This lining provides an orientation sleeve having an upper/edge forming a cam 50 . The lowermost portion of the cam leads into a key slot 51 .
[0034] As shown in FIGS. 5, 6 and 6 A a tubing string of production tubing 53 on a tubing hanger 54 is run in through the BOP 22 and spool tree 34 on a tool 55 until the tubing hanger lands by means of a keyed shoulder 56 on a landing in the spool tree and is locked down by a conventional mechanism 57 . The tubing hanger 54 has a depending orientation sleeve 58 having an oblique lower edge forming a cam 59 which is complementary to the cam 50 in the sleeve 45 and, at the lower end of the cam, a downwardly projecting key 60 which is complementary to the key slot 51 . The effect of the cams 50 and 59 is that, irrespective of the angular orientation of the tubing string as it is run in, the cams will cause the tubing hanger 54 to be rotated to its correct angular orientation relatively to the spool tree and the engagement of the key 60 in the key slot 51 will lock this relative orientation between the tubing hanger and spool tree, so that lateral production and tubing annulus fluid flow ports 61 and 62 in the tubing hanger 54 are in alignment with respective lateral production and tubing annulus fluid flow ports 63 and 64 through the wall of the spool tree. Metal to metal annulus seals 65 , which are set by the weight of the tubing string, provide production fluid seals between the tubing hanger 54 and the spool tree 34 . Provision is made in the top of the tubing hanger 54 for a wireline set plug 66 . The keyed shoulder 56 of the tubing hanger lands in a complementary machined step in the spool tree 34 to ensure ultimate machined accuracy of orientation between the tubing hanger 54 and the spool tree 34 .
[0035] FIG. 7 shows the final step in the completion of the spool tree. This involves the running down on drill pipe 67 through the BOP, an internal isolation stopper 68 which seals within the top of the spool tree 34 and has an opening closed by an in situ wireline activated plug 69 . The BOP can then be removed leaving the wellhead in production mode with double barrier isolation at the upper end of the spool tree provided by the plugs 66 and 69 and the stopper 68 . The production fluid outlet is controlled by a master control valve 70 and pressure through the tubing annulus outlet ports 62 and 64 is controlled by an annulus master valve 71 . The other side of this valve is connected, through a workover valve 72 to a lateral workover port 73 which extends through the wall of the spool tree to the void between the plugs 69 and 66 . With this arrangement, wireline access to the tubing annulus in and downstream of a tubing hanger is unnecessary as any circulation of fluids can take place through the valves 71 and 72 , the ports 62 , 64 and 73 , and the kill or choke lines of any BOP which has been installed. The spool tree in the completed production mode is shown in FIG. 8 .
[0036] FIG. 9 shows valve circuitry associated with the completion and, in addition to the earlier views, shows a production fluid isolation valve 74 , a tubing annulus valve 75 and a cross over valve 76 . With this arrangement a wide variety of circulation can be achieved down hole using the production bore and tubing annulus, in conjunction with choke and kill lines extending from the BOP and through the usual riser string. All the valves are fail/safe closed if not actuated.
[0037] The arrangement shown in FIGS. 1 to 9 is a mono production bore wellhead which can be accessed by a single wireline or drill pipe, and the external loop from the tubing annulus port to the void between the two plugs at the top of the spools tree avoids the need for wireline access to the tubing annulus bore.
[0038] FIG. 10 corresponds to FIG. 8 but shows a 5ยฝ inchร 2โ
inch dual production bore wellhead with primary and secondary production tubing 53A and 53B. Development and completion are carried out as with the monobore wellhead except that the spool tree 34A and tubing hanger 54A are elongated to accommodate lateral outlet ports 61A, 63A for the primary production fluid flow from a primary bore 80 in the tubing hanger to a primary production master valve 70A, and lateral outlet ports 62A, 64A for the secondary production fluid flow from a secondary bore 81 in the tubing hanger to a secondary production master valve 7013. The upper ends of the bores 80 and 81 are closed by wireline plugs 66A and 66B. A stopper 68A, which closes the upper end of the spool tree 34A has openings, in alignment with the plugs 66A and 66B, closed by wireline plugs 69A and 69B.
[0039] FIGS. 11 and 12 show how a wireline 77 can be applied through a single drill pipe to activate selectively one or other of the two wireline plugs 66 A and 66 B in the production bores 80 and 81 respectively. This involves the use of a selected one of two connectors 82 and 8 . In practice, a drilling BOP 22 is installed and the stopper 68 A is removed. Thereafter the connector 82 or 83 is run in on the drill pipe or tubing until it lands in, and is secured and sealed to the spool tree 34 A. FIG. 13 shows how the correct angular orientation between the connector 82 or 83 and the spool tree 34 A, is achieved by wing keys 84 , which are guided by Y-shaped slots 85 in the upper inner edge of the spool tree, first to bring the connectors into the right angular orientation, and then to allow the relative axial movement between the parts to enable the stabbing function when the wireline connector engages with its respective pockets above plug 66 A or 66 B. To ensure equal landing forces and concentricity on initial contact, two keys 84 A and 84 B are recommended. As the running tool is slowly rotated under a new control weight, it is essential that the tool only enters in one fixed orientation. To ensure this key 84 A is wider than key 84 B and its respective Y-shaped slots. It will be seen that one of the connectors 82 has a guide duct 86 which leads the wireline to the plug 66 B whereas the other connector 83 has a similar guide duct 87 which leads the wireline to the other plug 66 A.
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A wellhead has, instead of a conventional Christmas tree, a spool tree in which a tubing hanger is landed at a predetermined angular orientation. As the tubing string can be pulled without disturbing the tree, many advantages follow, including access to the production casing hanger for monitoring production casing annulus pressure, and the introduction of larger tools into the well hole without breaching the integrity of the well.
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention is directed to novel organic compounds and is particularly concerned with a 2,9-dihydro-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-ones and a process of production therefor.
The new compounds and the process of production therefor can be illustratively represented as follows: ##SPC4##
Wherein R' and R" are alkyl of 1 to 3 carbon atoms or the group ##EQU8## is pyrrolidino, piperidino, 4-methylpiperazino, or [4-(2-hydroxyethyl)]piperazino; wherein R 2 and R 3 are hydrogen, chloro, bromo, trifluoromethyl, or alkyl defined as above; and wherein R' 4 is alkyl as defined above or ##EQU9## in which n is the integer number 2 or 3 and R', R", or ##EQU10## are defined as above.
The invention therefore has as objective compounds of the formula IV and the pharmacologically acceptable acid addition salts of the compounds of formula IV: ##SPC5##
wherein R 1 , R 2 , and R 3 are defined as above and R 4 has the significance of hydrogen and R' 4 above.
The more desirable products of this invention are of the formula IVB: ##SPC6##
wherein R' o , R" o are alkyl of 1 to 3 carbon atoms or together ##EQU11## is 4-methylpiperazino or [4-(2-hydroxyethyl)piperazino]; and wherein R" 4 is methyl or ##EQU12## in which n is the integer 2 or 3, and R' o , R" o , or ##EQU13## are defined as above, and the pharmacologically acceptable acid addition salts thereof.
The most desirable product of this invention are of the formula IVC: ##SPC7##
wherein R'" 4 is hydrogen or alkyl of 1 to 3 carbon atoms inclusive, and the pharmacologically acceptable acid addition salts thereof.
The process of this invention comprises: heating a compound of the formula I with phosphorus pentasulfide in an inert organic solvent to obtain the thione II; heating II with an alkyl carbazate to obtain the triazolone III and if desired treating III with an alkylating agent R' 4 X wherein X is chlorine, bromine or iodine and R' 4 is defined as above to obtain the corresponding compound of formula IV.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Alkyl of 1 to 3 carbon atoms, inclusive, are exemplified by methyl, ethyl, propyl, and isopropyl.
The compounds of the formulae IV including acid addition salts thereof have sedative, tranquilizing, antitussive and muscle-relaxant effects in mammals, including man, and birds.
The acid addition salts of compounds of formula IV contemplated in this invention, are the hydrochlorides, hydrobromides, hydriodides, sulfates, phosphates, cyclohexanesulfamates, methanesulfonates and the like, prepared by reacting a compound of formula I with an excess of the selected pharmacologically acceptable acid.
Sedative effects of the novel compounds are shown by the following tests in mice:
Chimney test: [Med. Exp. 4, 145 (1961)]: The test determines the ability of mice to back up and out of a vertical glass cylinder within 30 seconds. At the effective dosage, 50% of the mice failed doing it.
Dish test: Mice in Petri dishes (10 cm. diameter, 5 cm. high, partially embedded in wood shavings) climb out in a very short time, when not treated. Mice remaining in the dish for more than 3 minutes indicates tranquilization. ED 50 equals the dose of the test compound at which 50% of the mice remain in the dish.
Pedestal test: The untreated mouse leaves the pedestal in less than a minute to climb back to the floor of the standard mouse box. Tranquilized mice will stay on the pedestal for more than 1 minute. At the ED 50 50% of the mice have left the pedestal.
Nicotine antagonism test: Mice in a group of 6 are injected with the test compound. Thirty minutes later the mice including control (untreated) mice are injected with nicotine salicylate (2 mg./kg.). The control mice show overstimulation, i.e., (1) running convulsions followed by (2) tonic extensor fits followed by (3) death. an intraperitoneal dosage of the test compound protects 50% of the mice against (2) and (3).
The antitussive action is determined in rats by the method of Engelhorn et al., Arzneimittelforschung 13, 474 (1963) in which the number of coughs per 30 minutes of treated and untreated rats is measured. For reason of comparison codeine-treated rats are often added to the experiment.
In these experiments the novel compounds showed their efficacy as well as low toxicity (measurements of LD 50 ) at a level of 2-30 mg/kg. preferably 5-20 mg./kg. In larger animals, more than 10 kg., the low unit dosages are preferably such as 1-10 mg. for each kg.
The pharmaceutical forms contemplated by this invention include pharmaceutical compositions suited for oral, parenteral, and rectal use, e.g. tablets, powder packets, cachets, dragees, capsules, solutions, suspensions, sterile injectable forms, suppositories, bougies and the like. Suitable diluents or carriers such as carbohydrates (lactose), proteins, lipids, calcium phosphate, cornstarch, stearic acid, methylcellulose and the like may be used as carriers or for coating purposes. Water and oils, e.g., coconut oil, sesame oil, safflower oil, cottonseed oil, or peanut oil may be used for preparing solutions or suspensions of the active drugs. Sweetening, coloring, and flavoring agents may be added.
For mammals and birds, food premixes, with starch, oatmeal, dried fishmeat, fishmeal, flour and the like can be prepared.
The starting compounds of formula I are partially known in the art (German Auslegesahrift No. 1,620,523) or can be obtained as shown in the preparations.
In carrying out the process a selected 11-aminoacetyl-11H-pyrido[2,3-b][1,5]benzodiazepine-5-(6H)-one I is treated with phosphorus pentasulfide in an inert organic solvent. In the preferred embodiment of the invention, the reagent, P 2 S 5 , may be used in a slight molar excess of 5-10% of the stoichiometrically calculated amount. As solvent pyridine dioxane, picoline, benzene or the like may be used, and the reaction mixture is heated to between 50ยฐ C. and the reflux temperature of the mixture. The reaction period is between 1 to 12 hours. At the termination of the reaction the solvent is removed (by vacuum distillation preferably) and the residue is recovered by extraction e.g. with chloroform, ethyl acetate, benzene, or the like. Evaporation of the solvent used in the extraction, gives the product II which can be purified by conventional means e.g. additional extractions, crystallization, or chromatography.
Compound II is heated with an alkyl carbazate of the formula:
H.sub.2 N--NH--COOAlk
In which the alkyl group is of 1 to 3 carbon atoms, inclusive. Usually ethyl carbazate is preferred, but higher alkyl carbazates are operative. In the preferred embodiment of this invention, compound II is heated with ethyl carbazate in large excess for 1/10 hour to 3 hours at 190ยฐ to 250ยฐ C. in an oil bath. The alkyl carbazate serves simultaneously as reagent and solvent. The product usually precipitates upon cooling of the reaction mixture and is recovered by filtration and purified by conventional means, e.g., extractions of impurities, chromatography or most commonly by recrystallization. The triazolone compound III is thus obtained.
Alkylation of III is achieved by reacting the product III with a strong base e.g. sodium or potassium hydride in an organic solvent, e.g. dimethylformamide, diethylformamide, diethylacetamide, tetrahydrofuran, dioxane, benzene or the like with an excess of the base, followed by reacting the alkali metal salt thus formed with R' 4 X in which X is chlorine, bromine, or iodine and R' 4 is defined as herein before. Both reactions, formation of salt and the reaction of this salt with R' 4 X are usually performed at elevated temperatures between 50ยฐ to 125ยฐ C. The conversion of III to its alkali salt is usually performed during 15-25 minutes. The reaction of the salt with the halide is carried out during a longer period of time by keeping the reaction mixture at the elevated temperature for 1 to 36 hours. The product IVA thus obtained is isolated and purified by conventional means e.g. extraction, crystallization, chromatography, and the like.
The following preparations and examples are illustrative of the processes and products of the present invention, but are not to be construed as limiting.
PREPARATION 1
6,11-Dihydro-8,9-dibromo-5H-pyrido-[2,3-b][1,5]benzodiazepin-5-one
A mixture of 0.1 mole of 2-bromonicotinic acid and 0.1 mole of 1,2-diamino-4,5-dibromobenzene is heated in an open vessel to 150ยฐ C. with vigorous stirring. After 3 minutes the source of heat is removed, and the reaction mixture is allowed to cool to room temperature and to crystallizes to give a solid. The solid is removed from the vessel, powdered, washed with dilute sodium hydroxide, and then with boiling water, and finally recrystallized from dioxane to give 6,11-dihydro-8,9-dibromo-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one.
If in this preparation 1,2-diamo-4,5-dibromobenzene is replaced with 1,2-diamio-4-bromobenzene, mixtures of 6,11-dihydro-8-(and 9-)bromo-5H-pyrido[2,3-b][1,5]benzodiazepine-5-ones are obtained. Isomeric mixtures are obtained in general in this reaction if only one substituent is present in the reagent 1,2-diaminobenzene.
PREPARATION 2
8,9-Dibromo-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one
a.) 11-Chloroacetyl-8,9-dibromo-6,11-dihydro-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one.
6,11-Dihydro-8,9-dibromo-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one (0.1 mol) in 300 ml. of water-free dioxane is dissolved by heating to reflux. To the boiling solution is added, dropwise over 30 minutes, a solution of 15. g. (0.14 mol) of chloroacetyl chloride, dissolved in 40 ml. of water-free dioxane, and simultaneously 14.4 (0.14 mol) of triethylamine, dissolved in 30 ml. of water-free dioxane. The mixture is refluxed for 8 hours and then filtered while hot. The filtrate is evaporated in vacuo, and the resulting residue is recrystallized from acetonitrile to give 11-chloroacetyl-8,9-dibromo-6,11-dihydro-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one.
b.) 8,9-Dibromo-6,11-dihydro-11[[4-(2-hydroxyethyl)-piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one.
11-Chloroacetyl-8,9-dibromo-6,11-dihydro-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one (0.05 mole) and 0.13 mole 4-(2-hydroxyethyl)piperazine, dissolved in 800 ml. ethanol are heated to reflux for a period of 20 hours. The hot solution is then filtered, the filtrate evaporated in vacuo and the remaining residue recrystallized from 2-propanol to give 8,9-dibromo-6,11-dihydro-11-[[4-(2- hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]-benzodiazepin-5-one.
In the manner given in the preparations 1, 2a and 2b, other starting compounds of formula I are produced. Representative compounds thus produced include:
8,9-dibromo-6,11-dihydro-11-[(diethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dibromo-6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dibromo-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dimethyl-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dimethyl-6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dichloro-6,11-dihydro-11-[(diethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dichloro-6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8- and 9-chloro-6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8- and 9-fluoro-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-difluoro-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-di(trifluoromethyl)-6,11-dihydro-11-[(dipropylamino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dimethyl-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dimethyl-6,11-dihydro-11-(pyrrolidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-diethyl-6,11-dihydro-11-(pyrrolidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-diethyl-6,11-dihydro-11-(piperidinoacetyl)-5H-pyrido-[2,3-b][1,5]benzodiazepin-5-one;
8,9-diisopropyl-6,11-dihydro-11-(piperidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-diisopropyl-6,11-dihydro-11-[(4'-methylpiperazino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8,9-dimethyl-6,11-dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
8-chloro-9-fluoro- and 9-chloro-8-fluoro-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b]-[1,5]benzodiazepin-5-one;
6,11-dihydro-11-[[-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b]-[1,5]benzodiazepin-5-one;
6,11-dihydro-11-(piperidinoacetyl)-5H-pyrido[2,3-b][1,5]-benzodiazepin-5-one;
6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
6,11-dihydro-11-(pyrrolidinoacetyl)-5H-pyrido[2,3-b]-[1,5]benzodiazepin-5-one;
6,11-dihydro-11-[(diethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one;
and the like.
EXAMPLE 1
6,11-Dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
A mixture of 6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one (0.14 mole), phosphorus pentasulfide (0.155 mole) and 1200 ml. of pyridine is heated at reflux temperature for 24 hours and the pyridine is then evaporated. Methylene chloride and water are added, and the organic layer is separated (some solid is present), washed with aqueous sodium bicarbonate until only a trace of solid is present, then with saturated salt solution, dried over anhydrous magnesium sulfate and evaporated. Trituration of the residue with methanol gives a solid which after crystallization from methylene chloride-methanol gives the product 6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 2
6,11-Dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 3
8,9-Dimethyl-6,11-dihydro-11-[(dipropylamino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 8,9-dimethyl-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 8,9-dimethyl-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 4
8,9-Dichloro-6,11-dihydro-11-[(dipropylamino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 8,9-dichloro-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]-benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 8,9-dichloro-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 5
8,9-Dibromo-6,11-dihydro-11-[(diethylamino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 8,9-dibromo-6,11-dihydro-11-[(diethylamino)acetyl]-5H-pyrido[2,3-b][1,5]-benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 8,9-dibromo-6,11-dihydro-11-[(diethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 6
6,11-Dihydro-11-[[4-(2-hydroxyethyl)piperazino]-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 6,11-dihydro-11-[[4-(2-hydroxymethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]-benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5-benzodiazepin-5-thione.
EXAMPLE 7
8,9-Dibromo-6,11-dihydro-11-[[4-(2-hydroxyethyl)-piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 8,9-dibromo-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 8,9-dibromo-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 8
6,11-Dihydro-11-(pyrrolidinoacetyl)-5H-pyrido-[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 6,11-dihydro-11-(pyrrolidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 6,11-dihydro-11-(pyrrolidinoacetyl)-5H-pyrido-[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 9
6,11-Dihydro-11-(piperidinoacetyl)-5H-pyrido-[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 6,11-dihydro-11-(piperidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 6,11-dihydro-11-(piperidinoacetyl)-5H-pyrido-[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 10
6,11-Dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 6,11-dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 6,11-dihydro-11-[(4-methylpiperazino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 11
8,9-Dimethyl-6,11-dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 8,9-dimethyl-6,11-dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 8,9-dimethyl-6,11-dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
EXAMPLE 12
8,9-Dimethyl-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione
In the manner given in Example 1, 8,9-dimethyl-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-one is reacted with phosphorus pentasulfide in pyridine to give 8,9-dimethyl-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione.
In the manner given in the preceding examples other compounds corresponding to formula II can be synthesized. Representative compounds, thus obtained, include:
8,9-difluoro-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione;
8,9-di(trifluoromethyl)-6,11-dihydro-11-[(dipropylamino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione;
8,9-di(trifluoromethyl)-6,11-dihydro-11-[(diethylamino)-acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione;
8-chloro-9-fluoro- and 9-chloro-8-fluoro-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b]-[1,5]benzodiazepin-5-thione;
8,9-dimethyl-6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione;
8,9-difluoro-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione;
8,9-diethyl-6,11-dihydro-11-(pyrrolidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione;
8,9-diisopropyl-6,11-dihydro-11-(piperidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione;
and the like.
EXAMPLE 13
2,9-Dihydro-9-[(dimethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
A mixture of 6,11-dihydro-11-[(dimethylamino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione (0.12 mole) and ethyl carbazate (1.2 mole) is heated in an oil bath preheated to 195ยฐ-205ยฐ C. using a take-off condenser (45 ml. is removed). The resulting solid is mixed with methylene chloride-water and the suspension is filtered. The filtrate is separated into layers, and the organic layer is washed with water, then brine solution and dried over anhydrous magnesium sulfate. The solvent is then evaporated and the resulting residue is repeatedly crystallized from methylene chloride to give 2,9-dihydro-9-[(dimethyl-amino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]-benzodiazepin-3-one.
EXAMPLE 4
2,9-Dihydro-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 13, 6,11-dihydro-11-[(dipropylamino)acetyl]5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 2,9-dihydro-9-[(dipropylamino)acetyl]-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 15
6,7-Dimethyl-2,9-dihydro-9-[(dipropylamino)-acetyl]-3H-pyrido[3,2-c-]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 13, 8,9-dimethyl-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]-benzodiazepin-5-thione is heated to about 200ยฐ C. wth ethyl carbazate to give 6,7-dimethyl-2,9-dihydro-9-[(dipropylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 16
6,7-Dichloro-2,9-dihydro-9-[(dipropylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 13, 8,9-dichloro-6,11-dihydro-11-[(dipropylamino)acetyl]-5H-pyrido[2,3-b][1,5]-benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 6,7-dichloro-2,9-dihydro-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo-[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 17
6,7-Dibromo-2,9-dihydro-9-[(diethylamino)-acetyl]-3H-pyrid[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 13, 8,9-dibromo-6,11-dihydro-11-[(diethylamino)acetyl]-5H-pyrido[2,3.tbd.-b][1,5]-benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 6,7-dibromo-2,9-dihydro-9-[(diethylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 18
2,9-Dihydro-9-[[4-(2-hydroxyethyl)piperazino]-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 13, 6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 2,9-dihydro-9-[[4-(2-hydroxyethyl)-piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 19
6,7-Dibromo-2,9-dihydro-9-[[4-(2-hydroxyethyl)-piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]-benzodiazepin-3-one
In the manner given in Example 13, 8,9-dibromo-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 6,7-dibromo-2,9-dihydro-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 20
2,9-Dihydro-9-(pyrrolidinoacetyl)-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 13, 6,11-dihydro-11-(pyrrolidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 2,9-dihydro-9-(pyrrolidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 21
2,9-Dihydro-9-(piperidinoacetyl)-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][ 1,5]benzodiazepin-3-one
In the manner given in Example 13, 6,11-dihydro-11-(piperidinoacetyl)-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 2,9-dihydro-9-(piperidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 22
2,9-Dihydro-9-[(4-methylpiperazino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 13, 6,11-dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 2,9-dihydro-11-[(4-methylpiperazino)acetyl]-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 23
6,7-Dimethyl-2,9-dihydro-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo-[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 11, 8,9-dimethyl-6,11-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-5H-pyrido[2,3-b][1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 6,7-dimethyl-2,9-dihydro-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin- 3-one.
EXAMPLE 24
6,7-Dimethyl-2,9-dihydro-9-[(4-methylpiperazino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 11, 8,9-dimetbhyl-6,11-dihydro-11-[(4-methylpiperazino)acetyl]-5H-pyrido[2,3-b]-[1,5]benzodiazepin-5-thione is heated to about 200ยฐ C. with ethyl carbazate to give 6,7-dimethyl-2,9-dihydro-9-[(4-methylpiperazino)acetyl]-3H-pyrido[3,2-c]-s-triazolo-[4,3-a][1,5]benzodiazepin-3-one.
In the manner given in the preceding examples 11 through 20, other compounds of formula III can be synthesized. Representative compounds thus obtained include:
6- and 7-fluoro-2,9-dihydro-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-di(trifluoromethyl)-2,9-dihydro-9-[(dipropylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
8-cloro-9-fluoro- and 9-chloro-8-fluoro-2,9-dihydro-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
2,9-dihydro-9-[(diethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-dimethyl-2,9-dihydro-9-[(dimethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazo[4,3-a][1,5]benzodiazepin-3-one;
6,7-difluoro-2,9-dihydro-9-[(dipropylamino)acetyl]-3H-pyrido[ 3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-diethyl-2,9-dihydro-9-(pyrrolidinoaceyl)-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-diisopropyl-2,9-dihydro-9-(piperidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one; and the like.
EXAMPLE 25
2,9-Dihydro-2-methyl-9-[(dimethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
Sodium hydride (0.178 g., 4.21 mmoles of a 57% dispersion in mineral oil) is added to a solution of 2,9-dihydro-9-[(dimethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one (4.21 mmoles) in 50 ml. of dimethylformamide and the mixture is heated at 95ยฐ C. for 35 minutes. The mixture is cooled to 50ยฐ C., a solution of methyliodide (4.21 mmole) is added and heating is continued at 95ยฐ C. for 21 hours. The mixture is evaporated and methylene chloride-water is added to the residue. The organic layer is separated and extracted three times with 10 ml. portions of 10% aqueous hydrochloric acid. The acid extract is cooled, made alkaline with 15% aqueous sodium hydroxide and the basic mixture is extracted with methylene chloride. The extract is washed with saturated salt solution, dried over anhydrous magnesium sulfate and evaporated. Crystallization of the residue from ether gives 2,9-dihydro-2-methyl-9-[(dimethylamino)acetyl]-3 H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepine.
EXAMPLE 26
2,9-Dihydro-2-[2-(dimethylamino)ethyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one
In the manner given in Example 21, to 2,9-dihydro-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling with (2-chloroethyl)dimethylamine in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 2,9-dihydro-2-[(dimethylamino)ethyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]-benzodiazepin-3-one.
EXAMPLE 27
6,7-Dimethyl-2,9-dihydro-2-[3-(dimethylamino)-propyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 25, to 6,7-dimethyl-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling 3-(dimethylamino)propylchloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 21 to give 6,7-dimethyl-2,9-dihydro-2-[3-(dimethylamino)-propyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepine-3-one.
EXAMPLE 28
6,7-Dichloro-2,9-dihydro-2-[2-[4-(2-hydroxyethyl)piperazino]ethyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 25, to 6,7-dichloro-2,9-dihydro-9-[(dipropylamino)acetyl]-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling 1-(2-chloroethyl)-4-(2-hydroxymethyl)piperazine in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 6,7-dichloro-2,9-dihydro-2-[2-[4-(2-hydroxyethyl)piperazino]-ethyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepine-3-one.
EXAMPLE 29
6,7-Dibromo-2,9-dihydro-2-propyl-9-[(diethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]-benzodiazepin-3-one
In the manner given in Example 25, to 6,7-dibromo -9-[(diethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo-[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling propyl chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in exanmple 25 to give 6,7-dibromo-2,9-dihydro-2-propyl-9-[(diethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]-benzodiazepin-3-one.
EXAMPLE 30
2,9-Dihydro-2-(2-piperidinoethyl)-3H-pyrido-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 25, to 2,9-dihydro-9[[4-(2-hydroxyethyl)piperazino]acethyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling (2-piperidinoethyl)chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 2,9-dihydro-2-(2-piperidinoethyl)-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-traizolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 31
2,9-Dihydro-2-methyl-9-[[4-(2-hydroxyethyl)-piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one
In the manner given in Example 25, 2,9-dihydro-11-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-traizolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling methyl chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 2,9-dihydro-2-methyl-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 32
2,9-Dihydro-2-(2-pyrrolidinoethyl)-9-(pyrrolidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 25, to 2,9-dihydro-9-[(pyrrolidino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling (2-pyrrolidinoethyl)chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 2,9-dihydro-2-(2-pyrrolidinoethyl)-9-(pyrrolidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one.
EXAMPLE 33
2,9-Dihydro-2-[2-(dimethylamino)ethyl]-9-(piperidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one
In the manner given in Example 25, to 2,9-dihydro-9-(piperidinoacetyl)-3 H-pyrido[3,2-c]-s-triazolo-[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling (2-chloroethyl)dimethylamine in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 2,9-dihydro-2-[2-(dimethylamino)ethyl]-9-(piperidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one.
EXAMPLE 34
2,9-Dihydro-2-(3-pyrrolidinopropyl)-9-[(4-methylpiperazino)acetyl]-3H-pyrido[3,2-c)-s-triazolo-[4,3-a][1,5]benzodiazepine-3-one
In the manner given in Example 25, to 2,9-dihydro-9-[(4-methylpiperazino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling (3-pyrrolidinopropyl)chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐC. for a period of 22 hours, evaporated and worked up as in example 25 to give 2,9-dihydro-2-(3-pyrrolidinopropyl)-9-[(4-methylpiperazino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 35
6,7-Difluoro-2,9-dihydro-2-[2-(4-methylpiperazino)ethyl]-9-[ (dipropylamino)acetyl]-3H-pyrido-[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 25, to 6,7-difluoro-2,9-dihydro-9-[ (dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylforamide is added a solution of sodium hydrided in mineral oil. The mixture is allowed to react at about 95ยฐC. for 40 minutes and after cooling [2-(4-methylpiperazino)-ethyl]chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 6,7-difluoro-2.9-dihydro-2-[2-(4-methylpiperazino)ethyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]-benzodiazepin-3-one.
EXAMPLE 36
6,7-Dimethyl-2,9-dihydro-2-[3-dimethylamino)-propyl]-9-[(dimethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 25, to 6,7-dimethyl-2,9-dihydro-9-[(dimethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react to about 95ยฐ C. for 40 minutes and after cooling [3-(dimethylamino)-propyl]chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 6,7-dimethyl-2,9-dihydro-2-[3-(dimethylamino)propyl]-9-[(dimethylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 37
6,7-Diethyl-2,9-dihydro-2-(3-pyrrolidinopropyl)-9-(pyrrolidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 25, to 6,7-diethyl-2,9-dihydro-9-(pyrrolidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling (3-pyrrolidinopropyl)chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 6,7-diethyl-2,9-dihydro-2-(3-pyrrolidinopropyl)-9-(pyrrolidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a]]1,5]benzodiazepin-3-one.
EXAMPLE 38
6-Chloro-7-fluoro- and 6-fluoro-7-chloro-2,9-dihydro-2-ethyl-9-[[4-(2-hydroethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 21, to a mixture of 6-chloro-7-fluoro- and 6-fluoro-7-chloro-2,9-dihydro-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling ethyl iodide in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give a mixture of 6-chloro-7-fluoro- and 6-fluoro-7-chloro-2,9-dihydro-2-ethyl-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
EXAMPLE 39
6,7-Dimethyl-2,9-dihydro-2-[3-(dimethylamino)-propyl]-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
In the manner given in Example 25, to 6,7-dimethyl-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling [3-(dimethylamino)propyl]-chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 6,7-dimethyl-2,9-dihydro-2-[3-(dimethylamino)propyl]-9-[[4-(2-hydroxyethyl)-piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo]4,3-a]-[1,5]benzodiazepin-3-one.
EXAMPLE 40
6,7-Dimethyl-2,9-dihydro-2-[3-(dimethylamino)-propyl]-9-[(4-methylpiperazino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one
In the manner given in Example 21, to 6,7-dimethyl-2,9-dihydro-9-[(4-methylpiperazino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one in dimethylformamide is added a solution of sodium hydride in mineral oil. The mixture is allowed to react at about 95ยฐ C. for 40 minutes and after cooling [3-(dimethylamino)propyl]chloride in xylene is added. The mixture is kept at 95ยฐ-100ยฐ C. for a period of 22 hours, evaporated and worked up as in example 25 to give 6,7-dimethyl-2,9-dihydro-2-[3-(dimethylamino)propyl]-9-[(4-methylpiperazino)-acetyl]-3-H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one.
In the manner given in the preceding examples, other compounds of formula IV can be synthesized. Representative compounds, thus obtained, include:
6- and 7-fluoro-2,9-dihydro-2-methyl-9-[(dipropylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-di(trifluoromethyl)-2,9-dihydro-2-[3-(diethylamino)-propyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
2,9-dihydro-2-[[4-(2-hydroxyethyl)piperazino]ethyl]-9-[(diethylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one;
6,7-dimethyl-2,9-dihydro-2-isopropyl-9-[(dimethylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-difluoro-2,9-dihydro-2-[(4-methylpiperazino)ethyl]-9-[(dipropylamino)acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]-[1,5]benzodiazepin-3-one;
6,7-diisopropyl-2,9-dihydro-2-[3-(4-methylpiperazino)-propyl]-9-(piperidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-diethyl-2,9-dihydro-2-(2-pyrrolidinoethyl)-9-(pyrrolidinoacetyl)-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-dimethyl-2,9-dihydro-2-propyl-9-[(4-methylpiperazino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a]benzodiazepin-3-one;
6,7-dibromo-2,9-dihydro-2-isopropyl-9-[[4-(2-hydroxyethyl)piperazino]acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3-one;
6,7-dipropyl-2,9-dihydro-2-methyl-9-[(dimethylamino)-acetyl]-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]benzodiazepin-3one;
and the like.
The novel compounds of formula IV (including III, IVA, IVB, and IVC) can be reacted with selected acids e.g. hydrochloric, hydrobromic, sulfuric, phosphoric, tartaric, citric, lactic, cyclohexanesulfamic, toluenesulfonic and other acids to give the corresponding pharmaceutically acceptable acid addition salts. This reaction is carried out under conventional conditions, in solvents such as ether, dioxane, tetrahydrofuran, and the like at room temperatures, and the resulting precipitated salts are collected by filtration. These salts can be used in place of the free base for the same pharmaceutical purpose described before.
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2,9-Dihydro-3H-pyrido[3,2-c]-s-triazolo[4,3-a][1,5]-benzodiazepin-3-ones ##SPC1##
Wherein R' and R" are alkyl of 1 to 3 carbon atoms, inclusive; or the group ##EQU1## together is pyrrolidino, piperidino, 4-methylpiperazino or [4-(2-hydroxyethyl)]piperazino; wherein R 2 and R 3 are hydrogen, chloro, bromo, trifluoromethyl, or alkyl defined as above and wherein R 4 is hydrogen, alkyl as defined above or ##EQU2## in which n is the integer 2 or 3 or R', R" or ##EQU3## are defined as above, are obtained by reacting a compound of the formula 1 ##SPC2##
Wherein R 2 , R 3 , R', R", or ##EQU4## are defined as above, with phosphorus pentasulfide to give the corresponding 5-thione compound (II); treating II with an alkyl carbazate to obtain the compound of formula III: ##SPC3##
wherein R 2 , and R 3 are defined as above and treating III with an alkyl halide of 1 to 3 carbon atoms inclusive, or ##EQU5## in which n, R', R", or ##EQU6## is defined as above, to obtain those compounds of formula IVA in which R 4 is alkyl or ##EQU7## as defined above. The compounds of formula IV (which include compounds III and IVA) and the pharmacologically acceptable acid addition salts thereof have sedative and anti-tussive activity and can be used in mammals.
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RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. ยง119 of U.S. Provisional Application No. 61/149,999, titled โMobile Device Battery Management,โ filed Feb. 4, 2009, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] This document relates to systems and techniques for managing power consumption on computing devices, such as mobile devices.
BACKGROUND
[0003] Mobile computing devices, such as smartphones, are becoming ever more powerful, both in terms of processing power and in terms of capabilities. Such expanded capabilities include capabilities to determine the geographic location of a device. For example, global positioning system (GPS) receivers on mobile devices can provide very fine positioning capabilities and are becoming very common on mobile devices. Other approaches, such as finding or at least estimating a location of a device using WiFi access points and Cell ID's can also be used. Such features may be particularly useful for various on-line location-based services that provide rich applications that, for proper functioning, need to be able to determine a user's location automatically. One such type of location-based service includes applications for identifying the current up-to-date locations of a user's friends or acquaintances. Such services can generate a map that is overlaid with an icon of each one of a user's friends. The services can help the friends determine that they should meet for food, drink, or just conversation, if they are proximate to each other.
[0004] Location-based services (LBS) can be expensive, however, in turns of electrical power consumption. The use of regular GPS readings to constantly pinpoint a user's location can cut a smartphone's battery time in half or more. Readings from WiFi access points generally require less power, but enough that repeated readings will also substantially decrease observed battery life for a user of such devices.
SUMMARY
[0005] This document describes systems and techniques that may be used to determine the location of a battery-operated device, such as a smartphone, without unduly using battery power from such a device. In general, lower-powered techniques for determining and reporting location are used here for relatively frequent measurements, and even these techniques are employed less frequently when a user is determined to not be moving or when a battery level on a device has fallen. Techniques that require more power from a device are reserved for particular situations in which closer tracking of a device is deemed to be desired by a user. The frequency with which a device determines and reports its location thus varies as a rough function of the need to report location, and in a manner aimed at reducing battery consumption to an acceptable level.
[0006] The determination of whether a user is moving my require some computation because certain minor or oscillating motion should not be taken as actual motion by a system. For example, a user of a mobile device might just be pacing back-and-forth inside a room if a system indicates minor oscillating motion, or conditions may change so that one local cell tower obtains a different signal from the device, so that the device is perceived by the system to be moving even though it is not. As discussed below, for example, cell ID and WiFi access point information can be used to determine whether a device is stationary or moving, where the status of a user can be determined with respect to a cluster of cells that are in proximity to each other.
[0007] The techniques described here may also involve particular methods by which a mobile device may report its location to a location-based service that is remote from the device. As one example, a mobile device can accompany information that it provides to the LBS regarding its locations, with information identifying the next time the device plans to report its location. The LBS can then set a timer or otherwise track elapsed time since the device reported its location, and can indicate that the location information is stale if the time has expired without hearing from the device again (or after some additional buffer time, e.g., a predetermined time period that is relative to the time for an update).
[0008] The techniques described here can be used with a variety of location-based services. In one example, a LBS helps users locate their acquaintances by gathering location data reported to the service by devices for the multiple users, and then providing corresponding information to other users who have an acquaintance relationship (e.g., through a social networking application), so that each of the users can view a map of an area, where icons corresponding to their acquaintances, and located at the last reported locations for their acquaintances, are superimposed over the map.
[0009] In certain implementations, such systems and techniques may provide one or more advantages. For example, location-based services typically rely on a variety of sensors to determine a location of a device, and those sensors can be power-hungry. Proper management of request for location information can thus extend battery life on a device substantially, without having to modify pre-existing battery management tools that might be on the device. A device that properly manages power consumption will also be a device on which a user employs more applications that would have previously consumed too much power (e.g., that would have prevented the device from operating a full day on one charge), so that the user experience on such a device improves. A vendor of such a device may then sell more devices, and a provider of location-based services may drive more users to their services. As a result, the provider may collect more in subscription revenue or in advertising revenue, and advertisers may more effectively push their message to users of mobile devices.
[0010] In general, one aspect of the subject matter described in this specification can be embodied in a computer-implemented power management method. Data representing a plurality of power management profiles for a battery-operated wireless computing device are stored on the device. The power management profiles correspond to different power consumption levels. Each power management profile defines a feature for determining a geographic location of the device from among a plurality of features that are available for determining the geographic location of the device, and a frequency for employing the feature to determine the geographic location of the device. A first battery level of the device is determined. If the determined battery level is lower than a first predetermined amount, the device switches from a first power management profile having a first consumption level to a second power management profile having a second consumption level that is lower than the first consumption level.
[0011] This and other implementations can optionally include one or more of the following features. A second battery level of the device may be determined subsequent to switching from the first power management profile to the second power management profile. If the second determined battery level is below a second predetermined amount, the device may switch to a third power management profile having a third consumption level that is lower than the second consumption level. Geographic location information may be determined for the device at a first frequency if the device is determined to be substantially stationary, and at a second frequency greater than the first frequency if the device is determined to be moving geographically. The first and second power management profiles may each define a frequency of obtaining location-based measurements. Location-based measurements are obtained at a higher frequency under the first power management profile than under the second power management profile. An application may be determined to be invoked. The application may rely on the device location to select location-specific content for display to a user of the device. A geographic location of the device may be determined in response to determining that the application is invoked using another location-based feature that is not one of the plurality of features. The plurality of features may include a transmitting cellular telephone tower identification and the another location-based feature may include space-based global navigation satellite system positioning identification.
[0012] Another aspect of the subject matter described in this specification can be embodied in a computer-implemented power management method. Information identifying a location of a particular remote computing device may be received, at a server system providing a location-based service. Information identifying a next time for an updated location from the particular remote computing device may be received with the information identifying the location. A reported location of a user associated with the particular remote computing device may be reported to be stale if an updated location is not received from the remote computing device before a predetermined time period that is relative to the identified next time for an update.
[0013] This and other implementations can optionally include one or more of the following features. Determining that a reported location of the user is stale can include adding information that indicates that a location of the user is unknown to transmissions made to acquaintances of the user as part of a friend finding application. Information that indicates that a reported location of the user is stale may be transmitted to another mobile device. An indication of a location of the user on a map and an interface element that indicates that the location of the user is stale may be presented on a display device of the another mobile device.
[0014] Another aspect of the subject matter described in this specification can be embodied in a computer-implemented power management method. Geographic movement of the mobile device may be monitored, using a source on the mobile device, using signals from electronic beacons. A frequency for obtaining information about a location of the device may be selected based on a determination, from the monitored geographic movement, whether the device is moving or stationary.
[0015] This and other implementations can optionally include one or more of the following features. A battery level for the mobile device may be monitored. The frequency obtaining information about the location of the device may also be based on the monitored battery level for the mobile device. The source on the device may be selected from a plurality of sources for monitoring geographic movement of the mobile device using signals from electronic beacons. The selection of the source may be based on the determination, from the monitored geographic movement, whether the device is moving or stationary. The plurality of sources may include a transmitting cellular telephone tower identification unit and space-based global navigation satellite system positioning unit. A lower frequency for obtaining location information may be selected if the device is stationary and a higher frequency for obtaining location information may be selected if the device is moving. The device may be determined to be moving by identifying a first cluster of transmitting antenna cell regions. The first cluster of cells may include a first cell associated with the location of the device. The first cluster of cells may form a clique that is based on a first cell that includes a location of the device and a list of cells that the device has historically been located within. A determination can be made that the device has changed locations to a different cell. A second cluster of cells forming a clique based on the different cell can be identified. A determination that the first cluster is not the same as the second cluster can be made. Determining that the device is stationary despite a change in cell by cam be performed by identifying a first cluster of transmitting antenna cell regions. The first cluster of cells can include a first cell associated with the location of the device. The cluster of cells may form a clique that is based on a first cell that includes a location of the device and a list of cells that the device has historically been located within. A determination can be made that the device has changed locations to a different cell. A second cluster of cells forming a clique based on the different cell can be identified. A determination that the first cluster is the same as the second cluster can be performed.
[0016] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a conceptual diagram of a wireless communication system that provides location based services.
[0018] FIG. 2 shows graphs of battery power for devices that do not, and do, manage electrical consumption by location based services.
[0019] FIGS. 3A and 3B are flow charts of example processes for updating a mobile device's location based on movement of the device.
[0020] FIG. 3C is a flow chart of an example process for determining whether a mobile device is moving.
[0021] FIG. 4 is a swim lane diagram showing a process for sharing location information for certain mobile devices with other mobile devices.
[0022] FIG. 5 is a schematic diagram of a mobile device having power management and location determination components.
[0023] FIG. 6 shows an example of a computer device and a mobile computer device that can be used to implement the techniques described here.
[0024] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0025] This document describes systems and techniques for managing the use of location identifiers on a computing device so as to increase battery life on the device. Such techniques may include setting a particular period at which a device will check its location based on whether the device is determined to be moving or stationary. (In this context, the concepts of moving and stationary are not absolute, but depend on whether the motion is sufficient to warrant recognition that a device has changed status. For example, from a location-based system level, motion of a few feet is irrelevant because the device has not moved enough to support reporting a new location to other users.) Updates to the device's location may be made frequently when the device is moving, because prior reported locations will quickly be far from the user's current location, and will thus become functionally stale quickly. Updates may be made less frequently when the device is stationary, such as determined by cell ID or WiFi access point information.
[0026] FIG. 1 is a conceptual diagram of a wireless communication system 100 that provides location based services. The system centers around two mobile devices 104 , 112 that are employed by users who are registered with a location-based service offered by a company that operates server system 106 . The server system 106 may include a number of different servers and sub-systems of servers for providing a number of services over a network 108 , such as the internet. For example, the server system 106 may provide search results, maps, e-mail hosting, and many other such services.
[0027] In this example, the service being employed on devices 104 , 112 is an application for finding the current location of acquaintances. Such a service may be provided where multiple users are registered with the service, and elect to have information that reflects their current geographic location reported to server system 106 . To address privacy concerns, users may be explicitly asked to opt into such a system, and the system may be operated only at particular times, such as when an acquaintance finder application is operating in the foreground or background on the device 104 , 112 .
[0028] In this example, the user associated with device 104 is looking at a map of the area around downtown Minneapolis, and is being shown images of three different acquaintances. Each of those acquaintances may have previously agreed to let the user of device 104 see their location information. The images are superimposed on the map of Minneapolis at locations where the devices for those users were previously (and recently) reported in to the server system 106 . Likewise, the user of device 112 has aimed their device at the Silicon Valley area, and is looking at two of their acquaintances. The user of device 104 could be one of the people shown on device 112 , and the user of device 112 may be one of the people shown on device 104 .
[0029] The accuracy of the locational representations on the maps is a function of the accuracy of a location determination system for each of the devices 104 , 112 , the speed at which each user is moving, and the time since the last location updates (the latency). A fast-moving device that has not reported its location in a long time is likely to be relatively far from the location reported by server system 106 . Great accuracy can be achieved by constantly checking a GPS unit on one of devices 104 , 112 and reporting any substantial changes in position (e.g., more than several feet) to the server system 106 for distribution to other users. However, GPS tends to be a power hungry location determination technique that can cut battery life in half or worse.
[0030] As a result, other location sensing mechanisms can be used that are not so power-hungry, such as cell ID and WiFi node determinations. In the figure, portions of two cell networks around device 104 and device 112 are shown, respectively. The first network portion includes four towers 102 a - d , with device 104 located near tower 102 d . The second network portion shows eight towers 110 a - h , with device 112 located nearly equidistant between towers 110 b , 110 f , and 110 g . For clarity, the towers are shown in the figure as being arranged in a rectilinear grid, although their physical arrangement would be much less regular in practice.
[0031] The locations of the devices can be estimated by determining the identity of a tower (for cell ID's) or access point (for WiFi) or other similar beacon with which a device 104 , 112 is communicating. In general, such localization (e.g., in GSM-network device location) may use multilateration that is device-based or network-based. The localization of a device may be determined by the beacons with which the device is communicating (and perhaps using beacons that it previously communicated with, such as when extrapolating a device location in a direction of its last-observed motion) and by the strength of signal of those beacons. For example, if a device is receiving signals from three towers, it can be assumed to be between or near the towers, and if its strongest signal is from a particular tower, it can also be assumed to be closest to that tower, all other factors being equal.
[0032] However, because network cells are discontinuous, non-smooth, and overlapping, the accuracy of such locational systems may be limited. For example, relatively small variations in a device's location or its radio environment may cause a device to switch between cells even if the device really has not moved an appreciable amount. Where a system changes its monitoring behavior based on whether a device is moving or not (e.g., by determining location more often when the device is moving), it can be more important to identify such small or non-existent motion as a false positive. Such determinations may be improved by treating cells that are near each other as a cluster, and setting a device's status (and by extension, its user's status) as moving or stationary based on whether the user has changed clusters. Each cell can represent a region in which a stationary cellular transmission antenna and a mobile device are able to communicate. Particular techniques for doing so are discussed more completely with respect to FIG. 3C below.
[0033] In such a manner, high-powered locational mechanisms like space-based global navigation satellite system receiving units (e.g., global positioning system (GPS)) may be reserved for times when it is observed that the user is particularly interested in an LBS, such as when an LBS application is the focus of a graphical user interface (e.g., it is in an active desktop window). Lower-powered mechanisms like cell ID (e.g., cell of origin mobile positioning that relies on an identification of a location of a base station or an antenna at the base station) and WiFi may be used at other times, and may be rationed so that they are triggered less often when a device is stationary than when it is moving. Satellite systems, cellular towers, and WiFi transmitters may be considered electronic beacons. This combination of techniques can substantially extend battery life, as discussed next.
[0034] FIG. 2 shows graphs of battery power for devices that do not, and do, manage electrical consumption by location based services. The top graph 202 shows remaining battery power for a device that triggers a GPS reading at a constant period, such as every two minutes. As can be seen, the battery power takes a substantial hit each time the GPS functionality is used, and the battery dies quickly as a result.
[0035] In the bottom graph 204 , GPS is used only when the location-based application is active, such as by being the focus of a graphical user interface. During these periods, the drain on battery is equivalent to the top graph, but these periods make up a relatively small portion of the device's total operational life. Rather, between times in which the location-base application is a focus, WiFi, cell ID, or a combination of the two is used to determine and report device location. As can be seen, the drain for each such determination is much less than when GPS is used. The drain can be reduced even more by hitting those services less often, such as when the device is not moving by any appreciable amount. And the downward slope can be reduced even more if the utilization of some or all of the location techniques is reduced as a function of a level of battery life that is determining to be remaining.
[0036] With respect to the difference between using GPS and other mechanisms to determine locations, calculations performed on a Nokia S60 device indicate that a network transaction over 3G takes at least 1 mAh (1.2 if the context is kept open), and a transaction over WiFi takes 0.75 mAh. Reading a GPS takes 1 mAh, while a WiFi scan takes only 0.1 mAh. Thus, for that device, intelligent selection and timing of location determinations, and of the reporting of such determinations, can significantly increase battery life.
[0037] FIGS. 3A and 3B are flow charts of example processes for updating a mobile device's location based on movement of the device. FIG. 3A focuses on the type of location determination and the frequency with which the determination is made in general. The types include GPS and a lower-power determination such as cell ID of WiFi (or both). At box 302 , the process of FIG. 3A first determines whether a location-based application is, or was recently, active. If so, then the device may take a GPS reading and may submit the reading over a network if the location has changed sufficient from the last reading (such a round trip with the network may also retrieve location information for other users so that such information may be used to plot locations of the other users on an electronic map). In one particular implementation, GPS may be read while the application is in focus, and for 15 minutes after it stops being the focus (under the assumption that the user may return to it soon), and the readings occur approximately every 3 minutes. This will permit a user who is very interested in the application to see and provide very accurate and up-to-date location information.
[0038] If the application has been out of focus for a sufficient time, the process checks whether the device is stationary or moving (box 306 ). Such a check may involve looking at clusters of cells around the device, such as by the process discussed with respect to FIG. 3C below. If the device is not stationary (box 308 ), then the device may read and send location updates to server at a first frequency, such as every 3 minutes (box 312 ). If the device is stationary, the device may read and send updates at a second, longer frequency, such as every 40 minutes. The device may also be set to react to all cell id changes, and may make a determination of whether the device is stationary or moving when such changes occur. After a cell id change, location determination and reporting may occur at a particular frequency for a predetermined time period, and may drop to a lower frequency after a period of no motion and no cell id changes either.
[0039] In summing up one example location reporting schedule, when the location-based application is in focus or in the foreground, WiFi, cell id and other beacon based location determination mechanisms operate according to a set schedule, and the GPS performs location look-ups. Updates may be sent to a remote server system on a predetermined schedule.
[0040] When the application is not the focus, or is in the background, WiFi scans may occur every 3 minutes (or another predetermined interval that may be reduced if the battery level drops) and cell id remains active also. Whether the device is stationary or moving may also be calculated to determined whether or not to change the frequency for scanning. GPS may not be used. And when the device determines to send an update to the server system, it syncs to a WiFi scan interval, looks up current cell and WiFi with the location-based application (if they are not already known) and sends the location update. Of course, should a GPS reading be taken at the initiative of a different application, the above described application can update its present location.
[0041] For example, the device may know its location from a recent reading of a GPS unit or from cell ID. The device may send updates to a server letting the server at a lower frequency know that it is still in the last determined position if the device is determined to be stationary. The device may send more frequent updates if the device determines that it is moving. The server can use the received updates to inform other mobile devices of the device's location.
[0042] FIG. 3B shows a similar process to that shown in FIG. 3A . For example, like in FIG. 3A , determinations are made regarding whether a device is moving or stationary (boxes 324 and 326 ), and update levels (e.g., frequencies for updating) may be set based on such a determination (boxes 328 and 330 ).
[0043] However, in FIG. 3B , the process also reacts to changes in battery levels on the device. Thus, at some point in the cyclical processโin this example, at the beginningโthe device checks its own battery level (box 320 ) and sets a power management mode (box 322 ) (also called a power management profile) based on the determined battery level. Such a power management mode may define a modification to the various parameters that control the method discussed in FIG. 3A , such as the frequency and period of location measurement and reporting on a device. For example, the frequency of updating may be dropped from once every 3 minutes to once every 6 minutes if the battery drops below 50%, and once every 9 minutes if the battery drops below 30%โwith the feature shut off entirely at 15%. Thus, at box 332 , the process implements a new update level that is tied to the particular power management mode, and at box 334 , the device reports its position and its next update time to a remote server system.
[0044] In the last step (box 334 ), one point bears additional attention. In particular, the device provides an indication to the server system of its next expected update time. In particular, because the timing of updates is variable in this example, and is controlled on the client side, the server system does not necessarily know when it โshouldโ hear from the client again. This creates a problem in the server being able to tell other users about how fresh the first user's location is. Although it can provide an indication of the number of minutes since the first user's device reported in, that indication might not reflect whether such delay is expected, or reflects that the user's device is not working properly and that the user is far away from their last-reported location.
[0045] Thus, where a device is moving quickly, it will expect to update its position frequently, and can tell the server system as much. A delay that exceeds or substantially exceeds that time period may be a strong indication that something is wrong, and also an indication that the fast-moving user has probably gone a long way since their last report. In contrast, a slow-moving or non-moving user may not check in very often at all, and can tell the server system as much, so that the server system may provide an appropriate context to other users when reporting how fresh or how stale the original user's location information isโwhere absolute time since a prior update is not an accurate indication because of the variability with which each device can control its reporting frequency.
[0046] Although not shown here, reporting of motion for a device may also rely on non-location based sensors such as a compass or accelerometer in a device. For example, if a device is not moving at all (e.g., it is simply sitting on a desktop), its accelerometer may be sensing nothing, and will be more sensitive to a total lack of motion than the other mechanisms described above. As such, if a device is set to a state of being stationary, that state may stay unchanged, and other motion determining mechanisms may be avoided, until the accelerometer reports some level of movement.
[0047] FIG. 3C is a flow chart of an example process for determining whether a mobile device is moving. As noted above, such as process may be used to reject spurious changes that are sensed in the location of a device, such as when the device does not move at all (but, e.g., a cell ID changes because of atmospheric changes in the area of the device), and also when the device moves an insignificant amount but is still in the same general area. The process begins by a system maintaining a cell transition graph for a device, which represents cell ID's that a device has passed through, along with, potentially, other information, such as the transition times. The graph may be undirected and include, for example, 100 cells. The cells may be least recently used (LRU) or time-spent-weighted LRU, such as using an exponential weighting.
[0048] At box 344 , the process identifies a current cluster, which is considered to be the maximum set of cells from consecutive cell history points that form a clique in the graph. (A break in the history can be inferred if the user stays in the same clique longer than a predetermined period of time.) In some implementations, a clique may be a maximum number of cells from consecutive cell history points that are adjacent to each other.
[0049] At box 356 , the process determines whether the cell for a device changes. If such a change is detected, it is determined whether the device was previously considered to be stationary (box 352 ). If it was considered to be stationary before the change, a new cluster for the device may be calculated in the manner discussed above (box 354 ). If the new cluster is unchanged (box 356 ), then the device may be considered to be stationary; otherwise, the device is considered to be moving (box 358 ). The device may also be considered to be moving if the cell change indicates that it is moving.
[0050] If no change in cell is detected at box 346 , the user is considered to be stationary after a predetermined period of time without a change in cell, such as 10 minutes, for example (box 350 ). The location for a user is then determined based on whether they are considered to be stationary or moving. If they are considered to be stationary, then their current location is described as the cell cluster. If they are considered to be moving, then their current location is described as the current cell.
[0051] FIG. 4 is a swim lane diagram showing a process for sharing location information for certain mobile devices with other mobile devices. In general, the process shows messages that may be exchanged between a Location Service, which may be implemented as a central server-based system, and two client devices operated by users who have registered accounts with the Location Service. In general, the user could be using a wide variety of location-based applications for which control over location detection is desired to increase battery life. In this example, they are exchanging their location information with each other, such as in the manner discussed above with respect to FIG. 1 .
[0052] Client 1 starts the process by setting its status as stationary (box 402 ), and then as reporting its location (box 404 ). Such a report may also include an indication of when Client 1 next expects to report in. Because the device has set itself as in a stationary mode, that time may be a relatively long time. The Location Service records the location information and the next update time information at box 406 , and returns to Client 1 those most recent known location of Client 2 (box 408 ), which Client 1 may display in a location-based application. In this manner, the process treats the reporting of Client 1 's location as a โpullโ for information from other clients belonging to users who are registered in the system as having a friend or acquaintance relationship with the user of Client 1 .
[0053] At box 412 , Client 2 sets its status as moving, such as by using the process described with respect to FIG. 3C , and reports its location (box 414 ). Client 2 can also report an expected time until a next update, which in this example may be relatively short because Client 2 is on the move, and thus needs to provide relatively frequent reports if its reported position is to accurately match its true position. Again, the Location Service records the location of Client 2 and the next update time computed by Client 2 and reported to the Location Service (box 418 ). And as before, the Location Service returns the last reported location (from box 404 ) of Client 1 to Client 2 under the assumption that Client 2 would like an update if it is providing an update (box 419 ). Client 2 then displays the information, such as via an icon showing the last reported location of Client 1 superimposed on a map of the area around that location (box 420 ).
[0054] Because Client 2 is moving and is thus updating its location more often, it is the next device to report an updated location ( 422 ) which again may be accompanied with an indication of a next expected time to report in. And again, the Location Service can record the received information (box 424 ), return the location of Client 1 to Client 2 (a location that has not changed), and have Client 2 display such unchanged information (box 428 ). The information about client 1 can be changed in certain relevant ways even if the reported location of Client 1 has not been updated. For example, if the time for Client 1 reporting in again has expired, the Location Service at box 426 , can accompany the information with an indication that the location information for Client 1 is to be considered stale or potentially inaccurate in a more-than-acceptable manner. The Location Service alternatively, or in addition, may transmit information so that Client 2 can indicate the absolute time since Client 1 last checked in. Such a number does not have the same context to it, but it could provide a viewer with an indication of how stale the location information for Client 1 might be.
[0055] FIG. 5 is a schematic diagram of a mobile device 502 having power management and location determination components. The device 502 operates within a computer system 500 that includes a location-based services server 526 , which can provide services to, and communicate with, mobile device 502 over network 524 , such as the internet. The server 526 may provide information such as that discussed above.
[0056] The device 502 is shown schematically as including a number of components that are directed to allowing the device 502 to deliver services that involve reporting of geographic location for the device 502 , and to do so in a manner that does not unduly drain power from device battery 522 . A first component is a user interface manager or managers 504 , which may be responsible for providing output (e.g., in a screen of device 502 ) and receiving and interpreting input (e.g. from a touchscreen) in a familiar manner. An application manager 510 may in turn be a portion of an operating system on the device 502 that may manage the launching and utilization of various custom applications that a user may have loaded or downloaded onto device 502 , such as from an on-line application store. The application manager 510 in this example addresses two applications application 1 (box 516 ) and application 2 (box 518 ). Either or both of the applications may be location-based applications that need to receive information regarding the current geographic location of device 502 . Such access may occur by a general location services module 512 , which may register applications that want access to information about device location and may obtain the information from the device, and may interface with the applications or application manager 510 to distribute such information, especially when multiple applications want the information at the same or substantially the same time.
[0057] A location updater 514 is a component that controls how often the location services module 512 seeks new location information, and also how often location information is reported to server 526 . The location updater may operate in manners discussed above to determine times at which to seek location information, and sources from which to get the information. The location updater 514 may also interface with a power manager 520 , such as to determine a remaining level of battery power available in a device, so as to change a frequency with which location information is sought.
[0058] Finally, the location services module 512 can be controlled by location updater 514 with respect to when it asks WiFi interface 506 and GPS unit 508 for location information. As indicated above, the location services module 512 may also interface to obtain information from an accelerometer on the device 502 .
[0059] In this manner, the location updater may assist the power manager 520 in maintaining battery power on the device 502 , by establishing a schedule for obtaining location information and an indicator of which component such information is to come from, in order to extend battery life for the device 502 .
[0060] FIG. 6 shows an example of a generic computer device 600 and a generic mobile computer device 650 , which may be used with the techniques described here. Computing device 600 is intended to represent various forms of digital computers, such as laptops, desktops, workstations, personal digital assistants, servers, blade servers, mainframes, and other appropriate computers. Computing device 650 is intended to represent various forms of mobile devices, such as personal digital assistants, cellular telephones, smartphones, and other similar computing devices. The components shown here, their connections and relationships, and their functions, are meant to be exemplary only, and are not meant to limit implementations of the inventions described and/or claimed in this document.
[0061] Computing device 600 includes a processor 602 , memory 604 , a storage device 606 , a high-speed interface 608 connecting to memory 604 and high-speed expansion ports 610 , and a low speed interface 612 connecting to low speed bus 614 and storage device 606 . Each of the components 602 , 604 , 606 , 608 , 610 , and 612 , are interconnected using various busses, and may be mounted on a common motherboard or in other manners as appropriate. The processor 602 can process instructions for execution within the computing device 600 , including instructions stored in the memory 604 or on the storage device 606 to display graphical information for a GUI on an external input/output device, such as display 616 coupled to high speed interface 608 . In other implementations, multiple processors and/or multiple buses may be used, as appropriate, along with multiple memories and types of memory. Also, multiple computing devices 600 may be connected, with each device providing portions of the necessary operations (e.g., as a server bank, a group of blade servers, or a multi-processor system).
[0062] The memory 604 stores information within the computing device 600 . In one implementation, the memory 604 is a volatile memory unit or units. In another implementation, the memory 604 is a non-volatile memory unit or units. The memory 604 may also be another form of computer-readable medium, such as a magnetic or optical disk.
[0063] The storage device 606 is capable of providing mass storage for the computing device 600 . In one implementation, the storage device 606 may be or contain a computer-readable medium, such as a floppy disk device, a hard disk device, an optical disk device, or a tape device, a flash memory or other similar solid state memory device, or an array of devices, including devices in a storage area network or other configurations. A computer program product can be tangibly embodied in an information carrier. The computer program product may also contain instructions that, when executed, perform one or more methods, such as those described above. The information carrier is a computer- or machine-readable medium, such as the memory 604 , the storage device 606 , memory on processor 602 , or a propagated signal.
[0064] The high speed controller 608 manages bandwidth-intensive operations for the computing device 600 , while the low speed controller 612 manages lower bandwidth-intensive operations. Such allocation of functions is exemplary only. In one implementation, the high-speed controller 608 is coupled to memory 604 , display 616 (e.g., through a graphics processor or accelerator), and to high-speed expansion ports 610 , which may accept various expansion cards (not shown). In the implementation, low-speed controller 612 is coupled to storage device 606 and low-speed expansion port 614 . The low-speed expansion port, which may include various communication ports (e.g., USB, Bluetooth, Ethernet, wireless Ethernet) may be coupled to one or more input/output devices, such as a keyboard, a pointing device, a scanner, or a networking device such as a switch or router, e.g., through a network adapter.
[0065] The computing device 600 may be implemented in a number of different forms, as shown in the figure. For example, it may be implemented as a standard server 620 , or multiple times in a group of such servers. It may also be implemented as part of a rack server system 624 . In addition, it may be implemented in a personal computer such as a laptop computer 622 . Alternatively, components from computing device 600 may be combined with other components in a mobile device (not shown), such as device 650 . Each of such devices may contain one or more of computing device 600 , 650 , and an entire system may be made up of multiple computing devices 600 , 650 communicating with each other.
[0066] Computing device 650 includes a processor 652 , memory 664 , an input/output device such as a display 654 , a communication interface 666 , and a transceiver 668 , among other components. The device 650 may also be provided with a storage device, such as a microdrive or other device, to provide additional storage. Each of the components 650 , 652 , 664 , 654 , 666 , and 668 , are interconnected using various buses, and several of the components may be mounted on a common motherboard or in other manners as appropriate.
[0067] The processor 652 can execute instructions within the computing device 650 , including instructions stored in the memory 664 . The processor may be implemented as a chipset of chips that include separate and multiple analog and digital processors. The processor may provide, for example, for coordination of the other components of the device 650 , such as control of user interfaces, applications run by device 650 , and wireless communication by device 650 .
[0068] Processor 652 may communicate with a user through control interface 658 and display interface 656 coupled to a display 654 . The display 654 may be, for example, a TFT LCD (Thin-Film-Transistor Liquid Crystal Display) or an OLED (Organic Light Emitting Diode) display, or other appropriate display technology. The display interface 656 may comprise appropriate circuitry for driving the display 654 to present graphical and other information to a user. The control interface 658 may receive commands from a user and convert them for submission to the processor 652 . In addition, an external interface 662 may be provide in communication with processor 652 , so as to enable near area communication of device 650 with other devices. External interface 662 may provide, for example, for wired communication in some implementations, or for wireless communication in other implementations, and multiple interfaces may also be used.
[0069] The memory 664 stores information within the computing device 650 . The memory 664 can be implemented as one or more of a computer-readable medium or media, a volatile memory unit or units, or a non-volatile memory unit or units. Expansion memory 674 may also be provided and connected to device 650 through expansion interface 672 , which may include, for example, a SIMM (Single In Line Memory Module) card interface. Such expansion memory 674 may provide extra storage space for device 650 , or may also store applications or other information for device 650 . Specifically, expansion memory 674 may include instructions to carry out or supplement the processes described above, and may include secure information also. Thus, for example, expansion memory 674 may be provide as a security module for device 650 , and may be programmed with instructions that permit secure use of device 650 . In addition, secure applications may be provided via the SIMM cards, along with additional information, such as placing identifying information on the SIMM card in a non-hackable manner.
[0070] The memory may include, for example, flash memory and/or NVRAM memory, as discussed below. In one implementation, a computer program product is tangibly embodied in an information carrier. The computer program product contains instructions that, when executed, perform one or more methods, such as those described above. The information carrier is a computer- or machine-readable medium, such as the memory 664 , expansion memory 674 , memory on processor 652 , or a propagated signal that may be received, for example, over transceiver 668 or external interface 662 .
[0071] Device 650 may communicate wirelessly through communication interface 666 , which may include digital signal processing circuitry where necessary. Communication interface 666 may provide for communications under various modes or protocols, such as GSM voice calls, SMS, EMS, or MMS messaging, CDMA, TDMA, PDC, WCDMA, CDMA2000, or GPRS, among others. Such communication may occur, for example, through radio-frequency transceiver 668 . In addition, short-range communication may occur, such as using a Bluetooth, WiFi, or other such transceiver (not shown). In addition, GPS (Global Positioning System) receiver module 670 may provide additional navigation- and location-related wireless data to device 650 , which may be used as appropriate by applications running on device 650 .
[0072] Device 650 may also communicate audibly using audio codec 660 , which may receive spoken information from a user and convert it to usable digital information. Audio codec 660 may likewise generate audible sound for a user, such as through a speaker, e.g., in a handset of device 650 . Such sound may include sound from voice telephone calls, may include recorded sound (e.g., voice messages, music files, etc.) and may also include sound generated by applications operating on device 650 .
[0073] The computing device 650 may be implemented in a number of different forms, as shown in the figure. For example, it may be implemented as a cellular telephone 680 . It may also be implemented as part of a smartphone 682 , personal digital assistant, or other similar mobile device.
[0074] Various implementations of the systems and techniques described here can be realized in digital electronic circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.
[0075] These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms โmachine-readable mediumโ โcomputer-readable mediumโ refers to any computer program product, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term โmachine-readable signalโ refers to any signal used to provide machine instructions and/or data to a programmable processor.
[0076] To provide for interaction with a user, the systems and techniques described here can be implemented on a computer having a display device (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor) for displaying information to the user and a keyboard and a pointing device (e.g., a mouse or a trackball) by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form, including acoustic, speech, or tactile input.
[0077] The systems and techniques described here can be implemented in a computing system that includes a back end component (e.g., as a data server), or that includes a middleware component (e.g., an application server), or that includes a front end component (e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the systems and techniques described here), or any combination of such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication (e.g., a communication network). Examples of communication networks include a local area network (โLANโ), a wide area network (โWANโ), and the Internet.
[0078] The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
[0079] A number of embodiments 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, much of this document has been described with respect to particular techniques for managing access to location-providing components of a battery operated system, other forms of managing activity to extend battery life may also be addressed.
[0080] In addition, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other embodiments are within the scope of the following claims.
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In general, the subject matter described in this specification can be embodied in methods, systems, and program products. Data representing a plurality of power management profiles for a battery-operated wireless computing device are stored on the device. The power management profiles correspond to different power consumption levels. Each power management profile defines a feature for determining a geographic location of the device from among a plurality of features that are available for determining the geographic location of the device, and a frequency for employing the feature to determine the geographic location of the device. A first battery level of the device is determined. If the determined battery level is lower than a first predetermined amount, the device switches from a first power management profile having a first consumption level to a second power management profile having a second consumption level that is lower than the first consumption level.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a setting agent accelerator for use with refractory material and a method of applying the refractory material using the setting agent accelerator to form a refractory structure or lining. More particularly, the invention is directed to a setting agent accelerator for use with refractory material for preserving or maintaining refractory structures or linings from mechanical erosion and/or attack by corrosive materials such as those produced during manufacture of metals or metal alloys including acid and basic slags. The refractory linings also are exposed to thermal shock which can cause premature failure of the refractory.
SUMMARY
[0002] The present invention is directed to a setting agent accelerator for use with refractory material and a method of applying the refractory material using the setting agent accelerator to a refractory structure or lining. The refractory material can be applied to a refractory structure such as the working lining of a vessel or ladle. In some embodiments, the refractory material can form a safety lining of a refractory structure. The refractory material is suitable for use for the maintenance of kilns, furnaces, electric arc furnaces, basic oxygen furnaces, and other metallurgical furnaces, vessels or ladles.
[0003] In some embodiments, the composition of the setting agent accelerator can be a set accelerating amount of sodium nitrate, sodium nitrite or mixtures thereof and calcium hydroxide.
[0004] In some embodiments, the composition of the setting agent accelerator can be from about 30 to 60 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 10 to 30 weight percent calcium hydroxide and 30 to 60 weight percent water.
[0005] In some embodiments, the composition of the setting agent accelerator can be from about 30 to 50 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 10 to 30 weight percent calcium hydroxide and 30 to 60 weight percent water.
[0006] In some embodiments, the composition of the setting agent accelerator can be from about 35 to 45 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 12 to 18 weight percent calcium hydroxide and 45 to 55 weight percent water.
[0007] Alternatively, the present invention can be an admixture of 69 to 75 weight percent sodium nitrate or sodium nitrite or mixtures thereof and 25 to 31 weight percent calcium hydroxide. In order to make the setting agent accelerator, water is added in the proportions described above to provide the present setting agent accelerator.
[0008] The present invention can be an admixture of 60 to 80 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 20 to 40 weight percent calcium hydroxide. In order to make the setting agent accelerator, water is added in the proportions described above to provide the present setting agent accelerator. An important aspect of the invention is that each component plays a different role in the final accelerator formula. The sodium nitrate, sodium nitrite or mixtures thereof in the setting agent accelerator promote flocculating and the calcium hydroxide promotes the final setting of the refractory material with which the setting agent accelerator is used.
[0009] Another aspect of the invention is that the above described setting agent accelerator can be used as setting agent accelerator for placing refractory material such as an ultra-low cement castable refractory material, a low cement castable refractory material or a regular castable refractory material. An ultra-low cement castable refractory material is defined as alumina and alumino-silicate castable refractories which contain hydraulic-setting cement and which have a total lime (calcium oxide) content of greater than 0.2 to 1.0 weight percent on a calcined basis. A low cement castable refractory material is defined as alumina and alumino-silicate castable refractories which contain hydraulic-setting cement and which have a total lime (calcium oxide) content of greater than 1.0 to 2.5 weight percent on a calcined basis. A regular castable refractory material is defined as alumina and alumino-silicate castable refractories which contain hydraulic-setting cement and which have a total lime (calcium oxide) content of greater than 2.5 weight percent on a calcined basis.
[0010] The sodium nitrate, sodium nitrite or mixtures thereof and the calcium hydroxide of the setting agent accelerator can be premixed and added to a refractory product to provide a sprayable, castable, moldable, projectable, pumpable, shotcretable or manually applied admixture which forms a monolithic refractory structure or lining.
[0011] The refractory material can be applied by a gunning system. The refractory material can also be applied by spraying, casting, molding, pumping, projecting, shotcreting, or a hybrid of the listed methods. Other manual methods such as pouring with or without tools can be used.
[0012] In the method of the invention, application of the refractory material can be applied to provide a layer of refractory material of a thickness of about 1 inch to about 24 inches both prior to exposing as well as after exposing the lining to corrosive materials. Desirably, application of the refractory material is performed prior to initial exposure of the refractory lining to the corrosive materials, and can be repeated after each exposure of the lining to those corrosive materials. Depending on the degree of erosion, corrosion or penetration of corrosive materials into the applied refractory material, the refractory material of the present invention need not be reapplied to the refractory material after every contact of corrosive materials with the refractory material.
[0013] Also, the refractory material used with the present setting agent accelerator can be applied as a safety lining to the shell of the refractory structure. Application of the refractory material can be performed while the target refractory structure is at a temperature of about 32 degrees F. to about 2500 degrees F.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The invention will now be described in detail by reference to the following specification and non-limiting examples. Unless otherwise specified, all percentages are by weight and all temperatures are in degrees Fahrenheit.
[0015] The setting agent accelerator has a pH of between 11 and 13. Preferably, the setting agent accelerator has a pH of from 12.0 to 12.4. In some embodiments, the setting agent accelerator can have a pH of less than about 12.4.
[0016] The setting agent accelerator can be added to a wetted refractory material in an amount of 0.01 weight percent to 5.0 weight percent of the total dry weight of the refractory material. In some embodiments the setting agent accelerator is added to a wetted refractory material in an amount of 0.1 to 3.0 weight percent of the total dry weight of the refractory material.
[0017] The components of the setting agent accelerator play different roles in the final setting agent accelerator formula. They must be combined to be effective as a setting agent accelerator and would not work as well separately. The sodium nitrate, sodium nitrite or mixtures thereof promote the initial flocculating, which is a change in the flow consistency of the refractory material and enables the refractory material to adhere to a refractory structure or lining. The refractory lining is still workable for the initial 20 to 50 minutes after being installed. During this period, the refractory lining can have a surface leveled or smoothed out if necessary, by the use of a hand tool such as a trowel. The calcium hydroxide promotes the final setting of the refractory material with which the setting agent accelerator is used and improves the strength prior to the dry out of the refractory lining. Therefore, 20 to 50 minutes after the refractory material installation, the equipment, such as a steel ladle, can be moved if required.
[0018] Sodium nitrate, sodium nitrite or mixtures thereof when used by itself as a setting agent accelerator admixture in a refractory material promotes initial flocking but is ineffective at promoting final set of the refractory material. Often when using sodium nitrate, sodium nitrate or mixtures thereof in a setting agent accelerator final set of the refractory material is well in excess of 50 minutes which is uneconomical because it delays the return to service of the vessel. Calcium hydroxide suspensions when used by themselves in a setting agent accelerator admixture in a refractory material are ineffective at promoting flocculation but do provide for an accelerated final set of less than 50 minutes. Without the initial flocculating, the refractory material is unable to adhere to a refractory structure or lining, and consequently, the refractory material is unable to be applied and remain on a vertical wall without sliding down or falling off the wall or to be applied overhead.
[0019] The present invention achieves good initial flocking and also promotes final setting of the refractory material in a sufficiently short period of time while providing a period of time of workability of the applied refractory material.
[0020] The components of the setting agent accelerator can be combined in the following ways. The calcium hydroxide component can be in the form of an aqueous suspension and can be added to the solid, preferably powdered, sodium nitrate, sodium nitrite or mixtures thereof. The above described powdered sodium nitrate, sodium nitrite or mixture thereof can be added to the calcium hydroxide component which can be in the form of an aqueous suspension. Similarly, the calcium hydroxide component can be in the form of a powder and can be added to the aqueous sodium nitrate, sodium nitrite or mixture thereof.
[0021] The composition of the setting agent accelerator can be a set accelerating amount of sodium nitrate, sodium nitrite or mixtures thereof and calcium hydroxide.
[0022] Either solid or powdered calcium hydroxide can be added to water and then the sodium nitrate, sodium nitrite or mixture thereof can be added to the water. Similarly, the sodium nitrate, sodium nitrite or mixture thereof can be added to the water and then the powdered or solid calcium hydroxide can be added to the solution of water and sodium nitrate, sodium nitrite or mixtures thereof.
[0023] Alternatively, the present invention can be an admixture of 69 to 75 weight percent sodium nitrate or sodium nitrate or mixtures thereof and 25 to 31 weight percent calcium hydroxide. In order to make the setting agent accelerator, water is added in the proportions described above to provide the present setting agent accelerator.
[0024] The present invention can be an admixture of 60 to 80 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 20 to 40 weight percent calcium hydroxide. In order to make the setting agent accelerator, water is added in the proportions described above to provide the present setting agent accelerator. The composition of the setting agent accelerator can be from about 30 to 60 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 10 to 30 weight percent calcium hydroxide and 30 to 60 weight percent water.
[0025] In some embodiments, the composition of the setting agent accelerator can be from about 30 to 50 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 10 to 30 weight percent calcium hydroxide and 30 to 60 weight percent water. Preferably the composition of the setting agent accelerator can be from about 35 to 45 weight percent sodium nitrate, sodium nitrite or mixtures thereof and 12 to 18 weight percent calcium hydroxide and 45 to 55 weight percent water.
[0026] Preferably, solid sodium nitrate or sodium nitrite or mixtures thereof are first dissolved in water preferably at water temperatures between 50 and 95 degrees Celsius and then solid calcium hydroxide is blended into the solution.
[0027] The above described setting agent accelerator can be used as setting agent accelerator for placing refractory material such as an ultra-low cement castable refractory material, a low cement castable refractory material or a regular castable refractory material. An ultra-low cement castable refractory material is defined as alumina and alumino-silicate castable refractories which contain hydraulic-setting cement and which have a total lime (calcium oxide) content of greater than 0.2 to 1.0 weight percent on a calcined basis. A low cement castable refractory material is defined as alumina and alumino-silicate castable refractories which contain hydraulic-setting cement and which have a total lime (calcium oxide) content of greater than 1.0 to 2.5 weight percent on a calcined basis. A regular castable refractory material is defined as alumina and alumino-silicate castable refractories which contain hydraulic-setting cement and which have a total lime (calcium oxide) content of greater than 2.5 weight percent on a calcined basis. In some embodiments, the above described setting agent accelerator can be used as a setting agent accelerator for placing regular castable refractory material having a total lime (calcium oxide) content of greater than 2.5 weight percent on a calcined basis and up to 5.0 weight percent on a calcined basis.
[0028] The setting agent accelerator can be admixed with a low-cement refractory structure such as alumina such as fused or tabular alumina, zircon, alumina silicates, etc. The setting agent accelerator can be used with a refractory material, preferably a low cement refractory material, having cement such as calcium aluminate cements.
[0029] The refractory material can be applied through any gunning system or applied by spraying, gunning, casting, ramming, molding, pumping, projecting, shotcreting, slurry coating, troweling, hot pouring or a hybrid of the listed methods. Other manual methods such as pouring with or without tools can be used. These methods can include dry, such as gunning and wet process shotcreting.
[0030] Preferably the setting agent accelerator is added to the refractory material during shotcreting. For example, the refractory material can be pumped through a hose and into a gun or nozzle for applying refractory materials. At the nozzle of the gun the setting agent accelerator can be added to the refractory material thus forming an admixture on a target refractory structure such as a vessel or ladle. The setting agent accelerator permits initial flocculating to take place followed by the final set of the refractory material. It is believed that the sodium nitrate, sodium nitrite or mixtures thereof promote initial flocculation of the refractory material and that the calcium hydroxide promotes the final setting of the refractory material.
[0031] In some embodiments, the refractory material forms a working lining of a refractory structure. The working lining refractory material has good slag and erosion resistance.
[0032] In some embodiments, the refractory material can form a safety lining of a refractory structure.
[0033] The refractory materials for working and safety lining are suitable for use for the maintenance of kilns, furnaces, electric arc furnaces, basic oxygen furnaces, and other metallurgical furnaces, vessels or ladles.
[0034] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
EXAMPLE 1
[0035] The following example illustrates the use of the present setting agent accelerator to form a low cement refractory material for applying onto a hot or cold refractory structure such as the slag line of a vessel or ladle which was used with a setting agent accelerator of the present invention.
[0036] First, powdered sodium nitrate was added to aqueous calcium hydroxide suspension such that the calcium hydroxide was present in the amount of 17 weight percent of the total weight of the setting agent accelerator and the sodium nitrate was present in the amount of 33 weight percent of the total weight of the setting agent accelerator and the balance of the setting agent accelerator was water. To prepare Sample A, the above described setting agent accelerator was mixed with OPTISHOTยฎ 85 which is a low cement refractory material available from Minteq International Inc. of New York, N.Y. OPTISHOTยฎ 85 comprises 65 to 85 weight percent of 90 to 100 weight percent alumina aggregates and 5 to 20 weight percent of 50 to 60 weight percent alumina aggregates, calcined aluminas, fumed silicas and two to six weight percent calcium aluminate cements. In addition, dispersants, retardants and fibers are present.
[0037] 1.5 weight percent of the above setting agent accelerator relative to the total dry weight of the low cement refractory material was added to the low cement refractory material.
[0038] Sample A produced the following results: initial flock occurred within 3 seconds and loses its initial flow meaning that the admixture of the low cement refractory material with the setting agent accelerator does not flow as prior to the addition of the setting agent accelerator. After initial flocking, Sample A had a โplay-dohโ consistency and was still workable and deformable. Sample A set hard to firm fingernail pressure in ten minutes.
EXAMPLE 2
[0039] The following example illustrates the use of the present setting agent accelerator to form a low cement refractory material for applying onto a hot or cold refractory structure such as the slag line of a vessel or ladle which was used with a setting agent accelerator of the present invention. First, powdered sodium nitrate was added to aqueous calcium hydroxide suspension such that the calcium hydroxide was present in the amount of 12.5 weight percent of the total weight of the setting agent accelerator and the sodium nitrate was present in the amount of 50 weight percent of the total weight of the setting agent accelerator and the balance of the setting agent accelerator was water. To prepare Sample B, the above described setting agent accelerator was mixed with OPTISHOTยฎ 85. 0.5 weight percent of the above setting agent accelerator relative to the total dry weight of the low cement refractory material was added to the low cement refractory material.
[0040] Sample B produces the following results: initial flocking occurred within 5 seconds and loses its initial flow meaning that the admixture of the low cement refractory material with the setting agent accelerator does not flow as prior to the addition of the setting agent accelerator. After initial flocking, Sample B had a โplay-dohโ consistency and was still workable and deformable. Sample B also exhibited good final set in thirty minutes meaning that the material was not deformable to firm fingernail pressure within thirty minutes.
EXAMPLE 3
[0041] The following example illustrates the use of the present setting agent accelerator to form a low cement refractory material for applying onto a hot or cold refractory structure such as the slag line of a vessel or ladle which was used with a setting agent accelerator of the present invention,
[0042] First, powdered sodium nitrate was added to aqueous calcium hydroxide suspension such that the calcium hydroxide was present in the amount of 15 weight percent of the total weight of the setting agent accelerator and the sodium nitrate was present in the amount of 40 weight percent of the total weight of the setting agent accelerator and the balance of the setting agent accelerator was water.
[0043] To prepare Sample C, the above described setting agent accelerator was mixed with OPTISHOTยฎ 85. 0.5 weight percent of the above setting agent accelerator relative to the total dry weight of the low cement refractory material was added to the low cement refractory material.
[0044] Sample C produces the following results: initial flocking occurred within 5 seconds and loses its initial flow meaning that the admixture of the low cement refractory material with the setting agent accelerator does not flow as prior to the addition of the setting agent accelerator. After initial flocking, Sample C has a โplay-dohโ consistency and was still workable, and deformable. Sample C also exhibited good final set in thirty minutes meaning that the material was not deformable to firm nail fingernail pressure within thirty minutes.
EXAMPLE 4
[0045] The following example illustrates the use of the present setting agent accelerator to form a low cement refractory material for applying onto a hot or cold refractory structure such as the slag line of a vessel or ladle which was used with a setting agent accelerator of the present invention.
[0046] First, powdered sodium nitrite was added to aqueous calcium hydroxide suspension such that the calcium hydroxide was present in the amount of 12.5 weight percent of the total weight of the setting agent accelerator and the sodium nitrite was present in the amount of 50 weight percent of the total weight of the setting agent accelerator and the balance of the setting agent accelerator was water. To prepare Sample D, the above described setting agent accelerator was mixed with OPTISHOTยฎ 85. 0.5 weight percent of the above setting agent accelerator relative to the total dry weight of the low cement refractory material was added to the low cement refractory material.
[0047] Sample D produces the following results: initial flocking occurred within 5 seconds and loses its initial flow meaning that the admixture of the low cement refractory material with the setting agent accelerator does not flowโas prior to the addition of the setting agent accelerator. After initial flocking, Sample D has a โplay-dohโ consistency and was still workable, deformable. Sample D also exhibited good final set in thirty minutes meaning that the material was not deformable to firm fingernail pressure within thirty minutes.
EXAMPLE 5
[0048] The following example illustrates the use of the present setting agent accelerator to form a low cement refractory material for applying onto a hot or cold refractory structure such as the slag line of a vessel or ladle which was used with a setting agent accelerator of the present invention.
[0049] First, powdered sodium nitrate was added to aqueous calcium hydroxide suspension such that the calcium hydroxide was present in the amount of 12.5 weight percent of the total weight of the setting agent accelerator and the sodium nitrate was present in the amount of 50 weight percent of the total weight of the setting agent accelerator and the balance of the setting agent accelerator was water.
[0050] To prepare Sample E, the above described setting agent accelerator was mixed with OPTISHOTยฎ 60 which is a low cement refractory material available from Minteq International Inc. of New York, New York. OPTISHOTยฎ 60 comprises 55 to 75 weight percent of 50 to 60 weight percent alumina aggregates, 10 to 20 weight percent of 80 to 90 weight percent alumina aggregates, calcined aluminas, fumed silicas and two to six weight percent calcium aluminate cements. In addition, dispersants, retardants and fibers are present.
[0051] 0.5 weight percent of the above setting agent accelerator relative to the total dry weight of the low cement refractory material was added to the low cement refractory material.
[0052] Sample E produces the following results: initial flocking occurred within 3 seconds and loses its initial flow meaning that the admixture of the low cement refractory material with the setting agent accelerator does not flow as prior to the addition of the setting agent accelerator. After initial flocking, Sample E has a โplay-dohโ consistency and was still workable, deformable. Sample E also exhibited good final set in twenty minutes meaning that the material was not deformable to firm finger pressure within twenty minutes.
[0053] The above described setting agent accelerator can be used with OPTISHOTยฎ AZS which is a low cement refractory material available from Minteq International Inc. of New York, N.Y. OPTISHOTยฎ AZS comprises 30 to 60 weight percent of 80 to 90 weight percent alumina aggregates, 20 to 40 weight percent of zircon sand and flours, 5 to 20 weight percent of 50 to 60 weight percent alumina aggregate, 5 to 20 weight percent of calcined and tabular aluminas, fumed silicas and two to eight weight percent calcium aluminate cements. In addition, dispersants, retardants and fibers are present.
EXAMPLE 6
[0054] The following example illustrates the use of the present setting agent accelerator to form a regular castable refractory material for applying onto a hot or cold refractory structure such as safety lining of a vessel or ladle or a working lining of (catalytic cracking systems, coking systems or fireproofing) which was used with a setting agent accelerator of the present invention.
[0055] First, powdered sodium nitrate was added to aqueous calcium hydroxide suspension such that the calcium hydroxide was present in the amount of 17 weight percent of the total weight of the setting agent accelerator and the sodium nitrate was present in the amount of 43 weight percent of the total weight of the setting agent accelerator and the balance of the setting agent accelerator was water.
[0056] To prepare Sample F, the above described setting agent accelerator was mixed with INSULSHOTโข FH which is a low cement refractory material available from Minteq International Inc. of New York, N.Y. INSULSHOTโข FH comprises 20 to 50 weight percent of 40 to 50 weight percent alumina aggregates, 15 to 25 weight percent of ceramic spheres, 12 to 18 weight percent fumed silicas, 12 tol 8 weight percent calcium aluminate cements, 5 to 15 weight percent silica aggregate, and 5 to 15 weight percent pyrophillite. In addition, dispersants, retardants and fibers are present.
[0057] The refractory material used in Example 6 can be considered a regular castable refractory material because the castable refractory material has a total lime (calcium oxide) content of 4.5 weight percent. As set forth earlier, regular castable refractory materials have a total lime (calcium oxide) content of greater than 2.5 weight percent on a calcined basis.
[0058] 1.35 weight percent of the above setting agent accelerator relative to the total dry weight of the regular castable refractory material was added to the INSULSHOTโข FH regular castable refractory material during a shotcrete installation.
[0059] Sample F produces the following results: initial flocking occurred within seconds and loses its initial flow meaning that the admixture of the regular cement refractory material with the setting agent accelerator does not flow as prior to the addition of the setting agent accelerator. After initial flocking, Sample F has a thicker, more viscous consistency and was still workable, deformable. Sample F also exhibited good final set in fifty minutes meaning that the material was not deformable to firm finger pressure within fifty minutes.
EXAMPLE 7
[0060] The following example illustrates the use of the present setting agent accelerator to form an ultra-low cement refractory material for applying onto a hot or cold refractory structure such as the slag line of a vessel or ladle which was used with a setting agent accelerator of the present invention. First, powdered sodium nitrate was added to aqueous calcium hydroxide suspension such that the calcium hydroxide was present in the amount of 14.7 weight percent of the total weight of the setting agent accelerator and the sodium nitrate was present in the amount of 37.8 weight percent of the total weight of the setting agent accelerator and the balance of the setting agent accelerator was water. To prepare Sample G, the above described setting agent accelerator was mixed with OPTISHOTยฎ 90 ULC. 0.5 weight percent of the above setting agent accelerator relative to the total dry weight of the ultra-low cement refractory material was added to the ultra-low cement refractory material. OPTISHOTยฎ 90 ULC comprises 65 to 85 weight percent of 90 to 100 weight percent alumina aggregates and 8 to 15 weight percent of calcined aluminas, fumed silicas and one to three and a half weight percent calcium aluminate cements. In addition, dispersants, retardants and fibers are present.
[0061] Sample G produces the following results: initial flocking occurred within 4 seconds and loses its initial flow meaning that the admixture of the low cement refractory material with the setting agent accelerator does not flow as prior to the addition of the setting agent accelerator. After initial flocking, Sample G had a โplay-dohโ consistency and was still workable and deformable. Sample G also exhibited good final set in twenty minutes meaning that the material was not deformable to firm fingernail pressure within twenty minutes.
[0062] Accordingly, it is understood that the above description of the present invention is susceptible to considerable modifications, changes and adaptations by those skilled in the art, and that such modifications, changes and adaptations are intended to be considered within the scope of the present invention.
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The present invention relates to a setting agent accelerator for use with an ultra-low cement, low cement and regular castable refractory materials and a method of applying the refractory materials using the setting agent accelerator to form a refractory structure or lining. More particularly, the invention is directed to a setting agent accelerator for use with an ultra-low cement , low cement and regular castable refractory material for preserving or maintaining the safety lining and the working lining of refractory structures or linings from mechanical erosion and/or attack by corrosive materials such as those produced during manufacture of cement, lime, metals or metal alloys including acid and basic slags. The setting agent accelerator has a set accelerating amount of sodium nitrate, sodium nitrite or mixtures thereof, calcium hydroxide and water.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for conveying bags, and more particularly to apparatus for aligning an element of a bag conveying line with an edge of a tubular or semitubular plastic web.
2. Description of the Prior Art
In apparatus for the continuous production of plastic bags, welding stations that sever plastic bags closed by seam welds from tubular or semitubular plastic webs are usually followed by wicketer stacking stations, which include pairs of transfer arms that are provided with suction cups or other gripping means and are arranged to receive the cut bags and then to rotate through 180 degrees to transfer the cut bags onto respective pairs of stacking pins carried by an endless conveyor of a stacking conveyor line, whereby respective stacks of bags are formed on the conveyor. To permit the formation of stacks of several bags on the stacking lines, the bags are provided with suitable locating holes, which are punched into the continuous web before the wicketer stacking station. If the direction of travel of the web deviates laterally from the initial longitudinal direction of the web, the stacking operation will be disrupted because the individual bags which have been severed and provided with seam welds and locating holes cannot be carried over to the stacking conveyor in the correct position by the wicketer transfer arms, and the locating holes will not be properly positioned relative to the stacking pins on the stacking conveyor.
In order to ensure that the bags which have been severed and welded will be transferred by the wicketer transfer arms to the pairs of stacking pins in the proper position, it is known to displace the entire wicketer stacking station and the entire stacking conveyor line in a transverse direction to the extent of the measured deviation of the web so that the locating holes of the bags will receive the pairs of stacking pins. But the transverse displacement of the entire wicketer stacking station and the entire stacking conveyor line requires relatively expensive means and can be effected only slowly because large masses must be moved.
It is known from German Patent Specification No. 24 28 113 that a frame carrying a core for winding a web can be pivotally carried by an intermediate plate, which is guided on a base plate for a transverse displacement. In that arrangement, the frame is provided with drive mean for imparting a pivotal movement to the frame and the intermediate plate is provided with drive means for imparting a transverse movement to the intermediate plate. By means of sensors scanning an edge of the web the drive means can be so controlled that the edge of the web being wound on the core will be properly aligned.
It is an object of the present invention to permit a simpler and more rapid adjustment of the wicketer station and stacking conveyor line in response to a lateral deviation of the web.
SUMMARY OF THE INVENTION
Briefly stated in accordance with one aspect of the present invention, a wicketer frame, in which transfer arms are rotatably mounted, is provided with at least one transverse rail, which is supported on rollers or a sliding surface of a carrying frame. The wicketer frame is connected by a beam to an end frame, which receives the receiving end of the stacking line and is supported on a base frame that is longitudinally displaceable and is rotatable through a small angle relative to the base frame. An actuator is mechanically connected only to the wicketer frame adjacent to the transverse rail and moves the wicketer frame laterally in response to signals received from web sensors positioned upstream of the wicketer. The apparatus in accordance with the present invention permits a fast adjustment of the wicketer stacking station and the stacking line in response to a lateral deviation of the web because only the wicketer frame is transversely displaced to the extent of the deviation. During displacement, the wicketer frame also undergoes a slight rotation about a pivotal axis disposed adjacent to the end frame so that the desired adjustment in response to the deviation of the web is effected merely by the transverse displacement of the wicketer frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevational view, partly in section, of bag handling apparatus in accordance with the present invention including a wicketer frame, a part of an upstream transverse welding apparatus, and a part of a downstream stacking conveyor.
FIG. 2 is a cross-sectional view taken along the line II--II of FIG. 1.
FIG. 3 is a fragmentary side elevational view of an end frame of the stacking conveyor.
FIG. 4 is a fragmentary plan view of the end frame of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An illustrative embodiment of the invention will now be explained in more detail with reference to the drawings.
Referring now to FIGS. 1 and 2, a wicketer frame 3 supports a wicketer 3' that includes a shaft 4 from which pairs of laterally spaced radial arms 5 extend. Wicketer frame 3 is defined by upstanding side panels 1, 2, in which shaft 4 is rotatably mounted. The shaft 4 carries radially extending transfer arms 5, which are provided in laterally spaced pairs and carry suction cups or other gripping means to grip bags that are cut from a web of material and to transfer the cut bags from a severing apparatus 6 to a stacking conveyor 12' by rotation of wicketer 3' through approximately 180ยฐ and in a clockwise direction as viewed in FIG. 1.
Positioned immediately upstream of the wicketer frame 3 is severing and welding station 6, which includes an intermittently driven pair of feed rollers 7, 7' for advancing a tubular or semitubular plastic web 10 in intermittent steps corresponding to the width or length of a bag. The welding apparatus includes an upper welding bar 8, which is adapted to be lifted and lowered relative to a lower welding roller 9. Welding bar 8 is provided with a knife edge (not shown) for cutting the bags from the web, and lower welding roller 9 serves as a backup surface in cooperation with welding bar 8 to permit a transverse weld to be made in web 10.
Feed rollers 7, 7' are preceded by a pair of transversely spaced web position sensors 11, which are positioned to scan respective side edges of the web. The sensors are preceded by a punching means (not shown) which punches spaced pairs of locating holes along an edge portion of the web at a predetermined spacing inwardly of the edge. Each of the sensors 11 can be fixed in position transversely relative to web 10 and can be an optical sensor including a plurality of transversely positioned light sources and photocells, or the like, positioned in opposite sides of the web for sensing the direction and the extent of transverse movement of web 10 relative to an initial position. Other web sensing means can also be used, as will be understood by those skilled in the art, so long as they can detect the presence and absence of the edges of the web if the web were to shift in a transverse direction, and provide signals indicative of the direction and extent of transverse web movement relative to an initial position.
The center-to-center spacing of the locating holes lengthwise of the web is equivalent to the center-to-center spacing of a pair of stacking pins 12, 13 carried by a stacking conveyor 12', that extends downstream from wicketer frame 3. The stacking pins 12, 13 are preferably each mounted on separate plates that are carried by an endless conveyor 14, which can be a chain or a cogged belt. Conveyor 14 passes around a forward sprocket 15, which is rotatably carried on a shaft (not shown) mounted in the wicketer frame 3, and around a rear drive sprocket 16 (see FIG. 3), which is rotatably carried on a shaft (not shown) mounted in an end frame 17, and which is driven by a suitable motor 33, or the like, for intermittently moving stacking conveyor 12'.
Wicketer frame 3 is connected to end frame 17 by a longitudinally extending rigid beam 18. A central beam 19 forming part of the structure of stacking conveyor 12' is also connected to wicketer frame 3 and to end frame 17 to provide an additional connection between the two frames 3 and 17 for increased rigidity. The connection between beam 19 and frames 3 and 17 can be any suitable connection means, as will be known to those skilled in the art.
As best seen in FIG. 2, side panels 1, 2 of wicketer frame 3 are interconnected by crossbeams 20, 21, the lower edge portions of each of which define transverse rails, each of which is supported on the peripheries of two pairs of cylindrical rollers 23, spaced transversely and longitudinally relative to wicketer frame 3. Rollers 23 are rotatably carried in respective cross members 22, 22' of a rectangular carrying frame 23' for rotation about horizontal axes, which are parallel to the longitudinal direction of the stacking conveyor 12'. Carrying frame 23' includes cross members 22, 22' and longitudinal members 23a, 23b all of which members are interconnected as shown in FIG. 2 to define frame 23'.
A pinion 25 is carried on a shaft (not shown) that is rotatably carried by cross member 22 and can be driven by a stepping motor 25' through a gear train 24. Pinion 25 is in meshing engagement with a rack 26, which is provided in an elongated opening 20' (see FIG. 1) in crossbeam 20, and that extends transversely relative to wicketer frame 3. Rack 26 extends in a direction parallel to the lower edge of cross beam 20.
Cross members 22, 22' of the carrying frame each include pairs of rollers 27, which are rotatably carried at each end of cross members 22, 22' for rotation about axes that extend transversely relative to wicketer frame 3. Rollers 27 are guided on rails 28, 28' which extend outwardly from wicketer frame 3 in a longitudinal direction parallel to stacking conveyor 12', and form a part of a wicketer base frame 29.
Referring now to FIGS. 3 and 4, end frame 17 includes four rollers 30, which are rotatably carried along the lowermost edges of a pair of spaced, opposed end panels 17', and are mounted for rotation about transverse axes. Rollers 30 bear against and are guided on rails 31, which form part of an end base frame 32.
In operation, severing and welding station 6, wicketer frame 3, stacking conveyor 12' and end frame 17 for stacking conveyor 12' are initially aligned relative to each other in that sequence. The operation of the the apparatus involves welding and severing bags from web 10 at welding station 6, and transferring the welded and severed bags by wicketer 3' from welding station 6 to stacking conveyor 12', which is maintained stationary, with the bags positioned on stacking conveyor 12' so that stacking pins 12, 13 are received in the locating holes that are punched through the bags. When the desired number of bags has been received and deposited on a pair of stacking pins 12, 13, stacking conveyor 12' is incrementally advanced by motor 33 to present the next pair of stacking pins adjacent the downstream end of wicketer 3' so that another stack of bags can be formed.
When web position sensors 11 detect a transverse deviation of the web 10 from a predetermined position, relative to severing and welding station 6, the sensors provide signals to a suitable control device (not shown) that initiates the operation of stepping motor 25' so that the wicketer frame 3 is moved transversely relative to carrying frame 23' and to severing and welding station 6 by engagement of pinion 25 with rack 26. The movement of wicketer frame 3 is in a direction and in an amount responsive to the sensor signals indicative of the direction and amount of transverse deviation of web 10, in order to restore proper transverse alignment of the wicketer 3' relative to the web so that the bags are properly positioned relative to stacking conveyor 12', and the stacking pins extend through the holes in the bags. Operation of stepping motor 25 can be continued until frame 3 is shifted transversely in the direction and in the amount of deviation of web 10 as sensed by sensors 11.
During transverse displacement of wicketer frame 3, both the wicketer frame and the stacking conveyor are rotated through a small angle about end frame 17, which itself rotates slightly but is not moved transversely to the same extent as is wicketer frame 3. End frame 17 can perform such a rotational movement because it is supported by rollers 30 that, in turn, are supported by the rails of the base frame 32, and rollers 30 are capable of only small transverse movement relative to rails 31.
By means which are not shown, the means for punching the locating holes in the bags are also readjusted to compensate for the measured deviation of the web so that a predetermined distance from the locating holes to the edge of the web 10 will be maintained.
Although particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit of the present invention. For example, transverse displacement of the wicketer frame can be effected by a fluid operable piston-cylinder unit, if desired. It is intended to cover in the appended claims all such changes and modifications that fall within the scope of the present invention.
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Apparatus for aligning a wicketer frame with an edge of a tubular or semitubular plastic web. The positions of the edges of the web are sensed and the wicketer frame is transversely displaced in response to and in dependence on the sensed deviation of the edges of the web from an initial position. The wicketer frame is provided with at least one transverse rail, which is supported on rollers or sliding surfaces of an underlying carrying frame to permit transverse movement of the wicketer frame relative to the web. The wicketer frame is connected by a beam to an end frame, which carries the downstream end of a stacking conveyor and is supported on a base frame. The end frame is longitudinally displaceable and is rotatable through a small angle relative to the base frame. A rack and pinion arrangement is provided for transversely moving the wicketer frame.
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FIELD OF THE INVENTION
This invention relates to a device and method for a break action cannon to deal with problems which arise in the weaponization and integration of regenerative liquid propellant system relative to deploying projectiles through gun tubes. The present invention enables, inter alia, efficient power and thermal management, superior firing cycle and high structural efficiency per unit weight, by enabling isolative loading of the gun tube.
SUMMARY OF THE INVENTION
The break action cannon of the present invention provides a device and method for segregating the process of loading a projectile into the gun tube from breech operations without impacting other critical firing cycle functions. Heretofore, devices and methods for regenerative liquid propellant breech loading include either swinging the breech block or vertically sliding a breech block or translating rearward and lifting a breech block to thereby provide unimpeded access to the gun tube. However, moving a regenerative liquid propellant breech assembly generally requires large power supply, complex structures and multiple controls. Further, existing devices are not flexible to promote integration into a weapon platform. Particularly, existing devices and methods, require complex gun mount structures which undetermine firing time cycles and pose severe design restrictions.
The present invention provides significant advantages over the prior practice. It provides both a method and mechanism for concurrent projectile ram and propellant charge at a lower power requirement and reduced component size. Further, reductions in swept volume and appreciable reductions in inertial forces for breech opening are realized.
Primarily, one of the significant advantages proffered by the present invention includes simultaneous loading of a projectile into a gun tube while a propellant charge system is primed. The breech is opened and the barrel is detachably tipped at an angle to accept a projectile while the propellant supply system is revitalized as needed.
Specific advances, features and advantages of the present invention will become apparent upon examination of the following description and drawings dealing with several specific embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an assembly drawing of the present invention with the gun tube, shown in phantom, tipped at an angle to accept a projectile.
FIG. 2A is a block diagram showing the integration of the present invention with an internal and external propellant supply. The gun tube is shown in a disengaged position inclined to accept a projectile.
FIG. 2B is a block diagram showing the barrel coupled to a closed breech.
FIG. 3A is a detail drawing showing connections between the barrel and the breech assembly.
FIG. 3B is a detail drawing of a face seal and the breech end of the barrel.
FIG. 4A is an enlarged elevation view of the barrel shifting and tipping mechanism.
FIG. 4B is an enlarged plan view of the barrel shifting and tipping mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is shown in FIG. 1. Gun assembly 10 comprises barrel 12 connected to the combustor and breech assembly 14. Cradle structure 16 encloses barrel 12 and breech assembly 14. Further, gun assembly 10 is supported at chassis deck 18. Deck 18 comprises bearings 24 to enable azimuth drive and trunnions 26 to enable elevation drive. The break action feature is depicted by barrel 12a which is rotatably tipped about fulcrum 29. Projectile feed path 28 is shown at breech end of cannon 12a.
FIG. 2A is a block diagram depicting the integrability and flexibility of the present invention. In the preferred embodiment, a propellant charge system is integrated with the components of the present invention. In FIG. 2A, barrel 12 is shown in a tipped position, accepting projectile 32 via projectile path 28. Breech assembly 14 houses combustor compartment 38 and internal propellant supply 40. The component assembly is mounted on chassis or deck mount 18. Feed line 42 connects internal propellant supply 40 to external propellant storage 44. In the embodiment shown, breech assembly 14 is open.
FIG. 2B is a block diagram showing barrel 12 in engagement with breech assembly 14. It depicts a sequential stage of FIG. 1 where breech assembly 14 is closed and the gun is ready to fire.
FIG. 3A shows the preferred embodiment connections between barrel 12 and breech assembly 14. Breech end of barrel 12 comprises machined surfaces and interupted threads 46 designed to provide a secure connection between barrel 12 and breech assembly 14. Barrel locking collar 52 connects barrel 12 with breech assembly 14. Further, actuator 54 is mounted on breech assembly 14 and operates barrel locking collar 52. Drive gear 56 is in mechanical contact with gear sector 58. Gear sector 58 is a part of barrel locking collar 52.
FIG. 3B is a detail of machined surfaces 46 comprising the breech end of barrel 12. Interrupted lug threads 64 are formed adjacent to octagonal barrel pilot 66. Octagonal barrel pilot 66 comprises the breech end point of barrel 12 and transmits rifling torque to the breech and subsequently to the cradle and other supporting structure. Obturator 68 forms a face seal as shown.
Referring now to FIGS. 4A and 4B, the barrel shifting and tipping mechanism is shown in elevation (FIG. 4A) and plan (FIG. 4B) views. In FIG. 4A, barrel 12 is shown with barrel shift collar 72. Barrel shift collar 72 mounts into cam plates 74 which are mounted to the cradle structure 16. Barrel shift actuator 76 is connected to barrel shift collar 72 at one end and cradle structure 16 (See FIG. 1) at the other. Barrel/Collar lock and actuator 78 is centrally disposed between barrel shift actuators 76 and is mounted on barrel shift collar 72. Cam follower 80 is attached to barrel shift collar 72. Barrel bearing 86 is mounted in cradle structure 16 (See FIG. 1). In FIG. 4A shifted barrel 12a is shown in broken lines indicating a tipping through a certain angle and a linear shift designated by "S".
The disclosure hereinabove relates to some of the most important structural features and organizations of the preferred embodiment. The functional and operational features are discussed hereinbelow.
Referring to FIG. 1, gun assembly 10 is shown wherein barrel 12 is normally engaged with breech assembly 14. Further, barrel 12a indicates the break action of the present invention. Here, the barrel is detached from breech assembly 14 and is ready to accept a projectile via projectile feed path 28. Some of the significant details of the break action, in the preferred embodiment, are discussed hereinbelow.
FIGS. 2A and 2B depict the operation of the break action cannon invention in conjunction with a regenerative liquid propellant system. In FIG. 2A, barrel 12 is tipped to accept projectile 32. In this set up, breech assembly 14 is open to refill/refurbish internal liquid propellant supply 40. The propellant mass is transmitted via feed line 42 which is connected to external propellant storage 44. As indicated in FIG. 2A, combustor compartment 38 in breech assembly 14, houses internal liquid propellant supply 40. When projectile 32 is loaded into barrel 12 and propellant is refurbished, breech assembly 14 is closed and barrel 12 engaged as shown in FIG. 2B.
In FIG. 3A, the connection between barrel 12 and breech assembly 14 is shown in detail. This connection is one of the significant aspects of the present invention and is therefore set forth in detail. The connection comprises, Barrel locking collar 52 and barrel lock/unlock actuator 54. Breech end of barrel 12 comprises machined surface 46 (See FIG. 3B). Machined surface 46 includes, interrupted lug threads 64 and octagonal barrel pilot 66. Further, obturator 68 forms a face seal. Barrel locking collar 52 includes a quarter turn interrupted lug internal threads to lock barrel 12 and breech assembly 14 for firing. Further, the connection between barrel locking collar 52 and breech assembly 12 comprises obturator 68 to thereby seal combustion gases. More particularly, interrupted lug threads 64 and octagonal barrel pilot 66 form a snug fit between barrel 12 and breech assembly 14 such that torque loads due to barrel 12 rifling are transferred. Heretofore, threaded connections are used between a barrel and a breech block to absorb firing pressures and resultant stresses. However, in the preferred embodiment of the present invention, the interrupted lug threads 64 provide a structural connection with barrel locking collar 52. Octagonal barrel pilot 66 are designed both to transmit rifling torque to breech assembly 14 and trunions 26 (see FIG. 1) and further enable a quick disconnect to promote the break action operation. Barrel lock/unlock actuator 54 is attached to cradle 16 (See FIG. 1). Drive gear 56 provides a positive static lock position and extends forward and rotates barrel locking collar 52 to either unlock or lock barrel 12 and breech assembly 14. Gear sector 58 is part of barrel locking collar 52 and is operated by drive gear 56.
Accordingly, when the break action of barrel 12 is initiated, barrel lock/unlock actuator 54 starts drive gear 56. Thereafter, drive gear 56 urges gear sector 58 and barrel locking collar 52 is rotated through a quarter turn to detach barrel 12 at interrupted lug threads 64. This retains barrel locking collar 52 secured to breech assembly 14 while releasing barrel 12. Particularly, obturator 68 is uniquely adaptable to repeated connection and disconnection cycles of barrel 12 and is replaceable as needed to maintain a positive pressure in the gun chamber and barrel 12 and to seal combustion gases therein.
During the detachment of barrel 12 from breech assembly 14, in the manner discussed hereinabove, barrel shift actuator 76 extends forward to drive barrel shift collar 72 forward. Cam plates 74, which are attached to cradle 16, guide the fore shift and tipping of barrel 12. Barrel/collar lock and actuator 78 locks barrel 12 to barrel shift collar 72 so they can together shift forward and tip. Barrel shift collar 72 mounts into cam plates 74 and maintains a controlled movement in the cam path. Cam followers 80 are attached to barrel shift collar 72 and are guided in the cradle mounted cam plates 74. When barrel 12 is thus shifted forward barrel bearing 86 guides barrel 12 and allows it to tip for projectile loading. One of the unique aspects of the break action cannon invention is the forward shifting of barrel 12 to provide tipping in order to create swing space and volume for loading projectiles without interfering with breech operations. The present invention accomplishes this advantage of employing simple and yet efficient mechanisms. More particularly, when barrel 12 is shifted a distance "S" forward, barrel bearing 86 is cooperation with cam plates 74 and cam followers 80 tip barrel 12 thus implementing the break action.
Barrel 12 is returned back to its original aligned position relative to breech assembly 14 when barrel shift actuator 76 is retracted and drives barrel shift collar 72 backwards and as well pulls barrel 12 via cam followers 80 which are guided in cam plates 74. Cam plates 74 thus guide the backward shift, and pull barrel 12 back up from its tipped position. Barrel/collar lock and actuator 78 locks barrel 12 to barrel shift collar 72 so that barrel 12 can shift backwards and return back to a non-inclined position. Thus, the forward and backward movements of barrel/collar lock and actuator 78 enable a forward shift or a backward pull of barrel 12 as indicated.
Accordingly, when breech end of barrel 12 is pulled into barrel locking collar 52, drive gear 56 extends forward and rotates barrel locking collar 52 to lock barrel 12 to breech assembly 14 thereby completing a cycle of the break action cannon.
While a preferred embodiment of the break action cannon has been shown and described, it will be appreciated that various changes and modifications may be made therein without departing from the spirit of the invention as defined by the scope of the appended claims.
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The break action cannon invention disclosed herein enables weaponization and integration of complex fire control systems concurrent with projectile loading operations in a gun system such that superior firing cycle and efficient power and thermal management are achieved. A barrel is detachably shifted and tipped at an angle to accept a projectile while breech operations and other firing preparations proceed unencumbered.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to a method to control the bulk density of packaged fried snack pieces. More specifically, this invention relates to imparting a random shape or curvature to each snack piece during cooking or frying in such a way as to control the resultant bulk density of such product when packaged.
[0003] 2. Description of Related Art
[0000] Random Frying
[0004] In the food industry, there are two typical methods of frying snack pieces such as potato chips: random frying and constrained frying. One popular random frying method is to fry uncooked pre-formed snack pieces in a random frying section of a multi-layer continuous fryer and allow buoyancy forces to impart a random shape or curvature to each snack piece. Several patents illustrate such random frying methods, as those disclosed in Pringle et al., U.S. Pat. No. 2,286,644 entitled โMethod and Apparatus for Processing Potatoesโ issued Jun. 16, 1942, and Anderson et al., U.S. Pat. No. 3,149,978 entitled โProcess for Cooking Corn Dough in the Form of Chipsโ issued Sep. 22, 1964 and assigned to Arthur D. Little, Inc.
[0005] U.S. Pat. No. 3,608,474 issued Sep. 28, 1971 to Liepa, discloses a random frying method for making potato chip products. Liepa '474 suggests. slicing raw potatoes, cooking these loose slices in a reservoir of hot oil for a predetermined time where the slices are fried to a crisp state, and then removing the fried chips from the oil. The chips so prepared have a random surface curvature which is influenced by the diameter and thickness of the potato slices and is dependent both upon the amount of time the slices are immersed in the hot oil and the temperature of the oil. In the prior art, a constrained or form frying method is difficult to use with snack pieces of different sizes or shapes. Instead, random frying is typically used on these pieces of varying size or shape.
[0006] Liepa '474 also teaches that the random shapes which the chips assume require that they be randomly packaged. Random packing is used because it is relatively cheap, requires less energy and is less complicated than packing snack pieces into a high-density nested arrangement or packed alignment. Randomly packed snack piece packages require larger amounts of store shelf and consumer pantry shelf space. Generally, when a consumer opens such package, the snack pieces have settled and the bulk density has increased leaving a substantial void within the package. It would be ideal if the randomly packed pieces filled the entire package at the time the package is opened even after some settling occurred during shipping and handling.
[0007] According to the prior art, and with reference to FIG. 1 , uncooked chip pre-forms 120 are continuously fed by an entrance conveyor 110 into cooking oil 104 of a random frying section 106 of a continuous fryer 102 . In a continuous fryer 102 , cooking oil 104 generally flows from an entrance conveyor 110 toward an exit conveyor 114 carrying chip pre-forms 122 with it. As relatively moist chip pre-forms 122 are first introduced into cooking oil 104 , their weight 122 is usually greater than the buoyancy forces acting on them and the moist chip pre-forms 122 remain submersed in the oil without aid. As chip pre-forms 122 continue to cook and move along the path inside the continuous fryer 102 (from left to right in FIG. 1 ), moisture escapes from the chip pre-forms 122 and the buoyancy forces become greater than the weight of the chip pre-forms 122 . At that point, the chip pre-forms 124 generally float near the surface of the oil as they approach a prior art submerger 112 . At this point, chip pre-forms 124 are generally, not rubbery, and do not have a tendency to stick to each other.
[0008] A prior art submerger 112 generally turns at a speed slower than the flow of cooking oil 104 . A prior art submerger 112 usually has one or more optional and generally straight paddles, cleats or fins 116 . These fins 116 help gather the roughly monolayer of floating chip pre-forms 124 into a multi-layer of submerged chip pre-forms 126 . The fins 116 also help ensure that submerged chip pre-forms 126 do not clump or stick together. By submerging the cooking chip pre-forms 126 , the pre-forms 126 are more evenly cooked on both sides. Cooked chips 128 leave the prior art submerger 112 and exit the continuous fryer 102 on an endless exiting conveyor 114 .
[0009] According to the prior art, reference to FIG. 1 a, the majority of submerged chip pre-forms 132 lay flat as they are transported along the cooking path. These pre-forms 132 leave the continuous fryer as generally flat cooked chips; any curvature in the cooked chips 128 is the result of random cooking forces acting on a submerged chip pre-form 132 . However, by chance a few submerged chip pre-forms 134 overlap or randomly press against a fin 116 or another submerged chip pre-forms 132 in such a way as to gain an exaggerated curvature. FIG. 6 illustrates typical resulting shapes of triangular snack pieces cooked according to the prior art. The snack pieces 128 are generally flat, but some have a minimal curvature. More or less curvature can be obtained by using the method of constrained frying.
[0000] Constrained Frying
[0010] The other typical method of frying snack pieces is through the use of constrained or form frying. Several patents disclose methods of imparting a curvature to chip-type products made from a dough sheet by constrained frying methods. For example, a method to produce rippled chip-type products is disclosed in U.S. Pat. No. 2,286,644 by Pringle et al., issued Jun. 16, 1942 entitled โMethod and Apparatus for Processing Potatoes.โ Other U.S. patents disclose other similar methods to impart a desired final curvature or shape to a snack piece. In U.S. Pat. No. 3,998,975 issued Dec. 21, 1976, Liepa et al. discloses a method to form uncooked snack pieces into a desired shape by drying the pieces sufficiently and frying the pieces to a finished state before packaging.
[0011] In U.S. Pat. No. 3,576,647 issued Apr. 27, 1971, Liepa discloses a constrained frying method wherein mold halves each provide multiple openings distributed over the mold surfaces to permit the frying oil to pass through and come into contact with the constrained food product. The mold halves cooperate to hold the dough sections and restrain them during the frying so that the fried products conform in surface curvature with that of the mold surfaces. Similarly, in related U.S. Pat. No. 3,608,474 issued Sep. 28, 1971, and U.S. Pat. No. 3,626,466 issued Dec. 7, 1971, Liepa discloses the same molds and passes them through frying oil and form-fries dough pre-forms into crisp chips thereby imparting a uniform size and shape to each chip.
[0012] U.S. Pat. No. 3,520,248, issued Jul. 14, 1970 to MacKendrick, discloses a machine to continuously and uniformly cut and cook snack pieces or chips from a sheet of dough. MacKendrick discloses a machine to positively convey snack pieces through the frying medium in the same controlled manner as disclosed by Liepa '474 where the resulting chips have a uniform color, texture, and shape. The MacKendrick invention improves the Liepa '474 machine by using a reciprocating cutter in place of a rotary cutter which can be operated at significantly higher speeds.
[0013] U.S. Pat. No. 3,149,978 entitled โProcess for Cooking Corn Dough in the Form of Chipsโ granted on Sep. 22, 1964 to Anderson et al., teaches a method of imparting a controlled bent configuration to a corn masa dough chip which is cooked by deep-fat frying. Further, this invention teaches an apparatus for inducing a desired shape to the corn chips during cooking. The desired configuration is done through the use of a series of parallel wires which are mounted on a frame such that the wires may be controllably moved within the oil. The spacing of the wires is adjusted so that it is somewhat less than the diameter or maximum dimension of the chip which is to be cooked. The wires may be periodically immersed into the cooking oil to strike a portion of the cooking chips and then withdrawn. When forcing the parallel wires into the cooking oil, the wires impart a curvature to the chips either when the wires strike the chips, pushing them deeper into the oil, or when the chips rise after being pushed momentarily deeper into the cooking oil, or by a combination of these actions. By this process not all of the chips are contacted and bent. Anderson et al. '978 teaches that it is preferred not to give a bend to all of the chips because it is desirable to package corn chips which are a combination of those having a flat and bent configuration, the latter amount consisting of about 25% to 75% of the total number of chips.
[0014] In a recent U.S. patent application, Dove, et al. discloses a single mold fryer. A single layer of cooking chips are given a uniform shape as chips are disposed against a curved or contoured submerged conveyor surface or mold surface by buoyancy forces. The Dove patent application has the same assignee as the present application and is entitled โSingle Mold Form Fryer with Enhanced Productโ having a filing date of Jan. 21, 2003 and Ser. No. 10/347,993. Such form frying imparts a relatively predictable and uniform shape to each snack piece, not a random curvature.
[0015] Anderson et al. '978 mentioned above teaches that curvature must be imparted during frying before a critical time when the frying chips assume their permanent configuration or shape. This critical time occurs when a given dough formulation reaches a glass transition point. FIG. 2 illustrates the various states of a generic polymer-like substance such as dough. Referring to FIG. 2 , polymer substances and farinaceous dough formulations can be pliable 202 , rubbery 204 or glassy 208 at a given temperature depending on the composition of the substance. The state of a dough is especially dependent on moisture concentration. In a typical case, the state of an edible chip product made of a given dough formulation, as it loses moisture while cooking at a constant given temperature, moves from a pliable rubbery state 204 through a glass transition state 206 into a permanent glassy state 208 . As the chip is cooled and subsequently packaged, the chip remains in a glassy state 208 . It is at the glass transition state 206 where a cooking chip pre-form loses its pliability and assumes its final shape. The glass transition state 206 is somewhat of a misnomer since the term โtransitionโ implies an equilibrium phenomenon that is invariant to the speed of the heating, cooling or other conditions. The actual transition point for a given product formulation may depend on the speed at which a substance is heated, cooled, or dehydrated (cooked).
[0000] Packaging
[0016] Cooked snack products are generally packaged in a random fashion in a bag or other similar container. Such random packing leads to a packaged product with a certain, relatively low bulk-density. Packages with low bulk density are essentially packages wherein the volume capacity of the package is much greater than the absolute volume of the snacks contained inside. The package could contain a much higher net weight of snack pieces than the volume capacity of the package if the pieces were not randomly packaged. This inefficiency is especially evident when chips have settled during shipping.
[0017] Curved snack pieces generally have a lower bulk density when randomly packed as compared to generally flat snack pieces when randomly packed. Curved snack pieces tend not to seat against one another and tend to leave relatively larger voids between pieces as compared to flat snack pieces. In U.S. Pat. No. 4,844,919, issued on Jul. 4, 1989, Szwerc teaches that the use of curved pieces lowers packed product bulk density. Szwerc '919 teaches that the snack piece's thickness, curvature, weight and orientation must be considered and potentially optimized to achieve densities above those obtained by randomly packing such pieces. Szwerc '919 teaches the production of curved snack chips by baking. In U.S. published patent application Ser. No. 09/851040 entitled โSnack Piece Having Increased Packed Density,โ Zimmerman et al. teaches that the shape and thickness of snack pieces can contribute to lower packed densities. Zimmerman teaches that the interference between adjacent snack pieces due to irregular sizing leads to increased space between nested pieces, subsequently leading to a lower bulk density.
[0018] However, the prior art does not teach methods which would provide sufficient control of the snack piece's thickness, curvature, weight, orientation, or shape to achieve a desired bulk density. Currently, the food industry does not design a product to have desired bulk density. The food industry conforms the size of a product package to a desired weight of randomly-packed product. The package is sufficiently large to accommodate variations in bulk density. Consequently, a need exists for a method to permanently impart a particular shape to snack pieces in such a way as to produce a snack product that will have a desired bulk density when randomly packaged. Further, a need exists for producing such a snack product without lowering the productivity or throughput of the process.
[0019] Further, a need exists for a method to control the amount of change in bulk density during the time a snack product package is exposed to settling forces during shipping and handling. Specifically, a need exists to prevent settling of chips wherein a substantial void remains in the product package. A need exists for an optimal packing that would also minimize breakage of chips. The benefit of filling this need would be an improved perception by consumers that the package is more substantially filled with product. Further, there is a need for loosely packed consumer products. In such a case there would be a lower bulk density and less shingling of chips within each package.
[0020] Further, a need exists for a method and apparatus which cooks snack pieces with a more consistent, controlled, and predictable cooking time. Such method and apparatus would produce chips with a more uniform color and texture. Such a method and apparatus would meet these criteria and could be used in a high-speed production environment. It is therefore an object of this invention to provide a method of imparting a controlled bent configuration to fried snack product pieces. These and other objects will become apparent in the following detailed description.
SUMMARY OF THE INVENTION
[0021] A method and apparatus are disclosed which provide packaged fried snack products having a desired bulk density without reducing production efficiency or throughput. Such method and apparatus are also useful in controlling the amount of change in bulk density or amount of settling of a packaged product when exposed to settling forces during shipping or handling. The shape of a contoured submerger imparts a random curvature to, and determines the final shape of, each snack piece before and during dehydration through the glass transition of the snack piece during frying.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
[0023] FIG. 1 is a side cross-sectional view of a continuous fryer apparatus with a continuous submerging conveyor according to the prior art;
[0024] FIG. 1 a is a close-up view of the continuous submerging conveyor shown in FIG. 1 ;
[0025] FIG. 2 is a generic rubber/glass transition diagram for a polymeric substance such as a dough used for making snack pieces or chips showing temperature increasing from bottom to top on the vertical axis, and moisture content increasing from left to right on the horizontal axis;
[0026] FIG. 3 is a side cross-sectional view of a batch fryer having a contoured submerger which imparts a random curvature to cooking chip pre-forms according to one embodiment of the present invention;
[0027] FIG. 4 is a perspective view of two contoured submergers used in embodiments of the invention each with a different V-shaped contour profile or cross-sectional shape;
[0028] FIG. 4 a is a close-up view of one of the contoured submergers shown in FIG. 4 showing a triangular chip pre-form pressed against one of the contours of the submerger;
[0029] FIG. 5 is a side cross-sectional view of a continuous fryer apparatus with a continuous contoured submerging conveyor according to one embodiment of the present invention;
[0030] FIG. 5 a is a close-up view of a continuous fryer apparatus with a continuous contoured submerging conveyor according to one embodiment of the present invention;
[0031] FIG. 6 is perspective view of triangular cooked snack pieces cooked under a flat submerger according to the prior art illustrating typical, slight, naturally-occurring curvatures of the cooked product;
[0032] FIG. 7 is perspective view of triangular cooked snack pieces cooked according to one embodiment of the present invention showing randomly generated curvatures imparted by a contoured submerger;
[0033] FIG. 8 is perspective view of a container of cooked snack pieces which were cooked under a flat submerger according to the prior art, and as shown in FIG. 6 ;
[0034] FIG. 9 is perspective view of a container of cooked snack pieces which were cooked according to the present invention under a contoured submerger, and as shown in FIG. 7 ; and,
[0035] FIG. 10 is a side cross-sectional view of various possible configurations of cross-sectional shapes of a contoured submerger according to the present invention.
REFERENCE NUMERALS
[0000]
102 continuous fryer
104 frying or cooking oil
106 random frying section of continuous fryer
108 submerging section of continuous fryer
110 entrance conveyor
112 prior art submerger
114 exit conveyor
116 paddle or fin
120 uncooked chip pre-form
122 frying chip pre-form
122 moist chip pre-form
124 rubbery floating chip pre-form
126 submerged chip pre-form
128 cooked snack pieces
132 submerged chip pre-form
134 submerged chip pre-form with exaggerated curvature
202 pliable state
204 rubbery state
206 glass transition state
208 glassy state
302 cooking chip pre-form
304 distance between subsequent contours
306 contours of the submerger
308 batch fryer oil
310 contoured submerger
320 batch fryer
402 chip pre-form conformed to contour of contoured submerger
404 contoured submerger having V-shaped contour profile
406 contoured submerger having V-shaped contour profile
512 contoured submerger
516 contours of contoured submerger
518 contour spacing
512 first contoured submerger
512 endless contoured submerger
526 cooking chip pre-form
528 shaped cooked snack piece
530 contour height
542 subsequent submerger
802 cylindrical container
804 void space
806 control snack piece
904 shaped snack piece
1002 V-shaped contour profile having uniform spacing
1004 V-shaped contour profile having non-uniform spacing
1006 sinusoidal contour profile having uniform spacing
1008 sinusoidal contour profile having non-uniform spacing
1010 crenellated contour profile having uniform spacing
1012 contour profile having tapered crenellations and non-uniform spacing
1014 contour profile composed of non-uniformly sized spheres
1016 contour profile composed of conical protrusions
DETAILED DESCRIPTION
[0086] While the invention is described below with respect to a preferred embodiment, other embodiments are possible. The concepts disclosed herein apply equally to other systems for frying various types of pliable snack pre-forms and imparting a random curvature to each snack piece.
[0087] The volume occupied by curved snack pieces is dependent upon the specific shape, dimensions, and arrangement of the individual snack pieces. In the present invention, randomly packed chips have a volumetric bulk density defined herein as the net weight of packaged snack pieces per the absolute volume of the container holding the snack pieces. Absolute volume, as used herein, is defined as the total liquid volume of the container holding the randomly packed snack pieces. As one example, the bulk density of randomly packed snack pieces can be measured by filling a cylindrical container of known volume and subsequently measuring the net weight of the container. The container is not packed or disturbed during the filling: the pieces may settle and ultimately take up less volume when exposed to settling forces. The bulk density after being exposed to such forces is termed the settled bulk density.
[0088] To control bulk density of snack pieces formed from a dough sheet, it is necessary to control the shape and curvature of each piece. However, merely creating snack pieces with curvature does not always produce higher or lower bulk densities as compared to flat pieces. A snack piece's thickness, curvature, weight and orientation must be considered and potentially optimized to achieve a desired bulk density. A desired bulk density may be obtained by imparting a certain random curvature to each snack piece.
[0089] Snack pieces generally achieve their final shape during their transition from a rubbery state to a glass state as pre-form snack pieces are cooked, usually by frying, as explained previously and with reference to FIG. 2 . A random curvature can be imparted to each snack piece during frying in a batch fryer using a contoured submerger while each snack piece transitions from a rubbery state to a glass state.
[0090] In one embodiment, and with reference to FIG. 3 , chip pre-forms 302 are placed in a batch fryer 320 underneath a contoured submerger 310 . As the chip pre-forms 302 cook, they are maintained against the contours of a contoured submerger 310 by buoyancy forces acting on the cooking chip pre-forms 302 . The chip pre-forms 302 are given a random shape by the contours 306 of the submerger 310 as the chip pre-forms 302 are cooked. After a certain time, the cooked chips 302 are removed from the fryer 320 and may be further processed and packaged.
[0091] In another embodiment and with reference to FIG. 5 , chip pre-forms 120 are first introduced continuously into a random frying section 106 containing frying oil 104 in a continuous fryer 102 . As randomly frying chip pre-forms 122 lose sufficient moisture, typically having from 30 to 60 percent moisture when first introduced into the oil 104 , and having about eight to fifteen percent moisture by weight when reaching a contoured submerger 512 , they no longer have a tendency to stick to one another. At this point, the rubbery chip pre-forms 124 can be submerged beneath an endless contoured submerger 512 . If frying chip pre-forms 122 reach, and are cooked under, a contoured submerger 512 with a higher than about ten percent moisture content, either in a single layer or in multiple layers, sticking and/or clumping can occur.
[0092] With reference to FIG. 5 , in a preferred embodiment, as rubbery chip pre-forms 124 reach a contoured submerger 512 , the chip pre-forms 124 are aggregated and submerged for further cooking. An endless contoured submerger 512 generally does not cover the entire length of a random fryer 102 . Chip pre-forms made of cereal flour and/or tuber flour have a residence time from about 15 to 90 seconds. Submerged chip pre-forms 526 may overlap to a lesser or higher degree such that there are multiple layers of chip pre-forms 526 along the length of the contoured submerger 512 . While chip pre-forms 526 are losing moisture through cooking under the contoured submerger 512 , the chip pre-forms 526 are going from a rubbery state through a glass transition and into a glass state. The final shape of each piece is obtained as each chip reaches this glass state. For a typical dough formulation, when cooking chip pre-forms 526 have about five percent moisture by weight, these pre-forms may be removed from the contoured submerger 512 without affecting the final shape of the finished shaped chip product 528 .
[0093] With reference to FIG. 5 , a contoured submerger 512 in a submerging section 108 of a continuous fryer 102 has contours 516 differing substantially from the prior art. A contoured submerger 512 is not merely a submerging conveyor belt with fins, as shown in a typical prior art embodiment in FIG. 1 . In one embodiment of the invention, a contoured submerger 512 has a V-shaped profile wherein each contour 516 has a contour height 530 . The distance between sequential contours 516 is the contour spacing 518 . In one embodiment, the contour spacing 518 is uniform from contour 516 to contour 516 . However, in other embodiments, the contour spacing 518 may be different between successive contours 516 .
[0094] The contours 516 provide improved aggregation of cooking rubbery chip pre-forms 124 as they reach a first contoured submerger 512 . Generally, per unit length of conveyor, there are more contours 516 than submerger fins ( 116 in FIG. 1 ). Contours are generally used in lieu of submerger fins and give improved functionality. With the use of contours 516 , each submerged chip pre-form 526 is forced under the oil 104 more consistently as the contours 516 of a first contoured submerger 512 engage the arriving rubbery chip pre-forms 124 . Since the contour spacing 518 is generally shorter than the distance between sequential fins on a prior art submerging conveyor, the submerged chip pre-forms 526 move along in improved plug flow.
[0095] With reference to FIG. 5 a, while the cooking chip pre-forms are pressed upward against the contours 516 of a contoured submerger by buoyancy forces, these pieces conform to the curvature or shape of the contours 516 . Because each piece 526 is located at a random place along the contours 516 , a random shape is imparted to each piece 526 . A preferred random curvature, and resultant bulk density, is obtained when the spacing between adjacent contours 518 is larger than the largest dimension of each snack piece 526 . However, other spacing of contours 518 can be used to produce finished shaped pieces 528 having a desired bulk density. The final curvature of each shaped, cooked piece 528 is dependent upon the overall profile or shape of a contoured submerger 512 , the spacing between subsequent contours 518 , the number of layers of cooking pre-forms 526 beneath the submerger 512 , and the dough formulation and shape of each pre-form 526 . A contour depth 530 of a contoured submerger 512 may be any size and may vary from contour 516 to contour 516 . However, the contour depth 530 is preferably large enough to accommodate multiple layers of cooking chip pre-forms 526 while maintaining all such pre-forms 526 in plug flow as the contoured submerger 512 directs them toward a fryer exit conveyor 114 .
[0096] In another embodiment, chip pre-forms 526 are maintained for a short duration in multiple layers on a first contoured submerger 512 . The duration depends upon the moisture content of the submerged cooking chip pre-forms 526 . The chip pre-forms obtain their final shape under a first contoured submerger 512 by passing into a glass state. At this point, cooking chip pre-forms 526 may pass to subsequent submergers without losing their shape. Subsequent submergers aid in cooking the cooking chip pre-forms 526 until they have a final desired moisture content; in one embodiment, a final moisture content is about two percent by weight. A final moisture content may be as low as one percent. Subsequent submergers may not be of the same shape, speed, contour, or size of a first contoured submerger 512 . Subsequent submergers may even resemble prior art submergers.
[0097] In a further embodiment, submerged cooking chip pre-forms 526 are not in their final shape when passed to subsequent submergers. In such an embodiment, submerged chip pre-forms 526 obtain an initial shape from a first contoured submerger 512 , and their final shape from subsequent submergers. Such submerged chip pre-forms pass into a glass state under subsequent submergers. Finished shaped chip products 528 are removed from the cooking oil 104 on an exit conveyor 114 .
[0098] Finished chip products 528 are subsequently packaged. Such finished chip products generally have a lower bulk density, and thus fill more of a container, even after finished chip product packages are exposed to settling forces such as during shipping and handling. Such lower bulk density generally provides finished chip products with higher consumer appeal than finished chip products having a higher bulk density.
[0099] Various embodiments of a contoured submerger are envisioned. FIG. 10 illustrates some of the various profiles or contours that may be used within the spirit of this invention. In certain embodiments, contours in a continuous fryer 102 generally lie perpendicular to the flow of chip pre-forms 302 . However, the contours may run in any direction, or may have no direction or may have no uniform shape at all. The contours may even lie parallel to the flow of oil and chip pre-forms 302 in a continuous fryer 102 . The contours may be composed of a non-repeating, non-continuous set of surface features.
[0100] With reference to FIG. 10 , in one embodiment, a contoured submerger has a V-shaped profile having uniform contour spacing 1002 , or alternatively, with non-uniform contour spacing 1004 . In an alternate embodiment, a contoured submerger has a sinusoidal profile with uniform contour spacing 1006 , or with non-uniform contour spacing 1008 . In still another embodiment, a contoured submerger has a crenellated profile 1010 that may or may not have uniform contour spacing. A variation of this embodiment is a contour profile having crenellations that are each tapered 1012 , and wherein the contour spacing may or may not be uniform.
[0101] In another embodiment, a contoured submerger is composed of non-uniformly sized spheres 1014 or, alternatively, conical protrusions 1016 . In a variation of such embodiment, a contoured submerger may be composed of a variety of similar shapes and/or profiles described herein. A contoured submerger may also have three dimensional contour profiles such as, but not limited to, an egg carton-like profile having peaks and valleys at regular or irregular intervals. Such embodiments shown in FIG. 10 are by way of illustration and not limitation. The following examples more fully illustrate the practice of the invention.
EXAMPLE 1
[0102] In a first example, various contoured submergers having different shapes or contours were used to cook chip pre-forms shaped as equilateral triangles. With reference to FIG. 3 , various shapes or profiles of a contoured submerger 310 were tested in a batch fryer 320 so as to affect the bulk density of a particular formulation and shape of snack piece. In this example, one contoured submerger 310 was shaped as a sinusoidal wave, and the bulk density of the resultant cooked snack pieces was about 7.5 lb/cu. ft. (0.0694 oz/cu. in.; 0.120 g/cu. cm) from that shape. Using a different contoured V-shaped submerger 310 , the resultant bulk density of snack pieces was about 6.25 lb/cu. ft. (0.0579 oz/cu. in.;0.100 g/cu. cm). Using various shapes of contoured submergers, resulting cooked and packaged chips had a bulk density over the range from about 6.0 lb/cu. ft. (0.0556 oz/cu. in.; 0.096 g/cu. cm) to about 7.5 lb/cu. ft. (0.0694 oz/cu. in.; 0.120 g/cu. cm) when cooked with these shaped or contoured submergers. Finally, a flat contoured submerger, as understood and routinely used in the prior art, was used to cook pre-form snack pieces of the same shape, the pieces cooked therewith serving as a reference. The bulk density from the use of the flat contoured submerger 310 was about 8.5 lb/cu. ft. (0.0787 oz/cu. in.; 0.136 g/cu. cm).
EXAMPLE 2
[0103] In a second example of the present invention, two contoured submergers, differing from the submergers used in Example 1, and having different V-shaped profiles, were evaluated as to their effect on the bulk density of a snack product. Batches of snack product pre-forms in the shape of equilateral triangles were made from a dough sheet before being batch fried. The pre-forms in Example 2 were made from a dough formulation substantially different from that used in Example 1. The bulk density of pieces fried under the two contoured submergers in this example were compared against the bulk density of pieces fried under a control contoured submerger: a flat stainless steel perforated sheet or steel mesh. The two contoured submergers 404 , 406 of Example 2 are shown in FIG. 4 and both have V-shaped contour profiles. One contoured submerger 404 has contours with a larger contour spacing, or distance between successive contours, as compared to the other contoured submerger 406 .
[0104] With reference to Table 1, batches of pre-form pieces were cooked with each of the three submergers described previously, and the resulting weight and volume were recorded for each sample. The control batches numbered 1-3 in Table 1 were cooked under the control or flat submerger. With reference to FIG. 4 , the S1 samples numbered 1-3 in Table 1 were cooked with the submerger having the more narrow V-shaped contours 406 as compared to the contours 404 of the submerger used to cook the S2 samples numbered 1-3.
[0105] Each batch of cooked chips of Example 2 were randomly packed into a rigid cylindrical container. Each batch received ten taps to simulate settling forces from shipping and handling. The volume after settling and the resultant settled bulk density of each batch are recorded in Table 1. For the control batches, the mean settled bulk density was 0.0506 ounces per cubic inch (oz/cu. in.) with a standard deviation of 0.0032 oz/cu. in. For the S1 samples, the mean bulk density was 0.0420 oz/cu. in. with a standard deviation of 0.0023 oz/cu. in. And for the S2 samples, the mean bulk density was 0.0366 oz/cu. in. with a standard deviation of 0.0010 oz/cu. in. These measurements of bulk density vary substantially from one another because of the differently shaped contours of the submerger used to cook the snack pieces.
TABLE 1 Results from frying snack pieces with two different V-shaped contoured submergers Volume Settled Bulk Settled Bulk Weight, Initial after Density, Density, Sample g Volume, L Settling, L oz/cu. in. g/cu. cm Control-1 302 4.0 3.7 0.0473 0.082 Control-2 334 4.0 3.8 0.0508 0.088 Control-3 353 4.2 3.8 0.0537 0.093 S1-1 259 4.0 3.8 0.0393 0.068 S1-2 285 3.9 3.8 0.0433 0.075 S1-3 278 3.9 3.7 0.0434 0.075 S2-1 256 4.2 4.0 0.0370 0.064 S2-2 246 4.1 4.0 0.0355 0.061 S2-3 245 4.1 3.8 0.0373 0.064
[0106] FIG. 8 and FIG. 9 are drawings taken from photographs of pieces packed in a cylindrical container. FIG. 8 shows control pieces 806 packed relatively densely. In FIG. 8 , there are many snack pieces 806 which lie substantially parallel with one another. There is substantial settling as evidenced by the void 804 at the top of the container where chip pieces 806 initially filled the container 802 . FIG. 9 shows S2 pieces 904 packed in an identical container 802 . There are many more void spaces and there is much less settling since there is very little void space formed at the top of the container 802 . The decreased bulk density, and thus larger volume of chips in the container, is generally preferred for appearance purposes by consumers.
[0107] While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
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A method and apparatus to impart a random curvature to frying pre-formed snack pieces in a multi-layer fryer through the use of a contoured submerger. The shape of the contours of a contoured submerger imparts a random final curvature to each snack piece as snack pieces pass through a glass transition during frying. The contours are chosen so as to achieve a desired bulk density for the packaged fried snack products. Such method and apparatus are also useful in controlling the amount of change in bulk density or amount of settling of a packaged product during shipping or handling.
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TECHNICAL FIELD
[0001] The present invention relates to a radar device which sequentially receives a signal obtained due to reflection by a target, by a plurality of antennas.
BACKGROUND ART
[0002] A radar device radiates radio waves from a point of measurement to space and receives a signal reflected from a target to thereby measure a distance, a direction, etc. from the point of measurement to the target. Development of a radar device capable of detecting not only a car but also a pedestrian or the like as a target by high-resolution measurement using short-wavelength radio waves such as microwaves or millimeter waves has advanced in recent years.
[0003] Generally, in a radar device, long-wavelength radio waves are so low in attenuation as to make detection of a distant place possible but are so low in resolution as to make accuracy of target detection low. On the contrary, short-wavelength radio waves are so high in attenuation as to make detection of a distant place difficult because of easy absorption or reflection by water vapor, cloud, rain, etc. contained in air but are so high in resolution as to make accuracy of target detection high. Radar devices disclosed in the following Non-Patent Literature and Patent Literature are known as conventional radar devices.
[0004] For example, Non-Patent Literature 1 has disclosed a radar device which scans an antenna mechanically and scans pulse waves or continuous waves electronically with a narrow-angle directional beam to thereby transmit radio waves and receive reflection waves reflected from a target. In the radar device according to Non-Patent Literature 1, the antenna scanning time is required for detecting the target because a single antenna is used for transmission/reception of radio waves.
[0005] For example, when a target moving at a high speed is to be detected, it is therefore difficult to detect the target while following the movement of the target because of the necessity of a lot of scans in accordance with required high-resolution measurement.
[0006] Non-Patent Literature 2 has disclosed a radar device in which a signal reflected from a target is received by a plurality of antennas disposed spatially and the phase of the received signal is measured without the necessity of a lot of scans so that an arrival angle is estimated with higher resolution than the directivity of each antenna though the beam directivity of each antenna is relatively wide.
[0007] According to the radar device of Non-Patent Literature 2, the arrival angle can be estimated by signal processing at thinned-out scanning intervals to thereby improve accuracy of target detection compared with the radar device of Non-Patent Literature 1. Moreover, even when the target is moving at a high speed, the arrival angle can be estimated following the movement of the target.
[0008] In Non-Patent literature 2, because a plurality of antennas are however used so that an RF (Radio Frequency) generator for amplifying a signal received by each antenna and down-converting the frequency of the signal to generate a baseband signal and a signal processor for applying A/D (Analog Digital) conversion to the generated baseband signal to calculate a desired arrival angle are provided in accordance with each antenna, the overall configuration of the receiver is complicated and a cost increase is brought.
[0009] Patent Literature 1 has disclosed a radar device and a target detecting method in which a switch for selecting one of antennas is provided so that a single transmitter and a single receiver can detect a target while the antenna receiving reflected waves from a target is sequentially selected by the switch. According to Patent Literature 1, simplification in configuration of the radar device can be attained because it is unnecessary to provide the RF generator and the signal processor in the Non-Patent Literature 2 in accordance with each antenna.
[0010] However, in Patent Literature 1, to correct a phase shift quantity generated by temporal change of operation in each of the transmitter and the receiver is unconsidered. The phase shift quantity generated by the temporal change is a variable phase shift quantity caused by temporal operation of a local oscillator provided in each of the transmitter and the receiver.
[0011] Accordingly, in the configuration of Patent Literature 1, a VCO (Voltage Controlled Oscillator) is connected only to the transmitter even if a reference signal is used in common for driving the local oscillators in the transmitter and the receiver. For this reason, PLL (Phase Locked Loop) circuits provided in the local oscillators respectively operate independently, so that a variable phase shift quantity is caused by temporal operation in between the transmitter and the receiver.
[0012] The arrival angle of the target is estimated on the condition that a phase difference dependent on the arrival angle of reflected waves from the target exists between antennas disposed in different positions. For this reason, when a phase shift quantity varying temporally is generated in each sequentially selected antenna and mixed with the signal received by the antenna, accuracy of phase detection according to each antenna deteriorates so that accuracy of target measurement deteriorates.
[0013] Moreover, Patent Literature 2 has disclosed a phase calibration device of an active phased array radar which switches a transmission signal as an input signal through a directional coupler and inputs the signal to the reception side as a reference signal in phase calibration.
[0014] However, in Patent Literature 2, because a process of distributing a part of the transmission signal through the directional coupler and inputting it to the reception side is performed by a switch, it is necessary to use the switch to notify the reception side of the output timing of the transmission signal whenever the transmission signal is transmitted. As a result, the process applied to the switch is complicated so that the overall configuration of the device is complicated.
[0015] However, in a configuration that a mechanism of inputting a part of the transmission signal to the reception side through the directional coupler in Patent Literature 2 is provided between the transmitter and the receiver in Patent Literature 1, a phase shift quantity temporally generated between the transmitter and the receiver can be measured by transmitting an attenuated signal of the transmission signal to the receiver even when the phase shift quantity is generated. Accordingly, there is an inference that deterioration of estimation accuracy of the arrival angle of the target can be reduced to some degree by correcting the measured phase shift quantity.
[0016] For example, when a calibration time is provided before a measurement time of a certain radar so that the phase shift quantity is measured in the calibration time, an actually measured phase difference between the transmitter and the receiver can be corrected in a measurement time of an actual radar device based on the phase shift quantity measured in the calibration time.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: JP-A-2009-031185
Patent Literature 2: JP-A-10-170633
Non-Patent Literature
[0000]
Non-Patent Literature 1: Shinichi Yamano and other six persons., โ76 GHz Millimeter Wave Automobile Radar Using Single Chip MMICโ, Fujitsu Ten Tech. J. Vol. 22, No. 1, pp. 12-19 (June 2004) Non-Patent Literature 2: JAMES A. Cadzow, โDirection of Arrival Estimation Using Signal Subspace Modelingโ, IEEE, Vol. 28, pp. 64-79 (1992)
SUMMARY OF INVENTION
Technical Problem
[0020] However, when a mechanism in which a part of the transmission signal in Patent Literature 2 is input to the reception side through a directional coupler is provided between the transmitter and the receiver in Patent Literature 1, it is necessary to add a port for the calibration to the switch separately. For this reason, there is a problem that both circuit configurations of the transmitter and the receiver are complicated, and that attenuation of the reception signal increases.
[0021] Moreover, because it is necessary to provide calibration time separately in addition to the measurement time in the radar device, there is a problem that the time allowed to be used for measurement as the radar decreases. On the other hand, when cyclic and continuous measurement is designed between the respective antennas inclusive of the calibration time, the measurement time in any one of the antennas is decreased. As a result, there is a problem that the measurement distance range in the antenna decreases.
[0022] These problems will be described with reference to FIG. 10 . FIG. 10 shows timing charts in the case where calibration is performed after reception by each antenna in a conventional radar device. In FIG. 10 , (a) and (c) show timing charts of pulse signals which are transmission signals. In FIG. 10 , (b) and (d) show states where a phase shift quantity measurement time for calibration is provided after measurement by each antenna.
[0023] In FIG. 10 , assume that Tr [sec] is the transmission cycle of the pulse signal, Tw [sec] is the transmission period of the pulse signal, and P [dB] is the transmission power of the pulse signal. The port of the switch is changed over to an antenna ANT 1 while a pulse signal is transmitted between time t 0 and time t 1 , so that measurement by the antenna ANT 1 is performed between time t 1 and t 2 . The port of the switch is changed over to an antenna ANT 2 while a pulse signal is transmitted between time t 2 and time t 3 , so that measurement by the antenna ANT 2 is performed between time t 3 and time t 4 .
[0024] The port of the switch is changed over to an antenna ANT 3 while a pulse signal is transmitted between time t 4 and time t 5 , so that measurement by the antenna ANT 3 is performed between time t 5 and time t 6 . Similarly, the port of the switch is changed over to an antenna ANT 4 while a pulse signal is transmitted between time t 6 and time t 7 , so that measurement by the antenna ANT 4 is performed between time t 7 and time t 8 .
[0025] The port of the switch is changed over to a port for calibration between time t 8 and time t 9 , so that calibration is performed between time t 9 and time t 10 . The port of the switch is changed over to the antenna ANT 1 in the manner between time t 11 ad time t 12 , and then the same processing is repeated.
[0026] In (b) in FIG. 10 , measurement is performed with an equal measurement time by each of the antennas ANT 1 to ANT 4 . However, a calibration period of time t 8 -t 10 is provided before the transmission time t 11 of the pulse signal which will be measured by the antenna ANT 1 continuously after the antenna ANT 4 .
[0027] The calibration period represented by time t 8 -t 10 is a period which is the sum of a period (time t 8 -t 9 ) for changing the port of the switch over to the calibration port for performing calibration and a calibration execution period (time t 9 -t 10 ). Because the calibration period is added as the phase shift quantity measurement time, the time allowed to be used for measurement as the radar decreases.
[0028] In (d) in FIG. 10 , measurement is performed with an equal measurement time by each of the antennas ANT 1 to ANT 3 . However, the measurement time in the antenna ANT 4 after the antenna ANT 3 is shorter by the calibration period than the measurement time in the other antennas ANT 1 to ANT 3 . That is, the sum of the measurement period (of time t 7 -t 8 ) in the antenna ANT 4 and the calibration period (of time t 8 -t 10 ) is equal to the measurement time in the other antennas ANT 1 to ANT 3 .
[0029] Accordingly, in the radar device using a plurality of antennas for performing measurement, when the measurement time in a certain antenna is shorter than the measurement time in any of the other antennas, the measurable distance range in that certain antenna becomes narrow. For this reason, as shown in (d) in FIG. 10 , the measurable distance in the antenna ANT 4 becomes shorter than those in the other antennas ANT 1 to ANT 3 .
[0030] The invention is accomplished in consideration of the circumstances in the background art. An object of the invention is to provide a radar device which suppresses deterioration of accuracy in estimation of an arrival angle of a target in such a correction manner that a phase shift quantity of a phase component in a correlation value between a reception signal received by each of reception antennas and a transmission signal is calculated properly while influence on a measurement time or measurement distance range is suppressed.
Solution to Problem
[0031] According to the invention, there is provided the radar device which is a radar device for transmitting a high-frequency transmission signal intermittently in a transmission cycle having a predetermined transmission period and a non-transmission period, receiving a signal reflected by a target by using a plurality of reception antennas, and detecting the target based on the reflected signal, the radar device including: a transmission signal generator which generates a transmission signal in baseband; a RF transmitter which converts the transmission signal generated by the transmission signal generator into a high-frequency transmission signal; a directional coupler which distributes the high-frequency transmission signal converted by the RF transmitter in accordance with a predetermined signal power ratio; a level adjuster which adjusts the high-frequency transmission signal distributed by the directional coupler to a predetermined level; a signal combiner which combines a signal output from the level adjuster and a reception signal received by the reception antennas; a RF receiver which converts the signal combined by the signal combiner into a reception signal in the baseband; a reference transmission signal generator which generates a reference transmission signal the same as the transmission signal generated by the transmission signal generator; a correlation value calculator which calculates a correlation value between the reference transmission signal generated by the reference transmission signal generator and the reception signal converted by the RF receiver; a phase shift quantity calculator which calculates a phase shift quantity in arbitrary one of the reception antennas based on the correlation value in a reference reception antenna which is specific one of the reception antennas, and the correlation value in any one of the other reception antennas; and a phase corrector which corrects a phase component of the correlation value in the arbitrary reception antenna based on the phase shift quantity calculated by the phase shift quantity calculator.
ADVANTAGEOUS EFFECTS OF INVENTION
[0032] According to the radar device according to the invention, deterioration of accuracy in estimation of an arrival angle of a target in such a correction manner that a phase shift quantity of a phase component in a correlation value between a reception signal received by each of reception antennas and a transmission signal is calculated properly while influence on a measurement time or measurement distance range is suppressed.
BRIEF DESCRIPTION OF DRAWINGS
[0033] FIG. 1 A block diagram illustrating the internal configuration of a radar device according to a first embodiment.
[0034] FIG. 2 A timing chart concerned with operation of the radar device according to the first embodiment, in which (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal, (b) is an explanatory view illustrating a timing chart of the high-frequency transmission signal input to a signal combiner, (c) is an explanatory view illustrating a period of measurement by each reception antenna, (d) is an explanatory view illustrating an output of a reception signal from a switch and a period of measurement by each antenna, (e) is an explanatory view illustrating an output from the signal combiner, a period of measurement by each reception antenna and a timing for calculating a phase shift quantity, and (f) is an explanatory view illustrating a period for storing a correlation value between a transmission signal and a reception signal.
[0035] FIG. 3 A block diagram illustrating the internal configuration of a radar device according to Modification 1 of the first embodiment.
[0036] FIG. 4 A block diagram illustrating the internal configuration of a radar device according to Modification 2 of the first embodiment.
[0037] FIG. 5 A block diagram illustrating the internal configuration of a radar device according to Modification 3 of the first embodiment.
[0038] FIG. 6 A timing chart concerned with operation of the radar device according to Modification 3 of the first embodiment, in which (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal, (b) is an explanatory view for explaining a timing chart of the high-frequency transmission signal input to a signal combiner, and (c) is an explanatory view illustrating a period of measurement by each reception antenna.
[0039] FIG. 7 A block diagram illustrating the internal configuration of a radar device according to Modification 4 of the first embodiment.
[0040] FIG. 8 A block diagram illustrating the internal configuration of a radar device according to a second embodiment.
[0041] FIG. 9 A timing chart concerned with operation of the radar device according to the second embodiment, in which (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal, (b) is an explanatory view illustrating a timing chart of the high-frequency transmission signal input to a signal combiner, (c) is an explanatory view illustrating a timing chart of a crosstalk signal caused by direct going of the high-frequency transmission signal to each reception antenna, (d) is an explanatory view illustrating a period of measurement by each reception antenna, (e) is an explanatory view illustrating an output of a reception signal from a switch and a period of measurement by each antenna, (f) is an explanatory view illustrating an output from the signal combiner, a period of measurement by each reception antenna and a timing for calculating a phase shift quantity, and (g) is an explanatory view illustrating a period for storing a correlation value between a transmission signal and a reception signal.
[0042] FIG. 10 A timing chart in the case where calibration is performed after reception by each antenna in a conventional radar device, in which (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal, (b) is an explanatory view illustrating a state where a phase shift quantity measurement period for calibration is provided after measurement by each antenna, (c) is an explanatory view illustrating a timing chart of a high-frequency transmission signal, and (d) is an explanatory view illustrating a state where a phase shift quantity measurement period for calibration is provided after measurement by each antenna.
[0043] FIG. 11 A block diagram illustrating the internal configuration of a radar device according to a third embodiment.
[0044] FIG. 12 A timing chart concerned with operation of the radar device according to the third embodiment, in which (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal, (b) is an explanatory view illustrating a timing chart of the high-frequency transmission signal input to a signal combiner from an attenuator, (c) is an explanatory view illustrating a period of measurement by each reception antenna, (d) is an explanatory view illustrating a reception signal output from the signal combiner and a period of measurement by each reception antenna, (e) is an explanatory view illustrating an output from the signal combiner, a period of measurement by each reception antenna and a timing for calculating a phase shift quantity, and (f) is an explanatory view illustrating a period for storing a correlation value between a transmission signal and a reception signal.
[0045] FIG. 13 A block diagram illustrating the internal configuration of a radar device according to Modification 1 of the third embodiment.
DESCRIPTION OF EMBODIMENTS
[0046] Respective embodiments of the invention will be described below with reference to the drawings. Although a radar device according to each of the following embodiments will be described in the case where a single pulse signal is used as an example of a transmission signal, the transmission signal is not limited to the single pulse signal. In the following description, a reception signal received by the radar device is a signal combined from a signal after a high-frequency transmission signal from the radar device is reflected by a target, and a noise signal around the radar device. Incidentally, signal power of the noise signal around the radar device is negligibly lower than the signal power of the signal reflected by the target.
First Embodiment
[0047] The configuration and operation of a radar device 1 according to a first embodiment will be described with reference to FIGS. 1 and 2 . FIG. 1 is a block diagram illustrating the internal configuration of the radar device 1 according to the first embodiment.
[0048] FIG. 2 is a timing chart concerned with operation of the radar device 1 . In FIG. 2 , (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal. In FIG. 2 , (b) is an explanatory view illustrating a timing chart of the high-frequency transmission signal input to a signal combiner 13 from an attenuator 4 . In FIG. 2 , (c) is an explanatory view illustrating a period of measurement by each of reception antennas ANT 1 to ANT 4 . In FIG. 2 , (d) is an explanatory view illustrating an output of a reception signal from a switch 11 and a period of measurement by each of the reception antennas ANT 1 to ANT 4 .
[0049] In FIG. 2 , (e) is an explanatory view illustrating an output from the signal combiner 13 , a period of measurement by each of the reception antennas ANTI to ANT 4 and a timing for calculating a phase shift quantity. In FIG. 2 , (f) is an explanatory view illustrating a period for storing a correlation value between a transmission signal and a reception signal.
[0050] As shown in FIG. 1 , the radar device 1 has an oscillator Lo, a radar transmitter 2 , a radar receiver 3 , a transmission antenna ANT 0 , reception antennas ANT 1 to ANT 4 , and an attenuator 4 . In the radar device 1 according to the first embodiment, a predetermined intermittent high-frequency transmission signal generated by the radar transmitter 2 is transmitted from the transmission antenna ANT 0 , a signal reflected by a target is received by a reception antenna sequentially selected from the reception antennas ANT 1 to ANT 4 , and the target is detected from the reception signal thus received. Incidentally, the target is an object such as a car or a person to be detected by the radar device 1 . The same thing applies to the following embodiments.
[0051] The radar transmitter 2 has a transmission signal generator 5 , a RF transmitter 7 , and a directional coupler 10 . Although the transmission signal generator 5 in FIG. 1 is formed to include an LPF (Low Pass Filter) 6 , the LPF 6 may be formed independent of the transmission signal generator 5 . The RF transmitter 7 has a frequency converter 8 , and a power amplifier 9 .
[0052] The transmission signal generator 5 generates a timing clock based on a reference signal generated by the oscillator Lo so that the reference signal is multiplied by a predetermined number. The transmission signal generator 5 cyclically generates a transmission signal r(n) of a baseband formed from a pulse train having a plurality of pulses based on the generated timing clock. The transmission signal generator 5 outputs a transmission signal r(n) of a predetermined limited band to the RF transmitter 7 through the LPF 6 .
[0053] Here, the parameter n expresses discrete time. As the transmission signal generated by the transmission signal generator 5 , not a continuous signal but a pulse train signal is used. Incidentally, the transmission signal is not limited to the pulse train signal. For example, a single pulse signal or a pulse signal including a plurality of pulse trains or a modulated signal due to frequency modulation or phase modulation of the single pulse signal or the pulse signal including a plurality of pulse trains may be used.
[0054] As shown in (a) of FIG. 2 , assume that Nr [pieces] of samples are provided as a baseband transmission signal r(n) in a period Tw [sec] of presence of a high-frequency transmission signal transmitted from the transmission antenna ANT 0 whereas Nu [pieces] of samples are provided as a baseband transmission signal r(n) in a period (TrโTw) [sec] of absence of the high-frequency transmission signal. The parameter Tr is a transmission cycle [sec] of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 .
[0055] The RF transmitter 7 generates a timing clock based on a reference signal generated by the oscillator Lo so that the reference signal is multiplied by a predetermined number. The RF transmitter 7 operates based on the generated reference signal. Specifically, the frequency converter 8 receives as an input a transmission signal r(n) generated by the transmission signal generator 5 and frequency-converts the input baseband transmission signal r(n) to generate a carrier frequency band high-frequency transmission signal. The frequency converter 8 outputs the generated high-frequency transmission signal to the power amplifier 9 .
[0056] The power amplifier 9 receives the output high-frequency transmission signal, amplifies the signal power of the input high-frequency transmission signal to predetermined signal power P [dB] and outputs the predetermined signal power P [dB] to the transmission antenna ANT 0 . The amplified high-frequency transmission signal is transmitted so as to be radiated to space through the directional coupler 10 and the transmission antenna ANT 0 .
[0057] The directional coupler 10 outputs the high-frequency transmission signal output from the power amplifier 9 of the RF transmitter 7 to the transmission antenna ANT 0 , distributes the high-frequency transmission signal in accordance with a predetermined signal power ratio and outputs the distributed high-frequency transmission signal to the attenuator 4 .
[0058] The transmission antenna ANT 0 performs transmission so that the high-frequency transmission signal output from the RF transmitter 7 is radiated to space. As shown in (a) of FIG. 2 , the high-frequency transmission signal is transmitted during a period of time t 0 -t 1 , during a period t 2 -t 3 , during a period of time t 4 -t 5 , during a period of time t 6 -t 7 and during a period of time t 8 -t 9 but not transmitted during a period of time t 1 -t 2 , during a period of time t 3 -t 4 , during a period of time t 5 -t 6 and during a period of time t 7 -t 8 . After time t 9 , transmission of the high-frequency transmission signal is repeated in the same manner.
[0059] As shown in (b) of FIG. 2 , the attenuator 4 attenuates the signal power of the high-frequency transmission signal output from the directional coupler 10 to predetermined signal power Y [dB] in sync with the transmission period of the high-frequency transmission signal. The attenuator 4 outputs the attenuated high-frequency transmission signal to the signal combiner 13 of the radar receiver 3 .
[0060] The radar receiver 3 has four reception antennas ANT 1 to ANT 4 , a switch 11 , a switch controller 12 , a signal combiner 13 , a RF receiver 14 , and a signal processor 17 . The RF receiver 14 has a power amplifier 15 , and a frequency converter 16 . The signal processor 17 has an A/D converter 18 , a reference transmission signal generator 19 , a correlation value calculator 20 , a timing controller 21 , a phase shift quantity calculator 22 , a phase corrector 23 , a storage 24 , and an arrival angle and distance estimator 25 .
[0061] The reception antennas ANT 1 to ANT 4 form an array antenna of four reception antennas ANT 1 to ANT 4 . The reception antennas ANT 1 to ANT 4 receive a signal obtained due to reflection of the high-frequency transmission signal transmitted from the radar transmitter 2 by a target and a noise signal around the radar device 1 as a reception signal. Although description will be made in the case where the number of elements of the array antenna in the radar device 1 according to the first embodiment is 4 as shown in FIG. 1 , the number of elements of the array antenna is not limited to 4.
[0062] The switch 11 is provided with switching ports corresponding to the reception antennas ANT 1 to ANT 4 so that the switch 11 is connected to the four reception antennas ANT 1 to ANT 4 .
[0063] In the switch 11 , the respective switching ports corresponding to the four reception antennas ANT 1 to ANT 4 are changed sequentially under control of the switch controller 12 . By this change, a single switching port is selected so that the switch 11 is connected to a reception antenna ANTs corresponding to the switching port. The parameter s satisfies s=1 to 4. The switch 11 outputs a reception signal received by the selected reception antenna ANTs to the signal combiner 13 .
[0064] The switch controller 12 controls the switch 11 so that the four reception antennas ANT 1 to ANT 4 are changed sequentially in a cycle of an integer multiple N (N: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal. In the first embodiment, as shown in (c) of FIG. 2 , the switch controller 12 controls the switch 11 so that the four reception antennas ANT 1 to ANT 4 are changed sequentially in the same cycle (N=1) as the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0065] Specifically, as shown in (c) of FIG. 2 , the switch controller 12 selects the reception antenna ANT 1 during a period of time t 0 -t 1 . Moreover, the switch controller 12 controls the switch 11 so that a reception signal received by the reception antenna ANT 1 is output to the signal combiner 13 during a period of time t 1 -t 2 . Incidentally, the period of time t 1 -t 2 is a measurement period in which a signal is received by the reception antenna ANT 1 (parameter s=1).
[0066] The switch controller 12 selects the reception antenna ANT 2 during a period of time t 2 -t 3 . Moreover, the switch controller 12 controls the switch 11 so that a reception signal received by the reception antenna ANT 2 is output to the signal combiner 13 during a period of time t 3 -t 4 . Incidentally, the period of time t 3 -t 4 is a measurement period in which a signal is received by the reception antenna ANT 2 (parameter s=2).
[0067] The switch controller 12 selects the reception antenna ANT 3 during a period of time t 5 -t 6 . Moreover, the switch controller 12 controls the switch 11 so that a reception signal received by the reception antenna ANT 3 is output to the signal combiner 13 during a period of time t 4 -t 5 . Incidentally, the period of time t 5 -t 6 is a measurement period in which a signal is received by the reception antenna ANT 3 (parameter s=3).
[0068] The switch controller 12 selects the reception antenna ANT 4 during a period of time t 6 -t 7 . Moreover, the switch controller 12 controls the switch 11 so that a reception signal received by the reception antenna ANT 4 is output to the signal combiner 13 during a period of time t 7 -t 8 . Incidentally, the period of time t 7 -t 8 is a measurement period in which a signal is received by the reception antenna ANT 4 (parameter s=4).
[0069] Incidentally, as shown in (d) of FIG. 2 , the reception signal output from the switch 11 in each of periods of times t 0 -t 1 , t 2 -t 3 , t 4 -t 5 , t 6 -t 7 and t 8 -t 9 is a noise signal around the radar device 1 .
[0070] The reception signal output from the switch 11 in each of periods of times t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 is a signal combined from the noise signal and a reception signal (not shown) corresponding to each of the measurement periods (of times t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 ). However, the noise signal is negligibly lower than the reception signal. The same thing applies to the following embodiments.
[0071] The signal combiner 13 combines a signal from the high-frequency transmission signal output from the attenuator 4 and the reception signal output from the switch 11 , and outputs the combined signal to the power amplifier 15 of the RF receiver 14 . Here, when the average signal power of the reception signal output from the switch 11 is Z [dB], the signal power of the combined signal output from the signal combiner 13 is (Y+Z) [dB].
[0072] Incidentally, it is preferable that the signal power Y [dB] of the high-frequency transmission signal output from the attenuator 4 is attenuated so as to be sufficiently higher (e.g. 3 [dB] to 10 [dB]) than the signal power received by the reception antenna ANTs in a period (of e.g. time t 0 -t 1 etc.) in which the switch controller 12 changes the switching port of the switch 11 .
[0073] When there are side lobes in autocorrelation characteristic of the high-frequency transmission signal, it is preferable that the attenuator 4 attenuates the signal power of the high-frequency transmission signal output from the directional coupler 10 to such signal power that the level of the side lobes has no influence on the measurement period of the radar device 1 .
[0074] Moreover, it is preferable that the timing in which the high-frequency transmission signal attenuated by the attenuator 4 is combined by the signal combiner 13 is synchronized with the transmission cycle Tw [sec] of the high-frequency transmission signal transmitted from the radar transmitter 2 and is kept without any time lag. The same thing applies to the following embodiments.
[0075] As shown in (e) of FIG. 2 , the combined signal output from the signal combiner 13 in each of periods of times t 0 -t 1 , t 2 -t 3 , t 4 -t 5 , t 6 -t 7 and t 8 -t 9 is a signal combined from a noise signal around the radar device 1 and the high-frequency transmission signal output from the attenuator 4 .
[0076] On the other hand, the combined signal output from the signal combiner 13 in each of periods of times t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 is a signal combined from the noise signal and a reception signal (not shown) corresponding to each of measurement periods (of times t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 ).
[0077] The RF receiver 14 generates a timing clock based on a reference signal generated by the oscillator Lo so that the reference signal is multiplied by a predetermined number. The RF receiver 14 operates based on the generated timing clock. Specifically, the power amplifier 15 receives as an input the combined signal combined by the signal combiner 13 , amplifies the signal power of the input combined signal to predetermined signal power, and outputs the combined signal to the frequency converter 16 .
[0078] The frequency converter 16 receives as an input the combined signal output from the power amplifier 15 , frequency-converts the input combined signal and phase-shifts the phase component of part of the combined signal by 90 [degrees] based on quadrature detection to thereby generate a baseband reception signal composed of an in-phase signal and a quadrature signal. The frequency converter 16 outputs the generated reception signal to the signal processor 17 .
[0079] The A/D converter 18 performs sampling at discrete time k for the baseband reception signal composed of the in-phase signal and the quadrature signal generated by the frequency converter 16 to thereby convert the reception signal into digital data.
[0080] Here, the reception signal at discrete time k in the reception antenna ANTs is expressed as a complex signal of a complex number x(s,k)=I(s,k)+jQ(s,k) in which I(s,k) is the in-phase signal of the reception signal and Q(s,k) is the quadrature signal of the reception signal. Incidentally, the parameter j is an imaginary unit.
[0081] Moreover, the parameter k expresses discrete time corresponding to the number of samples of the baseband transmission signal r(n) included in the high-frequency transmission signal. In the first embodiment, the timing of switching to the reception antenna ANTs is set at k=1 and at k=1 to (Nr+Nu). Accordingly, as shown in (e) of FIG. 2 , the parameter k satisfies k=1 at the timing of time t 0 , time t 2 , time t 4 , time t 6 and time t 8 . In addition, the parameter k satisfies k=Nr at the timing of time t 1 , time t 3 , time t 5 , time t 7 and time t 9 .
[0082] The reference transmission signal generator 19 generates a timing clock based on a reference signal generated by the oscillator Lo in the same manner as the transmission signal generator 5 in sync with the operation of the transmission signal generator 5 so that the reference signal is multiplied by a predetermined number. The reference transmission signal generator 19 cyclically generates a reference transmission signal r(n) of the same baseband as the transmission signal generated by the transmission signal generator 5 , based on the generated reference signal. The reference transmission signal generator 19 outputs the generated reference transmission signal r(n) to the correlation value calculator 20 .
[0083] The correlation value calculator 20 calculates a correlation value AC(s,k) between the complex signal x(s,k) of the reception signal received by the reception antenna ANTs and the reference transmission signal r(n) output from the reference transmission signal generator 19 . Assume now that a sliding correlation value as represented by the expression (1) is calculated as the correlation value.
[0084] The sliding correlation value AC(s,k) is a correlation value at discrete time k between the reception signal (including a reflected signal and a noise signal) received by the reception antenna ANTs and the reference transmission signal. The asterisk (*) in the expression (1) expresses a complex conjugate operator. The sliding correlation value AC(s,k) is calculated in periods at k=1 to (Nr+Nu). That is, the sliding correlation value AC(s,k) is calculated in periods of times t 0 -t 2 , t 2 -t 4 , t 4 -t 6 , t 6 -t 8 , etc.
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[0085] Incidentally, when the transmission signal generated by the transmission signal generator 5 is a baseband signal r(n) composed of real numbers, the signal r(n) is used as the reference transmission signal in the calculation of the sliding correlation value AC(s,k). On the other hand, when the transmission signal generated by the transmission signal generator 5 is a baseband signal r(n) composed of an in-phase signal and a quadrature signal, a complex conjugate value of the signal r(n) is used.
[0086] The timing controller 21 regards the timing k 0 of completion of the period Tw [sec] (transmission period) of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 as the timing of completion of calculation of the sliding correlation value AC(s,k 0 ) by the correlation value calculator 20 , and notifies the phase shift quantity calculator 22 of the timing information of completion of calculation of the sliding correlation value AC(s,k 0 ).
[0087] As shown in (c) and (e) of FIG. 2 , the timing k 0 of completion of the period Tw [sec] of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 and the timing of completion of calculation of the sliding correlation value AC(s,k 0 ) by the correlation value calculator 20 are the same times as the times t 1 , t 3 , t 5 , t 7 and t 9 and correspond to discrete time k 0 =Nr.
[0088] The timing controller 21 notifies the phase corrector 23 of the timing information for indicating that the sliding correlation value AC(s,k) corrected by the phase corrector 23 is stored in the storage 24 with respect to the sliding correlation value AC(s,k) between the complex signal x(s,k) of the reception signal received by the reception antenna ANTs and the reference transmission signal r(n) output from the reference transmission signal generator 19 . However, discrete time k satisfies k=2Nr to (Nr+Nu) (see (f) of FIG. 2 ).
[0089] Incidentally, the discrete time k can be also set in a range of k=(Nr+1) to (Nr+Nu). However, the start timing of discrete time k at which the sliding correlation value AC(s,k) is stored in the storage 24 is determined in the timing controller 21 not at k=Kr but at k=2Nr on the assumption that not a target nearest to the radar device 1 but a target at a predetermined distance [m] or farther from the radar device 1 is detected.
[0090] Accordingly, because it is not necessary to consider that the intensive reception level is received from a target nearest to the radar device 1 without distortion, the dynamic range in the radar receiver 3 of the radar device 1 can be reduced. With respect to the start timing of discrete time k at which the sliding correlation value AC(s,k) is stored in the storage 24 , in the timing controller 21 , the same thing applies to the flowing embodiments.
[0091] The phase shift quantity calculator 22 extracts a sliding correlation value AC(s,Nr) in the reception antenna ANTs and a sliding correlation value AC(s 0 ,Nr) in the reference reception antenna ANTs 0 (which will be described later) based on the timing information given from the timing controller 21 for indicating the completion of calculation of the sliding correlation value.
[0092] Here, a reception antenna ANTs 0 which is one of the four reception antennas ANT 1 to ANT 4 shown in FIG. 1 and which is provided as a reference for calculating a phase shift quantity is referred to as reference reception antenna. Assume further that the sliding correlation value AC(s 0 ,Nr) in the reference reception antenna ANTs 0 and the sliding correlation value AC(s,Nr) in the reception antenna ANTs have been already calculated by the correlation value calculator 20 .
[0093] The phase shift quantity calculator 22 calculates a phase shift quantity ฮฮธ(s) in the reception antenna ANTs in accordance with the expression (2) based on the sliding correlation value AC(s,Nr) in the reception antenna ANTs and the sliding correlation value AC(s 0 ,Nr) in the reference reception antenna ANTs 0 . The phase shift quantity calculator 22 outputs the calculated phase shift quantity ฮฮธ(s) to the phase corrector 23 .
[0000] [Expression 2]
[0000] ฮฮธ( s )=โ [ AC ( s,Nr ) AC *( s 0 ,Nr )]โโ(2)
[0000] Each of the parameter s and the parameter s 0 expresses the number of reception antennas. Each of s and s 0 expresses any one of 1, 2, 3 and 4. The asterisk (*) expresses a complex conjugate operator. โ [x] expresses a phase component of a complex number x and is represented by the expression (3).
[0000] [Expression 3]
[0000] โ [ x ]=tan โ1 ( Im[x]/Re[x ])โโ(3)
[0094] Incidentally, Im[x] expresses an imaginary part of the complex number and Re expresses a real part of the complex number.
[0095] The phase corrector 23 corrects the phase component of the sliding correlation value AC(s,k) in the reception antenna ANTs calculated by the correlation value calculator 20 in accordance with the expression (4) based on the phase shift quantity output from the phase shift quantity calculator 22 .
[0000] [Expression 4]
[0000] โ [ AC ( s,k )]โฮฮธ( s )โโ(4)
[0096] The phase corrector 23 stores the sliding correlation value (see the expression (5)) having the corrected phase component in the reception antenna ANTs at discrete time of k=2Nr to (Nr+Nu) in the storage 24 based on the timing information output from the timing controller 21 for indicating that the corrected sliding correlation value is stored.
[0000] [Expression 5]
[0000] | AC ( s,k )|exp( j{โ [AC ( s,k )]โฮฮธ( s )})โโ(5)
[0097] The arrival angle and distance estimator 25 performs calculation to estimate the arrival angle of the target and the distance to the target based on the sliding correlation value AC(s,k) having the corrected phase component in each reception antenna ANTs stored in the storage 24 . The calculation to estimate the arrival angle by the arrival angle and distance estimator 25 is a technique which has become publicly known. For example, this technique can be achieved by referring to Non-Patent Literature 2 which has been described above. Moreover, the calculation to estimate the distance to the target by the arrival angle and distance estimator 25 can be achieved by referring to Reference Non-Patent Literature 1 which will be described below.
(Reference Non-Patent Literature 1) J. J. BUSSGANG, et al., โA Unified Analysis of Range Performance of CW, Pulse, ad Pulse Doppler Radarโ, Proceedings of the IRE, Vol. 47, Issue 10, pp. 1753-1762 (1959)
[0099] For example, the arrival angle and distance estimator 25 calculates reception signal power in the reception antenna based on the correlation value having the corrected phase component in the reception antenna ANTs with respect to the arrival angle of the target. The reception signal power includes the phase component at the arrival angle of the target. The arrival angle and distance estimator 25 estimates the angle of the phase component in the case where the reception signal power takes a maximum value as the arrival angle of the target.
[0100] For example, the arrival angle and distance estimator 25 estimates the distance to the target based on the time difference between the discrete time in the case where the correlation value takes a maximum value and the transmission time of the high-frequency transmission signal based on the correlation value having the corrected phase component in the reception antenna ANTs with respect to the distance to the target.
[0101] As described above, in accordance with the radar device 1 according to the first embodiment, a phase shift quantity of a phase component in a correlation value between a reception signal received by each of reception antennas and a transmission signal can be calculated properly as measurement performance of the radar device while, for example, influence on the measurement time or measurement distance range is suppressed.
[0102] Moreover, the radar device 1 can correct the phase component of the correlation value in each reception antenna ANTs based on the properly calculated phase shift quantity to thereby suppress deterioration of accuracy of measurement of the arrival angle of the target and the distance to the target.
[0103] Moreover, in accordance with the radar device 1 , it is unnecessary to provide any switching port for calibration in the switch 11 , compare with the conventional radar device. Accordingly, the radar device 1 can perform calibration concerned with the phase for the reception antenna ANTs in accordance with transmission of the high-frequency transmission signal, so that accurate measurement can be performed compared with the conventional radar device.
[0104] Moreover, in accordance with the radar device 1 , because the transmission signal for calibration is the same as the transmission signal for measurement, execution can be made without addition of any correlation calculator for calibration to the signal processor 17 , so that execution can be made without complication of circuit configuration.
Modification 1 of First Embodiment
[0105] In the first embodiment, each reception antenna ANTs is directly connected to the switch 11 so that the reception signal by the reception antenna ANTs is input to the switch 11 . In Modification 1 of the first embodiment, the frequency of the reception signal is converted into a baseband by the frequency converter of the RF receiver so that the reception signal is input to the switch.
[0106] FIG. 3 is a block diagram illustrating the internal configuration of a radar device 1 a according to Modification 1 of the first embodiment. Although the difference in configuration and operation of Modification 1 of the first embodiment from the radar device 1 according to the first embodiment will be described with reference to FIG. 3 , description of the same configuration and operation as those of the radar device 1 according to the first embodiment will be omitted.
[0107] In FIG. 3 , a radar receiver 3 a has four reception antennas ANT 1 to ANT 4 , a signal combiner 13 a , a RF receiver 14 a , a switch 11 a , a switch controller 12 , and a signal processor 17 .
[0108] The signal combiner 13 a has a signal combiner 13 a 1 to which a reception signal by the reception antenna ANT 1 is input, a signal combiner 13 a 2 to which a reception signal by the reception antenna ANT 2 is input, a signal combiner 13 a 3 to which a reception signal by the reception antenna ANT 3 is input, and a signal combiner 13 a 4 to which a reception signal by the reception antenna ANT 4 is input. A high-frequency transmission signal attenuated by an attenuator 4 is input to the signal combiners 13 a 1 to 13 a 4 .
[0109] Each of the signal combiners 13 a 1 to 13 a 4 combines a signal from a reception signal by corresponding one of the reception antennas ANT 1 to ANT 4 connected to the signal combiners 13 a 1 to 13 a 4 respectively and the high-frequency transmission signal attenuated by the attenuator 4 , and outputs the combined signal to corresponding one of RF receivers 14 a 1 to 14 a 4 of the RF receiver 14 a , similarly to the signal combiner 13 according to the first embodiment.
[0110] The RF receiver 14 a has a RF receiver 14 a 1 to which the combined signal output from the signal combiner 13 a 1 is input, a RF receiver 14 a 2 to which the combined signal output from the signal combiner 13 a 2 is input, a RF receiver 14 a 3 to which the combined signal output from the signal combiner 13 a 3 is input, and a RF receiver 14 a 4 to which the combined signal output from the signal combiner 13 a 4 is input.
[0111] Each of the RF receivers 14 a 1 to 14 a 4 has the same configuration as that of the RF receiver 14 in the first embodiment. Like the RF receiver 14 , each of the RF receivers 14 a 1 to 14 a 4 receives and amplifies the combined signal output from corresponding one of the signal combiners 13 a 1 to 13 a 4 , and frequency-converts the amplified combined signal to generate a baseband reception signal composed of an in-phase signal and a quadrature signal. The reception signal generated by each of the RF receivers 14 a 1 to 14 a 4 is input to the switch 11 a.
[0112] The switch 11 a is provided with switching ports corresponding to the RF receivers 14 a 1 to 14 a 4 respectively so that the switch 11 a is connected to each of the RF receivers 14 a 1 to 14 a 4 .
[0113] The switch 11 a sequentially changes the switching ports corresponding to the RF receivers 14 a 1 to 14 a 4 under control of the switch controller 12 so that a single switching port is selected and the switch 11 a is connected to the RF receiver 14 a corresponding to the switching port.
[0114] The switch 11 a outputs a baseband reception signal generated by the selected RF receiver 14 a to the signal processor 17 by changing the switching port. Processing after that is the same as in the first embodiment.
[0115] As described above, in the radar device 1 a according to Modification 1 of the first embodiment, because the signal combiners 13 a and the RF receivers 14 a are provided in accordance with the reception antennas ANT 1 to ANT 4 , the configuration of the radar receiver 3 a is complicated compared with the radar device 1 according to the first embodiment.
[0116] However, in the switch 11 a , the switching port is changed in accordance with the baseband reception signal generated by the RF receiver 14 a . For this reason, power loss of the reception signal at the time of changing in the switch 11 a can be reduced compared with the radar device 1 according to the first embodiment in which the switching port is changed in accordance with the high-frequency reception signal.
[0117] Hence, in accordance with the radar device 1 a according to Modification 1 of the first embodiment, SNR (Signal Noise Ratio) at reception of a signal reflected by a target in a measurement period can be improved compared with the radar device 1 according to the first embodiment. As a result, in accordance with the radar device 1 a , accuracy of measurement of the target in the measurement period can be improved.
Modification 2 of First Embodiment
[0118] In the first embodiment, each reception antenna ANTs is directly connected to the switch 11 so that a reception signal by each reception antenna ANTs is input to the switch 11 . In Modification 2 of the first embodiment, the frequency of a reception signal is converted into an intermediate frequency band as an IF (Intermediate Frequency) band by the frequency converter of the RF receiver so that the reception signal is input to the switch.
[0119] FIG. 4 is a block diagram illustrating the internal configuration of a radar device 1 b according to Modification 2 of the first embodiment. Although the difference in configuration and operation of Modification 2 of the first embodiment from the radar device 1 according to the first embodiment will be described with reference to FIG. 4 , description of the same configuration and operation as those of the radar device 1 according to the first embodiment will be omitted.
[0120] In FIG. 4 , a radar receiver 3 b has four reception antennas ANT 1 to ANT 4 , a signal combiner 13 b , a RF receiver 14 b , a switch 11 b , a switch controller 12 , an IF receiver 26 , and a signal processor 17 .
[0121] The signal combiner 13 b has a signal combiner 13 b 1 to which a reception signal by the reception antenna ANT 1 is input, a signal combiner 13 b 2 to which a reception signal by the reception antenna ANT 2 is input, a signal combiner 13 b 3 to which a reception signal by the reception antenna ANT 3 is input, and a signal combiner 13 b 4 to which a reception signal by the reception antenna ANT 4 is input. A high-frequency transmission signal attenuated by an attenuator 4 is input to the signal combiners 13 b 1 to 13 b 4 .
[0122] Like the signal combiner 13 in the first embodiment, each of the signal combiners 13 b 1 to 13 b 4 combines a signal from a reception signal by corresponding one of the reception antennas ANT 1 to ANT 4 connected to the signal combiners 13 b 1 to 13 b 4 respectively and the high-frequency transmission signal attenuated by the attenuator 4 , and outputs the combined signal to corresponding one of RF receivers 14 b 1 to 14 b 4 of the RF receiver 14 b.
[0123] The RF receiver 14 b has a RF receiver 14 b 1 to which the combined signal output from the signal combiner 13 b 1 is input, a RF receiver 14 b 2 to which the combined signal output from the signal combiner 13 b 2 is input, a RF receiver 14 b 3 to which the combined signal output from the signal combiner 13 b 3 is input, and a RF receiver 14 b 4 to which the combined signal output from the signal combiner 13 b 4 is input.
[0124] Each of the RF receivers 14 b 1 to 14 b 4 has the same configuration as that of the RF receiver 14 in the first embodiment. Like the RF receiver 14 , each of the RF receivers 14 b 1 to 14 b 4 receives and amplifies the combined signal output from corresponding one of the signal combiners 13 b 1 to 13 b 4 , and frequency-converts the amplified combined signal to generate an intermediate frequency band reception signal. The reception signal generated by each of the RF receivers 14 b 1 to 14 b 4 is input to the switch 11 b.
[0125] The switch 11 b is provided with switching ports corresponding to the RF receivers 14 b 1 to 14 b 4 respectively so that the switch 11 b is connected to each of the RF receivers 14 b 1 to 14 b 4 . The switch 11 b sequentially changes the switching ports corresponding to the four RF receivers 14 b 1 to 14 b 4 under control of the switch controller 12 . By this changing, a single switching port is selected so that the switch 11 b is connected to the RF receiver 14 b corresponding to the switching port. The switch 11 b outputs an intermediate frequency band reception signal generated by the selected RF receiver 14 b to the IF receiver 26 by changing the switching port.
[0126] The IF receiver 26 has a power amplifier 27 and a frequency converter 28 . The IF receiver 26 generates a timing clock based on a reference signal generated by an oscillator Lo so that the reference signal is multiplied by a predetermined number. The IF receiver 26 operates based on the generated timing clock. Specifically, the power amplifier 27 receives as an input the intermediate frequency band reception signal output from the switch 11 b , amplifies the signal power of the input reception signal to predetermined signal power, and outputs the reception signal to the frequency converter 28 .
[0127] The frequency converter 28 receives as an input the reception signal output from the power amplifier 27 , frequency-converts the input reception signal and phase-shifts the phase component of part of the reception signal by 90 [degrees] based on quadrature detection to thereby generate a baseband reception signal composed of an in-phase signal and a quadrature signal. The frequency converter 28 outputs the generated reception signal to the signal processor 17 . Processing after that is the same as in the first embodiment.
[0128] As described above, in the radar device 1 b according to Modification 2 of the first embodiment, because the signal combiners 13 b and the RF receivers 14 b are provided in accordance with the reception antennas ANT 1 to ANT 4 , the configuration of the radar receiver 3 b is complicated compared with the radar device 1 according to the first embodiment. However, in the switch 11 b , the switching port is changed in accordance with the intermediate frequency band reception signal generated by the RF receiver 14 b . For this reason, power loss of the reception signal at the time of changing in the switch 11 b can be reduced compared with the radar device 1 according to the first embodiment in which the switching port is changed in accordance with the high-frequency reception signal.
[0129] Hence, in accordance with the radar device 1 b according to Modification 2 of the first embodiment, SNR at reception of a signal reflected by a target in a measurement period can be improved compared with the radar device 1 according to the first embodiment. As a result, in accordance with the radar device 1 b , accuracy of measurement of the target in the measurement period can be improved.
Modification 3 of First Embodiment
[0130] The first embodiment has been described to the effect that a phase shift quantity in each reception antenna ANTs is calculated by the signal processor 17 in sync with the transmission cycle Tr [sec] of the high-frequency transmission signal whenever the high-frequency transmission signal is transmitted.
[0131] In Modification 3 of the first embodiment, when variation in phase shift quantity in each reception antenna ANTs is initially set to be slow, a cycle of from the transmission start timing of the high-frequency transmission signal in the measurement period of the first reception antenna to the transmission end timing of the high-frequency transmission signal in the measurement period of the last reception antenna is set as a changeover cycle to switch whether the high-frequency transmission signal attenuated by the attenuator 4 is input to the signal combiner or not.
[0132] FIG. 5 is a block diagram illustrating the internal configuration of a radar device 1 c according to Modification 3 of the first embodiment. FIG. 6 is a timing chart concerned with operation of the radar device 1 c according to Modification 3 of the first embodiment. In FIG. 6 , (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal. In FIG. 6 , (b) is an explanatory view illustrating a timing chart of the high-frequency transmission signal input to a signal combiner 13 . In FIG. 6 , (c) is an explanatory view illustrating a period of measurement by each of reception antennas.
[0133] Although the difference in configuration and operation of Modification 3 of the first embodiment from the radar device 1 according to the first embodiment will be described with reference to FIGS. 5 and 6 , description of the same configuration and operation as those of the radar device 1 according to the first embodiment will be omitted.
[0134] In FIG. 5 , a radar receiver 3 c has four reception antennas ANT 1 to ANT 4 , a switch 11 , a second switch 29 , a switch controller 12 c , a signal combiner 13 , a RF receiver 14 , and a signal processor 17 .
[0135] The second switch 29 receives as an input the high-frequency transmission signal attenuated by the attenuator 4 . The second switch 29 uses a cycle of from the start timing of the measurement period of the first reception antenna ANT 1 to the end timing of the measurement period of the last reception antenna ANT 4 as a changeover cycle. The second switch 29 switches whether the input high-frequency transmission signal is input to the signal combiner 13 or not, in accordance with control of the switch controller 12 c in each changeover cycle.
[0136] Specifically, as shown in (b) of FIG. 6 , the switch controller 12 c uses a cycle of from time t 0 which is the start timing of the measurement period of the first reception antenna ANT 1 to time t 7 which is the end timing of the measurement period of the last reception antenna ANT 4 as a changeover cycle. The switch controller 12 c controls the second switch 29 so that the attenuated high-frequency transmission signal input in sync with the transmission period of the high-frequency transmission signal is input to the signal combiner 13 in accordance with each changeover cycle.
[0137] The switch controller 12 c controls the second switch 29 so that the attenuated high-frequency transmission signal input in sync with the transmission period of the high-frequency transmission signal is not input to the signal combiner 13 during a period of time t 8 -t 15 which is the next similar changeover cycle. Processing after that is the same as in the first embodiment.
[0138] Hence, in accordance with the radar device 1 c according to Modification 3 of the first embodiment, accuracy of estimation of the arrival angle of the target and the distance to the target can be kept equal to that in the radar device 1 according to the first embodiment. Moreover, in accordance with the radar device 1 c , there is a period in which inputting of the high-frequency transmission signal output from the attenuator 4 to the signal combiner 13 is blocked by the second switch 29 . In the period, the radar device 1 c need not perform calculation of the phase shift quantity in each reception antenna ANTs and calculation of phase correction, etc. Accordingly, the radar device 1 c can reduce power consumption caused by operation of the phase shift quantity and phase correction, etc. compared with the radar device 1 according to the first embodiment.
Modification 4 of First Embodiment
[0139] In the first embodiment, it is possible to correct the phase shift quantity in the reception signal due to operation of each element after the signal combiner 13 of the radar receiver 3 . When there is fixed phase error in each system from the reception antenna to the switch 11 which are respective elements before the signal combiner 13 , it is however difficult to correct the phase shift quantity inclusive of the fixed phase error.
[0140] In Modification 4 of the first embodiment, fixed phase error E(s) in each system from the reception antenna to the switch 11 is measured in advance so that the measured phase error E(s) is held in the signal processor.
[0141] The signal processor 17 d has an A/D converter 18 , a reference transmission signal generator 19 , a correlation value calculator 20 , a timing controller 21 , a phase shift quantity calculator 22 , an intersystem fixed phase error storage 30 , a phase corrector 23 , a storage 24 , and an arrival angle and distance estimator 25 .
[0142] The intersystem fixed phase error storage 30 stores phase error E(s) measured in advance as fixed phase error E(s) in each system from the reception antenna ANTs to the switch 11 before the radar device 1 d starts measurement for detecting the target. For example, the phase error E(s) is measured in accordance with each reception antenna ANTs and stored in a table format in accordance with the reception antenna ANTs.
[0143] For calculation of the phase shift quantity in each reception antenna ANTs, the phase shift quantity calculator 22 calculates the phase shift quantity ฮฮธ(s) in accordance with the expression (6) including intersystem fixed phase error E(s) corresponding to the reception antenna ANTs stored in the intersystem fixed phase error storage 30 instead of the expression (2). Processing after that calculation is the same as in the first embodiment.
[0000] [Expression 6]
[0000] ฮฮธ( s )=โ [ AC ( s,Nr ) AC *( s 0 ,Nr )]โ E ( s )โโ(6)
[0144] Hence, in accordance with the radar device 1 d according to Modification 4 of the first embodiment, the phase shift quantity in each reception antenna ANTs inclusive of the intersystem fixed phase error in each system from the reception antenna ANTs to the switch 11 can be corrected more accurately. Hence, in accordance with the radar device 1 d , deterioration of accuracy of measurement of the arrival angle of the target and the distance to the target can be suppressed.
Second Embodiment
[0145] In a second embodiment, a transmission antenna ANT 0 and reception antennas ANT 1 to ANT 4 are disposed so as to be located so that a high-frequency transmission signal transmitted from the transmission antenna ANT 0 can be directly received by each of the reception antennas ANT 1 to ANT 4 by using side lobes of the directional pattern of the transmission antenna ANT 0 , side lobes of the reception antennas ANT 1 to ANT 4 or the like. Moreover, in the second embodiment, the two measurement periods of a reference phase update period and an ordinary period are repeated at regular intervals so that calculation of the phase shift quantity in each reception antenna ANTs and correction of the phase component of the correlation value based on the calculated phase shift quantity are performed.
[0146] In the reference phase update period, the second switch 31 is turned on to perform inputting of the high-frequency transmission signal attenuated by the attenuator 4 to the signal combiner 13 in the same manner as in the first embodiment. Moreover, after inputting to the signal combiner 13 , the phase component of the correlation value in each reception antenna ANTs is corrected. Then, the second switch 31 is turned off to block inputting of the attenuated high-frequency transmission signal to the signal combiner 13 . In this state, a crosstalk signal directly received from the transmission antenna ANT 0 by the reception antenna ANTs is used so that the fixed phase error in each system of from the reception antenna ANTs to the switch 11 is calculated as a reference phase ฮฯ(s).
[0147] In the ordinary period, the second switch 31 is turned off to block inputting of the high-frequency transmission signal attenuated by the attenuator 4 to the signal combiner 13 after the reference phase ฮฯ(s) is calculated in the reference phase update period. In this state, the phase component of the correlation value in each reception antenna ANTs is corrected inclusive of the reference phase ฮฯ(s) calculated in the reference phase update period.
(Operation in Reference Phase Update Period in Radar Device 1 e According to Second Embodiment)
[0148] The configuration of the radar device 1 e according to the second embodiment and the operation in the reference phase update period will be described below.
[0149] The configuration and operation of the radar device 1 e according to the second embodiment will be described with reference to FIGS. 8 and 9 . FIG. 8 is a block diagram illustrating the internal configuration of the radar device 1 e according to the second embodiment. FIG. 9 is a timing chart concerned with operation in the reference phase update period of the radar device 1 e.
[0150] In FIG. 9 , (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal. In FIG. 9 , (b) is an explanatory view illustrating a timing chart of the high-frequency transmission signal input to the signal combiner 13 . In FIG. 9 , (c) is an explanatory view illustrating a timing chart of a crosstalk signal in the case where the high-frequency transmission signal directly goes to the reception antenna ANTs. In FIG. 9 , (d) is an explanatory view illustrating a period of measurement by each reception antenna ANTs.
[0151] In FIG. 9 , (e) is an explanatory view illustrating an output of the reception signal from the switch 11 and a period of measurement by each reception antenna ANTs. In FIG. 9 , (f) is an explanatory view illustrating an output from the signal combiner 13 , a period of measurement by each reception antenna and a timing for calculating a phase shift quantity. In FIG. 9 , (g) is an explanatory view illustrating a period for storing a correlation value between a transmission signal and a reception signal.
[0152] As shown in FIG. 8 , the radar device 1 e has an oscillator Lo, a radar transmitter 2 , a radar receiver 3 e , a transmission antenna ANT 0 , reception antennas ANT 1 to ANT 4 , and an attenuator 4 . Because the configuration and operation (see (a) of FIG. 9 ) of the radar transmitter 2 are the same as those in the first embodiment, description of the configuration and operation of the radar transmitter 2 will be omitted. Moreover, because the operation (see (b) of FIG. 9 ) of the attenuator 4 is the same as in the first embodiment, description of the operation of the attenuator 4 will be omitted.
[0153] The radar receiver 3 e has four reception antennas ANT 1 to ANT 4 , a switch 11 , a second switch 31 , a switch controller 12 e , a signal combiner 13 , a RF receiver 14 , and a signal processor 17 e.
[0154] The RF receiver 14 has a power amplifier 15 , and a frequency converter 16 . The signal processor 17 e has an ND converter 18 , a reference transmission signal generator 19 , a correlation value calculator 20 , a timing controller 21 , a reference phase storage 32 , a phase shift quantity calculator 22 , a phase corrector 23 , a storage 24 , and an arrival angle and distance estimator 25 .
[0155] The reception antennas ANT 1 to ANT 4 form an array antenna of four reception antennas ANT 1 to ANT 4 . The reception antennas ANT 1 to ANT 4 receive both a signal obtained due to reflection of a high-frequency transmission signal transmitted from the radar transmitter 2 by a target and a feeble high-frequency transmission signal transmitted from the transmission antenna ANT 0 and directly going to each of the reception antennas ANT 1 to ANT 4 (see (c) of FIG. 9 ).
[0156] The feeble high-frequency transmission signal directly going to the reception antennas ANT 1 to ANT 4 is based on side lobes of the directional pattern of the transmission antenna ANT 0 , side lobes of the reception antennas ANTI to ANT 4 , or the like.
[0157] Although description will be made on the assumption that the number of elements of the array antenna in the radar device 1 e according to the second embodiment is 4 as shown in FIG. 8 , the number of elements of the array antenna is not limited to 4.
[0158] The switch 11 is provided with switching ports corresponding to the four reception antennas ANT 1 to ANT 4 so that the switch 11 is connected to the reception antennas. In the switch 11 , the respective switching ports corresponding to the four reception antennas ANT 1 to ANT 4 for receiving signals reflected by a target are changed sequentially under control of the switch controller 12 e so that a single switching port is selected so that the switch 11 is connected to a reception antenna corresponding to the switching port. The switch 11 outputs a reception signal received by the selected reception antenna to the signal combiner 13 .
[0159] The second switch 31 switches whether the high-frequency transmission signal attenuated by the attenuator 4 is input to the signal combiner 13 or not, in accordance with control of the switch controller 12 e.
[0160] The switch controller 12 e controls the switch 11 so that the four reception antennas ANT 1 to ANT 4 are changed sequentially in a cycle of an integer multiple N (N: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 .
[0161] In the reference phase update period in the second embodiment, the switch controller 12 e controls the switch 11 so that the four reception antennas ANTI to ANT 4 are changed sequentially in a cycle N (integer satisfying Nโง2) not smaller than twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal. In FIG. 9 , (d) shows an example in which the switch 11 is controlled so that the four reception antennas ANT 1 to ANT 4 are changed sequentially in a cycle (N=2) twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0162] The switch controller 12 e controls the second switch 31 so that the high-frequency transmission signal attenuated by the attenuator 4 is input to the signal combiner 13 in the transmission period of the high-frequency transmission signal in a first half of the cycle (2Tr) twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0163] The switch controller 12 e controls the second switch 31 so that the high-frequency transmission signal attenuated by the attenuator 4 is not input to the signal combiner 13 in the transmission period of the high-frequency transmission signal in a second half of the cycle (2Tr) twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0164] Specifically, as shown in (b) and (d) of FIG. 9 , the switch controller 12 e changes the reception antenna for receiving a signal reflected by a target to the reception antenna ANT 1 in a period of time t 0 -t 1 . Moreover, the switch controller 12 e controls the switch 11 so that the reception signal received by the reception antenna ANT 1 is output to the signal combiner 13 in a period of time t 1 -t 2 .
[0165] Moreover, the switch controller 12 e controls the second switch 31 so that the high-frequency transmission signal attenuated by the attenuator 4 is input to the signal combiner 13 in a period of time t 0 -t 1 which is the transmission period of the high-frequency transmission signal in a first half of the cycle twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0166] Accordingly, the period of time t 1 -t 2 is used as a period of measurement by the reception antenna ANT 1 in the same manner as in the first embodiment. Moreover, the switch controller 12 e controls the second switch 31 so that the high-frequency transmission signal attenuated by the attenuator 4 is not input to the signal combiner 13 in a period of time t 2 -t 3 which is the transmission period of the high-frequency transmission signal in a second half of the cycle twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0167] In the period of time t 0 -t 1 and the period of time t 2 -t 3 , a crosstalk signal of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 because of side lobes of the directional pattern of the transmission antenna ANT 0 , side lobes of the reception antennas ANT 1 to ANT 4 , or the like, is received by the reception antenna ANT 1 in sync with the transmission period of the high-frequency transmission signal. The signal power of the crosstalk signal is considerably lower than the signal power of the attenuated high-frequency transmission signal.
[0168] Accordingly, with respect to the reception antenna ANT 1 , a correlation value having a phase shift quantity corrected based on the correlation value between the reference transmission signal and the reception signal in the reception antenna ANT 1 is calculated in a period of time t 0 -t 2 in the same manner as in the first embodiment. Moreover, with respect to the reception antenna ANT 1 , intersystem fixed phase error caused by direct reception of the crosstalk signal in the reception antenna ANT 1 is calculated as a reference phase ฮฯ(1) in a period of time t 2 -t 4 .
[0169] The switch controller 12 e controls the switch 11 so that the reception antenna is changed to the reception antenna ANT 2 in a period of time t 4 -t 5 and the reception signal received by the reception antenna ANT 2 is output to the signal combiner 13 in a period of time t 5 -t 6 .
[0170] Moreover, the switch controller 12 e controls the second switch 31 so that the high-frequency transmission signal attenuated by the attenuator 4 is input to the signal combiner 13 in a period of time t 4 -t 5 which is the transmission period of the high-frequency transmission signal in a first half of the cycle twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal. Accordingly, the period of time t 5 -t 6 is used as a period of measurement by the reception antenna ANT 2 in the same manner as in the first embodiment.
[0171] Moreover, the switch controller 12 e controls the second switch 31 so that the high-frequency transmission signal attenuated by the attenuator 4 is not input to the signal combiner 13 in a period of time t 6 -t 7 which is the transmission period of the high-frequency transmission signal in a second half of the cycle twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0172] In a period of time t 4 -t 5 and a period of time t 6 -t 7 , a crosstalk signal due to direct reception of the high-frequency signal transmitted from the transmission antenna ANT 0 because of side lobes of the directional pattern of the transmission antenna ANT 0 , side lobes of the reception antennas ANT 1 to ANT 4 , or the like, is received by the reception antenna ANT 2 in sync with the transmission period of the high-frequency transmission signal. The signal power of the crosstalk signal is considerably lower than the signal power of the attenuated high-frequency transmission signal.
[0173] Accordingly, with respect to the reception antenna ANT 2 , a correlation value having a phase shift quantity corrected based on the correlation value between the reference transmission signal and the reception signal in the reception antenna ANT 2 is calculated in a period of time t 4 -t 8 in the same manner as in the first embodiment. Moreover, with respect to the reception antenna ANT 2 , intersystem fixed phase error caused by reception of the crosstalk signal in the reception antenna ANT 2 is calculated as a reference phase ฮฯ(2) in a period of time t 6 -t 8 . The same thing applies to the other reception antennas ANT 3 and ANT 4 .
[0174] Incidentally, the reception signal output from the switch 11 shows a signal combined from a noise signal around the radar device 1 and the crosstalk signal in periods of times t 0 -t 1 , t 2 -t 3 , t 4 -t 5 , t 6 -t 7 and t 8 -t 9 as shown in (e) of FIG. 9 . Incidentally, because the signal power of the noise signal is very feeble compared with the signal power of the crosstalk signal, the reception signal output from the switch 11 can approximate the crosstalk signal.
[0175] The reception signal output from the switch 11 shows a signal combined from the crosstalk signal and a reception signal (not shown) corresponding to each measurement period (each of periods of times t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 ) in periods of times t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 .
[0176] The signal combiner 13 combines a signal from a signal in which inputting of the high-frequency transmission signal output from the attenuator 4 is turned on or off by the second switch 31 , and the reception signal output from the switch 11 , and outputs the combined signal to the power amplifier 15 of the RF receiver 14 .
[0177] When the second switch 31 is on, the signal combiner 13 combines a signal from the output of the attenuator 4 and the output of the switch 11 . In this case, the output of the switch 11 includes a crosstalk signal which goes through side lobes of the transmission or reception antenna. When the average power of the crosstalk signal is Z [dB], the signal power output from the signal combiner is (Y+Z) [dB].
[0178] The average power Z [dB] of the crosstalk signal which goes through side lobes of the transmission or reception antenna is set to be signal power allowed to be received by the RF receiver 14 when an antenna pattern including the side lobe level of the transmission/reception antenna is designed. Incidentally, the signal power Y of the attenuator output of the radar transmission signal is attenuated to a sufficiently higher level (3 dB to 10 dB) than the reception signal level Z in this interval and then mixed by the signal combiner of the radar receiver.
[0179] However, when autocorrelation characteristic of the radar transmission signal has side lobes, the signal power Y of the attenuator output of the radar transmission signal is set to be low so that the side lobe level is a level undisturbed by the radar measurement period. The timing of mixing the attenuator output of the radar transmission signal is synchronized with the radar transmission signal while the time lag is suppressed.
[0180] Because operation of the RF receiver 14 is the same as in the first embodiment, description of the operation of the RF receiver 14 will be omitted.
[0181] Because operation of the A/D converter 18 is the same as in the first embodiment, description of the operation of the ND converter 18 will be omitted.
[0182] Because operation of the reference transmission signal generator 19 is the same as in the first embodiment, description of the operation of the reference transmission signal generator 19 will be omitted.
[0183] The correlation value calculator 20 calculates a correlation value AC(s,k) between the complex signal x(s,k) of the reception signal received by the reception antenna ANTs and the reference transmission signal r(n) output from the reference transmission signal generator 19 . Assume now that a sliding correlation value as shown in the expression (1) is calculated as the correlation value.
[0184] Incidentally, when the transmission signal generated by the transmission signal generator 5 is a baseband signal r(n) composed of real numbers, this signal r(n) is used as the reference transmission signal for calculation of the sliding correlation value AC(s,k). On the other hand, when the transmission signal generated by the transmission signal generator 5 is a baseband signal r(n) composed of an in-phase signal and a quadrature signal, a complex conjugate value of this signal r(n) is used.
[0185] The timing controller 21 notifies the phase shift quantity calculator 22 of the timing information of termination of calculation of the sliding correlation value based on the timing k 0 of termination of the period Tw [sec] of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 and input to the signal combiner 13 through the attenuator 4 while the timing k 0 is regarded as the timing of termination of calculation of the sliding correlation value AC(s,k 0 ) by the correlation value calculator 20 .
[0186] As shown in (f) of FIG. 9 , the timing k 0 of termination of the period Tw [sec] of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 and input to the signal combiner 13 through the attenuator 4 is times t 1 , t 5 and t 9 and corresponds to discrete time k=Nr.
[0187] The timing controller 21 notifies the phase corrector 23 of the timing information indicating that the sliding correlation value AC(s,k) corrected by the phase corrector 23 is stored in the storage 24 , with respect to the sliding correlation value AC(s,k) between the complex signal x(s,k) of the reception signal received by the reception antenna ANTs and the reference transmission signal r(n) output from the reference transmission signal generator 19 . Incidentally, discrete time k is from 2Nr to (Nr+Nu) and from (Nr+Nu)+2Nr to 2(Nr+Nu) (see (f) of FIG. 9 ).
[0188] The phase shift quantity calculator 22 extracts the sliding correlation value AC(s,Nr) in the reception antenna ANTs and the sliding correlation value AC(s 0 ,Nr) in a reference reception antenna ANTs 0 (which will be described later) based on the timing information (e.g. time t 1 , t 5 , t 9 ) which is given from the timing controller 21 and which indicates that the period Tw [sec] of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 and input to the signal combiner 13 through the attenuator 4 is terminated.
[0189] Here, the reception antenna ANTs 0 which is one of the four reception antennas ANT 1 to ANT 4 shown in FIG. 8 and which is used as a reference for calculating the phase shift quantity is referred to as reference reception antenna. Moreover, the sliding correlation value AC(s 0 ,Nr) in the reference reception antenna ANTs 0 and the sliding correlation value AC(s,Nr) in the reception antenna ANTs have been already calculated by the correlation value calculator 20 .
[0190] The phase shift quantity calculator 22 calculates the phase shift quantity ฮฮธ(s) in the reception antenna ANTs in accordance with the expression (2) based on the sliding correlation value AC(s,Nr) in the reception antenna ANTs and the sliding correlation value AC(s 0 ,Nr) in the reference reception antenna ANTs 0 . The phase shift quantity calculator 22 outputs the calculated phase shift quantity ฮฮธ(s) to the phase corrector 23 .
[0191] Moreover, the phase shift quantity calculator 22 extracts the correlation value AC(s,Nr+Nu+Nr+dt) in the crosstalk signal calculated by the correlation value calculator 20 based on the timing information (e.g. time t 3 , t 7 ) which is given from the timing controller 21 and which indicates that calculation of the sliding correlation value is terminated. The phase shift quantity calculator 22 corrects the phase shift quantity ฮฮธ(s) in accordance with the expression (7) based on the extracted correlation value AC(s,Nr+Nu+Nr+dt). Moreover, the phase shift quantity calculator 22 calculates intersystem fixed phase error in each system including the reception antenna ANTs (reception antenna ANT 1 at time t 3 ) and the switch 11 as a reference phase ฮฯ(s) in the reception antenna ANTs.
[0192] Assume now that the sliding correlation value AC(s,Nr+Nu+Nr+dt) in the reception antenna ANTs has been already calculated by the correlation value calculator 20 .
[0000] [Expression 7]
[0000] ฮฮฆ( s )=โ [ AC ( s,Nr+Nu+Nr+dt )]โฮฮธ( s )โโ(7)
[0193] Here, as described above, discrete time k=Nr+Nu+Mr+dt shows timing when the crosstalk signal is received by the reception antenna ANTs. Here, dt [sec] shows a delay of arrival time of the signal directly received from side lobes of the transmission antenna ANT 0 through side lobes of the reception antenna. dt depends on arrangement of the transmission antenna ANT 0 and the reception antennas ANT 1 to ANT 4 (distance between the transmission antenna and each reception antenna). It is however preferable that dt is not smaller than one pulse width in the pulse train.
[0194] In this case, when the sliding correlation value AC(s,Nr) in the reception antenna ANTs is calculated based on the timing information indicating that the period Tw [sec] of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 and input to the signal combiner 13 through the attenuator 4 is terminated, a correlation value can be obtained so that the influence of the crosstalk signal superposedly received is reduced. Accordingly, the reference phase can be calculated more accurately.
[0195] The phase corrector 23 corrects the sliding correlation value AC(s,k) calculated by the correlation value calculator 20 in accordance with the expression (4) based on the phase shift quantity output from the phase shift quantity calculator 22 . The phase corrector 23 stores the phase component of the corrected sliding correlation value AC(s,k) in the storage 24 .
[0196] The phase corrector 23 stores the sliding correlation value (see the expression (5)) having the corrected phase component in the reception antenna ANTs at discrete time k=2Nr to (Nr+Nu) and (Nr+Nu+Nr) to 2(Nr+Nu) in the storage 24 based on the timing information output from the timing controller 21 for indicating that the corrected sliding correlation value is stored.
[0197] Because operation of the arrival angle and distance estimator 25 is the same as in the first embodiment, description of operation of the arrival angle and distance estimator 25 will be omitted.
(Operation in Ordinary Period in Radar Device 1 e According to Second Embodiment)
[0198] Although the difference of operation in the ordinary period of the radar device 1 e according to the second embodiment from the operation in the reference phase update period will be described below, description of the same in contents as the operation in the reference phase update period will be omitted.
[0199] The switch controller 12 e controls the switch 11 so that the four reception antennas ANT 1 to ANT 4 are sequentially changed in a cycle of an integer multiple N (N: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 . In the ordinary period in the second embodiment, the switch controller 12 e controls the switch 11 so that the four reception antennas ANT 1 to ANT 4 are sequentially changed in a cycle (N=2) twice as much as the transmission cycle Tr [sec] of the high-frequency transmission signal, similarly to (d) of FIG. 9 .
[0200] In the ordinary period, the switch controller 12 e controls the second switch 31 so that inputting of the high-frequency transmission signal attenuated by the attenuator 4 to the signal combiner 13 is blocked.
[0201] The correlation value calculator 20 calculates the sliding correlation value AC(s,Nr+dt) between the crosstalk signal in the reception antenna ANTs and the reference transmission signal in the same manner as the correlation value calculator 20 in the first embodiment.
[0202] The phase shift quantity calculator 22 extracts the correlation value AC(s,Nr+dt) between the crosstalk signal in the reception antenna ANTs and the reference transmission signal based on the timing of termination of calculation of the sliding correlation value output from the timing controller 21 , and corrects the phase shift quantity of the reception antenna ANTs in accordance with the expression (8) based on the reference phase ฮฯ(s) stored in the reference phase storage 32 .
[0000] [Expression 8]
[0000] ฮฮธ( s )=โ [ AC ( s,Nr+dt )]โฮฮฆ( s )โโ(8)
[0203] The phase corrector 23 corrects the sliding correlation value AC(s,k) calculated by the correlation value calculator 20 in accordance with the expression (4) based on the phase shift quantity output from the phase shift quantity calculator 22 . The phase corrector 23 stores the phase component of the corrected sliding correlation value AC(s,k) in the storage 24 .
[0204] The phase corrector 23 stores the sliding correlation value (see the expression (5)) having the corrected phase component in the reception antenna ANTs at discrete time k=2Nr to (Nr+Nu) in the storage 24 based on the timing information output from the timing controller 21 for indicating that the corrected sliding correlation value is stored.
[0205] As described above, in accordance with the radar device 1 e according to the second embodiment, like the radar device 1 according to the first embodiment, the phase shift quantity in the reception antenna can be calculated properly based on the correlation value between the reception signal reflected by the target and received by the reception antenna ANTs and the reference transmission signal.
[0206] Moreover, in accordance with the radar device 1 e , intersystem fixed phase error in the reception antenna ANTs can be calculated properly based on the correlation value between the crosstalk signal directly going from the transmission antenna ANT 0 to the reception antenna ANTs and the reference transmission signal.
[0207] Hence, in accordance with the radar device 1 e , intersystem fixed phase error in each system of the reception antenna ANTs and the switch 11 and the phase shift quantity based on the correlation value between the reference transmission signal and the reception signal can be calculated properly while the influence on measurement performance of the radar device is suppressed.
[0208] Moreover, in accordance with the radar device 1 e , the phase error can be corrected in real time even when the intersystem phase error in each system of the reception antenna ANTs and the switch 11 varies with time in a portion preceding the signal combiner 13 .
[0209] The radar device 1 e can suppress deterioration of accuracy of measurement of the arrival angle of the target ad the distance to the target by properly correcting the phase component of the correlation value in each reception antenna ANTs based on the properly calculated phase error and phase shift.
[0210] Moreover, in accordance with the radar device 1 e , like the radar device 1 according to the first embodiment, it is unnecessary to provide any switching port for calibration in the switch 11 compared with the conventional radar device. Accordingly, the radar device 1 e can perform calibration for the reception antenna ANTs in accordance with transmission of the high-frequency transmission signal, so that accurate measurement can be performed compared with the conventional radar device.
Third Embodiment
[0211] The configuration and operation of a radar device 1 f according to a third embodiment will be described with reference to FIGS. 11 and 12 . FIG. 11 is a block diagram illustrating the internal configuration of the radar device 1 f according to the third embodiment.
[0212] FIG. 12 is a timing chart concerned with operation of the radar device 1 f according to the third embodiment. In FIG. 12 , (a) is an explanatory view illustrating a timing chart of a high-frequency transmission signal. In FIG. 12 , (b) is an explanatory view illustrating a timing chart of the high-frequency transmission signal input to a signal combiner 13 f from an attenuator 4 . In FIG. 12 , (c) is an explanatory view illustrating a period of measurement by each of reception antennas ANT 1 to ANT 4 . In FIG. 9 , (d) is an explanatory view illustrating a reception signal output from the signal combiner 13 f and a period of measurement by each of the reception antennas ANT 1 to ANT 4 .
[0213] In FIG. 12 , (e) is an explanatory view illustrating an output of the signal combiner 13 f , a period of measurement by each of the reception antennas ANTI to ANT 4 and a timing of calculating a phase shift quantity. In FIG. 12 , (f) is an explanatory view illustrating a period for storing a correlation value between a transmission signal and a reception signal.
[0214] As shown in FIG. 11 , the radar device 1 f has an oscillator Lo, a radar transmitter 2 , a radar receiver 3 f , a transmission antenna ANT 0 , reception antennas ANT 1 to ANT 4 , and an attenuator 4 . Because the configuration of the radar device 1 f is the same as in the first embodiment except the radar receiver 3 f , description thereof will be omitted. With respect to the configuration of the radar receiver 3 f in the radar device 1 f , mainly different points in configuration and operation will be described below.
[0215] As shown in (a) of FIG. 12 , assume that Nr [pieces] of discrete time samples are provided as a baseband transmission signal r(n) in a period Tw [sec] of presence of a high-frequency transmission signal transmitted from the transmission antenna ANT 0 from the radar transmitter 2 whereas Nu [pieces] of discrete time samples are provided as a baseband transmission signal r(n) in a period (Tr-Tw) [sec] of absence of the high-frequency transmission signal.
[0216] The parameter Tr is a transmission cycle [sec] of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 . As shown in (a) of FIG. 12 , the high-frequency transmission signal is transmitted cyclically by the transmission cycle Tr in periods of times t 0 -t 1 , t 2 -t 3 , t 4 -t 5 , t 6 -t 7 and t 8 -t 9 but not transmitted in periods of times t 1 -t 2 , t 3 -t 4 , t 5 -t 6 and t 7 -t 8 . After time t 9 , transmission of the high-frequency transmission signal is repeated in the same manner.
[0217] As shown in (b) of FIG. 12 , the attenuator 4 attenuates the signal power of the high-frequency transmission signal output from the directional coupler 10 to predetermined signal power Y [dB] in sync with the transmission period of the high-frequency transmission signal.
[0218] The radar receiver 3 f has four reception antennas ANT 1 to ANT 4 , a transmission signal changer 40 , a switch controller 12 f , signal combiners 13 f 1 to 13 f 4 , RF receivers 14 f 1 to 14 f 4 , a phase controller 41 , phase shifters 42 - 1 to 42 - 4 , a signal adder 33 , and a signal processor 17 . The RF receiver 14 f has a power amplifier 15 and a frequency converter 16 . The signal processor 17 has an A/D converter 18 , a reference transmission signal generator 19 , a correlation value calculator 20 , a timing controller 21 , a phase shift quantity calculator 22 , a phase corrector 23 , a storage 24 , and an arrival angle and distance estimator 25 .
[0219] The reception antennas ANT 1 to ANT 4 form an array antenna of four reception antennas ANT 1 to ANT 4 . The reception antennas ANT 1 to ANT 4 receive both a signal obtained due to reflection of the high-frequency transmission signal transmitted from the radar transmitter 2 by a target and a noise signal around the radar device 1 as a reception signal. Although description will be made in the case where the number of elements of the array antenna in the radar device 1 f according to the third embodiment is 4 as shown in FIG. 11 , the number of elements of the array antenna is not limited to 4.
[0220] In the transmission signal changer 40 , respective switching ports corresponding to the four signal combiners 13 f 1 to 13 f 4 are changed sequentially under control of the switch controller 12 f . By this changing, a single switching port is selected so that a signal combiner 13 fq corresponding to the switching port is connected to the transmission signal changer 40 . Here, the parameter g is a natural number up to the number of reception antennas. In the case of FIG. 11 , g is 1 to 4. The transmission signal changer 40 outputs the high-frequency transmission signal from the attenuator 4 to the selected signal combiner 13 fq.
[0221] The switch controller 12 f sequentially changes the respective switching ports of the transmission signal changer 40 corresponding to the four signal combiners 13 f 1 to 13 f 4 in a cycle of an integer multiple N (N: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal. Although the third embodiment shows an example in which the switch controller 12 f controls the transmission signal changer 40 to sequentially change the respective switching ports of the transmission signal changer 40 corresponding to the four signal combiners 13 f 1 to 13 f 4 in the same cycle (N=1) as the transmission cycle Tr [sec] of the high-frequency transmission signal, the third embodiment is not limited thereto.
[0222] Specifically, the switch controller 12 f performs switching so that the output of the transmission signal changer 40 which is the high-frequency transmission signal from the attenuator 4 is input to the selected signal combiner 13 f 1 in a period of time t 0 -t 1 . Here, changeover transition time ฮTsw in the transmission signal changer 40 may be considered so that the changeover operation is performed prior to time t 0 -ฮTsw.
[0223] The switch controller 12 f performs switching so that the output of the transmission signal changer 40 which is the high-frequency transmission signal from the attenuator 4 is input to the selected signal combiner 13 f 2 in a period of time t 2 -t 3 .
[0224] The switch controller 12 f performs switching so that the output of the transmission signal changer 40 which is the high-frequency transmission signal from the attenuator 4 is input to the selected signal combiner 13 f 3 in a period of time t 4 -t 5 .
[0225] The switch controller 12 f performs switching so that the output of the transmission signal changer 40 which is the high-frequency transmission signal from the attenuator 4 is input to the selected signal combiner 13 f 4 in a period of time t 6 -t 7 .
[0226] After that, the switch controller 12 f performs switching in the same manner so that the signal is input to the signal combiner 13 fq in a cycle of an integer multiple N (N: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal. When the high-frequency transmission signal output from the attenuator 4 is not included as a result of interposition of the transmission signal changer 40 , the signal combiner 13 fq has only the reception signal output from the reception ANTq as shown in (c) of FIG. 12 .
[0227] On the other hand, when the high-frequency transmission signal output from the attenuator 4 is included as a result of interposition of the transmission signal changer 40 , the signal combiner 13 fq combiners a signal from the reception signal output from the reception ANTq and the high-frequency transmission signal output from the attenuator 4 and outputs the combined signal to the RF receiver 14 fq , as shown in (d) of FIG. 12 . Here, when the average signal power of the reception signal output from the reception ANTq is Z [dB], the signal power of the combined signal output from the signal combiner 13 fq is (Y+Z) [dB].
[0228] Incidentally, when the signal power Y [dB] of the high-frequency transmission signal output from the attenuator 4 is included in the signal combiner 13 fq as a result of interposition of the transmission signal changer 40 , it is preferable that the signal power is attenuated to sufficiently higher signal power (e.g. 3[dB] to 10[dB]) than the signal power received by the reception antenna ANTs in the transmission period (of e.g. time t 0 -t 1 etc.) of the high-frequency transmission signal. For this reason, when power of the high-frequency transmission signal output from the attenuator 4 is insufficient, a level adjuster for adjusting the level to a predetermined level is disposed in place of the attenuator 4 so that amplification through an amplification circuit included in the level adjuster makes up for shortage of power. The level adjuster may be formed from the attenuator 4 .
[0229] When there are side lobes in autocorrelation characteristic of the high-frequency transmission signal, it is preferable that the attenuator 4 attenuates the signal power of the high-frequency transmission signal output from the directional coupler 10 to such signal power that the side lobe level has no influence on the measurement period of the radar device 1 .
[0230] Each of the RF receivers 14 f 1 to 14 f 4 generates a timing clock based on a reference signal generated by the oscillator Lo so that the reference signal is multiplied by a predetermined number. Each of the RF receiver 141 f to 14 f 4 operates based on the generated timing clock. Each of the RF receivers 14 f 1 to 14 f 4 receives as an input the combined signal combined by corresponding one of the signal combiners 13 f 1 to 13 f 4 , amplifies the signal power of the input combined signal to predetermined signal power and frequency-converts the signal to a baseband signal.
[0231] Moreover, each of the RF receivers 14 f 1 to 14 f 4 shifts the phase component of part of the combined signal by 90 [degrees] based on quadrature detection to thereby generate a baseband reception signal composed of an in-phase signal and a quadrature signal, and outputs the generated reception signal to the phase shifter (PS: Phase Shifter) 32 . The baseband reception signal composed of an in-phase signal I(t) and a quadrature signal Q(t) which is the output of the RF receiver 14 fq at time t is described here as a complex signal xq(t)=Iq(t)+Qq(t).
[0232] The phase shifters 42 - 1 to 42 - 4 receive output signals of the RF receivers 14 f 1 to 14 f 4 as inputs respectively, and give phase rotations ฯ 1 to ฯ 4 designated by the phase controller 41 to the input output signals of the RF receivers 14 f 1 to 14 f 4 respectively.
[0233] The signal adder 33 applies an adding process to the respective outputs of the phase shifters 42 - 1 to 42 - 4 . Here, an output signal OS(t) of the signal adder 33 at time t can be represented by the expression (9). Incidentally, j is an imaginary unit.
[0000]
[
Expression
๎ข
๎ข
9
]
OS
๎ข
(
t
)
=
โ
q
=
1
4
๎ข
๎ข
x
q
๎ข
(
t
)
๎ข
exp
๎ข
(
j
๎ข
๎ข
ฯ
q
)
(
9
)
[0234] By operation of the phase shifters 42 - 1 to 42 - 4 and the signal adder 33 , the radar receiver 3 f can form directivity of the reception antenna array in a predetermined direction. For example, when reception antennas are disposed on a line at regular intervals of Dant, a reception beam (directivity of the reception antenna array) can be formed in a direction ฮธ as represented by ฯq=(qโ1)Dantยทsin ฮธยท2ฯ/ฮป.
[0235] The phase controller 41 can change the phase rotations ฯ 1 to ฯ 4 cyclically based on a control signal in a cycle of an integer multiple N2 (N2: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal in the switch controller 12 f . Accordingly, the reception beam can be changed in accordance with the cycle of an integer multiple N2 (N2: integer) of the transmission cycle Tr [sec].
[0236] The A/D converter 18 performs sampling at discrete time k for the output of the signal adder 33 to thereby convert the reception signal into digital data. The reception signal at discrete time k which is the output of the signal adder 33 in the case where the high-frequency transmission signal output from the attenuator 4 is included in the signal combiner 13 fq through the transmission signal changer 40 is described here as a complex signal of a complex number x(q,k)=I(q,k)+jQ(q,k) using an in-phase signal component I(q,k) and a quadrature signal component Q(q,k) in the output of the signal adder 33 . Incidentally, j is an imaginary unit.
[0237] Moreover, the parameter k shows discrete time corresponding to the number of samples of the baseband transmission signal r(n) included in the high-frequency transmission signal. In the third embodiment, the timing of transmitting the transmission signal is set at k=1 and k=1 to (Nr+Nu). Accordingly, as shown in (e) of FIG. 12 , the parameter k satisfies k=1 in the timing of time t 0 , time t 2 , time t 4 , time t 6 and time t s . Moreover, the parameter k satisfies k=Nr in the timing of time t 1 , time t 3 , time t 5 , time t 7 and time t 9 .
[0238] The reference transmission signal generator 19 generates a timing clock based on a reference signal generated by the oscillator Lo in the same manner as the transmission signal generator 5 in sync with operation of the transmission signal generator 5 so that the reference signal is multiplied by a predetermined number. The reference transmission signal generator 19 cyclically generates a reference transmission signal r(n) of the same baseband as the transmission signal generated by the transmission signal generator 5 based on the generated reference signal. The reference transmission signal generator 19 outputs the generated reference transmission signal r(n) to the correlation value calculator 20 .
[0239] The correlation value calculator 20 calculates a correlation value AC(q,k) between the complex signal x(q,k) which is the reception signal output at discrete time k from the signal adder 33 , and the reference transmission signal r(n) output from the reference transmission signal generator 19 . Assume now that a sliding correlation value as shown in the expression (1) is calculated as the correlation value.
[0240] The sliding correlation value AC(q,k) is a correlation value at discrete time k between the reception signal output at discrete time k from the signal adder 33 , that is, the reception signal (including a reflected signal and a noise signal) received by a reception beam having a predetermined direction, and the reference transmission signal. The asterisk (*) in the expression (1) shows a complex conjugate operator. The sliding correlation value AC(q,k) is calculated in periods of k=1 to (Nr+Nu). That is, the sliding correlation value AC(q,k) is calculated in periods of times t 0 -t 2 , t 2 -t 4 , t 4 -t 6 , t 6 -t 8 , etc.
[0241] Incidentally, when the transmission signal generated by the transmission signal generator 5 is a baseband signal r(n) composed of real numbers, the signal r(n) is used as the reference transmission signal in calculation of the sliding correlation value AC(q,k). On the other hand, when the transmission signal generated by the transmission signal generator 5 is a baseband signal r(n) composed of an in-phase signal and a quadrature signal, a complex conjugate value of the signal r(n) is used.
[0242] The timing controller 21 regards the timing k 0 of completion of the period Tw [sec] (transmission period) of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 as the timing of completion of calculation of the sliding correlation value AC(q,k 0 ) by the correlation value calculator 20 , and notifies the phase shift quantity calculator 22 of the timing information of completion of calculation of the sliding correlation value AC(q,k 0 ).
[0243] The timing controller 21 notifies the phase shift quantity calculator 22 and the phase corrector 23 of the timing of sequentially changing the respective switching ports of the transmission signal changer 40 corresponding to the four signal combiners 13 f 1 to 13 f 4 and the information of the selected signal combiner 13 f in a cycle of an integer multiple N (N: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal. The timing controller 21 notifies the phase shift quantity calculator 22 of the timing of permitting cyclical change the phase rotations ฯ 1 to ฯ 4 and the quantities of the phase rotations in the phase controller 32 based on a control signal in a cycle of an integer multiple N2 (N2: integer) of the transmission cycle Tr [sec] of the high-frequency transmission signal.
[0244] As shown in (c) and (e) of FIG. 12 , the timing k 0 of completion of the period Tw [sec] of presence of the high-frequency transmission signal transmitted from the transmission antenna ANT 0 and the timing of completion of calculation of the sliding correlation value AC(q,k 0 ) by the correlation value calculator 20 are the same points of time t 1 , t 3 , t 5 , t 7 and t 9 and correspond to discrete time k 0 =Nr.
[0245] The timing controller 21 notifies the phase corrector 23 of the timing information for indicating that the sliding correlation value AC(q,k) corrected by the phase corrector 23 is stored in the storage 24 with respect to the sliding correlation value AC(q,k) between the complex signal x(q,k) of the reception signal output at discrete time k from the signal adder 33 , that is, the reception signal received by a reception beam having a predetermined direction, and the reference transmission signal r(n) output from the reference transmission signal generator 19 . However, discrete time k satisfies k=2Nr to (Nr+Nu) (see (f) of FIG. 12 ).
[0246] Incidentally, the discrete time k can be also set in a range of k=(Nr+1) to (Nr+Nu). However, the start timing of discrete time k at which the sliding correlation value AC(q,k) is stored in the storage 24 is determined in the timing controller 21 not at k=Nr but at k=2Nr on the assumption that not a target nearest to the radar device 1 f but a target at a predetermined distance [m] or farther from the radar device 1 f is detected.
[0247] Accordingly, because it is not necessary to consider that the intensive reception level is received from a target nearest to the radar device 1 without distortion, the dynamic range in the radar receiver 3 of the radar device 1 can be reduced. With respect to the start timing of discrete time k at which the sliding correlation value AC(q,k) is stored in the storage 24 , in the timing controller 21 , the same thing applies to the flowing embodiments.
[0248] Or, the discrete time k can be set in a range of k=(Nr+1) to (Nu). Accordingly, the time range of superposing the high-frequency transmission signal on the sliding correlation value AC(q,k) can be eliminated so that deterioration of radar measurement performance can be prevented when the transmission signal directly goes to the radar receiver.
[0249] The phase shift quantity calculator 22 extracts a sliding correlation value AC(q,Nr) included in the high-frequency transmission signal output from the attenuator 4 to the signal combiner 13 fq through the transmission signal changer 40 and a sliding correlation value AC(q 0 ,Nr) in the reference reception antenna ANTs 0 (which will be described later) based on the timing information given from the timing controller 21 for indicating the completion of calculation of the sliding correlation value.
[0250] Here, a reception antenna q 0 which is one of the four reception antennas ANT 1 to ANT 4 shown in FIG. 11 and which includes a signal combiner 13 fq 0 as a reference for calculating a phase shift quantity is referred to as reference reception antenna. Assume further that the sliding correlation value AC(q 0 ,Nr) in the reference reception antenna ANTq 0 and the sliding correlation value AC(q,Nr) in the reception antenna ANTq have been already calculated by the correlation value calculator 20 .
[0251] The phase shift quantity calculator 22 calculates a phase shift quantity ฮฮธ(q) in the reception antenna ANTq in accordance with the expression (10) based on the sliding correlation value AC(q,Nr) in the reception antenna ANTq and the sliding correlation value AC(q 0 ,Nr) in the reference reception antenna ANTq 0 . The phase shift quantity calculator 22 outputs the calculated phase shift quantity ฮฮธ(q) to the phase corrector 23 .
[0000] [Expression 10]
[0000] ฮฮธ( q )=โ [ AC ( q,Nr ) AC *( q 0 ,Nr )]โโ(10)
[0252] In the expression (10), each of the parameter q and the parameter q 0 shows a natural number not larger than the number of reception antennas. Each of the parameters s and s 0 shows any one of 1, 2, 3 and 4. The asterisk (*) shows a complex conjugate operator.
[0253] The phase corrector 23 corrects the phase component of the sliding correlation value AC(q,k) in the reception antenna ANTq calculated by the correlation value calculator 20 in accordance with the expression (11) based on the phase shift quantity output from the phase shift quantity calculator 22 .
[0000] [Expression 11]
[0000] โ [ AC ( q,k )]โโ ฮธ( q )โฯ q โโ(11)
[0254] The phase corrector 23 stores the sliding correlation value (see the expression (12)) having the corrected phase component in the reception antenna ANTq at discrete time of k=2Nr to (Nr+Nu) in the storage 24 based on the timing information output from the timing controller 21 for indicating that the corrected sliding correlation value is stored.
[0000] [Expression 12]
[0000] | AC ( q,k )|exp( j{โ [AC ( q,k )]โฮฮธ( q )โฯ q })โโ(12)
[0255] The arrival angle and distance estimator 25 performs calculation to estimate the arrival angle of the target and the distance to the target based on the sliding correlation value AC(q,k) having the corrected phase component in each reception antenna ANTq stored in the storage 24 . The calculation to estimate the arrival angle by the arrival angle and distance estimator 25 is a technique which has become publicly known. For example, this technique can be achieved by referring to Non-Patent Literature 2 which has been described above. Moreover, the calculation to estimate the distance to the target by the arrival angle and distance estimator 25 can be achieved by referring to Reference Non-Patent Literature 1 which has described above.
[0256] For example, the arrival angle and distance estimator 25 calculates reception signal power in the reception antenna based on the correlation value having the corrected phase component in the reception antenna ANTq with respect to the arrival angle of the target. The reception signal power includes the phase component at the arrival angle of the target. The arrival angle and distance estimator 25 estimates the angle of the phase component in the case where the reception signal power takes a maximum value, as the arrival angle of the target.
[0257] For example, the arrival angle and distance estimator 25 estimates the distance to the target based on the time difference between the discrete time in the case where the correlation value takes a maximum value and the transmission time of the high-frequency transmission signal based on the correlation value having the corrected phase component in the reception antenna ANTq with respect to the distance to the target.
[0258] As described above, in accordance with the radar device 1 f according to the third embodiment, a phase shift quantity of a phase component in a correlation value between a reception signal received by each of reception antennas and a transmission signal can be calculated properly as measurement performance of the radar device while, for example, influence on the measurement time or measurement distance range is suppressed.
[0259] Moreover, the radar device 1 f can correct the phase component of the correlation value in each reception antenna ANTq based on the properly calculated phase shift quantity to thereby suppress deterioration of accuracy of measurement of the arrival angle of the target and the distance to the target.
[0260] Moreover, in accordance with the radar device 1 f , because the transmission signal for calibration is the same as the transmission signal for measurement, execution can be made without addition of any correlation calculator for calibration to the signal processor 17 , so that execution can be made without complication of circuit configuration.
[0261] Although the phase shifter 42 - q in the third embodiment gives phase rotation to the baseband signal which is the output of the RF receiver 14 fq , the third embodiment is not limited thereto. The same effect can be obtained even in a configuration that phase rotation is given to a high-frequency signal or an intermediate-frequency signal obtained in the RF receiver 14 fq . Or the same effect can be obtained even in a configuration that phase rotation is given to a signal of the oscillator Lo input to the RF receiver 14 fq.
[0262] Although the phase shifter 42 in the third embodiment analogically gives phase rotation to the baseband signal which is the output of the RF receiver 14 fq , the third embodiment is not limited thereto. FIG. 13 is a block diagram illustrating the internal configuration of a radar device 1 g according to Modification 1 of the third embodiment.
[0263] For example, a radar receiver 3 g shown in FIG. 13 uses ND converters 18 - 1 to 18 - 4 for converting baseband signals obtained in RF receivers 14 f 1 to 14 f 4 into discretely sampled digital signals respectively. Moreover, in the radar receiver 3 g , phase shifters 42 - 1 to 42 - 4 give phase rotations to the discretely sampled digital signals respectively. Moreover, the signal adder 33 adds the outputs of the phase shifters 42 in the same manner as in the radar device 1 f according to the third embodiment.
[0264] By the configuration, the same effect as in the radar device 1 f according to the third embodiment can be obtained in the radar device 1 g . In Modification 1 of the third embodiment, a larger number of ND converters are required but digital phase control can be given to obtain higher accuracy than analog phase control.
[0265] Although various embodiments have been described with reference to the accompanying drawings, it is a matter of course that the radar device according to the invention is not limited to the examples. It is obvious that various changes or modifications can be thought of in the category described in the scope of claim by those skilled in the art, and it is to be understood that those are included in the technical scope of the invention.
[0266] Incidentally, in the invention, when the average reception signal power in the reception antenna ANTs varies widely in the case where the reception antenna ANTs is changed in accordance with the measurement environment around the radar device 1 or the like, the attenuator 4 may change its attenuation quantity in accordance with the average reception signal power.
[0267] Incidentally, this application is based on Japanese Patent Application (Patent Application 2010 - 161799 ) filed on Jul. 16, 2010 and the contents of which are incorporated herein by reference.
INDUSTRIAL APPLICABILITY
[0268] The radar device according to the invention is useful as an array radar device in which phase shift quantities in a plurality of antennas are corrected properly without influence on a measurement time or measurement distance range so that deterioration of accuracy of estimation of the arrival angle of a target is suppressed.
REFERENCE SIGNS LIST
[0000]
1 , 1 a , 1 b , 1 c , 1 d , 1 e , 1 f , 1 g radar device
2 radar transmitter
3 , 3 a , 3 b , 3 c , 3 d , 3 e , 3 f , 3 g radar receiver
4 attenuator
5 transmission signal generator
6 LPF
7 RF transmitter
8 , 16 , 28 frequency converter
9 , 15 , 27 power amplifier
10 directional coupler
11 , 11 a , 11 b switch
12 , 12 c , 12 e , 12 f switch controller
13 , 13 a , 13 a 1 , 13 a 2 , 13 a 3 , 13 a 4 , 13 b 1 , 13 b 2 , 13 b 3 , 13 b 4 signal combiner
14 , 14 a , 14 a 1 , 14 a 2 , 14 a 3 , 14 a 4 , 14 b 1 , 14 b 2 , 14 b 3 , 14 b 4 , 14 f 1 , 14 f 2 , 14 f 3 , 14 f 4 RF receiver
17 , 17 a , 17 d , 17 e signal processor
18 , 18 - 1 , 18 - 2 , 18 - 3 , 18 - 4 ND convertor
19 reference transmission signal generator
20 correlation value calculator
21 timing controller
22 phase shift quantity calculator
23 phase corrector
24 storage
25 arrival angle and distance estimator
29 , 31 second switch
30 intersystem fixed phase error storage
32 - 1 , 32 - 2 , 32 - 3 , 32 - 4 phase shifter
33 signal adder
40 transmission signal changer
41 phase controller
42 phase shifter
ANT 0 transmission antenna
ANTI to ANT 4 reception antenna
Lo oscillator
|
The disclosed technique includes transmitting a signal intermittently according to a transmission cycle having a predetermined transmission period and a non-transmission period; receiving the signal reflected from a target with reception antennas; and detecting the target from the reflected signal. A high-frequency transmission signal attenuated during the transmission period and a receipt signal received during the non-transmission period are combined together. A correlation value between a reference transmission signal and the receipt signal in the combined signal is calculated, and the amount of phase shift in an arbitrarily selected reception antenna is calculated from the correlation value of a reference reception antenna, and the correlation values of the other reception antennas. The phase component of the correlation value of the arbitrarily selected reception antenna is corrected on the basis of the amount of phase shift.
| 6
|
FIELD OF THE INVENTION
The present invention relates to a process for purifying niobium alkoxides and tantalum alkoxides. In particular, the present invention relates to a process for removing a very small amount of impurity elements from niobium alkoxides and tantalum alkoxides.
BACKGROUND OF THE INVENTION
Niobium alkoxides and tantalum alkoxides are useful as starting materials for oxides including niobium oxides or tantalum oxides usable as materials for dielectrics. Such an alkoxide is calcined to form the powdery oxide; the alkoxide is hydrolyzed and then the hydrolyzate is calcined to form an oxide powder; the alkoxide is hydrolyzed, a coating film is formed from the hydrolyzate by the sol-gel method and then the film is burned to obtain an oxide film; or the alkoxide is used for forming an oxide film by MOCVD method. The composition of the oxides varies in a wide range from a single oxide to a composite oxides comprising plural components. When such an oxide is used as an electronic material for dielectrics, it is required to reduce the quantity of impurities such as transition metals typified by iron, alkali metals, e.g. sodium, alkaline earth metals, e.g. calcium, as well as uranium and thorium as far as possible. These impurity elements cause various disorders such as the reduction in the durability of electronic devices, increase in the leakage of current, and software errors. Recently, tantalum ethoxide is used for producing a tantalum oxide film which is a high dielectric constant paraelectric substance as a capacitor for DRAM (Dynamic Random Access Read/Write Memory) by MOCVD method. The use of niobium alkoxide or tantalum alkoxide as a starting material for a non-volatile memory by using a thin ferroelectric film of SrBi 2 Ta 2 O 9 or SrBi 2 Nb 2 O 9 will be further developed.
However, niobium alkoxides and tantalum alkoxides usually contain a very small amount of elements such as iron, calcium, sodium and uranium and compounds of them (hereinafter referred to as "impurities"). These impurities were incorporated thereinto from starting materials for the alkoxides or materials for the reactors; from the atmosphere surrounding the apparatuses, starting materials, intermediate materials and products; or from additives used for the synthesis or purification.
For removing the impurities from a niobium alkoxide or tantalum alkoxide, fractional distillation is considered to be easy. However, since the niobium alkoxide or tantalum alkoxide having a low vapor pressure necessitates the vacuum distillation, the separation and purification conducted taking the advantage of the difference in the vapor pressure between the alkoxide and the impurities is very difficult. Another disadvantage of this method is that the vapor pressure of the impurity is close to that of the niobium alkoxide or tantalum alkoxide, or that they form a double alkoxide to make the vapor pressures of them further closer. Still another disadvantage is that this method necessitates a complicated, expensive apparatus.
Japanese Patent Publication No. 58194/1989 discloses a process for purifying alkoxides of Al, Ga, In, Y, Si, Ti, Zr, etc. in the form of a solution and containing at least one of Ti, Fe, Cu, Si, Na and U impurities by hydrolyzing 0.1 to 50% of the metal alkoxides under stirring to form a solid reaction product and then separating the reaction product from the unreacted metal alkoxides by the distillation to recover the metal alkoxides. However, the specification is silent on niobium alkoxides and tantalum alkoxides which are pentavalent alkoxides. As for the degree of the purification, although the specification discloses that, for example, Fe content of aluminum isopropoxide as the starting material can be reduced from 750 ppm to 1 or <1 ppm by the purification, the specification is silent on the high degree of the purification intended by the inventors of the present invention which is about 0.01 to 0.001 ppm. In addition, the specification of Japanese Patent Publication No. 58194/1989 is silent on the removal of calcium and strontium.
The distillation is insufficient for the purification of niobium alkoxides and tantalum alkoxides having an ordinary purity to obtain a high purity. When impurities contained in niobium alkoxides and tantalum alkoxides in even only a very small amount of an order of ppb are not allowed, it is necessary to purify these alkoxides in the final stage of the production thereof because they are possibly contaminated in the course of the production of them even if the starting materials and additives are very carefully handled. However, efficient purification process which can be employed for this purpose on an industrial scale has not been developed yet.
The object of the present invention is to provide a process for efficiently removing a very small amount of impurities such as Fe, Ca, Sr, Na and U from niobium alkoxides and tantalum alkoxides to reduce the impurity level to an order of ppb.
SUMMARY OF THE INVENTION
After intensive investigations on the synthesis and purification of metal alkoxides and the analysis of minor impurities contained therein, the inventors have found that when a niobium alkoxide or tantalum alkoxide containing impurities is previously hydrolyzed under specified conditions and then distilled, the impurities are concentrated in the hydrolyzate and are substantially not contained in the distillate. The present invention has been completed on the basis of this finding. Namely, the present invention provides a process for purifying niobium alkoxides and tantalum alkoxides, characterized by dissolving a niobium alkoxide or tantalum alkoxide containing at least one of iron, calcium, stronitum sodium and uranium as impurities in a solvent to obtain a solution, hydrolyzing 1 to 20% of the alkoxide under stirring to form a solid reaction product, separating the reaction product from the unreacted alkoxide by distillation to recover the alkoxide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The metal alkoxides to be purified by the present invention are niobium alkoxides and tantalum alkoxides containing at least one of Fe, Ca, Sr, Na and U. The present invention is effective in removing also transition metal impurities such as Ni, Cr, Mn and Co contained in a very small amount. Although the impurity concentration is not particularly limited, usually a highly pure alkoxide having an impurity concentration of 1 to 0.001 ppm can be obtained from a starting alkoxide having an impurity concentration of 100 to 0.1 ppm.
The niobium alkoxides and tantalum alkoxides to be purified by the present invention are those which can be distilled. They include, for example, niobium pentamethoxide, niobium pentaethoxide, niobium pentapropoxide, niobium pentaisopropoxide, niobium pentabutoxide, niobium pentaisobutoxide, niobium penta-tert-butoxide, niobium penta-sec-butoxide, tantalum pentamethoxide, tantalum pentaethoxide, tantalum pentapropoxide, tantalum pentaisopropoxide, tantalum pentabutoxide, tantalum pentaisobutoxide, tantalum penta-tert-butoxide and tantalum penta-sec-butoxide.
In the process of the present invention, a liquid alkoxide can be purified as it is or in the form of a solution thereof in an organic solvent; and a solid alkoxide can be purified after dissolving it in an organic solvent. The organic solvents include, for example, hydrocarbons such as hexane, heptane and cyclohexane; aromatic hydrocarbons such as benzene and toluene; ethers such as diethyl ether, tetrahydrofuran and dioxane; and alcohols having the same alkyl groups as those of the alkoxides.
In the process of the present invention, the alkoxide containing the impurities is kept in liquid form and about 1 to 20% thereof is hydrolyzed under stirring. The hydrolysis rate is herein defined to be the percentage of the quantity of water added in the purification treatment to the quantity of water necessitated for the following formal reaction formula:
Ta(OR).sub.5 +3H.sub.2 Oโ1/2Ta.sub.2 O.sub.5 -H.sub.2 O+5ROH
(wherein R represents an alkyl group)
Namely, when 0.03 mol of water is added to 1 mol of Ta(OR) 5 , the hydrolysis rate is 1%.
After the completion of the hydrolysis of a predetermined amount of the niobium alkoxide or tantalum alkoxide, the unreacted alkoxide becomes substantially free from the impurities and the impurities are contained in the solid or sol/gel reaction product supposedly because the hydrolysis of the impurities occurs simultaneously to the hydrolysis of the niobium alkoxide or tantalum alkoxide or the coprecipitation reaction of the impurities with niobium oxide hydrate or tantalum oxide hydrate occurs preferentially.
When the solution is hydrolyzed without the stirring, the reaction occurs only locally and, therefore, the impurities cannot be substantially removed.
Water used for the hydrolysis is not limited to the water but also include water vapor. Although it is preferred to feed water after diluting it by dissolving or dispersing in the organic solvent so as to prevent the localized reaction, the water can be fed also as it is.
The quantity of water used in the present invention is that corresponding to a hydrolysis rate of the niobium alkoxide or tantalum alkoxide of about 1 to 20%. When the hydrolysis rate is below 1%, the removal rate of the impurities is reduced and, on the contrary, a hydrolysis rate of above 20% is economically disadvantageous, though the impurity-removal rate is increased.
After the completion of the hydrolysis, the alkoxide hydrate is in the form of a sol/gel suspension. The solvent is directly distilled out and then the product is obtained by the distillation. As a matter of course, the products formed by the hydrolysis can be separated, if necessary, by leaving to stand, filtration, centrifugation or the like.
The distillation is an indispensable step in the present invention. When this step is omitted, the effective removal of the impurities is impossible. It is also a characteristic feature of the present invention that the distillation may be simple distillation without necessitating multi-stage rectification. Since niobium alkoxides and tantalum alkoxides are thermally stable and they can be distilled at a temperature of 200ยฐ C. or higher without thermal decomposition, even the compounds which are in solid form at room temperature can be distilled by elevating the temperature to the melting point thereof or above.
By the process of the present invention, the impurity concentration can be easily lowered, for example, from 100 ppm to 1 ppm or from 0.1 ppm to 0.001 ppm, to obtain the niobium alkoxides and tantalum alkoxides having an extremely high purity.
Thus, by the process of the present invention, recovered, unreacted alkoxides used in CVD method or alkoxides contaminated under unexpected conditions can be reused after the purification.
The following Examples will further illustrate the present invention.
EXAMPLE 1
51.3 g (125 mmol) of tantalum pentaethoxide and 32 ml of dehydrated ethanol were fed into a 100 ml flask having a stirrer, condenser, dropping funnel and thermometer. Water in an amount shown in Table 1 was diluted with 6 ml of dehydrated ethanol and added to the resultant mixture through a dropping funnel under stirring at 35ยฐ C. for a period of 20 minutes to hydrolyze tantalum pentaethoxide. After aging at 70ยฐ C. for 1 hour, the reaction liquid was in the form of a translucent sol. After distilling off ethanol under reduced pressure followed by simple distillation under 0.3 Torr, 39 g (96 mmol) to 41 g (101 mmol) of colorless, transparent tantalum pentaethoxide was obtained at a distillation temperature of 130ยฐ C. to 145ยฐ C. (yield: 76 to 80%). The concentrations of impurity elements in thus purified tantalum pentaethoxide are shown in Table 1.
It is apparent from the results that by hydrolyzing at least 1% of the starting alkoxide, the impurities can be effectively removed from the starting material. As shown in Comparative Example, the significant results cannot be obtained when the hydrolysis rate is 0.1%.
TABLE 1______________________________________ Starting Purified tantalum alkoxideSample No. material 1 2 3 (Comp. Ex.)______________________________________Amount of water 0.28 0.10 0.01added (g)Hydrolysis rate (%) 4.3 1.5 0.1Impurity conc.(ppm)Fe 0.20 0.002 0.010 0.13Ca 0.37 0.001 0.005 0.21Sr 0.05 0.001 0.001 0.03Na 0.05 <0.01 <0.01 0.03U 0.02 <0.001 <0.001 0.01______________________________________
EXAMPLE 2
45.0 g (141 mmol) of niobium pentaethoxide and 35 ml of dehydrated toluene were fed into the same reactor as that used in Example 1. The resultant mixture was treated with 0.35 g (19 mmol) of water diluted with 7 ml of dehydrated ethanol under the same conditions as those in Example 1 (hydrolysis rate: 4.6 %). The solvent was distilled off under reduced pressure and then the simple distillation was conducted under 0.3 Torr to obtain 37 g (116 mmol) of colorless, transparent niobium pentaethoxide at a distillation temperature of 140ยฐ C. to 155ยฐ C. (yield: 82%). The concentrations of the impurity elements in the starting material and purified alkoxide are shown in Table 2.
TABLE 2______________________________________Impurity conc.(ppm) Starting material Purified niobium alkoxide______________________________________Fe 0.60 0.005Ca 0.25 0.001Sr 0.05 0.001Na 0.06 <0.01U 0.02 <0.001______________________________________
According to the present invention, niobium alkoxides and tantalum alkoxides containing Fe, Ca, Sr, Na, U, etc. as impurities can be very easily purified.
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A process, excellent in the mass productivity and economization, for purifying a niobium alkoxide or tantalum alkoxide containing Fe, Ca, Sr, Na, U, etc. as impurities to attain a purity necessitated for electronic materials or the like is provided. A niobium alkoxide or tantalum alkoxide containing the above-described impurities is dissolved in a solvent to obtain a solution, 1 to 20% of the alkoxide in the solution is hydrolyzed under stirring to form a solid reaction product, and the reaction product is separated from the unreacted alkoxide by the distillation to recover the alkoxide.
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FIELD OF THE INVENTION
This invention relates to the electrolytic removal across a cation selective membrane of sodium ions from aqueous solutions containing dissolved sodium tungstate.
BACKGROUND OF THE INVENTION
Several different processes are used to recover tungsten from minerals such as wolframite and scheelite. P. Borchers presented a review article entitled "Processing of Tungsten" (Published on page 64 of a book entitled "Tungsten". Proceedings of the First International Tungsten Symposium, Stockholm, 1979). Borchers indicated that it was common practice to dissolve the tungsten contained in various types of minerals in either acidic media (usually aqueous hydrochloric acid) or alkaline media (i.e. aqueous solutions containing stoichiometrically excess amounts of sodium carbonate and/or sodium hydroxide). It is reported in the literature, and it is known to those skilled in the art, that high grade scheelite-type concentrates are frequently processed using the aqueous hydrochloric acid route; wolframite is often processed using sodium hydroxide, and lower grades of scheelite-type concentrates are often processed using a pressure leaching route utilising aqueous sodium carbonate (with the possible addition of some sodium hydroxide). Processes for the purification and processing of such acidic and alkaline leach liquors to recover various tungsten-containing compounds are well described in the literature. In the alkaline routes the tungsten is frequently present in the form of dissolved sodium tungstate species which are present in aqueous solutions which may also contain sodium hydroxide and/or sodium carbonate. It is usual to neutralise chemically the sodium hydroxide and/or sodium carbonate using sulphuric acid, prior to the conversion of the sodium tungstate species to ammonium tungstate as an intermediate in the production of ammonium paratungstate crystals. To those skilled in the art it is known that even in the hydrochloric acid leaching processes, purification steps can exist in which the tungsten appears as dissolved sodium tungstate species, and that such species then need to be converted to ammonium tungstate prior to conversion to ammonium paratungstate crystals.
One of the methods for converting sodium tungstate to ammonium tungstate which has been accepted by industry, involves the use of a liquid solvent extraction process. T. M. Kim and M. B. MacInnis describe such a process. (Extractive Metallurgy of Refractory Metals. Edited by H. Y. Sohn et al. Proceedings of a symposium sponsored by the TMS-AIME Refractory Metals Committee and Physical Chemistry of Extractive Metallurgy Committee at the 110th AIME Annual Meeting, Chicago, Ill. 1981). During such a solvent extraction process the sodium associated with the tungstate anion is converted to sodium sulphate. Hence it is observed that existing processing technology results in the conversion of virtually all the sodium ions associated with sodium hydroxide, carbonate or tungstate to the soluble sodium sulphate form. Y. A. Topkaya and H. Eric (in a paper entitled "Laboratory Testing of Uludag Scheelite Concentrate for the Production of Ammonium Tungstate" presented at the MINTEK 50 International Conference on Recent Advances in Mineral Science and Technology at Sandton in South Africa during 1984) described the testing of a processing route which utilises some of the features indicated above, and demonstrates how all the sodium carbonate initially introduced to the process for leaching of the tungsten reports finally as sodium sulphate.
The existing tungsten extraction technology which produces aqueous effluents containing sodium sulphate and other types of contaminants such as calcium chloride and/or sodium chloride thus exhibit disadvantages as follows:
(a) The acid required to neutralise the sodium hydroxide, carbonate or tungstate effectively can represent a substantial cost, and the acid is not recovered or reused.
(b) The original source of the sodium ions in the process (i.e. sodium hydroxide or sodium carbonate) can also represent a substantial cost, and such bases are also not recovered or reused.
(c) The neutral dissolved salts which are ultimately produced represent pollutants. Environmental legislations for the disposal of aqueous effluents are generally becoming more stringent, and the cheap disposal of effluents containing significant concentrations of such dissolved salts is generally not possible.
(d) The water associated with substantial concentrations of dissolved salts cannot be recycled, and needs to be disposed of. This represents another cost, and a waste of water.
British Patent Specification No. 2 137 658 describes a method whereby sodium cations are removed from an anolyte through a cation selective membrane into a catholyte under the influence of an electrical potential. This method is used in the context of concentrating dilute caustic alkali and of increasing the life of the electrodes by periodic current reversal.
British Patent Specification No. 2 073 780 teaches the purification of molybdenum compounds by moving cations through a cation selective membrane in an electrolytic cell. It is to be noted, however, that the molybdenum compounds in this process are in essentially insoluble form.
SUMMARY OF THE INVENTION
According to this invention there is provided a process for removing sodium ions from an aqueous alkaline solution containing dissolved sodium tungstate including the steps of providing an electrolytic cell in which a cation selective membrane separates an anode compartment from a cathode compartment, passing the solution through the anode compartment passing an electrical direct current through the cell to cause the sodium ions to migrate through the cation selective membrane and tungstic acid to be produced in the anode compartment, and bleeding sodium-containing alkali from the cathode compartment at a rate sufficient to prevent build-up of alkali in the cathode compartment. The sodium tungstate solution will, of course, be substantially free of hydroxide-precipitate forming cations.
The present invention represents an improvement over the current tungsten extraction technology which has been discussed above in that the sodium ions associated with sodium hydroxide, sodium carbonate and sodium tungstate in an alkaline aqueous solution (anolyte) can be removed across a cation selective membrane using an electrical driving force in such a way that a solution containing sodium hydroxide (catholyte) is recovered. The sodium hydroxide in such catholyte can be converted to sodium carbonate using carbon dioxide if so desired, and this then permits the regeneration for re-use of the alkaline leaching reagents. The anolyte solution will contain tungstic acid and perhaps some uncovered sodium tungstate. The tungstic acid so produced, is present in a form which is initially soluble, but subsequently precipitates from the solution in a crystalline form. The dissolved or crystalline forms of the tungstic acid can then be simply treated with ammonia to produce ammonium tungstate. Thus this invention represents a new method for converting sodium tungstate to ammonium tungstate, and can be advantageously used as a purification step by effecting a separation of the tungsten species from certain impurities which are co-dissolved with the tungsten during leaching.
The current densities employed will typically be in the range 50 A/m 2 to 5000 A/m 2 preferably 500 A/m 2 to 2000 A/m 2 .
The tungstic acid may be recovered and optionally converted to tungstic oxide or it may be converted to ammonium tungstate by treatment with ammonia.
BRIEF DESCRIPTION OF THE DRAWINGS
The attached FIG. 1 is a diagram depicting a schematic arrangement of electrolytic membrane apparatus of the type used to generate the data for the examples.
The attached FIG. 2 is a schematic flowsheet of a process which utilises features of the present invention for the recovery of ammonium paratungstate from tungsten-containing minerals.
The attached FIG. 3 is a schematic flowsheet representing an existing hydrochloric acid route which has been modified by the inclusion of features of the present invention for the processing of tungsten-containing minerals.
DETAILED DESCRIPTION OF THE INVENTION
As mentioned previously, Y. A. Topkaya and H. Eric (in a paper entitled "Laboratory Testing of Uludag Scheelite Concentrate for the Production of Ammonium Tungstate" presented at the MINTEK 50 International Conference on Recent Advances in Mineral Science and Technology at Sandton in South Africa during 1984) described the testing of a processing route which utilises typical currently accepted technology, and demonstrates how all the sodium carbonate initially introduced to a soda ash pressure leaching process finally reports as sodium sulphate. This paper represents an example of a typical process presently used to process tungsten bearing minerals, and the advantage of the present invention become apparent when compared to the process described in this paper.
FIG. 1 illustrates an electrochemical cell consisting of an anode compartment 10 separated from a cathode compartment 12 by a cation selective membrane 14. The anode compartment 10 contains an anode plate 16 consisting for example of graphite or PGM coated titanium, although other materials of construction can be used. The cathode compartment contains a metallic cathode sheet 18 conisting for example of mild or stainless steel, although other materials of construction can be used. The anode and cathode plates are parallel to, and on either sides of, the cation selective membrane 14 as close as possible to the membrane but without actually contacting the membrane. The membrane used in the examples was manufactured by Ionac Chemicals in the U.S.A., and is identified as the MC-3470 cation selective type. Other cation selective membranes can, of course, be used. Solutions of electrolyte, which will presently be described, are required to flow through the electrode compartments between the electrodes and the membrane. It may be advantageous to install thin plastic turbulence promoter sheets between the electrodes and the membrane to increase turbulence at the membrane and electrode surfaces, and to prevent direct contacting between the electrodes and the membrane. The apparatus is provided with a rectifier 19 which converts a.c. (alternating current) electricity to d.c. (direct current electricity). The anolyte and catholyte solutions are pumped by pumps 20, 22 from their respective reservoirs 24, 26 through flow rate regulators 23, 25 to the electrolytic cell, from which they are allowed to flow continuously back to their respective reservoirs through condensers 28, 30. In practice, the solutions may be pumped through a bank of cells with or without intra-stage recirculation taking place.
In the examples described hereinafter anolyte solutions were used which initially contained sodium carbonate only, and also those which initially contained a mixture of sodium carbonate and sodium tungstate. In some of the examples the catholyte initially consisted of water which contained a small concentration of sodium hydroxide to provide electrical conductivity. It is believed that the reactions which take place are as follows. Assuming that the anolyte initially contains sodium carbonate and/or sodium tungstate, on applying a current across the cell water is dissociated at both the anode and the cathode, liberating oxygen gas at the anode and hydrogen gas at the cathode. These gases could conceivably be collected and used. The cation selective membrane separating the anode from the cathode will ideally only allow the movement of positive ions through it. Thus, if the anolyte contains sodium carbonate and sodium tungstate, the only cations present are the sodium ions and the hydrogen ions (which result from the dissociation of water at the anode). The sodium ions move through the membrane preferentially. It is possible to have an acid such as sulphuric acid initially present in the catholyte so that as hydrogen is liberated at the cathde, and as sodium ions migrate through the membrane, sodium sulphate is formed on the catholyte. As the anolyte loses sodium cations through the membrane, the carbonate anion takes up protons to form carbonic acid, (which under atmospheric conditions readily decomposes into water and carbon dioxide), and the tungstate ions take up protons to form tungstic acid (which because of its low solubility in water will, if allowed to stand long enough, precipitate out of solution in a crystalline form). Thus, the sodium carbonate is effectively removed from the anolyte solution. By means of this invention it has been shown to be possible to remove all the sodium carbonate completely and selectively and without removing any sodium ions from the sodium tungstate. This feature may be useful in the event of wanting to remove and recycle sodium carbonate from a leach solution without changing the form of the sodium tungstate so that the sodium tungstate can be further processed by alternative technology to that described herein (e.g. by means of a solvent extraction). Alternatively, it may be desirable to intrduce steps to remove various other impurities from the solution (such as silica, phosphorus, arsenic, molybdenum, etc.) prior to converting the sodium tungstate to ammonium tungstate by means of the electrolytic processes of the invention. It is well known to those skilled in the art that if carbon dioxide is absorbed into an aqueous solution containing sodium hydroxide, that a rapid reaction to form sodium carbonate takes place. Thus, it is feasible that carbon dioxide (formed as the result of the decomposition of carbonic acid) which is recovered from the anolyte, can be used to regenerate sodium carbonate which may then be recycled for reuse in a leaching operation. Alternatively, carbon dioxide from an independent source could be used for this purpose. It has also been shown in this invention, that where sufficient sodium ions are removed to permit the production of tungstic acid, that addition of ammonia to the solution before precipitation of the tungstic acid takes place, results in the rapid conversion of the tungstic acid to ammonium tungstate. In this event no separation of the tungsten from impurities in the catholyte will have taken place. However, it has also been shown generally that allowing the tungstic acid to precipitate, filtering the precipitate from the anolyte, and then adding ammonia to convert the tungstic acid precipitate to ammonium tungstate can result in a separation of the tungsten from certain other impurities contained in the catholyte.
It is useful at this stage to define the term "membrane current efficiency", as it is used in the examples which follow. The membrane current efficiency is defined as being the ratio of the actual measured flux of sodium ions across the membrane under the prevailing conditions, divided by the flux of sodium ions across the membrane which can be theoretically calculated (using the so-called Faraday's equation) under the assumption that all of the electrical current results in the transfer of sodium cations only (and no other cations) across the membrane. Thus, for example, at a 100% membrane current efficiency, the actual amount of sodium ions passed through the membrane equals the theoretically calculated amount. In practice because the competition of the hydrogen cations (which can also migrate through the membrane) with the sodium cations, the membrane efficiency is generally less than 100%.
In the following examples, a cell was used in which a stainless steel cathode, a lead anode and a cation selective membrane (each with the same area of 0,02 m 2 ), were located parallel to one another with plastic turbulence promoters present to ensure gap widths of about 5 mm between each of the electrodes and the membrane. In the examples, provision was made to pump (at regulated flowrates) the anolyte and the catholyte from their reservoirs to the anode and cathode compartments and back again to their respective reservoirs. About three liters of anolyte and three liters of catholyte were used in each experiment. An electrical rectifier was used to provide direct current to the cell. During each experiment, samples of the anolyte and the catholyte were taken for analysis, and measurements were made of the temperature, current and cell voltage drop respectively. The results of the examples are now presented.
EXAMPLE 1
In this example a liquor is used which was produced as follows: Various solutions from within an industrial tungsten process (for example, the supernatant liquor removed after preciptation of ammonium paratungstate (APT) and the wash water used to wash the APT crystals) was added to a stirred vessel and boiled with caustic soda added to maintain a pH value of about 9 so that all ammonium tungstate would convert to sodium tungstate. Three liters of this solution was passed as an anolyte through a cell as described previously. The catholyte used consisted of 3 liters of an aqueous sulphuric acid solution so that as the sodium ions transferred from the anolyte to the catholyte, the sulphuric acid would be neutralised and the change in acid concentration with time could be measured. The current density used was 1000 A/m 2 . The results of this experiment are shown in the following table 1.
The results on table 1 show that the sodium ions removed from the anolyte resulted in a stoichiometric decrease in the concentration of sulphuric acid in the catholyte. There was no change in the concentrations of tungsten in the anolyte demonstrating that no tungsten-containing chemical species passed through the cation selective membrane. The tungsten remained in the anolyte solution as dissolved tungstic acid. In previous experiments of this type it was demonstrated that on standing, the tungstic acid eventually precipitated from the final sodium deficient anolyte. In this experiment 170 ml of a 25% (m:m basis) solution of ammonium hydroxide was added to the final anolyte to raise the pH to 9,5 so that all the dissolved tungstic acid converted to ammonium tungstate. This final solution containing the ammonium tungstate was evaporated until crystals of APT were produced. Thus this example demonstrates the ability of the present invention to convert dissolved sodium tungstate species to dissolved tungstic acid, which on addition of ammonia converts to ammonium tungstate.
TABLE 1______________________________________Time Voltage Temp Catholyte Anolyte(mins) (V) (ยฐC.) H.sub.2 SO.sub.4 pH W Na.sup.+______________________________________ 0 11,4 20 52,8 9,4 103 29 60 5,5 32 39,0 8,0 -- --120 5,4 36 29,3 8,3 -- --180 6,0 38 14,5 6,6 -- --240 7,1 40 4,6 -- -- --280 6,4 40 1,5 5,7 103 4______________________________________
EXAMPLE 2
In this example, the results of nine experiments are summarised. Each experiment started with pure sodium carbonate in the anolyte such that the sodium concentration was initially 24 g/l, and each experiment started with pure sodium hydroxide in the catholyte such that the sodium concentration was about 1,7 g/l. The nine experiments were performed with current densities of 500 A/m 2 , 750 A/m 2 and 1000 A/m 2 at each of three temperatures, namely 26ยฐ C., 40ยฐ C. and 50ยฐ C. respectively. For each experiment, the resultant decrease in sodium ion concentration in the anolyte was matched by a stoichiometric increase in the sodium ion concentration in the catholyte. The membrane current efficiencies for all of the experiments were in excess of 95%, with the average being about 98%. The chemistry of the system was such that on removal of the sodium ions from the anolyte, carbonic acid was formed in the anolyte which decomposed to carbon dioxide and water. Thus in this example is demonstrated the ability of the present invention to remove sodium carbonate from an aqueous stream, and in so doing simultaneously generate caustic soda in another aqueous catholyte stream. It is clear to those skilled in the art that such regenerated sodium hydroxide can be treated with carbon dioxide to form sodium carbonate which can then be reused if so desired.
EXAMPLE 3
In this example pure sodium carbonate was added to an aqueous solution which contained sodium tungstate. The temperature was maintained at 26ยฐ C., and the current density at 1000 A/m 2 . The sodium carbonate added to the anolyte was the equivalent of 16 g/l of sodium ions. The sodium ions initially present in the catholyte as sodium hydroxide was 2,4 g/l. During the experiment the sodium ion concentration in the catholyte, and the overall cell voltage drop was monitored. The results for this experiment are presented in table 2.
TABLE 2______________________________________Time Cell Voltage Na.sup.+ in catholyte(hours) (V) (g/l)______________________________________0 8,2 2,4 0,25 8,1 3,90,5 7,5 5,2 0,75 7,2 6,71,0 7,2 8,11,5 6,9 10,82,0 6,8 -13,53,0 5,7 18,84,0 -- 23,25,0 7,2 28,06,0 8,1 31,87,0 10,2 35,2 8,25 11,9 37,4______________________________________
Interpretation of the data presented in table 2 reveals that during the first 2,5 hours about 15 g/l of the sodium ions are removed from the anolyte at a membrane current efficiency of about 97%. This amount of sodium ions represents the amount added to the anolyte as pure sodium carbonate. From 2,5 hours to 8,25 hours, about 22,5 g/l of additional sodium ions were removed from the anolyte at a membrane current efficiency of about 80%. It is evident that the sodium carbonate is first removed from the anolyte, and thereafter the sodium tungstate is converted to tungstic acid. It is obvious that the experiment could have been terminated after 2,5 hours, and thus the sodium carbonate would have been selectively removed from the sodium tungstate. Such selective prior removal of the sodium carbonate would be an advantage in the event of introducing one or more anolyte purification steps before converting the sodium tungstate to tungstic acid. The introduction of such purification steps (to remove for example molybdenum, silica, phosphorus, arsenic, etc) before conversion of the residual sodium tungstate to ammonium tungstate (i.e. via tungstic acid as an intermediate), could greatly benefit the subsequent APT precipitation step and result in even greater APT purity being achieved. It is noted on table 2 that the cell voltage decreased to a minimum of about 5,7, and thereafter increases to a value of nearly 12. It is expected that during truly continuous operation of the process that a constant steady state cell voltage would ultimately be achieved. However, the results do suggest that as the concentration of tungstic acid increases, the anolyte becomes less conductive indicating the weakly dissociated nature of the tungstic acid and the cell voltage tends to increase. It is clear to those skilled in the art, that the use of other materials of construction for the anode and the cathode, and optimisation of the design of the entire electrolytic membrane cell could result in lower cell voltages than those reported in table 2.
FIG. 2 represents a suggested flowsheet for a tungsten recovery process which embodies many of the features of this invention. For the purpose of the example exemplified by FIG. 2, scheelite concentrate is initially treated in a pressure leaching operation which utilised stoichiometric excess amounts of sodium carbonate. It is noted on FIG. 2 that after pressure leaching of the scheelite concentrate, the excess sodium carbonate is removed from the leach solution using an electrolytic membrane process of the type described in this invention. The resultant solution is then subjected to one or more purification steps if so desired, to remove impurities which are present with the sodium tungstate. The purified soluton is then further treated in an electrolytic cell operation to convert the sodium tungstate to tungstic acid, which on addition of ammonium hydroxide is converted to ammonium tungstate. The ammonium tungstate solution is then evaporated to precipitate ammonium paratungstate crystals. It is further noted that all the sodium hydroxide generated in the cell catholyte solutions can be recarbonated to result in the regeneration of sodium carbonate which can then be recycled for reuse in the pressure leaching operation. Carbon dioxide from the decomposition of carboxylic acid in the anolyte, as well as fresh make-up carbon dioxide from a cylinder could conceivably be used. It should be noted that in the event of permitting the tungstic acid to precipitate out of solution, that separation of such tungstic acid precipitate from the host liquor may result in substantial rejection of impurities with the host liquor. This may then remove the need to introduce the suggested purification steps.
FIG. 3 represents a process in which a tungsten-bearing concentrate is leached in hydrochloric acid, as has been described previously. The process requires the dissolution of the resultant crude tungstic acid (which was produced in the hydrochloric acid leaching step) by ammonia. The ammonium tungstate so produced is then subjected to a crystallisation step in which water is evaporated in order to crystallise and precipitate APT. The APT crystals are collected and washed. The leach residue (after dissolution of the crude tungstic acid) is digested in a solution containing caustic soda in an attempt to further solubilise any residual tungsten. After filtration and washing of the filter cake, the final residue is disposed of. The supernatant liquor from the APT crystallisation step (which contains most of the soluble impurities); the wash water used to wash the APT crystals, and the sodium tungstate soluton (produced by boiling the residue in caustic soda) is then combined and boiled with the addition of ammonium hydroxide to reduce the volume of water and convert all ammonium tungstate to sodium tungstate. This so-called "boildown" liquor is then treated as anolyte in electrolytic membrane apparatus according to the teachings of this invention to remove sodium ions from the anolyte, and the resultant dissolved tungstic acid is allowed to precipitate out of solution. The tungstic acid precipitate is separated from the host liquor. The host liquor containing the major part of certain impurities is discarded, whilst the tungstic acid is recycled and added to the step in which the crude tungstic acid (contained in the leach residue) is dissolved in ammonia. The caustic soda recovered in the cell catholyte can be recycled for reuse in the process. It may in practice be necessary to introduce one or more purification steps between the boildown step and the electolyte membrane step in order to remove certain impurities from the circuit (such as molybdenum, phosphorus, arsenic, silica, etc).
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A method of removing sodium ions from an alkaline aqueous solution such as a leach solution which contains dissolved sodium tungstate. The method involves passing the solutions through the anode compartment of an electrolytic cell and passing an electrical direct current through the cell causing the sodium ions to pass through the cation selective membrane and tungstic acid to be produced in the anode compartment. Sodium-containing alkali is bled from the cathode compartment at a rate sufficient to prevent build-up of alkali in the cathode compartment. The tungstic acid is typically converted to ammonium tungstate by treatment with ammonia and then the ammonium tungstate further treated for recovery of the tungsten values.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application 61/125,841 filed Apr. 29, 2008, and the complete contents of that application are fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention generally relates to materials, and more particularly, to foam matrices having an open pore structure where a metal or metal alloy coats the pores within the foam matrix. The invention is also generally related to electrolytic and electroless plating of foam matrices.
[0004] 2. Background of the Invention
[0005] Few references describe methods for applying metal coatings to foam matrices, and particularly ceramic foam matrices. U.S. Pat. No. 5,503,941 to Pruyn and U.S. Pat. No. 5,584,983 to Pruyn describe a metal foam. In the Pruyn process the starting material being plated is used only as a scaffold, and is then melted away. U.S. Pat. No. 6,395,402 to Lambert describes an electrically conductive polymeric foam. Wiechman et al., โHigh Thermal Conductivity Graphite Foam-Progress and Opportunitiesโ, Proceeding of the International Society for the Advancement of Materials and Process Engineering (SAMPE) Technical Conference, Dayton Ohio, 9 Sep. 2003, indicates that companies have been investigating plating metals on the surface of carbon foams by electrodeposition or electroless plating so that the graphite foam is coated prior to soldering.
[0006] A particular problem with coating foam matrices is the ability to coat the pores inside the foam. In prior art methods, the coating material is plated onto the top or bottom surface of a foam and does not penetrate into the foam and may also plug the passages of the foam at the surface. Ideally, penetration throughout the foam's interior will allow the foam to obtain the benefits of both the foam matrix and the metal plating. Further, conformal coating of the pores within the foam will allow the foam to have the same attributes of the foam matrices in terms of flow through passage and increased surface area; however, such devices and systems have not been heretofore realized.
SUMMARY OF THE INVENTION
[0007] According to the invention, methods have been devised to, preferably fully and uniformly, coat the surfaces of open pores throughout the thickness of foam materials with metal in a way that does not close the porosity and leaves fluid flow though the foams unhindered. Plating the foam matrix can be performed by electrochemical techniques, such as electroless or electrolytic deposition. Particularly promising results are obtained when utilizing a plating bath having a low surface tension. The baths can be controlled to vary the thickness of the metal coating, and can be used to plate electrically conductive or non-conductive foams. The combination of the large surface area of the foams and the numerous metals and alloys that can be deposited with this method results in a final composite with a broad range of applications in areas such as: improved solderability and thermal management (heat sinks, heat exchangers, phase-change cooling systems, thermally conducting structures); catalysis (catalytic converters, fuel cells, hydrogenation); electromagnetic interference (EMI) shielding, and acoustic dampening (gun silencers). The coatings lend properties to the foam matrix which stem from the deposited metal, such as increased strength; toughness; ferromagnetism; corrosion resistance; etc., to any application of the foams.
[0008] Ceramic matrix composite (CMC) systems according to the invention may include a matrix of carbon or graphite with a deposited layer of copper or nickel. Additional plating materials include but are not limited to palladium, platinum, silver, copper, nickel, tin, titanium, aluminum, their oxides, tungsten carbide, silicon carbide, chromium carbide, and combinations thereof for plating by either electroless or electrolytic means. Using this method, nearly any foamable material could be uniformly coated. The metal coated foams have a lower pressure drop for air flow across the width of the foam compared to unplated foam, suggesting that the metal coating assists in producing more laminar flow.
[0009] The surface tension of the plating bath can be adjusted directly by adding surfactants, solvents or other additives to the plating bath. In addition, these agents (surfactants, solvents and other additives which reduce surface tension) can be added indirectly by being carried in by fixturing and other hardware or by the foam itself. The surface tension may be reduced by heating the plating bath. In addition, the surface tension may be overcome by applying hydraulic pressure at the time the metal or metal alloy is plated on the pore surfaces of the foam. Also, combinations of surfactants, solvents, heat adjustment, and pressure adjustment can be used to assure deep penetration of the plating bath constituents in the foam material and possible plating throughout the width of the foam material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic diagram of a foam matrix where open pores throughout the thickness dimension can be coated with a metal or metal alloy by electrolytic or electroless plating;
[0011] FIG. 2 is a scanning electron micrograph off a graphite foam with open pores coated with copper;
[0012] FIG. 3 is a schematic diagram of a particle uses for colloidal catalysis, as an alternative to sensitization and activation catalysis;
[0013] FIG. 4 shows a cross-sectional view of a copper coating throughout the thickness of a graphite foam; and
[0014] FIG. 5 is a schematic drawing of a typical electrodeposition cell.
DETAILED DESCRIPTION
[0015] The cohesive force between liquid molecules is responsible for the phenomenon known as surface tension. Specifically, molecules at the surface of a liquid do not have other like molecules on all sides, and consequently the cohere more strongly to other like molecules directly associated with them on the surface. Surface tension prevents coating materials from penetrating deep within foam matrices.
[0016] By decreasing the surface tension of metal or metal alloy plating baths, it has been found that open pore ceramic foams (i.e., ceramic foams having pores of 10 nm-100 mm in diameter, and particularly ceramic foams having pores of 1 mm or smaller) can be effectively coated with a conformal metal or metal alloy coating which adheres to the surfaces of the pores inside the ceramic foams. The surface tension can be decreased, preferably by 25% or more and more preferably by 35% or 50% or more, by the addition of surfactants, solvents, or other constituents which decrease surface tension to plating bath compositions. It is advantageous if the plating bath composition has a surface tension of 50 dynes/cm or lower, and more preferably 40 dynes/cm or 30 dynes/cm or lower. However, benefits for applying a metal or metal alloy coating to the open pores of ceramic matrix foams can be achieved simply by reducing the plating bath surface tension by 15-20 dynes/cm or more. The additives which can accomplish the requisite reduction in surface tension of a plating bath include, but are not limited to, cationic, anionic, zwitterionic, nonionic surfactants, and fluorosurfactants such as โZonylโ and โTritonโ, including ordinary soaps such as โIvoryโ and โDawnโ, shampoos such as โSuaveโ and โPanteneโ, detergents such as โTideโ and โBoraxโ, fabric softener such as โDownyโ and โSnuggleโ, foaming agents such as sodium lauryl sulfate and ammonium lauryl sulfate, dispersants such as โNanoSperse AQโ and โVersatexโ, plasticizers such as โJayflexโ and โK-FLEXโ, emulsifiers such as gum arabic and cetostearyl alcohol, as well as other common chemicals which can be used to decrease the surface tension of water, including residues that may be left on hardware after cleaning, as well as combinations of any of the above constituents. In the practice of the invention, reduction in surface tension by the addition of one or more constituents which lower the surface tension of the coating bath relative to the coating bath in the absence of the constituents will promote coating infiltration into the foam. The base surface tension of water is 72 dyn/cm in air. Most alcohols exhibit surface tensions in the low twenties. Good results have been achieved when the bath is generally below 35 dyn/cm, which can be accomplished with the addition of surfactants. As a general rule of thumb, a surface tension of under 50 dyn/cm corresponds to an approximate ห30% reduction in surface tension, and a surface tension under 35 dyn/cm corresponds to an approximate ห50% reduction in surface tension
[0017] The surface tension altering constituents can be added directly to the bath (as discussed above. However, it should be understood that these constituents may also be carried in by fixturing and other hardware or by the foam itself. Fixturing and hardware would be anything that come into contact with the plating bath during the plating process (e.g., racks or baskets holding the foam; tubing or containers which hold or transport other bath constituents; etc.). Thus, it will be recognized that the plating bath can be altered so as to have a reduced surface tension by combining surface tension altering constituents to the fixturing or hardware used in the process. Furthermore, surface altering constituents might also be carried by the foam itself. For example, a piece of foam could be dipped in or spray coated with a surfactant prior to adding the foam to a plating bath. Alternatively, the foam could be pre-cleaned in a bath containing an excessive amount of surfactant, and then be added to the plating bath without a rinse in pure water in between so that there would be carryover of surfactant to the plating bath (this may work well with strong surfactants).
[0018] In addition, surface tension can be overcome by the application of hydraulic pressure to force plating batch compositions through the open pores of a ceramic matrix foam having pores of 10 nm to 100 mm in diameter. Hydraulic pressure which is applied should be sufficient to reduce the surface tension and advance plating bath composition through the tortuous pathways of open pores in the ceramic foam, but should not be strong enough to crush or compact the ceramic matrix foam, i.e., hydraulic pressures ranging from zero up to the fracture strength of the base foam would be suitable. For example, with ceramic matrix foams, suitable hydraulic pressure can have a force of 0.001 to 32,633 ksi, and particularly 0.01-100 ksi. Suitable mechanism for applying hydraulic pressure include the application and removal of a vacuum, pumping of the plating bath solution with or without jetted nozzles, and agitation or movement of the foam within the solution. In the practice of the invention, hydraulic pressure can be used alone or in combination with the use of temperature or the addition of surfactants, solvents or other constituents to lower the surface tension of the plating bath composition.
[0019] Also, surface tension can be overcome by the application of heat to the plating bath composition. The heat applied should elevate the temperature of the plating bath composition above the freezing point of the constituents to a point which is less than the boiling point of the base solvent of the plating bath composition. For example, in an aqueous plating bath containing metal salts as precursors, increasing the temperature to 50-90ยฐ C. may provide a reduction in surface tension sufficient to allow penetration of the plating bath composition through the open pores of a ceramic foam. In the practice of the invention, temperature elevation can be used alone or in combination with the use of hydraulic pressure or the addition of surfactants, solvents or other constituents to lower the surface tension of the plating bath composition.
[0020] The invention has particular application to ceramic matrix foams. For example, the foam matrix can be an open pore foam of graphite, titania, alumina, silicon carbide, or any other ceramic material, including oxides, carbides, borides, nitrides, silicides and glasses, which would benefit from having open pores coated with a metal or metal alloy. However, aspects of the invention might also be practiced with other foam matrices including, for example, polymer and metal foams. Exemplary foams which may benefit from the processes of this invention include, but are not limited to, those set forth in Table 1.
[0000]
TABLE 1
Al 2 O 3
ZrO 2 Al 2 O 3 Y 2 O 3
SiC
Al MgSi
Al 2 O 3 SiO 2
ZrO 2 MgO
ZrO 2 CaO
Al SiC Si
MgO Al 2 O 3 SiO 2
ZrO 2 Y 2 O 3
SiO 2 Na 2 O
Al Al 2 O 3
ZrO 2 Al 2 O 3 SiO 2
ZrO 2 Y 2 O 3 CaO
Al Si
Al SiC
Cordierite
zirconia
mullite
hydroxyl patitite
PZT
NZP
AlN
BN
B4C
HfC
TaC
ZrC
[0021] Exemplary suppliers of open-cell carbon form include Koppers, Inc. of Pittsburgh, Pa. which makes โKFOAMโ; Poco Graphite, Inc. of Decatur, Tex. which makes โPOCOfoamโ and โPOCO HTCโ; Touchstone Research Laboratory of Triadelphia, W. Va. which makes โCFOAMโ; and GrafTech International Holdings of Parma, Ohio which make โGRAFOAMโ. Other suppliers of open-cell ceramic foam (carbon and other ceramic foams) include Ultramet of Pacoima, Calif., ERG Materials and Aerospace Corporation of Oakland, Calif., SELEE Corproation of Hendersonville, N.C., Allied Foam Tech Corporation of Montgomeryville, Pa., Meiling Ceramic of P.R. China, and Foshan Ceramics Research Institute of P.R. China. The invention can be practiced with a variety of foam materials including carbon, graphite, silicon carbide, titania, aluminum oxide, zirconia, yittria, as well as other ceramic materials including oxides, carbides, borides, nitrides, silicides, and glasses.
[0022] In the practice of the invention, any metal forming a salt which can be dissolved into a solvent subsequently reduced upon the foam substrate can be employed for coating the open pores of the foam matrix. For example, ions of Cu 2+ can generally be added as Cu salts such as CuSO 4 , but halides, nitrates, acetates, and other organic and inorganic acid salts of Cu may also be used. Some examples of metals which can be used as salts (i.e., metal or metal alloy precursors) in a plating bath include Cu, Ni, Sn, Co, Ag, Au, Pt, Pd, Fe, Sb, As, Cd, In and Pb. Alloys of all the mentioned metals are also possible with the additional alloying elements of P, B, Re, Mo, W, Zn, as well as other elements. The solvents which can be used in the plating bath include any liquid capable of solvating the salt used as the metal source. Exemplary nonpolar solvents include hexane, benzene, toluene, diethyl ether, chloroform, and ethyl acetate. Polar aprotic solvents include 1,4-dioxane, tetrahydrofuran (THF), dichloromethane (DCM), acetone, acetonitrile (MeCN), dimethylformamide (DMF), and dimethyl sulfoxide (DMSO), Polar protic solvents include acetic acid, n-butanol, isopropanol (WA), n-propanol, ethanol, methanol, formic acid and water. Ionized solvents(molten salts) include chlorides, fluroides, nitrates, bromides, etc.
[0023] With reference to FIG. 1 , it can be seen that the foam matrix 10 will have height, width, and thickness dimensions. The processes contemplated herein have particular application to foams with open pores 12 which range from 10 nanometers to 100 millimeters in diameter. The processes are particularly advantageous with foams having smaller pore sizes of 1 mm or less. The pores 12 do not need to be uniform in size; however, the foam matrix must have some open pores so that metal or metal alloy can coat the inside of the pores either deep into or throughout the width or thickness dimension 14 of the foam. For exemplary purposes, the open pores 12 are shown on a portion of the top surface 13 and side surface 13 โฒ; however, it should be understood that the foam matrix 10 will generally be constructed entirely from foam pores 12 . Further, as will be discussed in more detail below, the foam matrix 10 can be part of a solid support or other device. In the practice of the invention, the plating bath solution will be driven into the foam matrix at least a distance 16 or 16 โฒ of two pores 12 from a surface 13 , and more preferably a distance 18 of five pores 12 or more from the surface 13 . The invention thus allows coating more than, for example, the top surface 12 of the foam matrix. That is, the invention enables coating the pores of the open pore matrix deep into the thickness dimension and most preferably throughout its thickness dimension 14 . The metal coating is conformal and does not plug the pores at the surface 13 of the foam matrix 10 . Pathway 20 illustrates that the openings in the pores create a tortuous path from the top to the bottom of the foam matrix. Ideally, the invention will allow the entire pathway 20 to be coated with metal or metal alloy.
[0024] FIG. 2 shows a scanning electron microscopy image of copper plated pores in a graphite foam according to an example according to the invention. The pores are โopenโ as can be seen by the dark areas of the image, and the inside of the pores are coated with copper. Graphite ligaments are shown between the pores.
[0025] Using the procedures described herein a variety of foam matrices can have open pores coated with a variety of different metals and metal alloys including copper, nickel, aluminum, titanium, silver, gold, cobalt, tin, platinum, palladium, iron, antimony, arsenic, cadmium, indium, lead, neodymium, boron, phosphorous, samarium, bismuth, molybdenum, germanium, zinc, gallium, tungsten, vanadium, thallium, scandium, chromium, manganese, yttrium, zirconium, niobium, technetium, ruthenium, rhodium, hafnium, tantalum, rhenium, osmium, iridium, mercury and alloys containing any of these constituents such as:
Magnetic alloys including but not limited to: Permalloy, Alnico, Mu-metal, Fernico, Cunife, SmCo 5 , Sm 2 Co 17 , Supermalloy, MKM steel, Solder and brazing alloys including but not limited to: Sn/Pb, Sn/Pb70/30, Sn/Pb63/37, Sn/Pb60/40, Sn/Pb50/50, SnAgCu (SnAg 3.5 Cu 0.7 , Sn Ag3.5Cu0.9 , SnAg 3.8 Cu 0.7 , SnA g3.8 C u0.7 S b0.25 , SnAg 3.9 Cu 0.6 ), SnCu 0.7 , SnZn 9 , SnZn 8 Bi 3 , SnSb 5 , SnAg 2.5 Cu 0.8 Sb 0.5 , SnIn 8.0 Ag 3.5 Bi 0.5 , SnBi 57 Ag 1 , SnBi 58 , SnIn 52 , Ni/Ag, bronze, brass
Structural and specialty alloys can also be plated onto foam matrices including but not limited to: Invar, Kovar, Nambรฉ, Silumin, Megallium, Stellite, Ultimet, Vitallium, Electrum, Elinvar, amalgam, Inconel, Monel, Cromel, Hastelloy, Nichrom, Nitinol, Nisil, Cupronickel, Alnico, Zircaloy, and catalytic alloys
[0028] The process contemplated by the invention uses electrochemical metal deposition techniques. Electrochemical deposition of metals and alloys involves the reduction of metal ions from aqueous, organic, and fused-salt electrolytes. These techniques are known to those of skill in the art, and for the purpose of explanation herein the focus will remain on aqueous solutions only. The reduction of metal ions M z+ in aqueous solution is shown by Eq 1.
[0000] M z+ in solution +ze โ โM lattice โโEq 1
[0000] This can be accomplished via two different processes: (1) an electrodeposition process in which z electrons (e โ ) are provided by an external power supply or (2) an electroless deposition process in which a reducing agent in the solution is the electron source and there is no external power supply involved. These two processes, electrodeposition and electroless deposition, constitute electrochemical deposition and will be addressed in the following two sections.
[0029] Electrochemistry and electrode potential are well understood by those of skill in the art. For exemplary purposes, when a metal M is immersed in an aqueous solution containing ions of that metal, M z+ there will be an exchange of metal ions between the solution and the metal. Some M z+ ions from the crystal lattice enter the solution, and some ions from solution enter the crystal lattice. Initially one of these will occur faster than the other. Let us assume that conditions are such that more M z+ ions leave than enter the crystal lattice. In this case, there is an excess of electrons in the metal and it acquires a negative charge, q M โ (charge on the metal per unit area). In response to the charging of the metal side of the interface, there is also a rearrangement of charges on the solution side. The negative charge on the metal attracts the positively charged M z+ ions from the solution and repels negatively charged ions. The result is an excess of positive M z+ ions in the solution in the vicinity of the metal/solution interface. At the same time, the solution side of the interface acquires opposite and equal charge, q s + (the charge per unit area on the solution side of the interface). This positive charge on the solution side slows down the rate of M z+ ions leaving the crystal lattice (due to repulsion) and accelerates the rate of ions entering the crystal lattice. After a certain period of time a dynamic equilibrium between the metal M and its ions in the solution will result according to Eq 2,
[0000] M z+ +ze M 0 โโEq 2
[0000] where z is the number of electrons involved in the reaction. In this reaction taken from left to right, electrons are consumed through the reduction of the metal ions. From right to left, electrons are released through the oxidation of M 0 . Again, equilibrium occurs when the rate at which both of these mechanisms occur is equal. When this is true, the charge on the metal (q m ) is equal to the charge of the solution (โq s ) at the interface.
[0030] Before and while this equilibrium is being reached, there exists a potential difference between that of the metal and the solution. In order to measure the potential difference of this interphase, it must be connected to another one forming an electrochemical cell. The potential difference can then be measured across the entire cell.
[0031] Electrochemical deposition takes advantage of the nonequilibrium transfer of ions to and from the solution. In the nonequilibrium state there is a steady state of ions either being deposited or dissolved from any electrode in contact with the electrolyte solution. During electroplating an external power source, commonly called a rectifier, is connected between two electrodes both of which are in contact with the electrolyte, and the applied voltage maintains a constant state of nonequilibrium causing constant deposition at the cathode. In electroless plating, the state of nonequilibrium is simply prolonged by complexing agents which bind metal ions allowing for controlled deposition of the plated species from a relatively concentrated electrolyte.
[0032] Electroless plating is also understood by those of skill in the art. For exemplary purposes, electroless (autocatalytic) plating involves the use of a chemical reducing agent to reduce chelated metal ions at the solution/substrate interface forming a uniform deposition upon the surface. This process can be done for several different metals and alloys including: Cu, Ni, Co, Pd, Pt, Au, Cr and a variety of alloys involving one or more of these constituents plus P or B. This process is deemed โelectrolessโ due to the lack of a need for external electrodes or a power supply. There is however a transfer of electrons from the reducing agent to the metal ion according to Eq 3,
[0000]
M
z
+
+
Red
๎ข
๎ข
โ
surface
catalytic
๎ข
M
0
+
Ox
Eq
๎ข
๎ข
3
[0000] where Ox is the oxidation product of the reducing agent, Red and M is the metal plated. According to mixed-potential theory, the overall reaction given by Eq 3 can be decomposed into one reduction (cathodic) reaction,
[0000]
M
z
+
+
ze
๎ข
๎ข
(
from
๎ข
๎ข
reducing
๎ข
๎ข
agent
)
๎ข
โ
surface
catalytic
๎ข
M
0
Eq
๎ข
๎ข
4
[0000] and one oxidation (anodic) reaction.
[0000]
Red
๎ข
๎ข
โ
surface
catalytic
๎ข
Ox
+
ze
Eq
๎ข
๎ข
5
[0000] These two partial reactions occur at one and the same electrode, the metal-solution interface. In order for electroless deposition to proceed, the equilibrium (rest) potential of the reducing agent must be more negative than that of the metal being plated.
[0033] However, Eq 5 can only occur only on a catalytic surface. Once the initial layer is deposited, the metallic layer itself acts as the catalytic surface, allowing for the process to continue. For most non-catalytic substrates, plating can be done, but only after some surface preparation rendering them catalytically active.
[0034] For deposition to occur, the metal must be reduced from solution. Controlled deposition can be promoted by the presences of a catalytic surface and generally leads to a more coherent coating. Various metals exhibit catalytic properties useful in chemical plating, including the precious metals Au, Ag, and members of the platinum metal family. Electroless plating can also occur on certain less noble metals such as Co, Ni, Cu and Fe, as well as conductive carbon, but these materials are not truly catalytic. Most useful electroless metal coating baths are autocatalytic, meaning the metal being deposited acts as a catalyst for further deposition, which allows the process to continue. The following are common methods to render a surface catalytic to electroless metal coating.
[0035] Exchange PlatingโWhen attempting to plate a metal onto a less noble one, an exchange of charges occurs at the surface in which some of the more noble metal in solution is reduced as the less noble metal at the surface is oxidized and dissolved into the solution. This results in a layer of the more noble metal being deposited, which acts as the catalyst on which electroless plating then occurs.
[0036] Electroplated Deposited Seed LayerโIf the base ceramic foam itself it conductive, catalytic material can be applied to the foam through traditional electroplating. Electroless plating can then initiate on the electroplated material, and subsequently self-propagate throughout the foam.
[0037] Sensitizing/Activation CatalysisโSensitizing and activation (S/A) involve the application of a catalytic metal to a non-catalytic surface. As implied by the name, this involves two steps. The first step, sensitizing, consists of adsorbing a readily oxidized material onto the surface to be plated. Solutions containing tin(II) or titanium(III) salts and small amount of acid are commonly used. The addition of acid inhibits hydrolyzation of the metal salts, which leads to the formation of insoluble oxychlorides. In the case of Sn, the amount of Sn on the surface of the sensitized substrate is about 10 ฮผg/cm 3 , and surface coverage is less than 25%. This Sn is in the form of dense clumps about 10-25 nm in size, consisting of particles on the order of 2.5 nm. Immersion in the sensitizing bath is normally done at 20ยฐ-30ยฐ C. for 1-3 min. Agitation can improve results, especially when plating complicated shapes. After this step, pieces must be thoroughly rinsed, as dragin of the sensitizer will destroy the activation bath. Avoid drying in air after this step, as the adsorbed Sn 2+ can form SnO at the surface.
[0038] It is during the activation step that the surface truly becomes catalytic. The most effective activation solutions contain precious metal salts, such as gold, silver, or the platinum group metals (Au, Pt, Rh, Os, Ag), along with small additions of acid. Here, the acid stabilizes the bath by both limiting the precipitation of Pd particles and decreasing the reduction rate. Activation baths are used at 20-45ยฐ C., with immersion times of 1-2 min. When the sensitized piece comes in contact with the activation solution, the adsorbed sensitizer is readily oxidized, thereby reducing the activating metal and depositing it in the metallic state forming nucleation centers on the surface, according to the example in Eq. 6
[0000] Pd 2+ +Sn 2+ โSn 4+ +Pd 0 โโEq 6
[0039] It is estimated that these catalytic nucleation centers are less than 1 nm in diameter, and their height is ห4 nm. As an example, the amount of Pd on a glass substrate is generally 0.04-0.05 ฮผg/cm 3 , which assuming uniform distribution corresponds to roughly 0.3 of a monolayer of Pd. 4 The surface density of catalytic sites is substrate material dependent. For glass this is roughly 10 14 sites/cm 2 .
[0040] Thorough rinsing should also follow the activation step, as dragin of precious metal salts will cause spontaneous seeding and breakdown of most plating baths. An example S/A recipe can be found in Table 2.
[0000] TABLE 2 Example sensitizing and activation recipe Purpose Constituents notes time, min ยฐ C. Sensitizing 120 ml DI water stir and bring to temperature 1-3 25-30 3.0 g SnCl 2 โข2H 2 O 98.2% pour over powder and stir 5 ml HCl do not allow undissolved SnCl 2 to be transferred DI rinse when done, 3x Avoid drying Activating 125 ml DI water stir and bring to temperature 1-2 40-45 0.03 g PdCl 2 99.9+% pour over powder and stir 0.063 ml HCl (~2 drops) do not allow undissolved PdCl 2 to be transferred DI rinse when done, 3x rinse once in ethyl-alcohol allow to dry in air
If, as sometimes is the case, a given metal can be reduced by the sensitizing ion, then it may not be necessary to utilize an activation bath. Instead, the substrate is immersed in the electroless bath immediately after sensitizing and rinsing. An example system, where this is the case, is electroless Cu or Ag when using a Sn(II) based sensitization bath.
Colloidal Catalysis
[0041] This method is an alternative to sensitization and activation catalysis, utilizing a mixed colloidal catalyst. The colloid particles contain a core of reduced, metallic Pd, also containing a small amount of Sn metal. This core is surrounded by a stabilizing layer of Sn +2 and Sn +4 ions, which attract dissolved chloride when in solution. Particle diameter can range from 2.5-35 nm, and is described by FIG. 2 (see particularly, Kanani, N. Electroplating and Electroless Plating of Copper & its Alloys , Finishing Publications, Ltd., Herts, UK, 2003.
[0042] Table 3 contains a recipe for a Sn/Pd colloid solution found by the author to catalyze a wide variety of plastic, ceramic and metallic substrates for electroless plating of Cu and Au. It is very stable and can be stored for long periods without deterioration.
[0000] TABLE 3 Recipe for a Sn/Pd colloidal catalyzing solution Purpose Constituents notes Time, min ยฐ C. Solution A 1.4 g Na 2 SnO 3 โข3H 2 O stir until all solids are 15-20 15-20 provides 9.6 g SnCl 2 โข2H 2 O 98.2% dissolved excess Sn ions 40 ml HCl for stability Solution B 0.2 g PdCl 2 99.9+% combine PdCl2, HCL, and See notes 40-45 formation of 20 ml HC1 water colloid 40 ml DI water stir until all solids are particles 0.4 g SnCl 2 โข2H 2 O 98.2% dissolved (10-15 min) add SnCl 2 and stir for 12 min, the color will change from and an initial dark green to dark olive brown Mixing pour solution B into A while quickly N/A stirring Activation cover 50-65 180 heat to 57ยฐ C. for 3 hrs Dilution can be diluted down to 15 v % N/A provided HCl makes up 10- 20 v % of the final volume
After mixing, the combination of solutions A and B is a concentrated solution containing roughly 58w % concentrated (37%) hydrochloric acid and 32w % water with the balance being Pd and Sn salts. It is immediately ready for use, but is made more aggressive by heating it to 50-65ยฐ C., for three hours.
[0043] An important variable in the preparation procedure, which affects the nature of the resulting colloid, is the length of time during which the stannous chloride is allowed to react with the palladium chloride in solution B, before it is combined with the balance of stannous chloride in solution A. This reaction time has a significant effect on the final particle size, size distribution and shape in the resulting colloid. Due to this, solution B must be stirred for approximately 12 min as times less than 10 minutes lead to marginal catalysis ability of the solution and times greater than 14 minutes lead to solution instability.
[0044] If the area to be plated requires high resolution as in the case of printed circuit boards, the prepared colloidal solution should be diluted 1:1 with DI water and with sufficient additional concentrated HCl to comprise 20-30v % of the final volume. For ordinary surface plating, the catalyzing solution should comprise 15v % prepared colloid, 10-20v % concentrated HCl, and the balance DI water.
[0045] Regardless of concentration, the substrate is immersed in or contacted with the activation solution for a minimum of 1 min at room temperature. Upon contact with the substrate, the colloidal particles adhere to the surface, forming catalytic nucleation sites. Following contact with the catalyzing solution, the substrate shall be thoroughly rinsed in DI water before immersion into a chemical plating bath. If the substrate is not to be immediately plated, it can be rinsed in alcohol, dried, and plated later.
[0046] After the catalytic solution is rinsed away, the ionic tin no longer plays a role, and can in fact bury the Pd core and detract from its catalytic activity. In some cases an acceleration step is required to remove the excess tin ions and expose the catalytic Pd surface. Some accelerating solutions include 1 M HCl, 1 M NaOH, 1 M NH4BF4, 1 M NH4HF2, 0.13 M EDTA at pH 11.7, and 0.13 M EDTA at pH 4.5. Substrates should be immersed for a minimum of 1 minute followed by thorough rinsing in DI water.
Example 1
[0047] Most traditional methods used to coat carbon foams with metal have only been successful in coating only the most exposed outer surfaces of the material with nearly no penetration through the thickness. This invention will significantly improve the properties and performance of the foams in numerous applications as the properties of the deposited material are lent to the foam. Benefits from the improvement of this product can include increased strength, solderability, durability, toughness, corrosion resistance, thermal and electrical conductivity, catalytic behavior, etc. FIG. 4 shows a cross-sectional view of a copper coating throughout the thickness of a graphite foam.
[0048] Plating temperature can also greatly affect the film properties. Plating is typically done between 25 and 70ยฐ C. when plating copper. In general a fine-grained structure is produced at low temperatures, while as temperature is increased the grain structure becomes coarser and hydrogen adsorption is decreased, leading to improved ductility and increased electrical conductivity.
[0049] Electroless Plating of CopperโTypical electroless copper solutions comprise deionized water, a source of copper ions, a complexing agent for copper ions, a pH regulator, a reducing agent, and a bath stabilizing agent. Plating is usually performed between 30-80ยฐ C. Most commercial baths utilize formaldehyde (HCHO) under basic conditions as the reducing agent, thus only baths of this type will be addressed here. In this case, electroless Cu plating is a result of the reaction given in Eq. 7.
[0000]
Cu
2
+
+
2
๎ข
๎ข
HCHO
+
4
๎ข
๎ข
OH
-
๎ข
โ
surface
catalytic
๎ข
Cu
0
+
2
๎ข
๎ข
HCOO
-
+
2
๎ข
๎ข
H
2
๎ข
O
+
H
2
Eq
๎ข
๎ข
7
[0000] Ions of Cu 2+ are generally added as Cu salts, such as CuSO 4 , but halides, nitrates, acetates and other organic and inorganic acid salts of Cu may be used. Since the solubility of Cu 2+ decreases with increasing pH, complexing (chelating) agents are also commonly added to the plating bath to avoid the precipitation of copper(II)hydroxide (Cu(OH) 2 ). These ligands form coordinate bonds with the Cu 2+ ions allowing them to stay in solution. Complexing agents are usually organic acids or their salts, such as EDTA, EDTP, and tartaric acid.
[0050] Basic conditions are generally realized through the addition of NaOH, elevating the pH to 12-13, where the plating rate reaches a maximum. Formic acid (HCOO โ ) is the oxidation product of the reducing agent, formaldehyde. Evolved H 2 gas and excess H 2 O are formed as byproducts of the reaction, with Cu 0 being left behind as a plated film on the catalytic surface.
[0051] Electrodeposition, the process used in electroplating and electroforming, is analogous to a galvanic or electrochemical cell acting in reverse. The part to be plated is the cathode of the circuit, while the anode generally provides ions of the metal to be plated. Both of these components are immersed into a solution containing one or more metal salts as well as other ions that permit the flow of electricity. A rectifier supplies a direct current to the cathode causing the metal ions in solution to lose their charge and plate out on the cathode. In most cases the electrical current flows through the circuit, the anode slowly dissolves and replenishes the ions in the bath, as seen in FIG. 5 . Some electroplating processes use a noble, nonconsumable anode. In these situations, ions of the metal to be plated must be periodically replenished in the bath as the plate forms out of the solution.
[0052] Electrodeposition in the form of electroplating involves the coating of an electrically conductive object with a layer of metal using electrical current. Usually, the process is used to deposit an adherent surface layer of a metal having some desired property (e.g., abrasion and wear resistance, corrosion protection, lubricity, etc.) onto a substrate lacking that property. In the case of heavy plating, it is also used to build up thickness on undersized or worn parts. Metal anodes act as a source of electrons and in most cases are soluble and replenish the metal content of the electrolyte. Due to its metal ion content, the electrolyte is conductive and closes the electrical circuit which is fed by a source of low voltage direct current.
[0053] The following steps outline an exemplary procedure for electrolessly plating graphite foam with copper (it being understood that the order of steps could be changed and that some of the steps could simply be eliminated).
1. Thoroughly clean the sample
Blow the foam with compressed air to free trapped particles Ultrasonically clean in an isopropyl alcohol bath
2. Prepare the bath solutions as seen in Tables 1 and 2* 3. Place foam in a preparation bath with a surfactant and water
Surfactants may include: dish soap, an alcohol, etc. Use a syringe to push out the trapped air within the pores When the foam sinks, enough water has saturated the material
4. Place the foam in each of the baths as seen in Tables 4 and 5 and thoroughly rinse the sample with DI water between each solution
Use a surfactant in each of the baths to reduce the surface tension of the fluids Continuously pump a syringe directly above the foam through each bath and rinsing solution
5. When the plating was completed, the sample was thoroughly rinsed with ethanol
*The sensitizing and activating steps (Table 4) are not necessary to successfully plate graphite foam with copper, but those steps serve to promote adhesion and enhance the bond between the graphite and copper interface.
[0000]
TABLE 4
Sensitizing and activating bath recipes
Purpose
Constituents
notes
time, min
ยฐ C.
Sensitizing
120 ml DI water
stir and bring to temperature
1-3
25-30
3.0 g SnCl 2 โข2H 2 O 98.2%
pour over powder and stir
5 ml HCl
do not allow undissolved
SnCl 2 to be transferred
DI rinse when done, 3x
Avoid drying
Activating
125 ml DI water
stir and bring to temperature
1-2
40-45
0.03 g PdCl 2 99.9+%
pour over powder and stir
0.063 ml HCl (~2 drops)
do not allow undissolved
PdCl 2 to be transferred
DI rinse when done, 3x
rinse once in ethyl-alcohol
allow to dry in air
[0000]
TABLE 5
Copper plating bath formulation
Purpose
Constituents
notes
time, min
ยฐ C.
Solution 1
30 ml DI water
stir until NaOH is dissolved
until
room
adjusts pH
5.5 g NaOH
dissolved
Solution 2
80 ml DI water
stir vigorously
to temp
50
provides
1.25 g CuSO 4 โข5H 2 O
bring to temp
Cu ions
98+%
add half of solution 1, bath
7.5 g EDTA 99.0-101.0%
color will change to light blue
and then change back to deep
blue
once all solids are dissolved,
add remainder of solution 1,
resulting pH should be ~12.5
Solution 3
2.5 ml HCOH 37 w % in
slowly pour into
until
50
reduces
H 2 O (10-15% methanol)
solution 2
coated or
Cu ions
let stand 1 min
bath is
add material to be plated
depleted
Example 2
[0066] The following steps outline an exemplary procedure for electrolessly plating graphite foam with nickel (it being understood that the order of steps could be changed and that some of the steps could simply be eliminated).
1. Thoroughly clean the sample
Blow the foam with compressed air to free trapped particles Ultrasonically clean in an isopropyl alcohol bath
2. Prepare the bath solutions as seen in Tables 6 and 7* 3. Place foam in a preparation bath with a surfactant and water
Surfactants may include: dish soap, an alcohol, etc. Use a syringe to push out the trapped air within the pores When the foam sinks, enough water has saturated the material
4. Place the foam in each of the baths as seen in Tables 6 and 7 and thoroughly rinse the sample with DI water between each solution
Use a surfactant in each of the baths to reduce the surface tension of the fluids Continuously pump a syringe directly above the foam through each bath and rinsing solution
5. When the plating was completed, the sample was thoroughly rinsed with ethanol
*The sensitizing and activating steps (Table 6) are not necessary to successfully plate graphite foam with nickel, but those steps serve to promote adhesion and enhance the bond between the graphite and nickel interface.
[0000]
TABLE 6
Sensitizing and activating bath recipes
Purpose
Constituents
Notes
time, min
ยฐ C.
Sensitizing
120 ml DI water
stir and bring to temperature
1-3
25-30
3.0 g SnCl 2 โข2H 2 O 98.2%
pour over powder and stir
5 ml HCl
do not allow undissolved
SnCl 2 to be transferred
DI rinse when done, 3x
Avoid drying
Activating
125 ml DI water
stir and bring to temperature
1-2
40-45
0.03 g PdCl 2 99.9+%
pour over powder and stir
0.063 ml HCl (~2 drops)
do not allow undissolved
PdCl 2 to be transferred
DI rinse when done, 3x
rinse once in ethyl-alcohol
allow to dry in air
[0000]
TABLE 7
Nickel plating bath formulation
Purpose
Constituents
notes
time, min
ยฐ C.
Solution 1
90 ml DI water
add NiSO 4 and Na 4 P 2 O 7 to DI
until
70
provides
2.5 g NiSO 4 โข6H 2 O
water
dissolved
Ni ions
5.0 g Na 4 P 2 O 7
stir until dissolved
2.3 ml NH 4 OH
slowly add NH 4 OH, color will
change from lime to emerald
green
bring to temp
Solution 2
10 ml DI water
add NaH 2 PO 2 to DI water
until
room
reducer
2.5 g NaH 2 PO 2
stir until dissolved
dissolved
add to solution 1
let stand 1 min
add material to be plated
Example 3
[0079] The invention allows virtually any foam, and particularly open pore ceramic foams to be plated with metal and metal alloys, without plugging the surface of the foam, and in a way that allows the resulting foam-metal product to benefit from the attributes of both the foam matrix and the metal plating. A metallic coating would improve the solderability of the foams without closing the porosity, allowing air or fluids to continue to flow through the material. The products produced according to the above-described processes can be used in a number of different applications. Below is a non-exhaustive, exemplary listing of certain applications.
[0080] Thermal and Electrical Management
[0081] Several existing technologies to aid in the dissipation of heat exist, but none offer the surface area of foams without further machining. In heat dissipation applications materials must have high thermal conductivities, be able to withstand high temperatures, have a low coefficient of thermal expansion (CTE), and have mechanical stability. The combination of graphite foam with a copper coating is an ideal solution. Graphite is a highly thermally conductive ceramic and copper is second only to silver in its thermal conductivity amongst metals. The foam structure gives a high surface area to dissipate heat without the added cost of machining. The copper coating increases the fracture toughness of the overall composite, while the graphite keeps the strength from deteriorating at high temperatures. Graphite foam has already been shown to have a low CTE, and adding the copper will not change that; it will however keep the copper from flaking off at high temperatures.
[0082] To use a ceramic as a heat sink requires bonding it to the device that is creating the heat. The addition of the copper onto the carbon makes this a trivial process of soldering the foam onto the necessary substrate. Such applications could take the form of heat sinks, heat exchangers, phase-change cooling systems, and thermally conducting structures. It would have applications on jet engines, satellite thermal panels, avionics enclosures, and computer chips.
[0083] EMI Shielding:
[0084] Another use of the copper coated graphite foam would be for use as electromagnetic interference shielding. EMI shielding is dependent on mesh size and thickness of the conducting material. The carbon foams have pore sizes in the area of half a millimeter, which would be sufficient to block out microwaves and radio waves.
[0085] Catalysis:
[0086] The speed of catalysis and ionization is limited by the available surface area that comes in contact with the requisite molecules. Foams, which consist of a large surface area to volume ratio, are well suited to catalyzing chemical reactions. Platinum and nickel are very common catalysts and are already used in devices such as catalytic converters. Nickel is also used as a catalyst for hydrogenation in the pharmaceutical, food, and petrochemical industries.
[0087] Nickel and Platinum are common catalyst materials. Fuel cells can use these to assist in the ionization of the hydrogen. It would be beneficial to use a plated graphite foam for two reasons. Firstly, the foam structure would give a large surface area of the catalyst that could be used for the ionization process. Secondly, the noble catalyst and carbon are both acid resistant. Fuel cells are very acidic (negative pH levels), and it is necessary to have a structure that can withstand such an environment. If a crack were to form in the catalyst coating, the graphite would still be able to function both mechanically and as a conductor of electrons so the fuel cell would continue to function.
[0088] Ferromagnetic Coatings
[0089] The ability to plate the foam with nickel or complex ferromagnetic alloys such as โPermalloyโ, could lend ferromagnetic properties. By placing a foam coated with such a material in an alternating magnetic field, it is possible to heat the foam though induction. This effect could be used to efficiently heat liquids.
[0090] Acoustic Dampening and Mechanical Strength:
[0091] Titanium is a very versatile material offering a few possibilities when plated onto a carbon foam. Titanium is even more chemically inert than nickel. It is chemically inert to dilute sulfuric and hydrochloric acid, most organic acids, most chlorine gas, and chloride solutions. Titanium also has the highest strength-to-weight ratio of any metal.
[0092] Titanium is chemically inert nature makes it ideal for use in the human body. Titanium coated carbon foams would be better than solid titanium for the use of bone repair and replacement because it would use less titanium than a solid piece (thus reducing cost) and would allow bone to grow throughout the porosity allowing the bone to more easily and sufficiently heal itself. Titanium coated foams would also be used, due to their superior acoustic dampening ability, for the manufacture of gun silencers.
[0093] While the invention has been described in terms of its preferred embodiments, those of skill in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims. Accordingly, the present invention should not be limited to the embodiments as described above, but should further include all modifications and equivalents thereof within the spirit and scope of the description provided herein.
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Open pore foams are coated with metal or metal alloys by electrolytic or electroless plating. The characteristics of the plating bath are adjusted to decrease the surface tension such that the plate bath composition can pass into the pores of the foam, preferably at least two and most preferably more than five pores in depth from the surface of the foam matrix. This can be accomplished by adding a surfactant, solvent or other constituent to reduce the surface tension of the plate bath. In addition, heat and pressure can be used to drive in the plate bath composition into the passage ways of connected open pores in the foam matrix. The net result is to plate the inside surfaces of the pores in the foam matrix, while maintaining the passageways through the foam. Pretreatment of the pore surfaces can be used to promote adhesion of the metal. Particularly advantageous results are achieved when the foam matrix is a ceramic foam.
| 8
|
This application is a continuation in part of Ser. No. 07/594,754 filed Oct. 9, 1990, now abandoned.
FIELD OF THE INVENTION
This invention relates to polymer precursors for aluminum nitride. This invention particularly relates to aluminum-nitrogen polymers having sites of organounsaturation that can be crosslinked by the application of heat.
BACKGROUND OF THE INVENTION
Aluminum nitride (AlN) is a refractory material melting at 2400ยฐ C., which exhibits several unique chemical and physical properties, e.g., it has a density of 3.26 g/cm 3 , a Young's modulus of 280 GPa, a flexural strength of 400 MPa and a Knoop hardness of 1200 kg/mm 2 . AlN is very stable in the presence of molten metals and therefore can be used, for example, for making crucibles to hold molten metal.
Aluminum nitride is also an electrical insulator with a bandgap of 6.2 electron volts, which makes it an attractive alternative substrate material to replace alumina and beryllia in electronic packaging. The thermal expansion coefficient of AlN is nearly identical to that of silicon. This is an important property in high power applications where thermal distortion can occur between a silicon chip and the substrate due to a mismatch in the coefficients of thermal expansion of the two materials. The thermal conductivity of aluminum nitride is nearly ten times higher than alumina and approximately equal to that of beryllia. Unlike beryllia, aluminum nitride is not restricted by processing constraints because of its toxicity.
There is currently a great deal of interest in polymer precursor materials that can be pyrolyzed to yield ceramic materials, including aluminum nitride. Aluminum-nitrogen polymers containing no alkyl substitution on the aluminum or nitrogen atoms are described in U.S. Pat. No. 4,767,607, in which thermolysis of a mixture of aluminum chloride and hexamethyldisilazane results in formation of a polymer with the repeating unit [(Cl)Al--N(H)] n . Pyrolysis of the polymer in ammonia or under vacuum yields crystalline AlN. An infusible polymeric aluminum amidimide [(NH 2 )Al--N(H)] n that can be pyrolyzed to form AlN is described by L. Maya, Adv. Ceram. Mat., 1986, 1, 150-153.
Polymers having the repeating unit [(R)Al--N(H)] n are disclosed in U.S. Pat. No. 4,696,968 and European Patent Application 259,164. Fibers can be melt spun from the thermoplastic precursor and pyrolyzed to AlN. L. V. Interrante et al., Inorganic Chem., 1989, 28, 252-257 and Mater. Res. Soc. Symp. Proc., 1986, 73, 359-366 reported the formation of volatile crystalline precursors that can be sublimed under vacuum. A two step pyrolysis of these precursors in ammonia resulted first in an insoluble aluminum imide polymer of the form [(R)Al--N(H)] n and ultimately AlN containing less than 0.5% residual carbon and oxygen. U.S. Pat. No. 4,783,430 discloses the formation of [(CH 3 )Al--N(H)] n , which can be pyrolyzed under helium, argon or vacuum to form hexagonal AlN.
Polymers having the repeating unit [(H)Al--N(R)] n are disclosed in U.S. Pat. No. 3,505,246 and are formed by the reaction of the alane adduct H 3 AlโN(C 2 H 5 ) 3 with a reagent such as acetonitrile. U.S. Pat. No. 4,687,657 discloses the preparation of a poly-N-alkyliminoalane that can be pyrolyzed in argon or under vacuum to form AlN.
Reacting an organic nitrile with diisobutylaluminum hydride produced organoaluminum imines having the formula RCHโNAl(i--C 4 H 9 ) 2 , which were not isolated (L. I. Zakharkin and I. M. Khorlina, Bull. Acad. Sci. USSR, Engl. Transl., 1959, 523-524 and Proc. Acad. Sci. USSR, 1957, 112, 879). A gas containing 85% isobutene and polymers having the repeating unit [Al--N(R)] n were produced on heating the organoaluminum imine to 220ยฐ to 240ยฐ C. During the formation of the polymer, aluminum alkyl groups of the organoaluminum imine are eliminated as isobutene, and aluminum-nitrogen bonds are formed.
European Patent Application 331,448 discloses that AlN can be deposited on a substrate by heating the substrate and contacting it with the vapor of an aluminum-nitrogen compound having the formula CH 3 (R 1 )Al--N(R 2 )(C 3 H 7 ), where R 1 is alkyl and R 2 is H, alkyl or aryl. A polymer of this compound is claimed, but the structure of the polymer is not disclosed.
SUMMARY OF THE INVENTION
The polymers of this invention comprise a backbone of alternating aluminum and nitrogen atoms both having pendant organic groups, at least some of the pendant organic groups being unsaturated.
Also according to the invention, the aluminum-nitrogen polymers are prepared by reacting a dialkylaluminum hydride with an unsaturated nitrile. The unsaturated aluminum-nitrogen polymers can be crosslinked by supplying energy to generate free radicals. The crosslinked polymers can be pyrolyzed to form an aluminum nitride containing ceramic.
DETAILED DESCRIPTION OF THE INVENTION
The aluminum-nitrogen polymers are prepared by (a) reacting an unsaturated organic nitrile having the formula RCN, where R is a 2-12 carbon alkenyl or alkynyl group, with a dialkylaluminum hydride having the formula R'R"AlH, where R' and R" are the same or different 1-12 carbon alkyl groups, to form an organoaluminum imine and (b) heating the organoaluminum imine to a temperature of from about 50ยฐ C. to about 400ยฐ C. Uncatalyzed crosslinking of the pendant unsaturated organic groups will occur above temperatures of about 180ยฐ C. It is therefore preferable to heat the organoaluminum imine below this temperature if an uncured polymer is desired.
A single unsaturated nitrile, a mixture of unsaturated nitriles or a mixture of saturated and unsaturated nitriles can be used to prepare the aluminum nitrogen polymers of this invention. Suitable unsaturated nitriles include, for example, acrylonitrile, methacrylonitrile, 3-butenenitrile, crotonitrile, 1-cyclohexenylacetonitrile, 1-cyclopentenylacetonitrile, 5-cyano-1-pentyne, cinnamonitrile, 1,4-dicyano-2-butene and 5-norbornene-2-carbonitrile.
The organoaluminum imine formed by the reaction of the organic nitrile and the dialkylaluminum hydride is typically a dimer that contains a heterocyclic core and has the structure ##STR1## Depending on the nature of the substituents R, R' and R", the imine can also be in the form of a monomer or a higher cyclic oligomer. The exact form of the imine is dictated by the steric and electronic properties of the substituents.
In the reactions described below, the notation for labeling the carbon atoms bonded to Al atoms will be the following: ##STR2##
Likewise, a hydrogen atom bonded to a Cฮฑ carbon atom will be called an ฮฑ-hydrogen atom.
The following units comprise the major components of the polymer, although small amounts of other components can also be present: ##STR3## where R has the same meaning as described above. R 2 is an unreacted alkyl group R' or R" on aluminum, introduced as part of the dialkylaluminum hydride. R 3 is an organic group derived from R 2 in the process of heating the organoaluminum imine, e.g., the formation of isobutenyl groups from isobutyl groups in Path A of the reaction scheme illustrated below. The values of x and y depend upon the time of heating, the temperature of heating, and the structure of the aluminum hydride reactant used. The heating can be carried out with or without a solvent, although it is preferably carried out without a solvent.
While not wishing to be bound by theory, the process of gas evolution in systems containing a ฮณ-hydrogen atom on one of the organic groups bonded to aluminum is believed to proceed by the following mechanism, using a diisobutylaluminum imine as an example: ##STR4##
In this mechanism the coordinated imine in the starting dimer (1) is reduced in the process of ฮฒ-hydride migration from a neighboring isobutyl group as shown in intermediate (2) in Path A. The imine reduction is accompanied by transfer of an acidic ฮณ-hydrogen from the isobutyl group involved in imine reduction to the other aluminum-bonded isobutyl group. Six membered ring intermediates appear to be involved. Loss of alkane results in an isobutenyl intermediate (3). Thermal polymerization to give polymer (4) then occurs. In the case of diisobutylaluminum hydride, the butenyl groups formed as a result of the elimination reaction shown in Path A further react to give C 8 alkyl groups and higher. This reaction is confirmed by polymer hydrolysis/gas chromatography mass spectrometric studies, which detect isobutylene and C 8 hydrocarbons as decomposition products of hydrolysis. In the case of methyl and ethyl substituents where no ฮณ-hydrogen is present, it is presumed that ฮฑ- or ฮฒ-hydride transfer results in loss of alkane and formation of highly reactive intermediates that cannot be detected but that quickly react either intramolecularly or intermolecularly to give R 3 moieties.
Alternatively, ฮฒ-hydride migration to reduce the coordinated imine can be accompanied by loss of alkene if Al--Cฮฑ bonds are broken in the process of ฮฒ-hydride migration (5) (Path B).
The aluminum-nitrogen polymer can be further dissolved in aprotic organic solvents such as hexane, toluene, xylene, or diethyl ether and treated with ammonia or a primary amine, R 4 NH 2 , where R 4 is a 1-12 carbon alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl or aryl group, for a time sufficient to introduce HN-- or R 4 N-groups into the polymer by transamination with concomitant release of RCH 2 NH 2 or by aluminum alkyl bond cleavage. The aluminum nitrogen polymer can also be treated with a mixture of ammonia and a primary amine.
In the polymer produced upon treatment of the aluminum-nitrogen polymer with ammonia or a primary amine, at least some of the units comprise the following: ##STR5## where R, R 2 , and R 3 have the same meaning as described above. R 5 is either H or R 4 . The values of a, b, c and d depend upon the original values of x and y as well as the amount of ammonia or primary amine added. Typically the aminated polymers are solids rather than viscous liquids and have a higher ceramic yield on pyrolysis compared to the non-aminated polymers.
The polymers of the present invention can be crosslinked by an energy input such as provided by heat. Other forms of energy input such as UV radiation, electron beam methods, microwave radiation, and anionic or cationic polymerization can also be used. Free radical generators such as organic peroxides or azo compounds, as well as UV sensitizers and other polymerization aids, can optionally be added to the polymer composition.
The aluminum-nitrogen polymer compositions according to the present invention can additionally contain fillers. Suitable fillers include, for example, SiO 2 , Si 3 N 4 , AlN, BN, B 4 C, Al 2 O 3 , B 2 O 3 , TiN, TiC, ZrO 2 , Si, Al, ZrC and SiC in the form of a powder, whiskers, or fibers.
An aluminum nitride-containing ceramic is produced by pyrolysis of the crosslinked aluminum-nitrogen polymers in a non-oxidizing atmosphere such as nitrogen or ammonia. Pyrolysis in nitrogen is carried out at from about 800ยฐ to about 2200ยฐ C., preferably 1200ยฐ to 2000ยฐ C., and most preferably 1400ยฐ to 1700ยฐ C. Pyrolysis in ammonia can be accomplished at a temperature as low as about 600ยฐ C.
The aluminum-nitrogen polymers of this invention can be used in the preparation of ceramic fibers, films, coatings, and foams; in the infiltration of a preform structure and subsequent pyrolysis to produce a composite aluminum nitride-containing structure, as a thin film for electronic applications or as a binder for ceramic or metal powders.
EXAMPLE 1
A 100 ml Schlenk round bottom flask was fitted with a pressure equalized dropping addition funnel and purged with nitrogen. 3-Butenenitrile (10 ml, 150 mmol) was added to the flask. The funnel was charged with diisobutylaluminum hydride (150 ml), 1.0M in toluene, 150 mmol) and the flask was cooled to 0ยฐ C. The diisobutylaluminum hydride was added dropwise over thirty minutes and stirred at 0ยฐ C. for an additional 30 minutes. The solution turned a bright yellow color. The flask was warmed to room temperature and the solution was stirred overnight. The solvent was removed under vacuum leaving 31 g of the aluminum imine [CH 2 โCHCH 2 CHโNAl(i--C 4 H 9 ) 2 ] 2 . The imine was a liquid containing butenyl groups on nitrogen, with a room temperature viscosity similar to that of water.
The aluminum imine was polymerized by heating to 150ยฐ C. for 8 hours under a flow of nitrogen. The resulting polymer is a liquid containing butenyl groups on nitrogen, with a viscosity slightly thicker than honey.
EXAMPLE 2
The polymer of Example 1 (0.5 g) was thermally cured by heating in nitrogen to 200ยฐ C. for 1 hour to form a red brittle solid. The cured polymer retained its shape and did not melt on further heating.
EXAMPLE 3
The polymer of Example 1 (0.34 g) was fired in a mullite tube furnace in an alumina boat to 1500ยฐ C. at 10ยฐ C./minute in a nitrogen atmosphere. X-ray diffraction of the fired product showed crystalline AlN as the only phase present.
EXAMPLE 4
A 100 ml Schlenk round bottom flask was fitted with a pressure equalized dropping addition funnel and purged. Methacrylonitrile (2.5 ml, 29.8 mmol) was added to the flask. The funnel was charged with diisobutylaluminum hydride (29.8 ml, 1.0M in toluene, 29.8 mmol) and the flask was cooled to 0ยฐ C. The diisobutylaluminum hydride was added dropwise over 60 minutes and stirred at 0ยฐ C. for 30 minutes. The flask was warmed to room temperature and the yellow solution was stirred overnight. The solvent was removed under vacuum leaving 5.7 g (92%) of light green waxy solid, [CH 2 โC(CH 3 )CHโNAl(i--C 4 H 9 ) 2 ] 2 , which melted at 50ยฐ C.
The aluminum imine was polymerized by heating to 140ยฐ C. for 4 hours under a flow of nitrogen. The resulting polymer was a black solid containing 2-methylpropenyl groups on nitrogen which melted at 82ยฐ C.
EXAMPLE 5
The polymer of Example 4 (2.1 g) was thermally cured by heating in nitrogen to 200ยฐ C. to form a dark green solid. The cured polymer retained its shape and did not melt on further heating.
EXAMPLE 6
The polymer of Example 1 (1.0 g) was mixed with AlN powder (1.0 g), poured into a mold, and heated to 200ยฐ C. under nitrogen to form a rigid, cured molded shape. The AlN-filled molded polymer was fired in a mullite tube furnace in an alumina boat to 1500ยฐ C. at 10ยฐ C./minute in a nitrogen atmosphere.
EXAMPLE 7
The polymer prepared in Example 1 was brushed onto an aluminum substrate, transferred to a vial, and cured to a solid film by heating to 200ยฐ C. under nitrogen.
EXAMPLE 8
This example confirms the loss of organic unsaturation in the crosslinked polymer of Example 2.
The aluminum imine [CH 2 โCHCH 2 CHโNAl(i--C 4 H 9 ) 2 ] 2 prepared in Example 1, the polymer prepared in Example 1, and the crosslinked polymer of Example 2, were analyzed by Raman spectroscopy and carbon-13 NMR spectroscopy. The Raman data indicate that carbon-carbon double bonds are present in the imine [CH 2 โCHCH 2 CHโNAl(i--C 4 H 9 ) 2 ] 2 , and in the polymer of Example 1 as determined by the presence of bands in the CโC region at 1600-1700 cm -1 . However, no evidence of carbon-carbon double bonds was evident in the crosslinked polymer of Example 2. The carbon-13 NMR data corroborate the Raman results. The carbon-13 spectra of the imine [CH 2 โCHCH 2 CHโNAl(i--C 4 H 9 ) 2 ] 2 and of the polymer of Example 1 displayed resonances in the ฮด 120-150 ppm region indicative of CโC bonds. The carbon-13 spectrum of the crosslinked polymer of Example 2 showed no resonances in the ฮด 120-150 ppm region.
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Aluminum-nitrogen polymers comprising a backbone of alternating aluminum and nitrogen atoms both having pendant organic groups, wherein some of the pendant organic groups are unsaturated, are prepared by reacting an unsaturated organic nitrile with a dialkylaluminum hydride. The polymers are crosslinked by supplying energy to generate free radicals. The crosslinked polymers can be pyrolyzed to form an aluminum nitride ceramic.
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BACKGROUND OF THE INVENTION
[0001] This application claims priority of provisional patent application No. 60,697,416, filed Jul. 8, 2005.
[0002] There are numerous inventions and discoveries relating to methods for folding sheets of material. Some of these methods relate to forming a three dimensional shape from a two dimensional sheet. Other methods take this a step further in that they provide for a folding and unfolding process that is smooth and continuous. One might term this second type โreversible origamiโ.
[0003] A critical inventive component of such methods are various tiling patterns that may be scored into sheets of material. One of the most famous of these patterns is โMiura-Oriโ (โoriโ being the Japanese term for folding)โnamed after its inventor Professor Koryo Miura, from Tokyo University. This particular pattern, consisting of a grid of parallelograms, allows for a sheet of material to be compacted down in two dimensions.
[0004] Also known in the art are various patterns including those disclosed in my own U.S. Pat. Nos. 5,234,727 and 4,981,732. These disclosures relate to novel shapes that may be developed from a sheet of material, which may then be smoothly folded down to compact bundles.
[0005] Such methods have numerous uses for foldable structures and products, including sails, tents, and novel packaging.
[0006] In general, these methods require sheets of material whose thickness is very minor when compared to their planar extent. To the degree that the sheet has a thickness of any significance, it is generally required that its material have flexibility and compressibility in order to allow folding to occur.
[0007] However, this requirement for flexibility results in significant limitations with regards to the provision of foldable forms requiring a high degree of structural rigidity. Applications that require rigidity include any large-scale structures, as well as products such as foldable furniture, boxes, or foldable dividers.
[0008] Accordingly, it would be desirable to provide foldable forms with a high degree of structural rigidity in which the sheets thereof can have significant thickness.
SUMMARY OF THE INVENTION
[0009] Generally speaking, in accordance with the invention, a method whereby a sheet of material of significant thickness and rigidity may be provided with a network of hinges that allow the assembly to smoothly fold down to a compact bundle, and then instantly open into an extended structurally rigid shape, is provided.
[0010] A critical innovation of the disclosed method is in the spatial arrangement of the hinges or โfold-linesโ. In the earlier inventions referred to above, all hinges lie within the basic plane of the sheet. As the sheet folds in such inventions, the hinges take on a three-dimensional arrangement, whereby neighboring hinges have intersecting axes.
[0011] In the present invention, provision is made for hinges that lie in different planes, whereby their axes do not intersect and thus are offset relative to each other and to the basic plane of the structure. Such offsets allow for a thick sheet of material to fold down into a cubic bundle.
[0012] Further disclosed herein are various applications for this folding method, which include folding chairs, tables and self-supporting space dividers.
[0013] It will therefore be shown that objects and advantages of the invention will be found in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a first link used in the inventive assembly;
[0015] FIG. 2 is an elevational view of the link of FIG. 1 ;
[0016] FIG. 3 is a plan view of the link of FIG. 1 ;
[0017] FIG. 4 is a second elevational view of the link of FIG. 1 ;
[0018] FIG. 5 is an exploded view of a first embodiment of the inventive link assembly;
[0019] FIG. 6 is a perspective view of the inventive link assembly of FIG. 4 ;
[0020] FIG. 7 is a perspective view of the link assembly of FIG. 5 in a partially folded condition;
[0021] FIG. 8 is a perspective view of the link assembly of FIG. 5 in a further folded condition;
[0022] FIG. 9 is a perspective view of the link assembly of FIG. 5 in a fully folded condition;
[0023] FIG. 10 is a perspective view of a second link used in the inventive assembly;
[0024] FIG. 11 is an elevational view of the link of FIG. 10 ;
[0025] FIG. 12 is a plan view of the link of FIG. 10 ;
[0026] FIG. 13 is a perspective view of a third link used in the inventive link assembly and superimposed over the link of FIG. 10 ;
[0027] FIG. 14 is a perspective view of the third link of FIG. 13 ;
[0028] FIG. 15 is an elevational view of the link of FIG. 14 ;
[0029] FIG. 16 is a plan view of the link of FIG. 15 ;
[0030] FIG. 17 is a perspective view of a second embodiment of the inventive link assembly;
[0031] FIG. 18 is a perspective view of a third embodiment of the inventive link assembly;
[0032] FIG. 19 is a perspective view of the assembly of FIG. 18 in a partially folded condition;
[0033] FIG. 20 is a perspective view of the assembly of FIG. 18 in a further folded condition;
[0034] FIG. 21 is a perspective view of the assembly of FIG. 18 in a completely folded condition;
[0035] FIG. 22 is a perspective view of a fourth embodiment of the inventive link assembly;
[0036] FIG. 23 is an elevational view of the link assembly of FIG. 22 ;
[0037] FIG. 24 is a perspective view of a fifth embodiment of the inventive link assembly;
[0038] FIG. 25 is a perspective view of the link assembly of FIG. 24 in a partially folded condition;
[0039] FIG. 26 is a perspective view of the link assembly of FIG. 24 in a further folded condition;
[0040] FIG. 27 is a perspective view of the link assembly of FIG. 24 in a completely folded condition;
[0041] FIG. 28 is a perspective view of a fourth link used in the inventive assembly;
[0042] FIG. 29 is an elevational view of the link of FIG. 28 ;
[0043] FIG. 30 is a plan view of the link of FIG. 28 ;
[0044] FIG. 31 is a perspective view of a fifth link superimposed over the link of FIG. 28 ;
[0045] FIG. 32 is a detailed perspective view of the fifth link of FIG. 31 ;
[0046] FIG. 33 is an elevational view of the link of FIG. 32 ;
[0047] FIG. 34 is a plan view of the link of FIG. 32 ;
[0048] FIG. 35 is a plan view of a sixth embodiment of the inventive link assembly;
[0049] FIG. 36 is a side elevational view of the link assembly of FIG. 35 ;
[0050] FIG. 37 is a perspective view of the link assembly of FIG. 35 in an unfolded condition;
[0051] FIG. 38 is a perspective view of the link assembly of FIG. 35 in a partially folded condition;
[0052] FIG. 39 is a perspective view of the link assembly of FIG. 35 in a further folded condition;
[0053] FIG. 40 is a perspective view of the link assembly of FIG. 35 in yet a further folded condition;
[0054] FIG. 41 is a perspective view of the link assembly of FIG. 35 in a fully folded condition;
[0055] FIG. 42 is a perspective view of a seventh embodiment of the inventive link assembly in a folded condition;
[0056] FIG. 43 is a perspective view of the link assembly of FIG. 42 in a partially folded condition;
[0057] FIG. 44 is a perspective view of the link assembly of FIG. 42 in an unfolded condition;
[0058] FIG. 45 is a perspective view of the link assembly of FIG. 42 in a second alternative unfolded condition;
[0059] FIG. 46 is a perspective view of an eight embodiment of the inventive link assembly in a partially folded condition;
[0060] FIG. 47 is a perspective view of the link assembly of FIG. 46 in a further folded condition;
[0061] FIG. 48 is a perspective view of a perspective view of the link assembly of FIG. 46 in a completely folded condition;
[0062] FIG. 49 is a perspective view of a ninth embodiment of a link assembly made in accordance with the invention;
[0063] FIG. 50 is a perspective view of the link assembly of FIG. 49 in a partially unfolded condition;
[0064] FIG. 51 is a perspective view of the link assembly of FIG. 49 in a further unfolded condition;
[0065] FIG. 52 is a perspective view of the link assembly of FIG. 49 in a still further unfolded condition;
[0066] FIG. 53 is a perspective view of the link assembly of FIG. 49 in a fully unfolded condition;
[0067] FIG. 54 is a perspective view of a tenth embodiment of the inventive link assembly;
[0068] FIG. 55 is a perspective view of the embodiment of FIG. 54 in a first folded condition;
[0069] FIG. 56 is a perspective view of the embodiment of FIG. 54 in a second folded condition; FIG. 57 is a perspective view of the embodiment of FIG. 54 in a third folded condition;
[0070] and
[0071] FIG. 58 is a perspective view of the embodiment of FIG. 54 in a fully folded condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0072] FIG. 1 shows a perspective view of a link 6 that is comprised of two planes 7 and 9 . Plane 7 has an axis 2 lying along one edge. Plane 9 has an axis 4 lying along one edge. Axes 2 and 4 do not intersect.
[0073] FIG. 2 shows link 6 in elevation view. Axis 2 forms an angle 3 relative to plane 9 .
[0074] FIG. 3 shows link 6 in plan view. Axis 4 forms an angle 5 relative to plane 7 .
[0075] FIG. 4 shows a second elevation view of link 6 .
[0076] FIG. 5 shows an exploded view of assembly 30 which is comprised of four links 6 , 8 , 14 and 20 . Link 6 has two non-intersecting axes 2 and 4 . Similarly, links 8 , 14 and 20 have two non-intersecting axes each, respectively 10 and 12 , 16 and 18 , 22 and 24 .
[0077] FIG. 6 shows a perspective view of assembly 30 . Link 6 has been attached to link 8 by pivotally joining axes 2 and 10 . Likewise, link 8 has been attached to link 20 by pivotally joining axes 12 and 24 . In a similar manner, axes 22 and 16 join links 20 and 14 , while axes 18 and 4 join links 14 and 6 .
[0078] Axes 2 , 10 lies in a common plane with axes 16 , 22 and therefore these axes intersect each other. Likewise, axes 12 , 24 and 4 , 18 intersect each other. However, axes 2 , 10 and 16 , 22 do not intersect axes 12 , 24 nor do they intersect axes 4 , 18 .
[0079] FIG. 7 shows assembly 30 in a partially folded position.
[0080] FIG. 8 shows assembly 30 in a further folded position. The relationships of the respective axes with regards to whether they intersect is unchanged from that which is described in FIG. 5 .
[0081] FIG. 9 shows assembly 30 in a fully folded position, wherein the four links 6 , 8 , 14 and 20 form a volumetric stack. The intersecting relationships between the axes remain unchanged.
[0082] FIG. 10 shows a perspective view of link 40 that is comprised of three planes 51 , 53 and 55 . Also shown are four axes; axis 42 which borders plane 55 , axis 46 which borders plane 51 , and axes 44 and 48 which border plane 53 . Axes 42 , 44 , 46 and 48 are non-intersecting.
[0083] FIG. 11 shows an elevation view of link 40 . Axis 42 forms an angle 43 with plane 53 . Likewise, axis 46 forms an angle 45 with plane 53 .
[0084] FIG. 12 shows a plan view of link 40 . Axis 44 forms an angle 47 with plane 55 . Axis 46 forms an angle 49 with plane 51 .
[0085] FIG. 13 shows a link 50 which is superimposed over link 40 (which is shown in dashed lines). Link 50 is constructed having a three dimensional volume, whereas link 40 is shown as constructed of three thin planes.
[0086] FIG. 14 shows link 50 in more detail. Link 50 has four axes 52 , 54 , 56 and 58 . The geometric relationship between these non-intersecting axes is identical to axes 42 , 44 , 46 and 48 as shown in FIG. 10 .
[0087] FIG. 15 shows an elevation view of link 50 . FIG. 16 shows a plan view of link 50 .
[0088] FIG. 17 shows an assembly 60 which is comprised of four links 62 , 64 , 66 and 68 which are pivotally joined by axes 72 , 74 , 76 and 78 respectively. Links 62 , 64 , 66 and 68 are each comprised of two planes and each have two non-intersecting axes. Axes 74 and 78 lie in a common plane; likewise, axes 72 and 76 lie in a common plane.
[0089] FIG. 18 shows an assembly 80 which is comprised of four links 82 , 84 , 86 and 88 which are pivotally joined by axes 92 , 94 , 96 and 98 respectively. Links 82 , 84 , 86 and 88 are constructed as three dimensional volumes. The geometric relationship between axes 92 , 94 , 96 and 98 is identical to that shown between axes 72 , 74 , 76 and 78 as shown in FIG. 17 .
[0090] FIG. 19 shows assembly 80 in a partially folded position. FIG. 20 shows assembly 80 in a further folded position. FIG. 21 shows assembly 80 in a fully folded position where links 82 , 84 , 86 and 88 are stacked into a cubic bundle. The relationships of axes 92 , 94 , 96 and 98 with regards to whether they intersect is unchanged throughout the folding process.
[0091] FIG. 22 shows a plan view of assembly 100 which is comprised of nine links 102 , 104 , 106 , 112 , 114 , 116 , 122 , 124 and 126 that are joined together in a three-by-three grid arrangement. Each link is pivotally attached to its neighbors by axes that lie in various different planes. For example, link 102 is joined to link 112 by axis 107 . Likewise, link 114 is joined to link 116 by axis 115 .
[0092] FIG. 23 shows an elevation view of assembly 100 . Axes 107 , 108 , 109 , 117 , 118 and 119 are shown; all lie in different planes.
[0093] FIG. 24 shows a perspective view of assembly 100 . It may be seen that links 102 , 104 , 106 , 112 , 114 , 116 , 122 , 124 and 126 form a common plane having significant thickness. Axes 103 , 113 and 123 lie on one side of the common plane. Axes 105 , 115 and 125 lie on the other side of the common plane. Axes 107 , 108 , 109 , 117 , 118 and 119 lie outside of the common plane.
[0094] FIGS. 25 and 26 show perspective views of assembly 100 as it is successively folded.
[0095] FIG. 27 shows assembly 100 in a fully folded state such that links 102 , 104 , 106 , 112 , 114 , 116 , 122 , 124 and 126 form a cubic bundle.
[0096] FIG. 28 shows a perspective view of link 130 that is comprised of three planes 131 , 133 and 135 . Also shown are four axes; axis 132 which borders plane 131 , axis 136 which borders plane 135 , and axes 138 and 134 which border plane 133 . Axes 132 , 134 , 136 and 138 are non-intersecting.
[0097] FIG. 29 shows an elevation view of link 130 . Axis 132 forms an angle 140 with plane 133 . Likewise, axis 136 forms an angle 142 with plane 133 .
[0098] FIG. 30 shows a plan view of link 130 . It may be seen that link 130 has an essentially square shape. Axis 138 forms a right angle 144 with plane 131 . Axis 136 forms a right angle 146 with plane 135 .
[0099] FIG. 31 shows a link 150 which is superimposed over link 130 which is shown in dashed line. Link 150 is constructed as a three dimensional volume whereas link 130 is shown as constructed of three thin planes.
[0100] FIG. 32 shows link 150 in more detail. Link 150 has four axes 152 , 154 , 156 and 158 . The geometric relationship between these non-intersecting axes is identical to axes 132 , 134 , 136 and 138 as shown in FIG. 28 .
[0101] FIG. 33 shows an elevation view of link 150 . FIG. 34 shows a plan view of link 150 .
[0102] FIG. 35 shows an elevation view of assembly 200 which is comprised of nine links 202 , 204 , 206 , 212 , 214 , 216 , 222 , 224 and 226 . The links form a three-by-three grid of square shapes. They are each connected to their neighbors by various axes that lie in different planes.
[0103] FIG. 36 shows a second elevation view of assembly 200 . Four axes 205 , 209 , 213 and 215 are shown in this view, all of which lie outside the main plane defined by assembly 200 .
[0104] FIG. 37 shows a perspective view of assembly 200 in its unfolded state wherein it forms a flat plane.
[0105] FIG. 38 shows assembly 200 in a partially folded state. It may be seen that links 202 , 212 and 222 continue to lie in a common plane. Links 204 , 214 and 224 also lie in a common plane that forms an angle with the plane of the previous three links. Likewise, links 206 , 216 and 226 lie in a common plane, also forming an angle with the previous two planes. In FIG. 39 assembly 200 has be further folded such that the three common planes formed respectively by 202 , 212 , 222 and 204 , 214 , 224 and 206 , 216 , 226 are stacked one over the other.
[0106] FIG. 40 shows assembly 200 in a further folded position such that the stacked links 202 , 204 and 206 form an angle with stacked links 212 , 214 and 216 which in turn form an angle with stacked links 222 , 224 and 226 . It may be observed that axes 209 and 205 are co-axial relative to each other. Likewise, axes 213 and 215 are co-axial relative to each other.
[0107] FIG. 41 shows assembly 200 in a fully folded position such that the nine links 202 , 204 , 206 , 212 , 214 , 216 , 222 , 224 and 226 are stacked one over the other. Thus, assembly 200 folds in a two-stage process with the first stage being illustrated by FIGS. 37-39 , and the second stage being illustrated by FIGS. 39-41 .
[0108] FIG. 42 shows an assembly 300 which is in a fully folded position.
[0109] FIG. 43 shows assembly 300 in a partially folded position. Assembly 300 is comprised of eighteen links arranged in three rows. The upper row is comprised of links 302 , 312 , 322 , 332 , 342 and 352 . The middle row is comprised of links 304 , 314 , 324 , 334 , 344 and 354 . The lower row is comprised of links 306 , 316 , 326 , 336 , 346 and 356 . Link 312 is connected to link 322 by hinge 313 . Links 312 and 322 are constrained to lie in a common plane because of the position of the assembly. Likewise, links 314 and 324 are constrained to lie in a common plane, and are connected each other by hinge 315 . Similarly, links 316 , 326 and 332 , 342 and 334 , 344 and 336 , 346 are connected by hinges 317 , 333 , 335 and 337 respectively and are constrained to lie in common planes relative to one another.
[0110] FIG. 44 shows assembly 300 in an unfolded position wherein all the links form a common plane. Hinges 313 , 315 and 317 share a common axis in this position. Likewise, hinges 333 , 335 and 337 share a common axis in the unfolded position.
[0111] FIG. 45 shows assembly 300 in a second alternative unfolded position where links 302 , 304 , 306 , 312 , 314 and 316 have been rotated along hinges 313 , 315 and 317 . Additionally, links 342 , 344 , 346 , 352 , 354 and 356 have been rotated along hinges 333 , 335 and 337 . In this way, assembly 300 becomes self-supporting and can be used as a divider or wall.
[0112] FIG. 46 shows an assembly 400 which is comprised of six links 402 , 404 , 406 , 412 , 414 and 416 . Link 402 is attached to link 412 by hinge 407 . Similarly, each link is attached to its neighboring links by hinges 403 , 405 , 408 , 409 , 413 and 415 . Assembly 400 is shown in a partially folded configuration so that the approximate shape of a chair is formed.
[0113] FIG. 47 shows assembly 400 in a partially folded position. FIG. 48 shows assembly 400 in a fully folded position.
[0114] FIG. 49 shows an assembly 500 that is in a fully folded position and is comprised of four links 502 , 504 , 512 and 514 which are essentially stacked one over the other. In addition to these four links, there are frame elements 522 and 526 . Also shown in FIG. 49 is hinge 520 which attaches links 502 and 512 .
[0115] In FIG. 50 , assembly 500 is shown in a partially unfolded position such that links 504 and 512 lie along side of one another. Links 502 and 512 also lie along side each other in this position.
[0116] FIGS. 51 and 52 show assembly 500 in positions that are successively further unfolded. Frame elements 522 , 524 , 526 and 528 are seen to extend as links 502 , 504 , 512 and 514 are unfolded.
[0117] FIG. 53 shows assembly 500 in a fully unfolded position forming a stable and self-supporting chair.
[0118] FIG. 54 shows an assembly 600 that is comprised of six links 602 , 604 , 606 , 612 , 614 and 616 that form the surface of a table.
[0119] FIGS. 55-57 show assembly 600 as it appears in successively further folded positions.
[0120] FIG. 58 shows assembly 600 in a fully folded position forming a compact cubic bundle.
[0121] The scope of the invention will now be set forth in the following claims.
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A linkage comprised of at least four links is provided. Each of the links has a polygonal profile with each link having at least two hinged axes that do not intersect one another. Each link is connected to at least two other links by the non-intersecting axes such that the linkage can smoothly transform from an extended surface into a compact bundle. The linkage can be constructed into the form of a foldable chair, a foldable table or a foldable wall.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/671,841 filed on Sep. 27, 2000, which is a continuation-in-part of U.S. patent application Ser. No. 09/527,395, filed Mar. 16, 2000. The disclosures of the above applications are incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The invention relates generally to fluid control valves for operating a fluid-actuating device and, more particularly, to fluid control valves employing one or more ball-poppets.
[0003] Fluid control valves are often used for a wide variety of high-pressure applications, such as blow-molding plastic bottles or other such containers. Although these control valves have generally functioned satisfactorily, they often have a short life span due to excessive wear caused by exposure to high fluid pressures and may also experience internal fluid leakage. These internal fluid leaks, such as cross-over leaks, may occur while opening the inlet port of the valve and simultaneously closing the exhaust port of the valve in order to drive the fluid-actuating device. As a result, these factors have contributed to the high operation costs and high maintenance costs of prior art systems.
[0004] Moreover, in many commercial applications it is preferable that the control valve be capable of outputting multiple pressures. For example, with regard to blow-molding plastic bottles, it is often desirable to initially introduce a relatively low pressure to the mold in order to introduce the plastic (or other material) into the mold cavity or cavities and then to introduce a relatively high pressure to force or expand the material to conform to the mold cavity.
[0005] Accordingly, there exists a need in the relevant art to provide a high-pressure or multi-pressure fluid control valve that is capable of minimizing the wear and internal fluid leakage thereof so as to maximize the useful life of the valve and minimize the associated operating and maintenance costs. Furthermore, there exists a need in the relevant art to provide a fluid control valve that is capable of selectively outputting multiple pressures to the fluid-actuating device.
[0006] In accordance with the broad teachings of the present invention, a primary control valve for operating a fluid-actuated device includes a fluid inlet, a fluid outlet and a passage in fluid communication between the fluid inlet and the fluid outlet, the passage defining a longitudinal axis. A valve seat is disposed in the passage and includes an upstream diameter and a downstream diameter. The downstream diameter is smaller than the upstream diameter. A ball poppet is positionable in a seated line contact position with the valve seat. The valve seat has a valve seat angle relative to a centerline of the longitudinal axis that is greater than an angle formed by the centerline and a line tangent to the ball poppet at the seated line contact position.
[0007] Each side of the preferred frusto-conical supply valve seat has a supply seat angle relative to the centerline of the supply valve seat that is greater than an angle formed by the centerline of the supply valve seat and a line tangent to the supply ball-poppet at the above-mentioned substantially line-contact when the supply ball-poppet is in its closed position. The included angular relationship of the valve seat angles on both sides of the centerline is preferably approximately ninety degrees. This results in a annular space being formed between the supply valve seat and the spherical supply ball-poppet, which defines a restricted supply flow area upstream of the above-mentioned substantially line-contact as the supply ball-poppet initially moves to its open position and as high-velocity and high-pressure working fluid initially flows downstream past the supply ball-poppet through the smaller-diameter end of the valve seat. This is greatly advantageous because any sonic flow erosion caused by the initial flow of the high velocity and high-pressure working fluid through the annular restricted supply flow area is thus shifted substantially immediately to an upstream surface of the supply valve seat that is adjacent to such annular restricted supply flow area. Most significantly, such upstream surface of the supply valve seat is an area that is not sealingly contacted by the supply ball-poppet. Therefore, this immediate shifting of the sonic damage-susceptible area substantially minimizes sonic erosion of the nearly โknife-edgeโ smaller-diameter downstream end of the supply valve seat that is substantially line-contacted by the supply ball-poppet. In control valves according to the present invention that have both supply valving and exhaust valving, a similar arrangement is preferably provided in the exhaust passage way in fluid communication for exhaust fluid between the load outlet passage (and load outlet) and the exhaust outlet. As mentioned above, this arrangement is equally applicable to a pressure selector fluid control valve, as described below.
[0008] In addition, the present invention preferably includes a generally cylindrical cavity immediately upstream of the larger-diameter upstream ends of the supply and/or exhaust valve seats, with such cavity preferably being larger in diameter than the larger-diameter upstream end of the respective valve seats. A cylindrical poppet guide or ball-poppet guide is located in this enlarged-diameter cavity of the fluid passage, with the ball-poppet guide having a central guide bore extending axially therethrough. A number of circumferentially spaced-apart axially-extending guide fins protrude radially inwardly into the guide bore, with the ball-poppet being received within the guide bore for axial movement within radially inward edges of the guide fins between its open and closed positions. The inner diameter of the above-mentioned cavity is preferably slightly greater than the outer diameter of the ball-poppet guide in order to allow the ball-poppet guide and the ball-poppet to float radially somewhat within the cavity. This allows the generally spherical ball-poppet to be substantially self-centering for sealing line-contact with the smaller-diameter end of the respective supply or exhaust valve seat. Such circumferentially spaced guide fins allow high pressure working fluid to flow therebetween, and the ball-poppet guide substantially minimizes wear on the ball-poppet and/or the valve seat that would result if it were to be allowed to rattle or otherwise move radially in the high-velocity fluid flow. Such a ball-poppet guide can also be used in a selector fluid control valve, as described below.
[0009] The present invention substantially also negates cross-over leakage in high-pressure fluid control valves having both supply and exhaust valving by energizing the exhaust ball-poppet actuator, thus closing the exhaust side of the control valve, just prior to energizing the supply ball-poppet actuator, which then opens the supply side and initiates supply flow to the load passage and port.
[0010] The above-mentioned ball-poppets (for either primary or selector fluid control valves) are preferably composed of a metallic material, such as a stainless steel, for example, and the above-mentioned ball-poppet guides are preferably composed of a synthetic material, such as nylon, for example. Those skilled in the art will readily recognize that other metallic, synthetic, or non-synthetic materials can also be employed for the ball poppets and/or the ball-poppet guides, depending upon the particular working fluid (pneumatic or liquid) being employed, as well as the particular working fluid pressures involved, as well as depending upon the particular application in which the fluid control valve of the present invention is employed.
[0011] The present invention also provides a pressure selector fluid control valve for selectively supplying at least two different working fluid pressures to a fluid-actuated device, either directly or by way of a primary fluid control valve, such as that discussed above. An exemplary selector fluid control valve according to the present invention preferably has a high-pressure inlet in fluid communication with a source of working fluid at a relatively high pressure, a low-pressure inlet in fluid communication with a source of working fluid at a relatively low pressure, and a load fluid outlet passage interconnected in fluid communication with the fluid-actuated device or primary fluid control valve inlet. Such a selector fluid control valve further includes a normally closed high-pressure valve mechanism in fluid communication between the high-pressure inlet and the load fluid outlet passage to selectively allow high-pressure fluid flow from the high-pressure inlet to the load fluid outlet passage, as well as a normally open low-pressure valve mechanism in fluid communication between the low-pressure inlet and the load fluid outlet passage to selectively allow low-pressure fluid flow from the low-pressure inlet to the load fluid outlet passage. A pilot actuator is provided and is selectively operable to force the normally closed high-pressure valve mechanism into an open position and allow said high-pressure fluid flow from the high-pressure inlet to the load fluid outlet passage. This high-pressure fluid being admitted into the load fluid outlet passage forces the normally open low-pressure valve mechanism into a closed position to prevent fluid flow between the low-pressure inlet and the load fluid outlet passage. Thus the selective actuation or energization of the pilot actuator, either the high-pressure or low-pressure working fluid (such as a pneumatic working fluid, for example) can be admitted to the inlet of a fluid-actuated device or the inlet of a primary fluid control valve, such as that described above or of virtually any type.
[0012] At least one or preferably both of the above-discussed high-pressure and low-pressure valve mechanisms can include a generally frusto-conical valve seat located in a valve fluid passage in fluid communication with the load fluid outlet passage, with the valve seat having a smaller-diameter downstream end and a larger-diameter upstream end. A generally spherical ball-poppet is selectively movable between respective closed and open positions into and out of substantially ball-poppet line-contact for sealing with said smaller-diameter end of the supply valve seat. The generally spherical ball-poppet preferably has a chord dimension at said line-contact with the smaller-diameter downstream end of the valve seat that is smaller than the larger-diameter upstream end of the valve seat. The generally frusto-conical valve seat preferably has a seat angle relative to the centerline of the supply valve seat that is greater than an angle formed by the centerline of the valve seat and a line tangent to the spherical ball-poppet at the ball-poppet line-contact when the ball-poppet is in said closed position, with such seat angle preferably being approximately forty-five degrees such that the overall seat angle between diametrically opposite portions of the valve seat is approximately ninety degrees. An annular space formed between the valve seat and the spherical ball-poppet thus defines a restricted flow area upstream of the ball-poppet line-contact between the spherical ball-poppet and the smaller-diameter downstream end of the valve seat as the spherical ball-poppet initially moves out of said line-contact to its open position and as the working fluid initially flows downstream past the ball-poppet through the smaller-diameter end of said valve seat. By such an arrangement, any sonic flow erosion caused by the initial working fluid flow past the opening ball-poppet is shifted substantially immediately to an upstream area of the valve seat that is adjacent the restricted flow area and that is not sealingly contacted by the spherical ball-poppet. This substantially minimizes sonic damage to the smaller-diameter downstream end of said valve seat against which the ball-poppet is sealingly engaged when in its closed position. This greatly increases the life of the control valve by minimizing the wear on the sealing portion of the valve seat.
[0013] One or both of the fluid valve passages can include a generally cylindrical cavity immediately upstream of the larger-diameter upstream end of the valve seat, the cavity being larger in diameter than the larger-diameter upstream end. The valve mechanism preferably includes a generally cylindrical ball-poppet guide located in the cavity of said fluid passage, with the ball-poppet guide having a central guide bore extending axially therethrough. The ball-poppet guide preferably has a number of circumferentially spaced-apart axially-extending guide fins protruding radially inwardly into the guide bore, with the ball-poppet being received within the guide bore for axial movement within radially inward edges of the guide fins between its open and closed positions. The inner diameter of the cavity is greater than the outer diameter of the ball-poppet guide in order to allow the ball-poppet guide to float radially within the cavity and to allow the spherical ball-poppet to be substantially self-centering for sealing line-contact with the smaller-diameter end of said frusto-conical valve seat.
[0014] An exemplary selector fluid control valve according to the present invention may alternatively include a high-pressure inlet in fluid communication with a source of working fluid at a relatively high pressure, a low-pressure inlet in fluid communication with a source of working fluid at a relatively low pressure, and a load fluid outlet passage interconnected in fluid communication with the fluid-actuated device or primary fluid control valve inlet having a selectively adjustable control stem. The control stem selectively adjusts to a plurality of positions including a closed position, a fully open position and a plurality of intermediate positions therebetween for limiting the flow of working fluid through the low pressure inlet.
[0015] In any of the primary or pressure selector fluid control valves according to the present invention, the frusto-conical valve seat can alternatively be located in a replaceable valve seat disc that is of a harder material than that of the valve body.
[0016] Additional objects, advantages, and features of the present invention will become apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings.
[0017] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0019] [0019]FIG. 1 is a cross-sectional illustration of an exemplary fluid control valve according to the present invention.
[0020] [0020]FIG. 2 is an end view of the fluid control valve of FIG. 1;
[0021] [0021]FIG. 3 is a top view of the fluid control valve of FIGS. 1 and 2, with the top cover or cap removed;
[0022] [0022]FIG. 4 is a top view of a ball-poppet guide for use with either or both of a supply ball-poppet and an exhaust ball-poppet of the control valve of FIG. 1;
[0023] [0023]FIG. 5 is a side view of the poppet guide of FIG. 4;
[0024] [0024]FIG. 6 is an enlarged detail view of the supply valving portion of the control valve of FIG. 1, with the supply ball-poppet shown in its closed position;
[0025] [0025]FIG. 7 is an enlarged detailed view similar to that of FIG. 6, but illustrating the supply ball-poppet in its initially opening condition;
[0026] [0026]FIG. 8 is an enlarged detail view of the exhaust valving portion of the control valve of FIG. 1, with the exhaust ball-poppet shown in its closed position;
[0027] [0027]FIG. 9 is an enlarged detail view similar to that of FIG. 8, but illustrating the exhaust ball-poppet in its initially opening condition;
[0028] [0028]FIG. 10 is a cross-sectional illustration of an exemplary dual-pressure selector fluid control valve according to the present invention;
[0029] [0029]FIG. 10 a is a cross-sectional view taken generally along line 10 a - 10 a of FIG. 10;
[0030] [0030]FIG. 11 is a top view of the exemplary dual-pressure selector fluid control valve of FIG. 10, operatively interconnected with a primary fluid control valve, such as is illustrated in FIGS. 1 through 9, both of which being mounted on a fluid manifold;
[0031] [0031]FIG. 12 is a front view of the fluid control valve arrangement of FIG. 11;
[0032] [0032]FIG. 13 is an end view of the fluid control valve arrangement of FIGS. 11 and 12;
[0033] [0033]FIG. 14 is a cross-sectional illustration of an exemplary pressure selector fluid control valve similar to that of FIG. 10, but showing an alternate tri-pressure version of the selector fluid control valve;
[0034] [0034]FIG. 15 is an enlarged detailed view of an alternate version of the ball-poppet portion of a control valve according to the invention, having a replaceable valve seat disc and which is applicable to any of the fluid control valves of FIGS. 1 through 14; and
[0035] [0035]FIG. 16 is a cross-sectional illustration of an exemplary dual-pressure selector fluid control valve including an adjustable control stem according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0037] Referring to FIG. 1, an exemplary primary fluid control valve 10 is shown having a body 12 , a pilot cap 14 , and a manifold 16 . Body 12 and pilot cap 14 are secured to manifold 16 by way of a number of bolts 18 . However, it should be understood that body 12 and pilot cap 14 may be coupled together by way of fluid piping, without the use of the manifold 16 , if threaded ports are alternately provided.
[0038] The exemplary primary control valve 10 includes an inlet port 20 , an outlet or load port 22 , and an exhaust port 24 . A working fluid supply passage 28 provides working fluid communication from the inlet port 20 to the outlet port 22 , which is connected, such as by way of the manifold 16 , to a fluid-actuated device. Similarly, an exhaust passage 30 provides exhaust fluid communication between the load port 22 and the exhaust outlet 24 .
[0039] In the exemplary primary control valve 10 , the supply and exhaust passages 28 and 30 respectively include a frusto-conical supply valve seat 36 and a frusto-conical exhaust valve seat 46 . The supply valve seat 36 includes a smaller-diameter end 38 and a larger-diameter end 40 . Similarly the exhaust valve seat 46 includes a smaller-diameter end 48 and a larger-diameter end 50 . A generally spherical supply ball-poppet 42 and a similar generally spherical exhaust ball-poppet 52 are provided for opening and closing movement with respect to their respective frusto-conical supply and exhaust valve seats 36 and 46 .
[0040] The supply ball-poppet 42 is preferably movably actuated by way of a supply pilot actuator 80 , which receives pilot air from a pilot air passage 97 , which is in turn connected in fluid communication with a pilot air inlet 96 . When the supply pilot actuator 80 is energized, the force of the pilot air is transmitted on to the supply piston 81 and in turn to supply push rod 82 to urge the supply ball-poppet 42 away from the supply valve seat 36 , thus opening the supply valving portion of the control valve 10 . When the supply pilot actuator 80 is deenergized, the ball-poppet 42 is returned to its closed position under the influence of the inlet fluid pressure and a return spring 58 .
[0041] Similarly, the exhaust ball-poppet 52 is urged into its closed position with respect to the exhaust valve seat 46 by way of the energization of an exhaust pilot actuator 90 . In this regard, pilot actuator 90 acts to exert the force of pilot air on to an exhaust piston 91 and in turn to exhaust push rod 98 in drawing (FIG. 1), to the exhaust ball-poppet 52 . Upon deenergization of the exhaust pilot actuator 90 , the exhaust ball-poppet 52 is urged back to its open position under the influence of high-pressure working fluid in the exhaust passage 30 .
[0042] One skilled in the art will readily recognize that actuators other than the exemplary electro-pneumatic supply pilot actuator 80 and electro-pneumatic exhaust pilot actuator 90 , can alternatively be employed. Such actuating devices could include for example, electromechanical solenoids, either local or remote, mechanical motion transmitting devices, or a wide variety of other actuating devices well-known to those skilled in the art.
[0043] Referring primarily to FIGS. 6 and 7, the exemplary high-pressure fluid control valve 10 depicted in the drawings also preferably includes a generally cylindrical supply cavity 60 immediately upstream of the larger-diameter upstream end 40 of the supply valve seat 36 . As illustrated in FIGS. 4 through 6, a generally cylindrical supply poppet guide 62 is provided upstream within the preferred diametrically-enlarged cylindrical supply cavity 60 . The supply poppet guide 62 includes a generally cylindrical central supply guide bore 64 extending axially therethrough, with a number of circumferentially spaced-apart and axially-extending supply guide fins 66 protruding radially inwardly into the supply guide bore 64 . The supply ball-poppet 42 is received within the supply guide bore 64 for axial movement within the radially inward edges of the supply guide fins 66 between its open and closed positions with respect to the supply valve seat 36 . As is perhaps best illustrated in FIGS. 6 and 7, the inner diameter of the supply cavity 60 is slightly greater than the outer diameter of the supply ball-poppet guide 62 , thus allowing the poppet guide 62 and the ball-poppet 42 to float radially within the supply cavity 60 . As such the generally spherical supply ball-poppet 42 is self-centering for sealing substantially line-contact 44 with the smaller-diameter end 38 of the supply valve seat 36 .
[0044] In addition, the supply guide fins 66 preferably extend axially downstream to form a supply guide fin extension portion 63 on one end of the supply poppet guide 62 . A resilient ring 61 , such as an O-ring, surrounds the extension portion 63 in order to resiliently urge the poppet guide 62 toward the opposite, upstream end of the supply cavity 60 . This action results from compression of the resilient ring 61 between the floor of the supply cavity 60 and the remainder of the supply ball-poppet guide 62 .
[0045] It should be noted that the above arrangement, as depicted in FIGS. 4 through 7, is substantially typical with respect to the frusto-conical exhaust valve seat 46 . Explained further, the smaller-diameter upstream end 48 is arranged to engage in substantial line-contact the generally spherical exhaust poppet 52 , all of which are shown in FIG. 1. The supply poppet guide 62 depicted in FIGS. 4 and 5 is also substantially typical for the exhaust poppet guide 72 , which is received within the diametrically-enlarged generally cylindrical exhaust cavity 70 and has a similar central exhaust guide bore 74 and similar exhaust guide fins 76 , and which can also be seen in FIGS. 1, 8 and 9 .
[0046] Referring in particular to FIGS. 6 and 7, an enlarged detail view of the supply valving portion of the exemplary control valve 10 is shown. The ball-poppet 42 is shown in its closed position in FIG. 6. Wherein the ball-poppet 42 is sealingly engaged in substantial line-contact 44 with the edge of the smaller-diameter end 38 of the supply valve seat 36 . Similarly, the ball-poppet 42 is shown partially opened and thus moved out of such substantial line-contact 44 in FIG. 7. The frusto-conical supply valve seat 36 preferably has a valve seat angle 37 (with respect to the centerline 57 of the valve seat 36 ) that is slightly larger than the tangent angle 59 of the tangent line 56 to the ball-poppet 42 (with respect to the centerline 57 ) when the ball-poppet 42 is in substantial line-contact 44 shown in FIG. 6.
[0047] This valve seat arrangement results in an annular space 43 that creates a restricted supply flow area just upstream of the supply line-contact 44 and the smaller-diameter end 38 . The restricted flow area is created as the supply ball-poppet 42 initially moves out of such line-contact 44 to its open position shown in FIG. 7 as working fluid flows downstream past the ball-poppet 42 through the smaller-diameter end 38 of the supply valve seat 36 . Consequently, any sonic flow erosion damage caused by such initial flow of high-pressure working fluid is shifted substantially immediately to an upstream area 45 of the supply valve seat 36 . This is highly advantageous in that it shifts such wear or damage caused by such sonic flow erosion to an area of the supply valve seat 36 that is adjacent to the annular space 43 rather than in contact with ball-poppet 42 . Accordingly, the sonic damage to the smaller-diameter downstream sealing end 38 of the supply valve seat 36 is minimized, As a result, the damage to and wear of the actual sealing surface of the valve seat 36 on the ball-poppet 42 is likewise substantially minimized and the functional life of the exemplary control valve 10 is correspondingly greatly extended. In this regard, the downtime and the maintenance costs are reduced for a system employing a control valve 10 according to the present invention.
[0048] As will be readily recognized by one skilled in the art, the above-described function of the ball-poppet 42 with respect to the supply valve seat 36 as shown in FIG. 6 and FIG. 7 is similar to that of the function and relationship of the exhaust ball-poppet 52 and exhaust valve seat 46 .
[0049] Referring primarily to FIGS. 8 and 9, the exemplary high-pressure fluid control valve 10 depicted in the drawings also preferably includes a generally cylindrical exhaust cavity 70 immediately downstream of the larger-diameter downstream end 50 of the exhaust valve seat 46 . A generally cylindrical exhaust poppet guide 72 (similar to that of the supply poppet guide 62 of FIGS. 5 and 6) is provided downstream within the preferred diametrically-enlarged cylindrical exhaust cavity 70 . The exhaust poppet guide 72 includes a generally cylindrical central exhaust guide bore 74 extending axially therethrough, with a number of circumferentially spaced-apart and axially-extending exhaust guide fins 76 protruding radially inwardly into the exhaust guide bore 74 . The exhaust ball-poppet 52 is received within the exhaust guide bore 74 for axial movement within the radially inward edges of the exhaust guide fins 76 between its open and closed positions with respect to the exhaust valve seat 46 . The inner diameter of the exhaust cavity 70 is slightly greater than the outer diameter of the exhaust ball-poppet guide 72 , thus allowing the poppet guide 72 and the exhaust ball-poppet 52 to float radially within the exhaust cavity 70 . As a result, the generally spherical exhaust ball-poppet 52 is self-centering for sealing substantially line-contact 54 with the smaller-diameter end 48 of the exhaust valve seat 46 .
[0050] The exhaust guide fins 76 preferably extend axially upstream to form an exhaust guide fin extension portion 73 on the exhaust poppet guide 72 . A resilient ring 71 , such as an O-ring, surrounds the extension portion 73 in order to urge the poppet guide 72 toward the opposite, downstream end of the exhaust cavity 70 . This action results from compression of the resilient ring 71 between the floor of the exhaust cavity 70 and the remainder of the exhaust ball-poppet guide 72 .
[0051] Referring in particular to FIGS. 8 and 9, an enlarged detail view of the exhaust valving portion of the exemplary control valve 10 is shown. The exhaust ball-poppet 52 is shown in its closed position in FIG. 8 wherein the ball-poppet 52 is sealingly engaged in substantial line-contact 54 with the edge of the smaller-diameter end 48 of the exhaust valve seat 46 . Similarly, the ball-poppet 52 is shown partially opened and thus moved out of such substantial line-contact 54 in FIG. 9. The frusto-conical exhaust valve seat 46 preferably has an exhaust valve seat angle 47 (with respect to the exhaust centerline 67 of the valve seat 46 ) that is slightly larger than the exhaust tangent angle 69 of the exhaust tangent line 65 to the exhaust ball-poppet 52 (with respect to the centerline 67 ) when the ball-poppet 52 is in substantial line-contact 54 shown in FIG. 8.
[0052] This valve seat arrangement results in an annular space 53 that creates a restricted exhaust flow area just downstream of the exhaust line-contact 54 and the smaller-diameter end 48 . The restricted flow area is created as the exhaust ball-poppet 52 initially moves out of such line-contact 54 to its initially opening position shown in FIG. 9 as exhaust fluid flows downstream past the ball-poppet 52 through the smaller-diameter end 48 of the exhaust valve seat 46 . Consequently, any sonic flow erosion damage caused by such initial flow of high-pressure exhaust fluid is shifted substantially immediately to an upstream flow area adjacent the exhaust valve seat 46 . This is highly advantageous in that it shifts such wear or damage caused by such sonic flow erosion to annular space 53 rather than in contact with the ball-poppet 52 . Accordingly, the sonic damage to the smaller-diameter upstream sealing end 48 of the exhaust valve seat 46 is minimized. As a result, the damage to and wear of the actual sealing surface of the valve seat 46 on the ball-poppet 52 is likewise substantially minimized and the functional life of the exemplary control valve 10 is correspondingly greatly extended. Valve seat 46 is preferably made of a rigid metal such as but not limited to stainless steel. In this regard, the downtime and the maintenance costs are reduced for a system employing a control valve 10 according to the present invention.
[0053] Referring primarily to FIG. 1, the cross-over leakage of the exemplary fluid control valve 10 depicted in the drawings is substantially minimized by energizing the exhaust pilot actuator 90 to close the exhaust ball-poppet 52 just slightly prior to energizing the supply pilot actuator 80 to open the ball-poppet 42 . Because of the equipment and energy necessary to elevate the working fluid to such a high-pressure state, minimizing cross over leakage greatly reduces the operating costs that would otherwise result from excessive waste or exhaust of high-pressure working fluid. Such high-pressure working fluid, which can be either pneumatic or hydraulic, but which is preferably pneumatic, is often in the range of 300 psig to 900 psig, and is typically approximately 600 psig in the above-mentioned blow-molding processes.
[0054] Finally, either or both of the ball-poppets 42 and 52 are preferably composed of a metallic material, such as stainless steel or other metallic or non-metallic materials deemed advantageous by one skilled in the art for a given application. Similarly, either or both of the supply poppet guide 62 and the exhaust poppet guide 72 are preferably composed of a synthetic material, such as nylon, but can also be composed of a metallic material, such a stainless steel, or other suitable materials known to those skilled in the art.
[0055] [0055]FIGS. 10 through 15 illustrate various versions of a selector fluid control valve that can be used either alone or in conjunction (on the supply side) with the primary fluid control valve discussed above in connection with FIGS. 1 through 9. Because many of the components of the valves illustrated in FIGS. 10 through 15 are either identical or substantially similar, at least in function, with those of the valves depicted in FIGS. 1 through 9, such components in FIGS. 10 through 15 are indicated by reference numerals that are the same as those in FIGS. 1 through 9, but which have two hundred, three hundred, or four hundred prefixes.
[0056] In FIGS. 10 through 13, an exemplary selector fluid control valve 210 includes a body 212 , a pilot cap 214 , and a manifold 216 (as shown in FIGS. 11 through 13). Body 212 and pilot cap 214 are secured to manifold 216 in a manner similar to that depicted above in connection with FIGS. 1 through 9. However, it should be understood that body 212 and pilot cap 214 may be coupled together by way of fluid piping, without the use of manifold 216 , if threaded ports are alternatively provided.
[0057] The exemplary selector fluid control valve 210 includes an inlet port 220 and 221 , which are in fluid communication with separate sources of working fluid. Inlet port 220 is configured for communicating with fluid at a relatively higher pressure whereas inlet port 221 is configured for communicating with fluid at a relatively lower pressure. Such relatively higher pressures will be referred to herein as โhigh-pressureโ, and such relatively lower pressures will similarly be referred to as โlow-pressureโ. It should be appreciated that the inlet and outlet ports described herein may alternatively be threaded.
[0058] A load fluid outlet passage 228 extends through the body 212 of the selector fluid control valve 210 and is in fluid communication with an outlet load port 222 . The selector fluid control valve 210 can be used either alone, or in combination with a primary fluid control valve, such as the primary fluid control valve 10 of FIGS. 1 through 9. In such an application, the selector fluid control valve 210 can have its load outlet port 222 interconnected in fluid communication with the inlet port 20 of the primary fluid control valve 10 , either by fluid piping or by way of the manifold 216 of FIG. 11.
[0059] The selector fluid control valve 210 also includes a normally closed high-pressure valve mechanism in fluid communication between the high pressure inlet port 220 and the load fluid outlet passage 228 . Similarly, a normally open low-pressure valve mechanism is in fluid communication between the low-pressure inlet port 221 and the load fluid outlet passage 228 . In the exemplary selector fluid control valve 210 , the high-pressure valve mechanism includes a frusto-conical valve seat 236 , which in turn includes a smaller-diameter end 238 and a larger-diameter end 240 . A ball-poppet 242 , which is preferably generally spherical in shape and configuration, engages the valve seat 236 in a substantially line-contact engagement, in a manner as previously explained in more detail in connection with the valve seat 36 and the ball-poppet 42 of FIGS. 1 through 9. Similarly, the low-pressure valve mechanism includes a valve seat 246 having a smaller-diameter end 248 and a larger-diameter end 250 , with the low-pressure ball-poppet 252 engaging the small-diameter end 248 in the same type of line-contact as is discussed above.
[0060] The high-pressure ball-poppet 242 is received within a high-pressure ball-poppet guide 262 similar to the ball-poppet guide 62 of FIGS. 1 through 9. In a similar manner, the low-pressure ball-poppet 252 is received within a low-pressure ball-poppet guide 272 . The guides 262 and 272 maintain the radially-floating and ball-poppet centering capabilities, associated with the guides 62 and 72 of FIGS. 1 through 9. In contrast however, the fins 266 and 276 do not necessarily extend axially beyond the end of their respective guides 262 and 272 as with the fins 66 and 76 from the above-discussed guider 62 and 72 . In such an arrangement, instead of the O-rings 61 and 71 of FIGS. 1 through 9, resilient wavy washers or spring wave washers 261 and 271 are provided to resiliently bias the respective guides 262 and 272 toward their respective proper positions within the respective guide bores 264 and 274 . In substantially all other respects, however, the ball-poppet guides 262 and 272 perform in a substantially identical manner as the corresponding ball-poppet guides 62 and 72 discussed above.
[0061] In the preferred selector fluid control valve 210 , the high-pressure ball-poppet 242 is biased toward its normally closed position by a return spring 258 acting on the ball-poppet 242 by way of a ball-poppet perch 275 . A pilot actuator 280 is provided in connection with the high-pressure ball-poppet 242 and is selectively actuable to force the ball-poppet 242 off of its respective valve seat 236 and into its open position, with the pilot actuator 280 acting through the high-pressure actuating piston assembly 281 and the push rod 282 .
[0062] In the low-pressure valve mechanism, the ball-poppet 252 is in a normally-open position under the influence of the low-pressure working fluid from the low-pressure inlet 221 acting on the ball-poppet 252 and against the biasing force of a low-force retaining spring 251 . The low-pressure ball-poppet 252 is held in place by a retainer plug 249 having a generally U-shaped opening 278 extending therethrough, as is illustrated in FIG. 10 a. The opening travel of the low-pressure ball-poppet 252 is limited by its contact with a stop rod or pin 277 fixedly interconnected with the retainer plug 249 and extending into the retainer plug passage 278 .
[0063] In operation, the selector fluid control valve 210 can be used to selectively supply one of two different pressures of working fluid (preferably a pneumatic working fluid) to either a fluid-actuated device or to the inlet of a primary control valve (such as the primary fluid control valve 10 discussed above) by way of the outlet load port 222 of the selector fluid control valve 210 . Initially, a source of relatively low-pressure working fluid is supplied to the low-pressure inlet port 221 and passes by the normally-open ball-poppet 252 to the load fluid outlet passage 228 and the outlet load port 222 . Such relatively low-pressure working fluid exerts sufficient force on the low-pressure ball-poppet 252 to maintain it in its open position against the biasing force of the low-pressure retaining spring 251 as long as fluid is flowing in the circuit. Thus, in this condition, as is illustrated in FIG. 10, relatively high-pressure working fluid supplied to the high-pressure inlet port 220 is isolated from the relatively low-pressure working fluid in the load fluid outlet passage 228 by the normally closed high-pressure ball-poppet 242 . The normally closed high-pressure ball poppet is forced against its respective valve seat 236 under the influence of the return spring 258 . In this condition, such relatively low-pressure working fluid is supplied to the outlet load port 222 .
[0064] However, when it is desired to admit relatively high-pressure working fluid to the load fluid outlet passage 228 and to the outlet load port 222 , the pilot actuator 280 is selectively energized. It should be noted that the pilot actuator 280 can be pneumatically operated, electrically operated, or mechanically operated, for example.
[0065] The energization of the pilot operator 280 causes the piston assembly 281 and the push rod 282 to force the high-pressure ball-poppet 242 to its open position against the biasing force of the return spring 258 and the high-pressure fluid in the inlet 220 . This opening of the high-pressure ball-poppet 242 allows relatively high-pressure working fluid from the high-pressure inlet port 220 to pass into the load fluid outlet passage 228 . The high-pressure working fluid now admitted into the load fluid outlet passage 228 acts (in conjunction with the low-force retaining spring 251 ) to urge the normally open low-pressure ball-poppet 252 to its closed position in sealing engagement with the valve seat 246 . Thus, in this condition, the relatively low-pressure working fluid from the low-pressure inlet port 221 is isolated from the relatively high-pressure working fluid in the load fluid outlet passage 228 , the retainer plug passage 278 , and the outlet load port 222 . As mentioned above, this allows for selective supply of either the relatively low-pressure working fluid or the relatively high-pressure working fluid from the outlet load port 222 to a fluid actuated device or to the inlet 20 of a primary valve such as that of the primary control valve 10 illustrated in FIGS. 1 through 9. This latter arrangement is illustrated in FIGS. 11 through 13 where the selector fluid control valve 210 and the primary control valve 10 are mounted together on a manifold 216 . Again manifold 216 may alternately be replaced by separate fluid piping if alternate threaded ports are provided.
[0066] In FIG. 14, an alternate embodiment of a selector fluid control valve according to the present invention is depicted for purposes of illustrating that the present invention is equally applicable to such control valves adapted for supplying more than two different working fluid pressures to a fluid-actuated device, either directly or through a primary fluid control valve, such as the primary fluid control valve 10 discussed above and shown in FIGS. 1 through 9. The selector fluid control valve 410 in FIG. 14 has numerous components that are either identical or functionally substantially similar to those of the fluid selector control valve 210 in FIG. 10. In FIG. 14, however, such corresponding components are indicated by reference numerals having four-hundred prefixes and a or b suffixes in the case of components that are identical with each other.
[0067] The body 412 of the selector fluid control valve 410 includes two of the above-discussed high-pressure inlets 420 a and 420 b, with two of the above-described pilot actuators 480 a and 480 b, each of which are separately and selectively operable to urge their respective ball-poppets 442 a and 442 b into their respective open positions. In virtually all other respects, however, the selector fluid control valve 410 operates in substantially the same manner as the above-described selector fluid control valve 210 .
[0068] The operational difference between the selector fluid control valve 410 and the selector fluid control valve 210 is that the pilot actuators 480 a and 480 b can be separately and selectively actuated or energized, or de-actuated or de-energized, in order to allow for the selective supply of three different pressures or working fluid to the fluid-actuated device, by way of the load outlet port 422 , either directly or by way of the above-mentioned primary fluid control valve. It should be noted that FIG. 14 illustrates merely an exemplary multi-pressure application of the present invention, and one skilled in the art will now readily recognize that any number of different pressures can be accommodated by the selector fluid control valve of the present invention.
[0069] In FIG. 15, still another alternate arrangement of the present invention is depicted, in which the resilient spring wave washer 361 is moved to an opposite position with respect to the ball-poppet guide than that depicted in FIG. 10. In this arrangement, a replaceable valve seat disc 388 , which includes the valve seat 336 therein, is trapped between the ball-poppet guide 362 and the downstream end of the guide bore 364 . The valve seat disc 388 includes a chamfered edge 386 that is sealingly engaged by an O-ring 384 and is preferably composed of a harder material than that of the valve body. Such an arrangement allows for convenient replacement of a worn valve seat 336 by merely replacing the valve seat disc 388 , without the necessity of discarding or re-machining the valve seat 236 of the body 212 in FIG. 10. Thus, one selector fluid control valve can be partially disassembled and repaired by such replacement of the valve seat disc 388 while another selector fluid control valve is in service. Such repaired selector fluid control valve can then be maintained in reserve for immediate replacement of a worn selector fluid control valve that is currently in service. It should be noted that a similar replaceable valve seat disc can also alternatively be used in conjunction with any of the valve mechanisms or arrangements shown in FIGS. 1 through 15.
[0070] Finally, the preferred pneumatic high-pressure working fluid or fluids can be at virtually any pressure above that of the low-pressure working fluid, such as, for example, pressures in the range of 300 psig to 900 psig, with one application requiring a high-pressure working fluid at approximately 600 psig. Similarly, the low-pressure working fluid can be at virtually any pressure lower than that of the high-pressure working fluid, such as, for example, pressures in the range of 10 psig to 300 psig, with at least one application requiring such low-pressure working fluid at a pressure of approximately 100 psig. Furthermore, as mentioned above, the primary fluid control valves and the selector control valves of the present invention have wide-ranging applicability in various liquid or pneumatic fluid control or actuation systems. One example of such an application is a pneumatic system for blow molding of plastic bottles or other containers, which requires a first relatively lower pressure to urge the plastic material into the mold cavity, followed by a relatively higher pressure working fluid to complete the blow molding process by forcing the plastic material against the internal contours of the mold. One skilled in the art will readily recognize, however, that this is merely one example of the many applications of the present invention.
[0071] Turning now to FIG. 16, an alternate embodiment of the selector fluid control valve according to the present invention is shown. The selector fluid control valve 610 in FIG. 16 has numerous components that are either identical or functionally substantially similar to those of the fluid selector control valve 210 in FIG. 10. In FIG. 16, however, such corresponding components are indicated by reference numerals having five-hundred prefixes in the case of components that are identical with each other. Furthermore, components corresponding to selector valve 610 incorporating adjustment stem 602 are referenced with numerals having a six-hundred prefix.
[0072] The body 512 of the selector fluid control valve 510 includes the above-discussed high-pressure inlet 520 , with the above-described pilot actuator 580 which is selectively operable to urge ball-poppet 542 into its respective open position. It is noted that wave springs 561 and 571 have been relocated to opposite sides of ball-poppets 542 and 552 . In addition, as will be explained in greater detail later, the normally-open low-pressure ball poppet 552 cooperates with fluid control adjustment stem 602 . In virtually all other respects, however, the selector fluid control valve 610 operates in substantially the same manner as the above-described selector fluid control valve 210 .
[0073] With continued reference to FIG. 16, fluid control adjustment stem 602 is selectively linearly actuated through bore 604 upon rotation of flow control knob 606 . In this regard, the linear travel of adjustment stem 602 is restricted between surfaces 608 and 612 by collar 611 . Threads 624 are incorporated in plug 616 for cooperating with complimentary threads 618 on adjustment stem 602 . Fasteners 626 threadably secure plug 616 to pilot cap 614 . A jam nut 640 and washer 642 are positioned between control knob 606 and pilot cap 614 . Jam nut 640 engages threads 622 to lock stem 602 to pilot cap 614 . Pin or engagement portion 630 extends from a distal end of adjustment stem 602 for engaging ball poppet 552 and limiting the allowable displacement thereof. A return spring 632 is incorporated around pin 630 .
[0074] The operation of adjustment stem 602 will now be described in greater detail. The flow rate allowed around ball poppet 552 is determined by the displacement of ball poppet 552 from valve seat 546 . In this regard, the flow rate is increased as ball poppet 552 moves away from valve seat 546 . The allowable displacement of ball poppet 552 from valve seat 546 is controlled by the location of pin 630 extending from adjustment stem 602 . Explained further, fluid flow through low-pressure inlet port 521 urges ball poppet 552 away from valve seat 546 into contact with pin 630 . In this manner, the adjustment stem 602 may be positioned at a predetermined location to obtain a desired flow rate around ball poppet 552 . Once a desired flow rate is reached, jam nut 640 may be advanced into engagement with pilot cap 614 to preclude inadvertent rotation of control knob 606 .
[0075] The foregoing discussion discloses and describes merely exemplary embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications, and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.
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A control valve for operating a fluid-actuated device includes a fluid inlet, a fluid outlet and a passage in fluid communication between the fluid inlet and the fluid outlet, the passage defining a longitudinal axis. A valve seat is disposed in the passage and includes an upstream diameter and a downstream diameter, the downstream diameter smaller than the upstream diameter. A ball poppet is positionable in a seated line contact position with the valve seat. The valve seat has a valve seat angle relative to a centerline of the longitudinal axis that is greater than an angle formed by the centerline and a line tangent to the ball poppet at the seated line contact position.
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FIELD OF THE INVENTION
The present invention relates to the field of transistors and method of forming transistors; more specifically, it relates to transistors having stressed channel regions and method of fabricating transistors having stressed channel regions.
BACKGROUND OF THE INVENTION
In microelectronic technology there is an ongoing search for transistors with increased performance. While many methods exist for increasing transistor performance, new and improved transistor structures with even more performance and methods of fabricating transistor structures with even more performance than currently available are continually sought after. Accordingly, there continues to be an unsatisfied need for transistors with increased performance.
SUMMARY OF THE INVENTION
A first aspect of the present invention is a method, comprising: (a) forming gate stack on a silicon layer of a substrate; (b) forming two or more SiGe filled trenches in the silicon layer on at least one side of the gate stack, adjacent pairs of the two or more SiGe filled trenches separated by respective silicon regions of the silicon layer; and (c) forming source/drains in the silicon layer on opposite sides of the gate stack, the source/drains abutting a channel region of the silicon layer under the gate stack.
A second aspect of the present invention is a structure, comprising: a gate stack on a silicon layer of a substrate; two or more SiGe filled trenches in the silicon layer on at least one side of the gate stack, adjacent pairs of the two or more SiGe filled trenches separated by respective silicon regions of the silicon layer; and source/drains in the silicon layer on opposite sides of the gate stack, the source/drains abutting a channel region of the silicon layer under the gate stack.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention are set forth in the appended claims. The invention itself, however, will be best understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIGS. 1A through 1F are cross-sectional drawings illustrating fabrication of a stressed transistor according to a first embodiment of the present invention;
FIGS. 2A through 2C are cross-sectional drawings illustrating fabrication of a stressed transistor according to a second embodiment of the present invention;
FIGS. 3A through 3F are cross-sectional drawings illustrating fabrication of a stressed transistor according to a third embodiment of the present invention; and
FIGS. 4A and 4B are cross-sectional drawings illustrating alternative process steps applicable to all embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Stress is a measure of the average amount of force exerted per unit area. Stress is a measure of the intensity of the total internal forces acting within a body across imaginary internal surfaces, as a reaction to external applied forces and body forces. Strain is the geometrical expression of deformation caused by the action of stress on a physical body.
Silicon-Germanium (SiGe) has an increased crystal lattice spacing compared to silicon alone. By embedding SiGe regions on either side of silicon channel of a field effect transistor (FET) the channel region will be put in compressive stress. In p-channel field effect transistors (PFETs) the mobility of the majority carriers (holes) is greater than (and electron mobility is less) when the channel region is in compressive stress in the direction of current flow. Increasing the mobility of majority carriers increase the performance of the device in terms of both speed and gain. However, as the area of an embedded SiGe region increases (e.g., allowing increased SiGe surface deflection), the strain within the SiGe region decreases, thus reducing the stress on adjacent the silicon channel region.
FIGS. 1A through 1F are cross-sectional drawings illustrating fabrication of a stressed transistor according to a first embodiment of the present invention. In FIG. 1A , a silicon-on-insulator (SOI) substrate includes a single-crystal silicon layer 105 and a supporting substrate 110 (e.g., single-crystal silicon) separated by a buried oxide (BOX) layer 115 . In one example BOX layer 115 comprises silicon dioxide. Formed on silicon layer 105 are first and second gate stacks 120 A and 120 B. Gate stacks 120 A and 120 B each comprise a gate dielectric layer 125 on a top surface 127 of silicon layer 105 , a gate electrode a 130 on a top surface of gate dielectric layer 125 and a dielectric capping layer 135 on a top surface of gate electrode 130 . In one example, gate electrode 135 comprises polysilicon. In one example, capping layer 135 comprises silicon dioxide or silicon nitride. Formed on sidewalls of gate stacks 120 A and 120 B are dielectric sidewall spacers 140 . In one example, sidewall spacers 140 comprise silicon dioxide or silicon nitride.
In FIG. 1B , a hardmask layer 145 is formed on exposed surfaces of silicon layer 105 , capping layer 135 and sidewall spacers 140 . In one example, hardmask layer 145 comprises silicon dioxide or silicon nitride. In one example, hardmask layer 145 is a conformal layer.
In FIG. 1C , hardmask layer 145 is patterned to form openings 147 through the hardmask layer with regions of silicon layer 105 exposed in openings 147 so there are regions of silicon layer 105 not protected by hardmask layer 145 , gate stacks 120 A and 120 B and sidewall spacers 140 . Openings 147 are formed in a photolithographic process followed by a wet or dry etch. An example of a dry etch is a reactive ion etch (RIE). In FIG. 1C , after patterning, hardmask layer 145 has been removed from sidewall spacers 140 and capping layer 135 . Depending upon the etch properties of the particular etch process and the materials of capping layer 135 , sidewall spacers and 140 hardmask layer 145 , it is possible for spacers formed from hardmask layer 145 to be formed on sidewall spacers 140 as illustrated in FIG. 4A and described infra.
A photolithographic process is one in which a photoresist layer is applied to a surface, the photoresist layer exposed to actinic radiation through a patterned photomask and the exposed photoresist layer developed to form a patterned photoresist layer. When the photoresist layer comprises positive photoresist, the developer dissolves the regions of the photoresist exposed to the actinic radiation and does not dissolve the regions where the patterned photomask blocked (or greatly attenuated the intensity of the radiation) from impinging on the photoresist layer. When the photoresist layer comprises negative photoresist, the developer does not dissolve the regions of the photoresist exposed to the actinic radiation and does dissolve the regions where the patterned photomask blocked (or greatly attenuated the intensity of the radiation) from impinging on the photoresist layer. After further processing (e.g., an etch or an ion implantation), the patterned photoresist is removed. The photoresist layer may optionally be baked at one or more of the following steps: prior to exposure to actinic radiation, between exposure to actinic radiation and development, after development.
In FIG. 1D , an etch process has been performed to etch trenches 150 into silicon layer 105 wherever silicon layer 105 is exposed by openings 147 . In one example, the etch process comprises a wet etch, a plasma etch or a RIE. Gate electrode(s) 130 is protected by capping layer 135 and sidewall spacers 140 from the silicon etching process. In FIG. 1D , the edges of trenches 150 are aligned to the edges of sidewall spacers 140 and openings 147 in hardmask layer 145 . Depending upon the chemistry of the etchant, the sidewalls of trenches 150 may extend under edges of sidewall spacers 140 and openings 147 in hardmask layer 145 as illustrated in FIG. 4B and described infra.
In FIG. 1E , trenches 150 (see FIG. 1D ) are filled with SiGe to formed SiGe regions 155 between silicon regions 160 . Portions of silicon region 160 under gate electrodes 130 will become the channel regions of FETs as illustrated in FIG. 1F and described infra. The SiGe is selectively grown (e.g., by epitaxial deposition) on silicon layer 105 but not on capping layer 135 , sidewall spacers 140 or hardmask layer 145 . In FIG. 1E , SiGe regions 155 have a width W 1 , silicon regions 160 have a width W 2 and gate electrodes 130 have a width W 3 . Gate stacks 120 A and 120 B are pitched apart a distance P 1 . In one example W 1 is between about 20 nm and about 60 nm, W 2 is between about 20 nm and about 60 nm and W 3 is between about 20 nm and about 60 nm. W 1 may be equal to W 2 , less than W 2 or greater than W 2 . Silicon layer 105 has a thickness T 1 and SiGe regions extend a distance D 1 into silicon layer 105 . In one example, T 1 is between about 120 nm and about 160 nm. In one example, D 1 is between about 80 nm and about 100 nm. In one example, T 1 is greater than D 1 . In one example P 1 is between about 120 nm and about 200 nm. In FIG. 1E , there are, by way of example, two silicon regions 160 and three SiGe regions 155 between first and second gate stacks 120 A and 120 B. There may be as few as one silicon region 160 between two SiGe regions 155 or more than two silicon regions 160 between corresponding numbers of SiGe regions 155 . It should be understood, that there may be as few as one silicon region 160 between two SiGe regions 155 or more than two silicon regions 160 between corresponding numbers of SiGe regions 155 on both sides of gate stacks 120 A and 120 B and that the number of silicon regions 160 and SiGe regions 155 need not be the same on opposite sides of either of gate stacks 120 A or 120 B.
In FIG. 1F , hardmask layer 145 (see FIG. 1E ) has been removed and source/drains 165 formed in silicon layer 105 (e.g., by ion implantation). Top surfaces of SiGe regions 155 are essentially coplanar with top surfaces of silicon regions 160 . Top surfaces of silicon regions 160 are exposed between adjacent SiGe regions in source/drains 165 . Source/drains 165 include silicon regions 160 and SiGe regions 155 . While illustrated in FIG. 1F as contained within source/drains 165 , SiGe regions 155 may extend through source/drains 165 . While illustrated in FIG. 1F as not contacting BOX layer 115 , source/drains 165 may abut BOX layer 115 . While illustrated in FIG. 1F as not contacting BOX layer 115 , SiGe regions 155 may abut BOX layer 115 . Gate stacks 120 A and 120 B may either be separate gates of two different FETs or two gate fingers of a multi-gate FET. SiGe regions 155 exert compressive stress on silicon regions 160 . In one example, silicon layer 105 is doped N-type and source/drains 165 are doped P-type. By reducing the surface area of SiGe regions 155 (because of intervening silicon regions 160 ), the ability for strain relief due to surface deformation is reduced and more stress is induced in the channel region of the FET than in an otherwise identical FET where there are no intervening silicon regions 160 .
While an SOI substrate has been illustrated in FIGS. 1A through 1F , the first (and second and third) embodiments of the present invention may be practiced on other semiconductor substrates including conventional bulk silicon substrates (i.e., substrates consisting of solid single-crystal silicon).
FIGS. 2A through 2C are cross-sectional drawings illustrating fabrication of a stressed transistor according to a second embodiment of the present invention. Prior to the steps illustrated in FIG. 2A , the steps illustrated in FIGS. 1A , 1 B, 1 C and 1 D have been performed. In FIG. 2A , hardmask layer 145 (see FIG. 1D ) is removed. Gate electrode(s) 130 are still protected by capping layer 135 and sidewall spacers 140 .
In FIG. 2B , trenches 150 (see FIG. 2A ) are over filled with SiGe to form SiGe layer 170 having thin SiGe regions 175 over silicon regions 160 and thick SiGe regions 180 between silicon regions 160 , thick regions 180 also filling trenches 150 (see FIG. 2A ). Thus portions of gate stacks 120 A and 120 B extend above and below a top surface of SiGe layer 170 . In FIG. 2B , there are, by way of example, two silicon regions 160 between first and second gate stacks 120 A and 120 B. There may be as few as one silicon region 160 between two SiGe regions 180 or more than two silicon regions 160 between corresponding numbers of SiGe regions 180 . It should be understood, that there may be as few as one silicon region 160 between two SiGe regions 180 or more than two silicon regions 160 between corresponding numbers of SiGe regions 180 on both sides of gate stacks 120 A and 120 B and that the number of silicon regions 160 and SiGe regions 180 need not be the same on opposite sides of either of gate stacks 120 A or 120 B. SiGe regions 175 have a thickness T 2 . In one example T 2 is between about 10 nm and about 40 nm thick. Thus, at least portions of each of gate stacks 120 A and 120 B are embedded in SiGe layer 170 .
In FIG. 2C , source/drains 185 are formed in silicon layer 105 (e.g., by ion implantation). Source/drains 185 include silicon regions 160 and SiGe layer 170 . While illustrated in FIG. 2C as contained within source/drains 185 , SiGe regions 180 may extend through source/drains 185 . While illustrated in FIG. 2C as not contacting BOX layer 115 , source/drains 185 may abut BOX layer 115 . While illustrated in FIG. 2C as not contacting BOX layer 115 , SiGe regions 180 may abut BOX layer 115 . Gate stacks 120 A and 120 B may either be separate gates of two different FETs or two gate fingers of a multi-gate FET. SiGe regions 180 exert compressive stress on silicon regions 160 . In one example, silicon layer 105 is doped N-type and source/drains 185 are doped P-type.
FIGS. 3A through 3F are cross-sectional drawings illustrating fabrication of a stressed transistor according to a third embodiment of the present invention. Prior to the steps illustrated in FIG. 3A , the step illustrated in FIG. 1A has been performed. In FIG. 3A , a single-crystal epitaxial silicon layer 190 has been selectively grown (e.g., by epitaxial deposition) on exposed regions of silicon layer 105 , but not on capping layer 135 or sidewall spacers 140 . In FIG. 3B , hardmask layer 145 is formed (as described supra with respect to FIG. 1B ) on exposed surfaces of epitaxial silicon layer 190 , capping layer 135 and sidewall spacers 140 . In FIG. 3C , openings 147 are formed in hardmask layer 145 (as described supra with respect to FIG. 1C ). In FIG. 3D , trenches 195 are formed (similarly as to trenches 150 of FIG. 1D ) through epitaxial silicon layer 190 into silicon layer 105 wherever silicon layer 105 is not protected by hardmask layer 145 , gate stacks 120 A and 120 B and sidewall spacers 140 . In FIG. 3E , trenches 195 (see FIG. 3D ) are filled with SiGe to formed SiGe regions 200 . The SiGe is selectively grown (e.g., by epitaxial deposition) on silicon layers 105 and 190 but not on capping layer 135 , sidewall spacers 140 or hardmask layer 145 and hardmask layer 145 (see FIG. 3D ) is removed. Thus, at least a portion of each of gate stacks 120 A and 120 B extends below a surface formed by SiGe regions 200 and remaining regions of epitaxial silicon layer 190 . In FIG. 3 E, there are, by way of example, two silicon regions 160 between first and second gate stacks 120 A and 120 B. There may be as few as one silicon region 160 between two SiGe regions 200 or more than two silicon regions 160 between corresponding numbers of SiGe regions 200 . It should be understood, that there may be as few as one silicon region 160 between two SiGe regions 200 or more than two silicon regions 160 between corresponding numbers of SiGe regions 200 on both sides of gate stacks 120 A and 120 B and that the number of silicon regions 160 and SiGe regions 200 need not be the same on opposite sides of either of gate stacks 120 A or 120 B. In FIG. 3F , source/drains 205 formed in silicon layer 105 (e.g., by ion implantation). Source/drains 205 include regions of silicon layers 105 and 190 and SiGe regions 200 . While illustrated in FIG. 3F as contained within source/drains 205 , SiGe regions 200 may extend through source/drains 205 . While illustrated in FIG. 3F as not contacting BOX layer 115 , source/drains 205 may abut BOX layer 115 . While illustrated in FIG. 3F as not contacting BOX layer 115 , SiGe regions 200 may abut BOX layer 115 . Gate stacks 120 A and 120 B may either be separate gates of two different FETs or two fingers of a multi-gate FET.
FIGS. 4A and 4B are cross-sectional drawings illustrating alternative process steps applicable to all embodiments of the present invention. In FIG. 4A , after etching hardmask layer 145 to form openings 147 , sidewall spacers 145 A (remnants of the hardmask layer 145 on sidewall spacers 140 ) are formed on sidewall spacers 140 . In FIG. 4B , trenches 155 A undercut hardmask layer 145 and sidewall spacers 140 because the etch has a small lateral etch rate. If spacers 145 A (see FIG. 4A ) were formed, then in FIG. 4B , trenches 155 A could extend under spacers 145 A and not under sidewall spacers 140 or could extend under both spacers 145 A and sidewall spacers 140 .
Thus, the embodiments of the present invention provide transistors with increased performance and methods of fabricating transistors with increased performance.
The description of the embodiments of the present invention is given above for the understanding of the present invention. It will be understood that the invention is not limited to the particular embodiments described herein, but is capable of various modifications, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, it is intended that the following claims cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A method of forming a field effect transistor and a field effect transistor. The method includes (a) forming gate stack on a silicon layer of a substrate; (b) forming two or more SiGe filled trenches in the silicon layer on at least one side of the gate stack, adjacent pairs of the two or more SiGe filled trenches separated by respective silicon regions of the silicon layer; and (c) forming source/drains in the silicon layer on opposite sides of the gate stack, the source/drains abutting a channel region of the silicon layer under the gate stack.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field of the Invention
[0004] The present invention relates to aqueous solutions including mixtures of inorganic metal ions, their preparation, and applications. More particularly, the present invention relates to compositions and methods for the preparation of performance enhancing (e.g., wear-reducing) coatings comprising silicon for metal surfaces that can prolong engine life and/or improve fuel consumption, using complex aqueous mixtures of ions.
[0005] 2. Description of the Related Art
[0006] The successful deposition of silicon has long been sought in the plating art. For example, U.S. Pat. No. 4,029,747 to Merkl, entitled โMethod Of Preparing Inorganic And Polymeric Complexes And Products So Producedโ describes purportedly new compositions and methods of manufacture for multi-metal amides. Merkl describes these complexes as suitable for โthe production of soaps and detergentsโ and โfor plating of one or more of the various metals of groups I-VIII of periodic table on various substrates.โ
[0007] A characteristic of the Merkl inorganic polymeric complexes with respect to plating is that through the use of these complexes it is purportedly possible to plate certain metals which have not been previously capable of plating, for example, to the refractory metals such as titanium, tantalum, and niobium, as well as to silicon. While silicon has been previously reported as being deposited by vacuum deposition and sputtering techniques, there appears to be no record of the successful plating of silicon metal, according to Merkl.
[0008] Merkl describes several experiments wherein silicon is put into solution with an ammonium hydroxide, an alkali metal hydroxide, and a non-alkaline metal. Several analytical methods described in the Merkl patent show that nitrogen can be stabilized in an alkaline medium. Merkl describes a process that requires an endothermic phase and an exothermic phase in order to make the polymeric complexes. Merkl teaches that if the reaction is not as described, then silicates will form and cannot be reversed rendering the resulting product useless for polymeric purposes. As will be demonstrated, this is no longer true in accordance with the present invention.
[0009] Silicon is an abundant, brittle, nonmetallic element that is found in sand, clay, bauxite, granite and many other minerals. Silicon chemicals were first developed in the 1860's and have since found wide uses in many industrial applications as sodium silicate, potassium silicate, ferrosilicon and high purity silicon. Sodium and potassium silicates are used as desiccants, components of detergents, fire retardants, in cements, and as additives in steel manufacturing to harden the steel. See, generally, Silicon Chemistry: From the Atom to Extended Systemsโ, P. Jutzi and U. Schubert (eds.) (2003) WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim, ISBN 3-527-30647-1.
[0010] U.S. Patent 4,634,540 to Ropp, describes several methods of making sodium and/or potassium silicates by reacting silicon rocks with an alkali metal hydroxide. Ammonium ions were not used in the Ropp reactions.
[0011] Many attempts have been made in the past to improve the surface properties of metals in order to widen their applications. For example, U.S. Pat. No. 4,533,606 to Teng et al. describes methods and aqueous compositions said to be suitable for electrodepositing co-deposits of zinc, silicon, and phosphorus on metal substrates. However, only co-deposits including phosphorus and zinc with silicon are described, and the electro deposition requires substantial time.
[0012] U.S. Pat. Nos. 5,084,263 and 5,310,419 to McCoy et al., describe more rapid electroplating with โinorganic polymeric water complexesโ of many metals, however, silicon is not among them. U.S. Pat. No. 5,540,788 to Defalco et al. describes forming an iron-phosphate conversion surface in situ, in internal combustion engines. However, the methods described by both McCoy et al. and Defalco at al. require the use of strongly acidic components in their preparation.
[0013] Silicon nitrides were developed in the 1960s and 70s in attempts to develop fully dense, high strength ceramics as replacements for steel, particularly in internal combustion engines. Studies on silicon nitrides showed high temperature properties for retaining high strength and oxidation resistance. Silicon nitrides come in at least three categories, namely: 1) reaction bonded silicon nitride; 2) hot pressed silicon nitride; and 3) sintered silicon nitrides. The sintered silicon nitrides have higher density and are more widely used than the other two processes. The important properties of silicon nitride surfaces include: good density, high-temperature strength, superior thermal shock resistance, excellent wear resistance, good fracture toughness, prevention of mechanical fatigue and creep, good oxidation resistance, and enhanced lubricity.
[0014] However, the difficulty of the manufacturing processes has kept this material from becoming a major product in the replacement of metals for many applications. The manufacture of silicon nitride ceramic bodies can be relatively complex. For example, U.S. Pat. No. 6,784,131 to Komatsu et al. describes a silicon nitride sintered body constituting a wear resistant member that is produced by at least the following steps: mixing a predetermined amount of a sintering assistant agent, a required additive, such as an organic binder, and a compound of Al, Mg, AlN, Ti or the like, to a fine powder of silicon nitride, which has a predetermined fine average grain size and contains a very small amount of oxygen; molding into a compact having a predetermined shape via molding methods such as single-axial pressing method, the die-pressing method or the doctor-blade method, rubber-pressing method, CIP (cold isostatic pressing) or the like. Multiple heating steps to remove the additives and binders, sintering at high temperature under vacuum, and high temperature curing, follow the molding steps.
[0015] While the method of manufacture has several drawbacks, silicon nitrides have nevertheless found uses in components of internal combustion engines such as glow plugs for quicker start-up, pre-combustion chambers for lower emissions, and in turbochargers for reduced lag and emissions control. Wider use of silicon nitrides can only be achieved by better manufacturing procedures that will drive down costs and make parts competitive. Accordingly, the ability to deposit silicon nitride surfaces on metals using an aqueous solution would be of tremendous commercial value to the automotive industry, not to mention the aerospace industry and others.
[0016] The search for methods of improving fuel economy and reducing toxic emissions has been the driving force behind the development of silicon nitride coatings for small parts for internal combustion engines. Recently, automobile regulations such as regulations regarding fuel consumption and exhaust emissions have become more and more severe. The reasons behind this are well known, and include environmental problems such as air pollution, acid rain, and the like, and policies for the protection of finite global hydrocarbon resources out of concerns for depletion of petroleum energy and minimization of greenhouse gases. As a countermeasure, reducing fuel consumption is, at least arguably, the most cost-effective solution, at present.
[0017] Many of the approaches of materials science that have historically been available for increasing efficiency and improving performance are also being constrained, however. For example, as described by U.S. Pat. No. 6,784,143 to Locke et al., the need for less toxic emissions from exhaust gases is becoming more demanding, mainly because of environmental problems such as the emission of pollutants such as hydrocarbons, carbon monoxide and nitrogen oxides. Catalytic converters in the exhaust systems of automobiles have been used for some time now to reduce the emission of pollutants. Such converters generally use a combination of catalytic metals, such as platinum or variations thereof and metal oxides, and are installed in the exhaust streams, e.g., the exhaust pipes of automobiles to convert the toxic gases to non-toxic gases. Phosphorus components, such as the decomposition products of the wear-reducing additive zinc dithiophosphate, an effective anti-wear oil additive, are believed to poison the catalyst in these converters. Also, it is likely that sulfur components poison the catalyst components used in reduction of nitrogen oxides. Notwithstanding the above, Locke still requires significant, though reduced, concentrations of phosphorus and sulfur.
[0018] Thus, there is clear automotive industry pressure towards reducing the phosphorus and sulfur content in fuel and lubricating oil additive compositions for emissions considerationsโrather than in increasing them for wear-reduction purposes. Reducing the phosphorus concentrations can, obviously, be readily accomplished by reducing the allowable amount of zinc dithiophosphate that can be used in the oil composition, but this comes at the expense of diminishing the anti-wear and anti-oxidant properties of the oil (and fuel) composition. As is well known in the art, engine manufacturers have already experienced substantial difficulties with premature engine failures as a result of changing fuel and oil specifications to reduce the concentration of known anti-wear components (notably sulfur).
[0019] Accordingly, a process providing for the electroless in situ deposition of silicon and nitrogen on the wearing surfaces of metals, including but not limited to metals in the internal combustion would be both a breakthrough in engine technology and of substantial commercial importance.
BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS
[0020] It is thus an object of the present invention to overcome the deficiencies of the prior art and thereby to provide unique and new uses for a chemical composition of silicon, silicon/nitrogen/alkali, or silicon/nitrogen bimetallic metal.
[0021] As will be described in detail below, we have found that when sodium and/or potassium silicate are dissolved in water and ammonium hydroxide is placed in the aqueous solution, and then an alkali metal hydroxide, including without limitation potassium hydroxide and sodium hydroxide, is added into the aqueous solution, which is then heated, that new complex mixtures of ions are formed, which we postulate may include silicon complexes. The temperature may preferably be raised rapidly by heating to above 180ยฐ F. The reaction may preferably be allowed to go through its own further exotherm, and produce a clear viscous solution with a pH of 14 and a Specific Gravity of 1.1. A panel of 1010 steel immersed in the solution for 30 seconds then formed a visible film on the metal that was extremely slippery. The immersed panel and an untreated panel were then immersed in a solution of 3% sodium chloride for three days, extracted, and allowed to dry. There was visible red corrosion on the untreated panel and no corrosion on the treated panel, indicating the new surface imparted superior corrosion resistance. As will be recognized by those skilled in the art, other silicates may of course be used without departing from the scope of the present invention including, without limitation, metasilicates (inosilicates), cyclosilicates, orthosilicates (nesosilicates), and silicates produced by reacting other silicate minerals, although sodium and potassium silicates are currently most preferred.
[0022] The Merkl patent discussed above recites at col. 10, 11. 57-64: โOn the other hand, if the feed of the alkali hydroxide is too slow, and as result, there is insufficient NH2 group formation and hydrogen release, the eroded non-alkaline metal tends to bind with the metal in the form of a salt, such as sodium silicate. When this occurs, it does not appear possible to reverse the reaction to achieve the product of the desired complexes.โ Accordingly, Merkl teaches that an alkali metal silicate cannot be used to form inorganic polymeric complexes. Merkl does not postulate the ability to form new polymeric complexes using sodium or potassium silicates.
[0023] Example 1 of Merkl describes a low purity silicon/potassium/ammonia reaction. The reaction phase is described with an endothermic phase that lasted for six hours and then an exothermic reaction that lasted for 45 minutes. Using the same elements as described in the Merkl Example, a low purity ferrosilicon of 98.5% silicon and 1.5% iron was reacted with ammonium hydroxide and potassium hydroxide and water. The solution was heated to above 180ยฐ F. and exhibited an exotherm within 20 minutes. No endothermic reaction was involved. The solution continued on its own exotherm for several minutes and then stopped. A viscous, clear solution with a specific gravity of 1.2 resulted. After cooling down, a panel of 1010 steel was immersed in the solution and a clear, tenacious, thin film was formed on the panel. The surface formed was very slippery. The panel was then left in the open, humid air of Houston, Texas for thirty days and no red corrosion was visible. Accordingly, the requirement of Merkl for an endothermic reaction appears to be unnecessary with the present invention.
[0024] We experimented further with the postulated silicon complexes described herein to determine if the complexes could be used as a lubricating oil additive and/or as a fuel additive. The complexes, as will be described in more detail later, were dehydrated in a lubricating oil by heating the oil until all the water content had been removed and the oil became clear and bright. At a certain elevated temperature, the chemical salts present in the complex precipitated out of the oil solution. A simple test was devised to determine if there was any active ingredient remaining in the oil solution. A panel of 1010 steel was immersed for one minute in the oil solution. The panel was extracted from the oil solution, wiped dry, and a noticeable, thin, bright film was present on the surface of the panel, which is taken as an indication that the active ingredient was still available for deposition on a conductive substrate from a hydrocarbon solution. There are no prior references of which the inventors are aware claiming to make silicon soluble in a hydrocarbon solution, much less using the complexes for deposition of silicon/nitrogen or silicon/nitrogen bimetallic surfaces, to conductive substrates in internal combustion engines.
[0025] The inventive oil solutions were also tested in small two-cycle engines to determine if the silicon would aid in improving fuel economy of two-cycle engines. Surprisingly, as detailed below, these tests showed a positive trend in improving fuel economy and reducing emissions from two-cycle engines.
[0026] One of the preferred embodiments of the present invention comprises solubilizing silicon/nitrogen and silicon/nitrogen bi-metallic complexes in hydrocarbons and alcohols, and using the hydrocarbons to carry the active silicon/nitrogen to the surface of conductive substrates in the combustion chamber while the engine is running. This provides a new, easy, and non-obvious method of forming a thin silicon/nitrogen film on metal surfaces in engines, gearboxes, differentials, etc. by an inexpensive process.
[0027] Hydrogen is postulated as having an effect on the activity level experienced in these postulated silicon complexes. According to Merkl at col. 21, 11. 14-19, โIn a further study using mass spectroscopy it has been observed that nitrogen and atomic hydrogen are released by the inorganic polymeric complex. The atomic hydrogen appears to be released all the way from room temperature through 1550ยฐ C. The nitrogen is released at 875ยฐ C.โ As will be detailed later, in accordance with the present invention, hydrogen preferably has an effect on the fuel economy of the hydrocarbons.
[0028] As discussed above, Ropp describes methods of making sodium and/or potassium silicates but does not describe use of ammonium ions. Ropp (at col. 2, 1. 63-col.3, 1. 40) describes extensively the release of hydrogen gas from the silicate composition as follows: โThe formation of this complex Si(OH)y allows an exchange of hydrogen atoms and electrons between the silicon particle surface and the trapped oil to hydrogenate certain oil components to produce gaseous products and to thin the oil. The soluble silicate thereby produced has a definite effect on oil viscosity as well as affecting the direction of modification of certain oil components. . . . The oil modification agent is negatively charged silicon particle surfaces in a basic medium. . . . . The negatively charged hydroxyl ion transfers its charge to the semi-conducting silicon surface of the particle and attaches itself thereto. When two or more hydroxyl ions are attached to the silicon surface, hydrogen gas is produced. . . .โ
[0029] The Merkl patent teaches, by using mass spectrometry analytic techniques, that Atomic Hydrogen is released from a silicon/ammonium/alkali metal complex throughout a significant temperature range from ambient up to 1550ยฐ C. Ropp teaches that hydrogen obtained from an alkali silicate solution modifies unrefined hydrocarbons. We postulate in accordance with the present invention that the hydrogen available in our silicate compositions will act as a hydrogenation catalyst on refined fuels in the combustion chamber. The breaking up of larger hydrocarbon molecules into smaller gaseous molecules will have an effect on improving the combustion properties of refined fuels such as diesel and gasoline. It is further postulated that the hydrogenation of the refined hydrocarbon will give a percussion effect to the combustion process. It was well established that tetraethyl lead imparted a percussion effect to the combustion process and resulted in better burn characteristics and better fuel economy.
[0030] We have found that there is a stable electric charge in our water based silicon complexes. It is well known in the literature that free electrons cannot exist for more than 1/10 4 seconds in water. It is postulated that the silicon acts as a clathrate to hold the atomic hydrogen and the electrons separately and apart in a shell and allows for further chemical reactions under the right conditions. A process for stabilizing atomic hydrogen and solvated electrons in water would have wide implications in the world of chemistry and lead to many new chemical applications.
[0031] Clay is one of the most abundant minerals on earth. Clay has multiple uses because of its unique properties for hydrating in the presence of fresh water. Clay is primarily an aluminum silicon complex with minor impurities. Clays are used in zeolites as the first stage in the refinery process for cleaning and treating crude oils and catalysis. Clays are charged particles and in the presence of fresh water will โswellโ and form a solid wall to allow water, oils and hazardous materials to be contained in clay pits. The swelling of clays presents major problems in oil drilling operations by slowing down the rate of penetration by the drilling rigs into the earth. Clays are also responsible for โtight sandsโ. Tight sands are heavily packed with various clays, with bentonite being one of the most common clays encountered in oil and gas reservoirs. The presence of clays in many reservoirs prevents the use of water flood techniques for enhanced oil recovery. As a result, many billions of barrels of crude oil are considered unrecoverable because of the swelling clays. As an example, the Department of Energy estimates that over 10 billion barrels of light gravity crude are still in the Venango sandstones, a formation that spreads across Pennsylvania, West Virginia, Ohio, and under Lake Erie into Ontario, Canada. These formations are very shallow, ranging in depth from 200 to 1200 feet, but because of fresh water these formations have only yielded 5% of the total oil in place. An inexpensive method of breaking up the clays present in these shallow formations could lead to the ability to water flood these reservoirs, adding billions of barrels of recoverable oil to the nation's supply and help achieve energy independence.
[0032] Because the silicon compositions of the present invention are water-soluble across a wide pH range, we decided to test whether montmorillonite ((Na,Ca)(Al, Mg) 6 (Si 4 O 10 ) 3 (OH) 6 -nH 2 O, hydrated sodium calcium aluminum magnesium silicate hydroxide) a clay commonly called โgumboโ, could be delaminated in fresh water using the silicon compositions prepared in accordance with the present invention. Surprisingly, the gumbo fell apart into constituent particles in fresh water. Accordingly, the present invention thus provides a novel process for delaminating clays, including montmorillonite clays. This discovery should lead to much improved enhanced oil recovery techniques and uses in tight gas sands, opening up permeability and porosity in those formations, particularly as montmorillonite is the major component of bentonite, which is used in drilling muds. Likewise, improved breaking of bauxiteโthe clay-like material comprising aluminum oreโinto its constituents may reduce the high costs of processing aluminum.
[0033] In other preferred embodiments, the present invention also includes a mold and mildew treatment and prevention method. Mold and mildew create huge problems, particularly in the humid areas of the United States and around the world. Mold in housing is believed to be a leading cause of asthma and other pulmonary disease. The silicon composition in the water phase in accordance with the present invention was used to spray a concrete stone 18โณร18โณร2โณ that had an extensive growth of mildew. The mildew was destroyed in less than 30 minutes and the silicon formed a surface on the concrete that remained mildew free after 60 days.
[0034] Black mold had grown on several windows in an apartment and was causing allergic reactions. The silicate composition of the present invention was used to spray the aluminum panels where the mold was attaching. The mold was wiped off and the surface of the aluminum panels was rubbed with the silicon composition. After 90 days there was no re-growth of the mold, indicating a very long-term application for prevention of mold in households.
[0035] In other preferred embodiments, the present invention includes a concrete sealing method. A piece of concrete was immersed in the silicon composition and then was placed in a glass Mason jar containing 18 API gravity crude oil. Oil is tenacious on concrete and cannot be readily removed even with steam cleaning. Surprisingly, when the treated concrete piece was extracted from the oil and dropped into a mason jar containing only fresh water, the oil immediately released from the concrete and floated to the top of the water with no visible residue on or in the concrete piece. A coating that seals concrete and makes the surface oleo-phobic would have commercial uses.
[0036] In other preferred embodiments, the tenacious, lubricating surface produced on metals in accordance with the silicon/nitrogen composition of the present invention indicated that an application would be to the cutting edges of knives, razor blades, saws, etc., for extending the life of the edge. A stainless steel razor blade sold under the Walgreen's label was used as a test piece. A drop of the silicon solution was wiped onto the blade surface. It was immediately apparent that the blade had much more lubricity and that shave was much smoother and comfortable. These blades have a life of about 5 shaves before being discarded. The treated blade shaved smoothly for 30 days and then was treated again and the life of the edge was extended for another 30 days. Thus an inexpensive, easy to apply coating for razor blades, and all other sharp edges such as saws, knives and medical instruments has been discovered.
[0037] Similarly, two kitchen knives made of 410 stainless steel were used for a test. One knife was coated with the silicon/nitrogen complex and the other knife was untreated. A butane torch was then held against the untreated knife and the metal became cherry red in one minute. When cooled the surface had turned a bluish color indicating that the high heat had affected the properties of the stainless steel. The treated knife was subjected to the same procedure and the metal did not turn to a cherry red for several minutes. The knife was allowed to cool down there was no visible change in the color of the stainless steel. Stainless steel is considered to be an inert material and extremely difficult to have a surface applied either electrolessly or by electroplating. Accordingly, the present invention also includes preferred embodiments comprising new methods of enhancing the properties of stainless steel.
[0038] The ability to form a thin silicon nitrogen coating on medical instruments could lead to savings in the nation's ongoing attempts to rein in medical costs. Bacterial contamination in the metal interstices of medical instruments requires an extensive cleaning operation in an autoclave to destroy the bacterial contaminants. The silicon nitride composition forms a thin coating on metal surfaces and into the metal interstices, filling up the holes and preventing bacteria from residing in the metal. This property should lead to a less costly method of sterilization of operating room tools.
[0039] Other preferred embodiments of the present invention include ice release treatment compositions and methods. Two 3โณร3โณรโ
โณ panels of 6061T6 aluminum were used. One was coated with a thin film of the silicon/nitrogen composition in accordance with Example 2A (below) of the present invention, while the other panel was left untreated. The silicon/nitrogen coating was identified by EDAX (Energy Dispersive X-Ray Analysis). The two panels then had a thick water film formed on the surfaces and were placed in a freezer at โ18ยฐ C. (0ยฐ F.). After one hour the panels were extracted from the freezer and the frozen surfaces subjected to a light bend test. The panel with the silicon/nitrogen surface immediately released the ice in a cracked almost monolithic sheet; the untreated panel would not release the ice sheet by cracking; the ice was melted off the surface of the aluminum substrate. The aviation industry spends much time and money in deicing airplane wings with a toxic chemical, ethylene glycol. A process that would prevent the water from attaching to the aluminum and forming adhesive ice crystals would be of commercial value and also to ease environmental problems caused by the deicing chemicals.
[0040] Silicates have been widely used as flame-retardants since their discovery in the 1 860s. The property of silicates of swelling in the presence of a flame and providing an insulating barrier is well established. However, the use of silicates for flame retardation has been limited in the conventional art, as they do not attach tenaciously to the surfaces of wood, cloth, or steel. It is thus another preferred embodiment of the present invention to provide flame-retardant compositions and methods suitable for solving the related problems in the conventional art. A sample of old, dried lumber was immersed in a silicate solution in accordance with the present invention and allowed to dry. It was then immersed in water, extracted, and allowed to dry. A butane torch was used to hold a flame front on the surface of the dried lumber. The flame was held against the wood for five minutes and only a slight charring effect was noticeable. At no time did the timber support a flame. We postulate that not only would the silicate composition flameproof the wood, but also act as a surface to prevent formation of mold and mildew and possible termite infestation. Two panels of 12 gauge 1010 steel were used to test the efficacy of preferred embodiments of the invention including methods to impede heat transfer. One panel was immersed in the silicate composition for one minute and then extracted. The other panel was untreated. A butane torch was used to heat the metals to โcherry redโ. The panels were held by hand and the flame applied to the panels. The untreated panel reached cherry red condition is less than a minute and transferred the heat down the length of the panel and became too hot to hold. The treated panel took approximately twice as long to reach a cherry red condition but the heat transfer was significantly impeded. The silicate foamed up and impeded heat transfer to the metal substrate. The panel could be held for several minutes before heat finally made the steel to hot too handle. The ability of the silicon compositions to form a thin tenacious film on metals that impedes heat transfer into the basic metal has broad uses in several commercial areas. For example, steel pillars treated with silicon compositions in accordance with the present invention could possibly impede enough heat transfer sufficiently to increase the period of time they can withstand buckling and collapse.
[0041] Ethanol is an alcohol that is the product of fermentation of organic matter. Ethanol is used as an additive to fuels to improve the cleaner burning of fuels to reduce emissions. In some countries such as Brazil, ethanol has been used solely as a renewable energy source. Ethanol is also mandated in the U.S. as one of the additives for oxygenating fuels. The use of ethanol has wide political and environmental support. A major barrier to the further use of ethanol however, is that it is highly corrosive to metals. A process that would reduce the corrosive activity of ethanol would find a very large market in the U.S. and around the world. Accordingly, it is another preferred embodiment of the present invention to provide compositions and methods to reduce the corrosivity of ethanol to metal surfaces. This embodiment has been demonstrated by placing 100 grams of ethanol in a glass beaker. Five grams of the silicon composition in accordance with an embodiment of the present invention as described in Example 1A (below), was then added to the ethanol. There was an immediate settling of salts from the solution and the materials appeared to be incompatible. The ethanol was decanted from the salts into a separate beaker. A 1010 steel panel was immersed in the ethanol solution for one minute and then extracted. A thin, tenacious film had formed on the steel panel. The panel was left in the open air in the humid Houston, Tex. climate for thirty days. No corrosion was visible on that coated part of the panel. Surprisingly, the active ingredient in the silicon composition was apparently solubilized in the alcohol and maintained its electrochemical activity, which allowed for deposition on a metal substrate using ethanol. Ethanol is sufficiently corrosive that it is transported in stainless steel trucks and pipelines. The corrosive properties of ethanol preclude its wider use as an oxygenating agent for fuels. A product that could be added to ethanol to inhibit corrosion would thus be of substantial commercial value.
[0042] Accordingly, in some preferred embodiments, the present invention provides that ammonium hydroxide is added to a solution of sodium silicate, to which potassium hydroxide is added.
[0043] In other preferred embodiments, ammonium hydroxide is added to a solution of sodium silicate to which sodium hydroxide is then added.
[0044] In other preferred embodiments, the above processes may be varied by maintaining the temperature of the resulting reaction mixture above 180ยฐ F. for a predetermined period of time. By way of illustration and not limitation, said predetermined period of time may preferably be ten minutes or more, in some preferred embodiments.
[0045] In other preferred embodiments, ammonium hydroxide is added to a solution of sodium silicate, to which potassium hydroxide or sodium hydroxide is added, and the resulting liquid is dehydrated in a light mineral oil, and any resulting solids are removed by decantation.
[0046] In other preferred embodiments, ammonium hydroxide is added to a solution of potassium silicate, to which potassium hydroxide and/or sodium hydroxide is added, and the resulting liquid is dehydrated in a light mineral oil, and any resulting solids are removed by decantation.
[0047] In other preferred embodiments, ammonium hydroxide is added to a solution of sodium or potassium silicate, to which potassium hydroxide or sodium hydroxide is added, and the resulting liquid is dehydrated in a light mineral oil, and any resulting solids are removed by decantation. The liquid phase is then added to the crankcase (as an oil additive) or combustion chamber (as a 4-cycle fuel additive or as a 2-cycle fuel or oil additive) of a 2-cycle or 4-cycle engine.
[0048] In other preferred embodiments, ammonium hydroxide is added to a solution of sodium or potassium silicate, to which potassium hydroxide and/or sodium hydroxide is added, to produce an aqueous solution of ion mixtures, and the resulting liquid is dehydrated in a light mineral oil, and any resulting solids are removed by decantation.
[0049] In other preferred embodiments, ammonium hydroxide is added to a solution of sodium or potassium silicate, to which potassium hydroxide or sodium hydroxide is added, to produce an aqueous solution of ion mixtures, and the resulting liquid is dehydrated in a light mineral oil, and any resulting solids are removed by decantation, and the resulting liquid is added to either the lubricating oil or fuel of an internal combustion engine.
[0050] In other preferred embodiments, ammonium hydroxide is added to a solution of sodium or potassium silicate, to which potassium hydroxide or sodium hydroxide is added, to produce an aqueous solution of ion mixtures, and the resulting liquid is dehydrated in a light mineral oil, and any resulting solids are removed by decantation, and the resulting liquid is added to either the lubricating oil or fuel of a gasoline internal combustion engine.
[0051] In other preferred embodiments, ammonium hydroxide is added to a solution of sodium or potassium silicate, to which potassium hydroxide or sodium hydroxide is added, to produce an aqueous solution of ion mixtures, and the resulting liquid is dehydrated in a light mineral oil, any resulting solids are removed by decantation, and the resulting liquid is added to either the lubricating oil or fuel of a diesel engine.
[0052] In other preferred embodiments, a thin adherent layer comprising silicon and nitrogen is electrolessly applied to metal wear surfaces by application of a precursor prepared by the combination of the aqueous ion solution resulting from the mixture of sodium or potassium silicate with ammonium hydroxide and an alkali metal hydroxide to produce an aqueous inorganic complex, with a light oil at a temperature sufficient for dehydration, followed by incorporation of the complex into either lubricating oil or fuel.
[0053] In other preferred embodiments, an additive to lubricating oils that significantly decreases the coefficient of friction is applied according to means described by the present invention.
[0054] Other preferred embodiments comprise a fuel additive for introduction of a complex to accomplish the deposition of a silicon-nitrogen surface on internal wear parts of an internal combustion engine. Other related preferred embodiments comprise a lubricating oil additive for introduction of a complex to accomplish the deposition of a silicon-nitrogen surface on internal wear parts of an internal combustion engine.
[0055] Other preferred embodiments include an additive for ethanol with improved corrosion resistance.
[0056] Other preferred embodiments include addition of the above compositions and use of the above methods to provide compositions for applications to the delamination of clays, particularly montmorillonite clays related to the recovery of petroleum hydrocarbons.
[0057] Still other preferred embodiments include processes and materials for inhibiting corrosion, mildew, mold, heat, and fire, thus extending the life of objects thus endangered, as well as providing for their improvement.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0058] FIG. 1 is a 29 Si NMR spectrum of an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0059] FIG. 2 is a 29 Si NMR spectrum of an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0060] FIG. 3 is a summary scan XPS spectrum of a steel panel treated with an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0061] FIG. 4 is a high-resolution XPS spectrum of the Si2p peak of a steel panel treated with an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0062] FIG. 5 is a high-resolution XPS spectrum of the N1s peak of a steel panel treated with an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0063] FIG. 6 is an EDAX spectrum of a steel panel treated with an aqueous solution comprising a complex mixture of ions including in accordance with the present invention.
[0064] FIG. 7 is an EDAX spectrum of an aluminum panel treated with an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0065] FIG. 8 is a summary scan XPS spectrum of a steel panel treated with an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0066] FIG. 9 is a high-resolution XPS spectrum of the Si2p peak of a steel panel treated with an aqueous solution comprising a complex mixture of ions in accordance with the present invention.
[0067] FIG. 10 is a high-resolution XPS spectrum of the N1s peak of a steel panel treated with an aqueous solution comprising a complex mixture of ions in accordance with the invention.
[0068] FIG. 11 is an EDAX spectrum of a steel panel treated with an aqueous solution comprising a complex mixture of ions including silicon and tungsten in accordance with the present invention.
[0069] FIG. 12 is an EDAX spectrum treated with an oil-based solution comprising silicon in accordance with the present invention.
[0070] FIG. 13 is an EDAX spectrum of a steel panel treated with an aqueous solution of complex ions including silicon and molybdenum in accordance with the present invention.
[0071] FIG. 14 is an EDAX spectrum of a steel panel treated with a solution made with ferrosilicon in accordance with the present invention.
[0072] FIG. 15 is an EDAX spectrum treated with an oil-based solution comprising silicon in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0073] Herein will be described in detail specific preferred embodiments of the present invention, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. The present invention is susceptible to preferred embodiments of different forms or order and should not be interpreted to be limited to the specifically expressed methods or compositions contained herein. In particular, various preferred embodiments of the present invention provide a number of different configurations and applications of the inventive method, compositions, and their applications.
EXAMPLES
Composition 1
Example 1 A
[0074] The following equipment was used in experiments described below: 4000 ml Kimax beaker; Thermolyne Cimarec 2 with magnetic mixer; Acculab V600 scale with a 0.1 gram readability; and Accurite 100ยฐ-400ยฐ F. thermometer.
[0075] A solution comprising a complex mixture of ions was produced by the steps of adding the following reagents to the beaker: 200 ml water; 50 grams of sodium silicate (solid); 25 grams of ammonium hydroxide (29ยฐ Baume); 50 grams of potassium hydroxide (flakes).
[0076] A slight ammonia odor was detectable. The solution was forced into exotherm by heating while stirring. The temperature was maintained above 180ยฐ F. for 10 minutes and then turned off. The solution continued its exotherm for several more minutes and then was allowed to cool down. The solution was examined by liquid-phase 29 Si NMR (Nuclear Magnetic Resonance) Spectroscopy, which identified SiO 4 as illustrated by the spectrum of FIG. 1 .
Example 1 B
[0077] A solution comprising a complex mixture of ions was produced in accordance with Example IA except that sodium hydroxide was substituted for potassium hydroxide. The solution was examined by liquid-phase 29 Si NMR (Nuclear Magnetic Resonance) Spectroscopy, which identified SiO 4 as illustrated by the spectrum of FIG. 2 .
Example 2A
[0078] A 1010 steel coupon was immersed in the solution comprising a complex mixture of ions prepared in accordance with Example 1A when the temperature was below 140ยฐ F. with no external electromotive force required. A visible, tenacious film formed on the steel panel. The panel was examined by XPS (X-Ray Photoelectron Spectroscopy) and the presence of silicon and nitrogen on the surface of the panel was detected, as illustrated by FIG. 3 (summary scan spectrum), FIG. 4 (high-resolution spectrum of Si2p peak), and FIG. 5 (high-resolution spectrum of N 1 s peak). Another steel panel immersed in this solution was analyzed via EDAX with the results illustrated in the spectrum of FIG. 6 1 . An aluminum panel immersed in this solution was analyzed via EDAX with the results illustrated in the spectrum of FIG. 7 . 1 Table 4 provides semi-quantitative, ZAF-corrected and normalized EDAX results (atomic-%).
Example 2B
[0079] A 1010 steel coupon was immersed in the solution comprising a complex mixture of ions prepared in accordance with Example 1B when the temperature was below 140ยฐ F. with no external electromotive force required. A visible, tenacious film formed on the steel panel. The panel was examined by XPS and the presence of silicon and nitrogen on the surface of the panel was detected, as illustrated by FIG. 8 (summary scan spectrum), FIG. 9 (high-resolution spectrum of Si2p peak), and FIG. 10 (high-resolution spectrum of N1s peak).
Example 3
[0080] In each of two glass beakers, 70 grams of montmorillonite I clay was immersed in 100 grams of fresh water. In one beaker 5 ml of the solution comprising a complex mixture of ions prepared in accordance with Example 1A was added to the fresh water. Both beakers were observed closely. In the beaker to which the inventive solution had been added, the clay slowly began to delaminate and fall to the bottom of the beaker as finely divided particles. In the other beaker there was no visible delamination of the clay. After 24 hours the clay in treated beaker had been completely separated into constituent elements. In the other beaker, the clay was still intact and there was a slight indication of the clay swelling.
Example 4
Preparation of โCon1]โ
[0081] 600 grams of Penrecog Drakeolยฎ 5 was added to a glass beaker with 120 grams of the solution comprising a complex mixture of ions prepared in accordance with Example 1 A. The heater was turned on with continuous stirring. The temperature of the mixture was raised above 265ยฐ F. and boiled at that temperature for 20 minutes, at which time salts formed and precipitated from the solution to the bottom of the beaker. The oil phase was bright and clear. This solution will hereinafter be referred to as โCon1โ.
Example 5
Preparation of โAdditive 1โ
[0082] 5 grams of Con1, prepared in accordance with the procedure described in Example 4, was mixed with 100 grams of Drakeolยฎ 5 and stirred. The resulting solution will hereinafter be referred to as โAdditive 1โ. 10 ml of the Additive 1 was mixed into 200 ml of diesel fuel. The Additive 1 was completely miscible in the diesel fuel.
Example 6
[0083] 4 grams of Additive 1 and 225 grams of unleaded gasoline were mixed in a beaker. The Additive 1 was miscible in the gasoline.
[0000] Two-Cycle Engine Tests
[0084] The mixture prepared in accordance with Example 6 was used in experiments for testing on two-cycle engines to measure fuel economy and โdo no harmโ. The engine chosen for the test procedure was a Homelite two-cycle leaf blower with a 70cc engine. The need to turn the blower at high rpm places a load on the small engine. The engine is run in the 7200 rpm range with a constant load at all times. Two-cycle engines, which typically use a mixture of fuel to oil at a 50:1 ratio, are difficult to lubricate and are not fuel-efficient. The two-cycle lubricants currently being widely used to lubricate and protect against engine damage contain a large amount of โbright stockโ, a heavy fraction in oils that is very toxic and polluting. A two-cycle engine of this type, if not properly lubricated, will typically seize up within 20 minutes or less. It would thus not be expected that a lubricant made with a silicon-containing component would provide protection for a two-cycle engine against seizure and failure.
Example 7
[0085] The fuel was prepared using standard two-cycle oil at a fuel:oil mix ratio of 50:1. Two control runs were made with a new engine; each run using 225 grams of gasoline mixed with 4.5 grams of standard two-cycle oil. A โbaselineโ control run length (i.e., time to fuel exhaustion) was determined by averaging the lengths of the two runs, which resulted in a baseline of 29 minutes, 45 seconds. A one-pint volume of treated two-cycle oil was then prepared that contained 5% (by weight) of Con1, which had been prepared in accordance with Example 4. Four identical test runs were then performed; each using 225 grams of gasoline mixed with 4.5 grams of the treated two-cycle oil, running the test engine until it shut down for lack of fuel. The time to fuel exhaustion was measured in each of the four tests. Results from the four runs were as shown below in Table 1:
TABLE 1 Run Time (min, sec) Baseline 29 minutes, 45 seconds 1 34 minutes, 40 seconds 2 36 minutes, 18 seconds 3 32 minutes, 0 seconds 4 32 minutes, 15 seconds
[0086] The average of the four test runs (using the Con1 as an additive) was 33 minutes and 13 seconds compared with control runs (baselineโno additive) of 29 minutes and 45 seconds or a decrease in fuel usage for identical runs. There was also a noticeable reduction in particulate emissions with the test mixtures prepared using the Con1 additive. The engine did not seize and, in fact, appeared to run smoother with the test mixtures prepared using Con1. This test demonstrated that the Con1 additive improved fuel economy and reduced emissions, and did not harm the engine.
Example 8
[0087] 300 grams of methyl ester (Soy Methyl Ester, Columbus Foods, Chicago, Ill.) were placed in a beaker to which 15 grams of the solution comprising a complex mixture of ions prepared in accordance with Example 1A was added. The solution was heated to above 200ยฐ F., began to foam, and on cooling formed soap. This example mixture was deemed not to be a candidate as a fuel or lubricant additive.
Example 9
[0088] 5 grams of Con1 was added to 100 grams of methyl ester, in which it was completely miscible. The resulting mixture was used as a fuel additive at a rate of approximately one ounce of fuel additive mixture to 10 gallons of automotive gasoline or diesel fuel.
Example 10
[0089] 0.1 grams ammonia paratungstate (solid) was added to 40 grams of the complex mixture of ions produced in accordance with Example 1A with stirring until the solid dissolved. A 1010 steel panel was then immersed in the resulting solution and extracted after 1 minute. A visible thin, tenacious, adherent film had formed on the metal substrate. The panel surface was examined by EDAX and the results that were obtained are illustrated by the spectrum shown in FIG. 11 . The presence of tungsten and silicon was detected on the surface of the metal.
[0090] The above-described solution of ammonia paratungstate was then dehydrated with Drakeolยฎ 5 using the general procedure described in Example 4, by heating to above 300ยฐ F. with stirring until salts formed and precipitated to the bottom of the glass beaker. A 1010 steel panel was inserted in the resulting solution while the temperature was about 180ยฐ F. and a visible, thin film was present on the panel. This panel was then analyzed by EDAX. The results that were obtained are illustrated by the spectrum provided at FIG. 12 . The presence of tungsten and silicon was detected on the surface.
Example 11
[0091] 0.1 grams of ammonia molybdate (solid) was added to 40 grams of the complex mixture of ions produced in accordance with Example 1A, with stirring until the solid dissolved. A 1010 steel panel was then immersed in the resulting solution and extracted after 1 minute. A visible, thin, tenacious, adherent surface had formed on the metal. The panel surface was then analyzed by EDAX. The results are illustrated by the spectrum provided at FIG. 13 . Silicon and molybdenum were detected on the metal surface.
[0092] The electroless deposition of tungsten and molybdenum from aqueous solutions is another novel characteristic of the present invention. The conventional art teaches that such deposition is not possible. For example, the conventional text by Frederick A. Lowenheim, โ Electroplating: Fundamentals of Surface Finishing โ (1977) McGraw-Hill Book Company (TX), ASIN 0070388369 (pg. 141) teaches that โfrom the standpoint of their electrode potentials, it should be possible to electroplate such metals as tungsten and molybdenum from aqueous solutions with a pH of about 5. Nevertheless (in spite of claims in the literature) these metals cannot be deposited in pure form from aqueous solutionsโ. Therefore, the electroless deposition of tungsten and molybdenum, together with other refractory metals, from aqueous solutions is new in the art. Silicon/refractory metal surfaces would find wide fields of commercial use in, for example, protection of metal surfaces, reducing coefficients of friction, inhibiting corrosion, hardening metals and, as previously described, could impart high heat resistance. Other specific areas of potential usage include as fuel additives for jet turbine engines in aircraft in addition to ground use turbine applications. A thermal barrier could easily be formed by the methods of the present invention for use on components designed for hostile thermal environments, such as super-alloy turbines and the combustor and augmentor components of gas turbine engines. The silicon-nitrogen could diffuse into the surface of the jet turbine components and form a heat resistant (and potentially reflective) coating. There is no method known today for coating jet turbine engine components that does not involve taking the engine apart and either replacing components or applying metallizing sprays. The methods currently used obviously place a heavy financial burden on turbine owners because of both the downtime and the replacement costs for parts and materials.
[0093] Another commercial use segment of significant potential value is burners for industrial combustion systems, such as gas-fired furnaces for heat-treating and low-NO X industrial pyrolysis furnaces. The combustion of natural gas generates substantial quantities of nitrogen oxides and much time and money has been spent on improving natural gas burner designs to lower their NO X emissions. The new low NO X burners will reduce NO X emissions for periods of time, but it is expected that metals in natural gas in the parts per billion range will slowly build up on the nozzles of the burners and affect flow patterns to increase NO X emissions. A heat resistant coating on industrial burners would significantly extend the useful life of the burners with continued low NO X emissions. Such a heat resistant coating has the further advantage of potentially permitting the use of less expensive burner materials. The thin coating of the silicon nitride, for example, could improve the flow characteristics of combustion gases giving further benefits in terms of burner design options for lowering NO X emissions and improving burner performance.
[0000] FourโCycle Engine Tests
Example 12
[0094] For the tests of this Example, a 2000 model year Lincoln Town Car with a 4.6-liter engine and an automatic transmission was used. A base line fuel consumption figure was first established by running the vehicle for over 300 miles at about 72 MPH continuously with regular unleaded fuel. The resulting baseline average fuel consumption was 22.4 MPG. The fuel tank was then refilled using the additive in accordance with the present invention as described above in Example 9 (one ounce of fuel additive per 10 gallons of Diamond Shamrock brand regular unleaded fuel). The test car was then driven over approximately the same highway at about the same speed (72 MPH) and at generally the same ambient conditions. The onboard computer indicated that the car achieved 25.9 MPG with the additive-treated fuel. This amounts to a decrease in fuel usage of 3.5 gallons per tank, or a 15.6% improvement in fuel economy.
Example 13
[0095] A 1991 Ford F150 pickup with a 4.9L engine, a standard five speed manual transmission, and 325,000 miles of usage, which had an established baseline of 15.5 MPG using regular unleaded fuel, was tested using Additive 1 prepared in accordance with the procedure described above in Example 5, using 1 ounce of Additive 1 per 10 gallons regular unleaded fuel. Under test conditions similar to those described above with respect to Example 12, this test vehicle obtained a fuel usage of 19.67 MPG, which is a fuel economy benefit of 26.9%.
Example 14
[0096] A 1998 Chevrolet CK3500 4x4 with a 6.5-L diesel engine with 184,165 miles was used as a test vehicle. A baseline mileage was established at 14.7 MPG. One test run was then made with the test vehicle to establish a baseline. Three test runs were then made using Additive 1 in standard on road automotive diesel fuel. The ratio of addition was 1 ounce of Additive 1 to 10 gallons of diesel fuel. The results were as follows in Table 2:
TABLE 2 Tank Fuel Consumption (MPG) Change (%) 1 15.9 +8.2% 2 16.8 +14.7 3 17.0 +15.6
Example 15
[0097] For the following Example, a diesel-electric generator with a 150 KW Fiat engine was used. The Fiat engine had 13,850 hours of use prior to testing. The purpose of the test was to determine the effect if any of additives prepared in accordance with the present invention on fuel efficiency and environmental emissions. The engine typically released substantial particulates upon start-up, and generally continued visible smoking during operation. The generator was set at 33% load capacity for this test. A base line of fuel usage was determined by filling the fuel tank to the top of the tank. The diesel engine was then started, and the generator was run with a 33% load for 8 hours. The fuel tank was then refilled and the amount used to fill the tank was noted to determine fuel consumption. The fuel tank capacity was 100 gallons.
TABLE 3 Run Fuel (gal) Time (hrs) Fuel Consumption (gal/hr) Base 32.6 8 4.075 Test 83.6 23 3.634
[0098] As noted in Table 3, the base line fuel consumption (with no Additive 1) was 4.075 gallons per hour, as compared to the test fuel consumption of 3.634 gallons per hour using Additive 1 as described above. This amounts to a reduction in fuel consumption of approximately 9.24%.
[0099] Further, as noted, the test engine had relatively heavy particulate emissions during startup for the baseline run, which is not atypical for a diesel engine. The engine had noticeably significant reductions in startup particulates after treatment, indicative of improvement in the combustion process.
TABLE 4 Elemental Analysis via EDAX (ZAF-Corrected, Normalized) Atomic-% (ZAF Corrected, Normalized) Example Ex. 2A Ex. 2A Ex. 10 Ex. 10 (steel) (alum.) (aq.) (oil) Ex. 11 Ex. 17 Ex. 18 Spectrum Element Oxygen โ12.642 16.764 โ1.911 โ4.334 โ6.289 โ8.272 โ2.186 Sodium โ 0.378 โ โ โ โ โ Aluminum โ 80.970 โ โ โ โ โ Silicon 0.389 1.475 1.516 0.346 0.518 0.315 0.499 Phosphorus 0.005 0.098 0.003 โ0.015 โ0.009 0.098 โ0.015 Chlorine 0.126 0.063 โ0.015 โ0.009 0.104 0.092 0.091 Calcium โ 0.161 โ โ โ โ โ Iron 111.777 0.091 99.904 103.760 105.279 107.776 101.172 Molybdenum โ0.016 โ โ0.002 0.003 0.051 โ0.008 โ0.004 Manganese 0.360 โ 0.474 0.239 0.345 โ 0.464 Tungsten โ โ 0.032 0.010 โ โ โ0.021 Total 100.000 100.000 100.000 100.000 100.000 100.000 100.000
Composition 2
[0100] In Merkl, a study of low purity silicon/potassium is described (see Example 1 of Merkl at column 23). As discussed above, the Merkl method employed an endothermic phase that lasted 6 hours followed by an exothermic phase that lasted for 45 minutes. In accordance with certain embodiments of the present invention, a reaction scheme was employed comprising a novel variant wherein the rate of addition of the alkali metal is varied and no endothermic reaction is employed.
Example 16
[0101] This Example used 616 grams of ferrosilicon rocks containing about 75% silicon with about 25% iron, and a rock size of approximately 1 cm (about ยฝ inch). Other reagents included 2000 grams ammonium hydroxide (26ยฐ Baume) and 616 grams potassium hydroxide (flakes). The ingredients were added as quickly as possible and then forced into an exothermic reaction by applying heat to the vessel. The exothermic reaction lasted for 45 minutes and a clear viscous fluid resulted. Specific gravity was then measured at 1.2. The resulting solution was decanted from the unreacted ferrosilicon rocks.
Example 17
[0102] Approximately one hour after preparation of the solution as described in Example 16, a panel of 1010 steel was immersed in the solution for 30 seconds and then extracted. The panel was then analyzed via EDAX. The analytical results are provided in the spectrum provided at FIG. 14 . Silicon was detected on the surface of the metal.
Example 18
Preparation of โCon2โ
[0103] 600 grams of Drakeolยฎ 5 was placed in a 3000-ml beaker and 120 grams of a ferrosilicon solution prepared in accordance with Example 16 was added. The solution was heated with stirring. Above 300ยฐ F. salts precipitated, leaving a clear and bright solution, indicating that all the water had been removed. The heat was turned off and the temperature dropped to 180ยฐ F., at which time a panel of 1010 steel was immersed in the oil solution for 1 minute. The panel was extracted and a thin, tenacious film was observed on the metal. The panel was then analyzed via EDAX. The result is provided in the spectrum shown in FIG. 15 . Silicon was detected on the metal surface, which indicates that a soluble silicon species in the oil is deposited on the metal from the oil-based solution. This solution is hereinafter referred to as โCon2โ.
[0104] Con2 was added to 150 solvent neutral BP 901 base oil at a ratio of 1 gram Con2 to 20 grams solvent neutral oil, to provide make an oil and lubricant additive. Although 150 solvent neutral BP 901 base oil was used in this Example, those skilled in the art will recognize that any similar oil, such as any base oil manufactured from solvent refined paraffinic lube distillates or a US 350H group 2 oil may be used with satisfactory results.
[0000] FourโCycle Engine Tests
Example 19
[0105] 5 grams of Con2 prepared in accordance with Example 18 was stirred into 100 grams of Drakeolยฎ 5. The resulting mixture, referred to hereinafter as โAdditive 2โ was placed in the fuel tank of the model year 2000 Lincoln Town Car previously referred to in the context of Example 12, at the rate of one ounce of the Additive 2 per ten gallons of regular Diamond Shamrock brand unleaded fuel. As noted with respect to Example 12, base line fuel consumption for this vehicle had previously been established at 22.4 MPG. The test vehicle was then driven 310 miles at an average speed of 72 MPH. During the first 100 miles the onboard computer registered at 24.5 MPG. For the balance of the test the onboard computer registered 27.4 MPG, for an improvement in fuel economy of 5 MPG or 22.3%. This represents a further increase in fuel efficiency over the Example 12 results using Con1 of 3.5 mpg or 15.6%.
Example 20
[0106] In this Example, Additive 2 was tested in the Ford 150 pickup of Example 13 (now with 334,000 miles of usage) at the ratio of 1 ounce per 10 gallons of Diamond Shamrock brand regular unleaded fuel. The vehicle was then driven for 220 miles and an average of 19.37 MPG was achieved, which is similar to the result achieved in Example 13.
[0107] While the preferred embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims.
[0108] The examples provided in the disclosure are presented for illustration and explanation purposes only and are not intended to limit the claims or embodiment of this invention. While the preferred embodiments of the invention have been shown and described, modification thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. Process criteria, pendant processing equipment, and the like for any given implementation of the invention will be readily ascertainable to one of skill in the art based upon the disclosure herein. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. Use of the term โoptionallyโ with respect to any element of the invention is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the invention.
[0109] The discussion of a reference in the Description of the Related Art is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated herein by reference in their entirety, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.
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A composition and method for providing a silicon-nitrogen surface on metals wherein is reacted a source of silicon, a source of ammonium ions, an alkali metal hydroxide in an aqueous medium to produce an electrolyte solution comprising a complex ion mixture. The electrolyte solution can be used to deposit a silicon surface on conductive substrates. The electrolyte solution can be dehydrated in a hydrocarbon medium, thus providing novel materials for use as lubricating oil additives and as fuel additives. The fuels and lubricants can be used as carriers for depositing the complex to form a silicon/nitrogen and silicon/nitrogen bimetallic surfaces on metal surfaces including, but not limited to, metals in the combustion chamber either through an aqueous phase or through a hydrocarbon phase. These new silicon/nitrogen surfaces may significantly reduce coefficient of friction, smooth the flame front, reduce corrosion, enhance fuel economy, and reduce hydrocarbon emissions when used in internal combustion engines.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of Taiwan application serial no. 101146419, filed on Dec. 10, 2012. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification.
TECHNICAL FIELD
The disclosure relates to a semiconductor device module, and relates to a stacked type power device module.
BACKGROUND
Currently, the design of a commercialized power device module is that the device is arranged directly on the planar substrate having the heat dissipating effect and the electrical and signal connections of the device are achieved through wire bonding. Although such an arrangement may enhance heat dissipating efficiency, the area required by the module is also increased. Meanwhile, large amount of wire bonding may cause current crowding, which leads to the failure of the device module.
SUMMARY
An embodiment of the disclosure provides a stacked power device module, including at least one substrate having a first surface and a second surface, at least one first device, at least one second device, a circuit pattern, and at least one filler layer. The at least one first device is located on the first surface of the substrate and is electrically connected to the substrate; the at least one second device is located on the at least one first device and is electrically connected to the substrate; the at least one filler layer covers on the first surface of the substrate and encapsulates the at least one first device and the at least one second device, and the at least one filler layer includes a plurality of first conductive plugs and at least one second conductive plug. The circuit pattern is located on the at least one second device and is located on the at least one filler layer. The circuit pattern is connected to the at least one second device via the plurality of first conductive plugs. The circuit pattern is connected to the at least one first device via the at least one second conductive plug, wherein the height of the at least one second conductive plug is greater than the height of each of the at least one first conductive plug.
In order to make the aforementioned features of the disclosure more comprehensible, embodiments accompanying figures are described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1H illustrate a cross-sectional schematic view of manufacturing processes of a stacked type power device module according to an embodiment of the disclosure.
FIGS. 2A-2H illustrate a cross-sectional schematic view of manufacturing processes of a stacked type device module according to another embodiment of the disclosure.
FIG. 3 is a schematic cross-sectional view of a stacked type device module in an embodiment of the disclosure.
FIG. 4A is a schematic cross-sectional view of a stacked type device module in another embodiment of the disclosure.
FIG. 4B is a schematic top view of an exemplary stacked type device module of the disclosure.
DESCRIPTION OF EMBODIMENTS
The disclosure relates to a three dimensional packaging process in which a plurality of chips and/or package structures may be joined together by way of vertically stacking, and therefore wire bonding joints can be reduced. Also, the overall volume and size of the package structure can be decreased, and an electrical connection path of the device may be shortened so that electrical property is improved. The design of the disclosed structure is compatible for additional heat dissipating module(s) to help the heat generated in the module to be dissipated.
FIGS. 1A-1H illustrate a cross-sectional schematic view of manufacturing processes of a stacked type power device module according to an embodiment of the disclosure.
Referring to FIG. 1A , a substrate 100 is provided for carrying a metal substrate 12 , and the substrate 100 may be unloaded or removed in the process. The metal substrate 12 is, for example, a lead frame 120 which is formed of a metal such as copper or aluminum alloy. The lead frame 120 includes at least one void region 122 and a plurality of half etching blocks 124 and a sidewall block 126 . The void region 122 exposes an upper surface 101 a of an adhesive layer 101 . The adhesive layer 101 is disposed on the substrate 100 . The metal substrate 12 is disposed on the adhesive layer 101 . The half etching block 124 currently shown in the figure will become the electrically connection portion of the lead frame 120 (i.e. a bonding contact terminal) in the process. The sidewall block 126 of the lead frame may become an external electrical connection terminal in the subsequent process. The lead frame 120 may include more than one half etching block and/or more than one void region, even though only one is shown in the figure.
The relative disposing position between the void region and the lead frame or the number thereof described in the embodiment is not intended to limit the scope of this disclosure, and may be adjusted or changed depending on the type of the used chip and device or the package structure.
Referring to FIG. 1B , a first device 20 is disposed on the upper surface 101 a of the adhesive layer 101 exposed by the void region 122 of the metal substrate 12 . The first device 20 is, for example, a power device such as a metal-oxide-semiconductor field-effect transistor (MOSFET), an insulated gate bipolar transistor (IGBT), or diode, etc., or a packaged device. At least one device is disposed in each void region 122 of the metal substrate 12 . The size of the void region 122 of the metal substrate 12 is at least larger than the size of the correspondingly carried device or die thereby. The pattern design of the void region 122 may be adjusted according to the device used therein or depending on the requirement of heat dissipating efficiency.
Referring to FIG. 1C , a first filler layer 202 is formed and disposed on the substrate 100 , covering the exposed upper surface 101 a of the adhesive layer 101 as well as encapsulating the first device 20 and filling up the voids between the first device 20 and the sidewall block 126 of the lead frame 120 . A material of the first filler layer 202 is, for example, an ultraviolet curable polymer, a thermosetting polymer, epoxy resin, polyimide or benzocyclobutene (BCB), and may be formed by molding or lamination. During the molding process, generally a mold is used and at a specific position an encapsulation material is injected into the mold. After curing the encapsulation material by thermal treatment or ultraviolet light irradiation, the filler layer 202 is formed and the mold is removed. For the lamination, a dielectric material layer with a predetermined thickness is directly laminated onto the lead frame 120 and the substrate 100 to form the first filler layer 202 . For example, in one embodiment, the thickness of the first filler layer 202 is roughly equivalent to the thickness of the first device 20 , and the first filler layer 202 at least exposes a bonding pad 201 and a bonding pad 203 of the first device 20 . By equivalent thickness it means that an upper surface 202 a of the first filler layer 202 is coplanar with an upper surface 20 a of the first device 20 . For example, in one embodiment, the upper surface 202 a of the first filler layer 202 is coplanar with an upper surface 124 a of the half etching block 124 . After curing and forming the filler layer 202 , the substrate 100 may be removed with the mold or after removing the mold.
Referring to FIG. 1D , a conductive adhesive layer 204 is formed on the upper surface 202 a of the first filler layer 202 and the upper surface 20 a of the first device 20 . A material of the conductive adhesive layer 204 is, for example, conductive adhesive, silver paste or solder paste, formed by coating, screen printing, or film lamination. The conductive adhesive layer 204 may be formed by plating metal layers at the to-be-contact positions of the first device 20 and a second device 30 . An inter-diffusion may occur between both metal layers after treating with the thermomechanical process, and then an intermetallic compound (IMC) may be formed at the interface to achieve the connection.
Referring to FIG. 1E , the second device 30 is disposed on the conductive adhesive layer 204 , covering a portion of the upper surface 202 a of the first filler layer 202 and a portion of the bonding pad 203 of the first device 20 . The second device 30 may partially overlap with the first device 20 to expose the wire bonding pads 201 and 301 on the first and second devices 20 and 30 . The electrical connection between the first and second devices 20 and 30 may be achieved via the conductive adhesive layer 204 . The second device 30 is, for example, a power device such as MOSFET, IGBT, diode, or a packaged device.
Referring to FIG. 1F , a plurality of wires 32 and 34 formed by wiring are respectively connected to the first and second devices 20 and 30 as well as to the corresponding half etching block 124 of the lead frame 120 . A first end of the wire 32 is connected to the bonding pad 201 of the first device 20 , and a second end of the wire 32 is connected to the half etching block 124 . A first end of the wire 34 is connected to the bonding pad 301 of the second device 30 , and a second end of the wire 34 is connected to the half etching block 124 .
Referring to FIG. 1G , a conductive block 38 is placed on a contact pad 302 of the second device 30 at an end of the second device 30 . The conductive block 38 may be fabricated by a metal material (such as copper) and connected in the same way for connecting the devices 20 and 30 , which may function as an electrode in the subsequent process.
Referring to FIG. 1H , a second filler layer 310 is formed and disposed on the first filler layer 202 , encapsulating the second device 30 , wires 32 and 34 , conductive block 38 and covering the first device 20 and the first filler layer 202 . The second filler layer 310 fills up the space between the sidewall 126 of the lead frame 120 and the second device 30 as well as the conductive block 38 . The thickness of the second filler layer 310 is roughly equivalent to or slightly less than the thickness of the conductive block 38 , at least exposing a portion of an upper surface 38 a of the conductive block 38 for electrical connection in the process. By equivalent thickness it means that an upper surface 310 a of the second filler layer 310 is coplanar with an upper surface 38 a of the conductive block 38 . For example, in one embodiment, the upper surface 310 a of the second filler layer 310 is coplanar with an upper surface 126 a of the sidewall 126 of the lead frame 120 . A material of the second filler layer 310 is, for example, an ultraviolet curable polymer, a thermosetting polymer, epoxy resin, polyimide, or benzocyclobutene (BCB), formed by molding or lamination, depending on the type of the device to be packaged. The first and second filler layers 202 and 310 may be formed of the same material or different materials. The material for forming the first and the second filler layers 202 and 310 may be a dielectric material with a high heat-dissipating efficiency or may further include one or a plurality of additives that enhance heat dissipation, such as boron nitride (BN) particles, silica (SiO 2 ) particles, alumina (Al 2 O 3 ) particles, and etc.
FIGS. 2A-2H illustrate a cross-sectional schematic view of manufacturing processes of a stacked type device module according to another embodiment of the disclosure.
Referring to FIG. 2A , a substrate 22 having an upper surface 22 a is provided and a first device 20 is disposed on the upper surface 22 a . The substrate 22 may be a metallic substrate formed of a metal such as copper or aluminum alloy. The substrate 22 may also be a printed circuit board or even a ceramic substrate with metallic circuit. The substrate 22 at least includes a void region 222 . The void region 222 may be a hole, recess, or concave. The substrate 22 may include a plurality of patterns, of which some may be continuous or discrete, including at least a metallic block pattern 24 that is used for carrying the first device 20 and also for dissipating heat. An adhesive layer 230 may be selectively formed between the metallic block pattern 24 and the first device 20 . The adhesive layer 230 may be formed of the same material as that of the conductive adhesive layer 204 in the previous embodiment, such as conductive adhesive, silver paste, or solder paste, formed by coating, screen printing, or film lamination. The conductive adhesive layer 204 may be formed by plating metal layers at the to-be-contact positions of the first device 20 and a second device 30 . An inter-diffusion will occur between both metal layers after treating with the thermomechanical process, and then an intermetallic compound (IMC) is formed at the interface to achieve the connection. The first device 20 is, for example, a power device such as MOSFET, IGBT, diode, or etc. in the form of a chip or even a packaged device.
In FIG. 2B , the first filler layer 202 is formed and disposed on the substrate 22 , encapsulating the exposed upper surface 22 a and covering the first device 20 . The first filler layer may be formed of, for example, an ultraviolet curable polymer, a thermosetting polymer, epoxy resin, polyimide, or benzocyclobutene (BCB), formed by molding or lamination. With regard to the lamination, a dielectric material layer with a predetermined thickness is directly laminated onto the upper surface 22 a of the substrate 22 and fills up the void region 222 to form the filler layer 202 . For example, in one embodiment, the thickness of the first filler layer 202 is greater than the thickness of the first device 20 . That is, the upper surface 202 a of the first filler layer 202 may be higher than the upper surface 20 a of the first device 20 .
In FIG. 2C , an opening forming step is performed to the first filler layer 202 . A first via 206 is formed by drilling from the upper surface 202 a of the first filler layer 202 downward until the upper surface 20 a of the first device 20 is exposed. A second via 208 is formed by drilling from the upper surface 202 a of the first filler layer 202 downward until the upper surface 22 a of the substrate 22 is exposed. The first and second vias 206 and 208 may be formed at the same time or in turn by using mechanical drilling or laser drilling.
For example, when the laser drilling technique is adopted for fabricating the via, parameters such as, laser output power, processing speed and the repetition times of processing may be adjusted, avoiding damages to the underlying material of the opening. The laser via may be intact devoid of forming a protection layer on the pad.
In FIG. 2D , a plating process is performed. A metallic conductive material 214 is plated to cover the upper surface 202 a of the first filler layer 202 and filled in the first and second vias 206 and 208 to form first and second conductive plugs 216 and 218 . A first circuit pattern 220 is formed on the upper surface 202 a of the first filler layer 202 through a patterning step. The metallic conductive material 214 is, for example, copper. The first circuit pattern 220 may be a metal circuit pattern for re-distribution and therefore may also be regarded as a re-distribution pattern.
Referring to FIG. 2E , a second device 30 is disposed on a surface of the metallic conductive material 214 . Optionally, an adhesive layer 330 may be formed between the metallic conductive material 214 and the second device 30 by conductive adhesive, silver paste, solder paste, and etc., formed by coating, screen printing, or film lamination. The conductive adhesive layer 204 may be formed by plating metal layers at the to-be-contact positions of the first device 20 and a second device 30 . An inter-diffusion may occur between both metal layers after treating with the thermomechanical process, an intermetallic compound (IMC) is formed at the interface to achieve the connection. The second device 30 is, for example, a power device such as MOSFET, IGBT, diode, or etc., a chip, or even a packaged device. The first device 20 and the second device 30 may have different functions or may be formed of different materials.
In FIG. 2F , a second filler layer 310 is formed and disposed on the substrate 22 , covering the metallic conductive material 214 and the exposed upper surface 202 a of the first filler layer 202 as well as encapsulating the second device 30 . The second filler layer 310 is formed of, for example, an ultraviolet curable polymer, a thermosetting polymer, epoxy resin, polyimide, or benzocyclobutene (BCB), formed by molding or lamination. For example, in one embodiment, the height of the second filler layer 310 may be greater than the height of the second device 30 . That is, an upper surface 310 a of the second filler layer 310 may be higher than an upper surface 30 a of the second device 30 .
In FIG. 2G , another opening forming step is performed to the second filler layer 310 . A third via 306 is formed by drilling from the upper surface 310 a of the second filler layer 310 downward until the upper surface 30 a of the second device 30 is exposed. A fourth via 308 is formed by drilling from the upper surface 310 a of the second filler layer 310 until the metallic conductive material 214 is exposed. The third and fourth vias 306 and 308 may be formed at the same time or in turn by using mechanical drilling or laser drilling.
In FIG. 2H , a plating process is performed. Another metallic conductive material 314 is plated to cover the upper surface 310 a of the second filler layer 310 and filled in the third and fourth vias 306 and 308 to form third and fourth conductive plugs 316 and 318 . A second circuit pattern 320 is formed on the upper surface 310 a of the second filler layer 310 through a patterning step. The second circuit pattern 320 may be a metal circuit pattern for re-distribution and therefore may also be regarded as a re-distribution pattern.
The relative disposing position between the via/conductive plug(s) and the device or the number thereof as described in the embodiments of the disclosure is exemplary and is not intended to limit the scope of the disclosure. The relative disposing position or the number thereof may be adjusted or changed depending on the type of device used or the design of the actual products. The pattern design of the re-distribution metal pattern may be changed depending on the electrical connection terminal or electrical requirement of the vertically stacked device. The conductive plug described in the embodiments of the disclosure may be a build-up conductive via depending on the size of the via and the filling level of the conductive material, may be formed by plating.
FIG. 3 is a schematic cross-sectional view of a stacked type device module in an embodiment of the disclosure. Referring to FIG. 3 , a semiconductor package module 400 includes a substrate 410 , at least one first device 420 , at least one second device 430 , at least one filler layer 440 , at least one electrode 450 , and a plurality of wires 460 , 461 .
A substrate 410 is designed to have at least one sinking region 412 , at least one platform region 414 , and a sidewall block 416 located at the side for external connection. The substrate 410 may be, for example, a multi-layer printed circuit board or a laminated circuit board, which is fabricated via laminating metal boards with dielectric layers, and the substrate 410 may further include an internal circuit and a metallic conductive plug or a through via.
Referring to FIG. 3 , a first device 420 is disposed on an upper surface 412 a of the sinking region 412 of the substrate 410 . A second device 430 is disposed on an upper surface 420 a of the first device 420 and covers a portion of an upper surface 414 a of the platform region 414 . The electrode 450 is disposed on an upper surface 430 a of the second device 430 . The filler layer 440 covers over the substrate 410 and fills up the space between the device and the sidewall block 416 and also encapsulates the wires 460 , 461 . Although the electrode 450 is located on the upper surface 430 a of the second device 430 , at least one portion of an upper surface of the electrode 450 is exposed from the filler layer 440 for external connection. In one embodiment, all of an upper surface of the electrode 450 is exposed from the filler layer 440 for external connection. The electrode 450 may also be a part of the metal pattern or the circuit pattern and the shape of the electrode 450 varies depending on the design of the products.
Referring to FIG. 3 , the second device 430 partially, instead of completely, overlaps with the first device 420 to expose the wire bonding pads 421 and 431 on the first and second devices. The depth of the sinking region 412 is roughly equivalent to the thickness of the first device 420 so that the second device 430 stacked on the first device 420 may partially rest on the platform region 414 without inclination. A plurality of wires 460 , 461 respectively connect the first and second devices 420 and 430 to the corresponding sinking region 412 and the platform region 414 of the substrate 410 . A first end of the wire 460 is connected to the wire bonding pad 421 of the first device 420 , and a second end of the wire 460 is connected to the sinking region 412 . A first end of the wire 461 is connected to the wire bonding pad 431 of the second device 430 , and a second end of the wire 461 is connected to a half etching block of the platform region 414 .
In the embodiment, the functions of the sinking region 412 , the platform region 414 and the block 416 of the substrate 410 in FIG. 3 approximately are similar to that the functions of the void region 122 , the half etching block 124 , and the sidewall block 126 of the lead frame 120 in FIG. 1A .
The electrical connection between the first device 420 and second device 430 and between first device 420 and sinking region 412 may be achieved via the conductive adhesive layers 470 and 425 . The conductive adhesive layers 425 and 470 are formed of, for example, silver paste or other appropriate adhesives. The first and second devices 420 and 430 may independently and respectively be a power device such as MOSFET, IGBT, diode, or a packaged device. The first device 420 and second device 430 may have different functions or may be formed of different materials. The wire 460 / 461 is, for example, a gold wire, copper wire, or aluminum wire. The electrical connection between the first and second devices 420 and 430 may be achieved via solid liquid inter-diffusion (SLID) technique, for example. The SLID technique is to form metal layers respectively on the contact surfaces of both devices and perform the thermomechanical treatment to cause inter-diffusion between the contact surfaces. The metal layer(s) may include elements such as copper, nickel, tin, silver, gold, titanium, and etc.
The filler layer 440 is formed of, for example, an ultraviolet curable polymer, a thermosetting polymer, epoxy resin, ajinomoto built-up film (ABF film), polyimide, or benzocyclobutene (BCB), by molding or lamination, depending on the type of the device to be packaged. The material of the filler layer may be a dielectric material with high heat-dissipating efficiency or may further include additives that enhance heat dissipation.
The substrate 410 shown in FIG. 3 further includes an external contact surface 418 located at the bottom layer of the substrate 410 . A filler material 415 and one or more through vias 417 are disposed between the external contact surface 418 and the sinking region 412 for electrical connection and heat dissipation. The first and second devices 420 and 430 are, for example, power devices. The electrode 450 as an emitter and the sidewall block 416 as a gate may be located at the same side, while the external contact surface 418 as a collector may be located at the opposite side.
FIG. 4A is a schematic cross-sectional view of a stacked type device module in another embodiment of the disclosure. FIG. 4B is a schematic top view of an exemplary stacked type device module of the disclosure.
Referring to FIG. 4A , according to another embodiment of the disclosure, the difference between a semiconductor package module 500 and the semiconductor package module 400 as shown FIG. 3 lies in that all the circuits are connected by plating through vias without involving any wiring process. The semiconductor package module 500 includes a substrate 510 , at least one first device 520 , at least one second device 530 , at least one filler layer 540 , a plurality of conductive plugs 550 , and at least one circuit pattern 560 .
Referring to FIG. 4A , the substrate 510 and the substrate 410 as shown FIG. 3 are similarly designed, having at least one sinking region 512 and at least one platform region 514 . The substrate 510 is, for example, a multi-layer printed circuit board or a laminated circuit board which may be fabricated via laminating metal boards with dielectric layers, and may further include an internal circuit and metallic conductive plugs or through vias. The design of the sidewall may be omitted from the substrate 510 as the connection can be achieved via the conductive plugs.
Referring to FIG. 4A , a first device 520 is disposed on the sinking region 512 of the substrate 510 , and a second device 530 is disposed on the first device 520 , covering a portion of an upper surface 514 a of the platform region 514 . The filler layer 540 covers over the substrate 510 and encapsulates the first and second devices 520 and 530 . The first device 520 and the substrate 510 as well as the 520 / 530 may be connected by using the conductive adhesive layers 515 and 570 . The conductive adhesive layers 515 and 570 may be formed of, for example, solder paste or silver paste. Alternatively, the connection technique such as a solid liquid inter-diffusion (SLID) technique may also be used to achieve the electrical connection there-between.
Referring to FIG. 4B , the second device 530 partially, instead of completely, overlaps with the first device 520 to expose contact pads 521 and 531 on the first and second devices 520 and 530 . The depth of the sinking region 512 may be equivalent to the thickness of the first device 520 so that the second device 530 disposed on the first device 520 may partially rest on the platform region 514 without inclination.
The circuit pattern 560 includes a central circuit pattern 562 as an emitter terminal and a gate contact terminal 564 in the periphery of the circuit pattern. The central circuit pattern 562 may be connected to the second device 530 via a plurality of conductive plugs 552 . The contact pads 521 and 531 on the first and second devices are electrically connected to the gate contact terminal 564 via the conductive plugs 556 and 554 . Since the first and second devices 520 and 530 may be vertically stacked, the length (depth) of the conductive plug 556 may be greater than that of the conductive plugs 554 and 552 . In one embodiment, through the conductive plugs 550 and the circuit pattern 560 , the electrodes of the first and second devices 520 and 530 are connected to the corresponding external connection terminals. The substrate 510 shown in FIG. 4A further includes an external contact surface 518 located at the bottom-most layer of the substrate 510 . Take a power device as an example, the circuit pattern 562 as an emitter and the gate contact terminal 564 as a gate are at the same side, while the external contact surface 518 as a collector is located at the opposite side.
Depending on the products, the outer-most portion of the circuit pattern may be used as a heat-dissipating structure through pattern design to enhance heat-dissipating efficiency.
The electrical connection between the first and second devices 520 and 530 may be achieved via the conductive adhesive layer 570 . The conductive adhesive layer 570 is formed of, for example, solder paste or silver paste. Connection techniques such as SLID technique may be used to complete electrical connection between the two devices. The first and second devices 520 and 530 may independently and respectively be a power device such as MOSFET, IGBT, or diode etc., or a chip, or a packaged device. The first device 520 and the second device 530 may have different functions or may be formed of different materials. The first device 520 and the second device 530 may be a semiconductor chip such as a transistor, a radio-frequency (RF) chip, or a light emitting diode (LED). The conductive plug 550 is formed of, for example, copper or copper alloys.
In the embodiments of the disclosure, in order to integrate one or more devices, a lead frame with at least a void region and a half etching block as well as a substrate with a sinking region and a platform region are provided for embedding devices, to reduce the overall size or volume of the package and promote electrical transmission.
In the embodiments of the disclosure, the connection between the device and substrate as well as the connection between the devices may be achieved by using conductive materials (such as solder paste, silver paste, and etc.) or other connection techniques (such as SLID technique and etc.).
In the embodiments of the disclosure, redistribution and fanning out the electrode contacts may be achieved by laminating dielectric layers and metal patterns (build-up layers). By using the laser drilling technique to fabricate a via, intact via openings are obtained and there is no need to fabricate a protection layer over the contact pad. Also, a plating process may be used to fill the via opened to form the conductive plug (such as copper or its alloy) therein. Upon the completion of the electrical connection, an intermetallic compound (IMC) may be formed between the conductive plug and the joint point following the subsequent thermal treatment process, which enhances long term reliability.
When the module is operated under a heavy current mode, a heat-dissipating structure or module may be required. The design of the disclosure may incorporate the heat-dissipating module. Since the dielectric layer or the filler material encapsulates and protects the device(s), the module of the disclosure may have better heat-conducting efficiency than the module using wire bonding.
Although the disclosure has been disclosed by the above embodiments, the embodiments are not intended to limit the disclosure. It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the disclosure without departing from the scope or spirit of the disclosure. Therefore, the protecting range of the disclosure falls in the appended claims.
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The disclosure relates to a stacked type power device module. May use the vertical conductive layer for coupling the stacked devices, the electrical transmission path may be shortened. Hence, current crowding or contact damages by employing the conductive vias or wire bonding may be alleviated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to integral normalized surface regions formed in situ on bulk sensitized stainless steel by laser beam scanning.
2. Description of Prior Art
Heretofore, normalized stainless steel has been made by annealing a specimen of stainless steel in the solution temperature range for a time sufficient to allow a homogenization of the chromium concentration in the stainless steel, followed by quenching of the same specimen by bringing it in contact with a cold fluid.
With a sufficiently fast quench, the homogeneous chromium concentration is retained on quenching and a normalized stainless steel specimen is obtained. However, such a bulk quenching technique is not always feasible because forming operations, welding operations or the generation of large thermal stresses may prevent such a quenching step.
Stainless steels are alloys of iron and chromium or iron, chromium, and nickel with occasionally small amounts of other elements added to enhance their corrosion resistance or mechanical properties. In regard to corrosion resistance, the chromium content appears to be the controlling variable although the effect of chromium can be enhanced by the additions of nickel and molybdenum.
Stainless steels are available in three grades: namely, martensitic, ferritic, and austenitic. The martensitic grade containing about 12 wt% chromium is distinguished by its high hardness and is used for valves, valve seats and cutlery requiring a durable cutting edge. The ferritic grade containing about 16wt% chromium is more corrosion resistant but much less hard than the martensitic grade and can be formed and drawn. The austenitic grade has a fcc structure instead of the tetragonal and bcc structure of the martensitic and ferritic grades, respectively.
The basic and most widely used grade of the austenitic type is the "18-8" type containing 18 wt% chromium, 8 wt% nickel with 0.03 to 0.20 wt% carbon. Because of its high chromium content, it has excellent corrosion resistance. In addition, because of its fcc structure, it posseses very good ductility and is used in making the seamless stainless-steel tubing used in light water reactors. 304 stainless steel is a subclass of the "18:8" austenitic grade of stainless. Its carbon content is slightly higher than the average austenitic grade.
Although 304 stainless is generally very resistant to corrosion, under certain conditions it can become "sensitized" so that it is susceptible to susceptible to catastrophic intergranular corrosion. FIG. 1 shows the equilibrium phase diagram for 304 stainless with the temperature plotted against its carbon content. It must be stressed that this is the equilibrium diagram, although the phase diagram indicates that ฮฑ-ferrite can only be produced by severe cold working of the 304 stainless steel because of the extreme sluggishness of the ฮณ-to-ฮฑ phase transformation. Consequently, in practice the ฮณ-austenite is retained as a metastable phase at room temperature and, thus, 304 stainless in its annealed unstrained state is austenitic.
In FIG. 1, it can be seen that the solubility of carbon in the alloy rapidly decreases with temperature between 900ยฐ C. and 400ยฐ C. Since most 304 stainless steels have about 0.1 wt% carbon, a super-saturated solution of carbon forms as the alloy is cooled below 900ยฐ C. Given a sufficient amount of time in the "sensitization" temperature range, it is found experimentally that carbon will precipitate out along grain boundaries in the form of chromium carbide, Cr 23 C 6 , FIG. 2. These thin two-dimensional-like carbides form on the grain boundary because the boundary is the only region where chromium atoms have sufficient mobility at these temperatures to diffuse to a carbide nucleus.
According to chromium-depletion theory of sensitization, the formation of these chromium-rich carbides along the boundary depletes the boundary and adjacent zones of chromium since at these temperatures chromium diffusion from the matrix is not rapid enough to replenish the chromium removed around the carbide. Thus, the chromium concentration at the boundary falls below that required for passivation, FIG. 2, allowing the boundary region to be corroded. A second theory also based on chromium depletion holds that the severe grain-boundary attack is a result of the galvanic cell that is formed between the bulk and the grain-boundary-zone ฮณ-austenite and that a fall of chromium concentration below that required for passivation is not necessary.
It is found that if a stainless-steel specimen is cooled rapidly through the sensitization temperature range (FIG. 1), sensitization can be avoided. However, such a bulk treatment is not always feasible because forming operations, welding operations, or the generation of large thermal stresses may prevent such a quenching operation. In such cases, other ways must be found to prevent the severe intergranular corrosion that is associated with sensitization.
An object of this invention is to provide protective coating for a body or region of sensitized austenitic grade stainless steel.
Another object of this invention is to provide a new form of normalized stainless steel that can be employed in circumstances where bulk normalized stainless steel can not be formed.
A further object of this invention is to provide a body of sensitized stainless steel with an integral surface region of normalized stainless steel formed in situ by melting and rapidly quenching the material of the surface region.
Other objects of this invention will, in part, be obvious and will, in part, appear hereafter.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the teachings of this invention there is provided a body having a core of sensitized austenitic grade stainless steel such as Type 304 stainless steel. An integral outer surface region of normalized stainless steel encompasses the core to impart passivity to the stainless steel article in a corrosive environment.
The microstructure of the material of the body has carbon precipitated in the grain boundaries as chromium carbide in the sensitized material of the core. The integral outer surface region has a homogenized chromium concentration throughout its microstructure.
The structure of the integral outer surface region of normalized stainless steel consists of a series of mutually overlapping integral scallop shape regions. The thickness of the normalized region may be up to 10 millimeters.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is the equilibrium phase diagram of 304 stainless steel with its carbon content plotted versus temperature. The "solution" temperature range in which carbon may be readily dissolved in ฮณ-austenite is shown as well as the "sensitization" range where chromium carbides are observed to precipitate out on the grain boundaries of stainless steel causing sensitization thereof.
FIG. 2 is a schematic illustration of the chrome depletion mechanism of stainless steel sensitization.
FIG. 3 is a schematic illustration of laser processing of a sensitized stainless steel rod with two different overlapping scan modes.
FIG. 4 is the temperature-time-sensitization diagram for 304 stainless steel.
FIG. 5 is a schematic illustration of a cross-section perpendicular to the path of a laser beam which is melting the surface of a sensitized 304 stainless steel slab.
FIG. 6 is a photomicrograph of a cross-section of a sensitized 304 stainless steel rod which has been laser surface melted (63X).
FIG. 7 is a photomicrograph of a cross-section of a sensitized stainless steel specimen after a 72 hour exposure to a boiling solution of 10% H 2 SO 4 , 10% CuSO 4 , and 80% H 2 O.(275x)
FIG. 8 is a photomicrograph of a cross-section of a sensitized stainless steel rod identical to the rod of FIG. 6 except for a surface normalization by laser surface melting (275X).
DESCRIPTION OF THE INVENTION
We have discovered that by scanning a laser beam over the entire, or a portion of the, surface of a body of sensitized stainless steel, a thin layer of the stainless steel contiguous to the surface is first melted, and then rapidly self-quenched, forming a barrier layer of normalized austenite (normalized=nonsensitized) at the surface from the original material of the body. In subsequent corrosion tests, it has been discovered that this normalized barrier completely prevents intergranular corrosion. The integral normalized surface region has a homogeneous chromium concentration throughout the normalized region. The depth, or thickness, of the normalized region may be as great as 10 millimeters.
Referring now to FIG. 3, there is shown a rod-like body 10 of sensitized stainless steel undergoing laser surface normalization. The body 10, or portion thereof, whichever is applicable, is cleaned by a suitable method such as shotpeening, chemical etching, sand blasting, and the like. An opaque coating is then applied to the portion of the surface to be normalized. Suitable materials are black paint, a coating of black chrome, a coating of finely divided nickel and the like. The opaque coating is applied to minimize the reflection of a laser beam or an electron beam and to retain and/or absorb heat more efficiently for practicing the invention.
Although an electron beam or a flame may be employed in practicing this invention, the preferred method is the utilization of a laser beam. Presently, it is the most economical of the methods suggested and further, it does not require the use of a vacuum chamber.
The passes across the workpiece necessary to achieve the end result can be accomplished in several ways. The work piece, the beam or both can be moved in an X-Y direction to provide the necessary relative translation. Additionally, an optical system may be employed to scan the workpiece and process the surface region as required.
A laser beam 100 impinges on the stainless steel body 10 forming a melt path 200 on the surface 12 of the body 10. The body 10 is forced to undergo simultaneously a rotation 300 about the major axis of body 10 and a gradual translation 301 parallel to the major axis of body 10. This simultaneous rotation 300 and translation 301 causes the laser beam 100 to form a series of overlapping passes 202 over the surface of body 10. The overlapping distance is sufficient to ensure complete normalization of the surface region treated.
The power of the laser beam 100 is sufficient at the given laser beam scan rate to form a melt puddle 200 of a predetermined depth. The rapidly quenched (ห100ยฐ C./sec or greater) material 202 in the surface layer 12 of body 10 is normalized and resists intergranular corrosion.
In order for the resolidified surface layer to be normalized, sufficient time must elapse at high temperatures for diffusion leveling of the chromium-concentration gradient. Since the diffusion constant in the liquid D L is much greater than the diffusion constant D s in the solid, the time ฯ that the surface layer is liquid is important. If ฮด is the radius of the melt pool beneath the laser beam moving at velocity V, then
ฯ=2ฮด/V (1)
The diffusion distance X over which concentration homogenization can occur is ##EQU1## From Equation (2) and the condition that X>L(the width of the chromium depleted zone - see FIG. 2), the maximum laser-scan velocity V max with which normalization will still occur is
V.sub.max โฆ2D.sub.L ฮด/L.sup.2 (3)
Homogenization in the liquid is also aided by the fluid flow that occurs in the melt puddle beneath the laser beam. This mixing phenomenon, however, also dies out above a critical velocity estimated to be about 9 cm/sec for 304 stainless steel.
A similar analysis can be carried out to determine whether normalization can occur in the solid beneath the melt puddle. In this case, the liquid diffusion coefficient is replaced by the much smaller solid-state diffusion coefficient D s . The maximum laser scan velocity then equals about 3ร10 -2 cm/sec, in order to allow enough time for normalization in the solid.
As shown above, a maximum critical laser velocity exists above which normalization will not occur. In addition, there is a minimum critical laser velocity below which permanent normalization is not possible. The physical cause of the maximum laser velocity limit was the time reqwuired for diffusional homogenization in the liquid. In contrast, the physical source of the minimum laser velocity limit is the minimum quench rate required to cool the material through the sensitization range without resensitizing the material normalized by laser surface melting.
Referring now to FIG. 4, the temperature-time-sensitization diagram for 304 stainless steel is shown. Specimens held for times and temperatures shown in the sensitization zone would be susceptible to corrosion. Several time-temperature quenching curves are superimposed on FIG. 4. From them it can be seen that a minimum quench rate of 100ยฐ C./sec is required to prevent resensitization.
Referring now to FIG. 5, a cross-section perpendicular to the path of a laser beam 100 melting the surface of the body 10 of sensitized stainless steel. Beneath the laser beam 100, a puddle 200 of liquid stainless steel is formed which subsequently resolidifies to form the laser beam melt path 202. The temperature of material of body 10 is raised by the beam so that material in zone 400 passes through the sensitization temperature range. Material in zone 400 must pass through this sensitization temperature range quickly to avoid sensitization.
The quench rat ##EQU2## of material in zone 400 is simply related to the laser surface scanning velocity V by ##EQU3## where VT is the temperature gradient in the material. If the laser beam is moving in the X direction, by dimensional analysis, the time-averaged temperature gradient at a point in the specimen with temperature T is approximately ##STR1## where V is the laser velocity, T is the temperature and D T is the thermal diffusion constant of the material. By setting T=T sens and combining Equations (4) and (5), the time-averaged quench rate of material in the sensitization range is found to be ##EQU4##
Equation (6) can be rearranged to determine the minimum laser-scan velocity V min to prevent resensitization. ##EQU5## For a minimum quench rate of -100ยฐ C./sec from FIG. 4, the minimum allowed laser velocity is V min โง1.3ร10 -1 cm/sec. This value compares with the maximum permissible laser-scan velocity of 6 cm/sec required for initial normalization. Thus there is approximately only an order-of-magnitude window in laser-scanning rates which are compatible with surface normalization of sensitized stainless steels by laser surface melting.
The following example is illustrative of the teachings of this invention.
Specimens of 304 stainless steel with the properties shown in the following Table were annealed for 1 h at 1100ยฐ C. in the solution temperature range (FIG. 1) so that any precipitated carbon in the sample would redissolve. After this solution treatment , the specimens were water quenched and then annealed at 650ยฐ C. in the sensitization temperature range for 24 h to cause chromium carbides to form on the grain boundaries of the specimen. Following the sensitization anneal at 650ยฐ C. the samples were then water quenched. The samples were rod specimens 0.32 cm in diameter by 5 cm in length.
TABLE______________________________________Properties of 304 Stainless Steel Specimens______________________________________Composition (wt %):Cr Ni Mn Si C S P Cu Mo______________________________________18.3 9.1 1.6 0.6 0.06 0.03 0.03 0.09 0.3Yield strength: 2.31 ร 10.sup.9 dyn/cm.sup.2Ultimate tensile strength: 5.78 ร 10.sup.+9 dyn/cm.sup.2Ductility: 66% plastic deformation before failureYoung's modulus: 2 ร 10.sup.+12 dyn/cm.sup.2Poisson's ratio: 0.28Thermal expansion coefficient: 18.4 ร 10.sup.-6 /ยฐC.Grain size: approximately 8 ร 10.sup.-3 cm______________________________________
A cwCO 2 laser (maximum power, 350W) with a spot size diameter of 2.5ร10 -2 cm scanned at a rate of 0. 5 and 1 cm/sec at power levels of 70, 80, 140, 180, and 200W, respectively over sensitized specimens of 304 stainless steel 0.32 and 0.65 cm in diameter.
For reasons of convenience, the test rods were scanned by rotating the rod about its major axis under the laser beam while gradually translating the rod parallel to its major axis.
FIG. 6 is a photomicrograph at 63X of a cross-section of 0.32-cm-diam Type 304 stainless steel rod after laser processing by the mode depicted in FIG. 3. Processing was done at a scan rate of 0.5 cm/sec and a laser power of 140W. The observed penetration depth of 1ร10 -2 cm agrees well with theoretical predictions. The scallop shape of each pass is visible in FIG. 6 as well as the fact that the surface is well covered because of the overlay between adjacent passes. The normalized surface region produced from the original material comprising the body completely encases the core of sensitized stainless steel. There are no sighns of sensitization in the normalized surface region.
The processed specimens were subjected to the standard Strauss test (ASTM-A262 practice E test solution) in a boiling solution of 10% H 2 SO 4 and 10% CUSO 4 for 7 hours. As expected, there was complete grain-boundary disintegration of rods which were not surface treated by the laser scanning technique (FIG. 7). In contrast, in the rod where laser surface melting had occurred, there was a complete absence of attack (FIG. 8). The protective effect in the form of a normalized surface region obtained from laser surface melting is thus shown.
Although the invention has been described relative to the surface treatment of sensitized stainless steel, the same surface treatment may be practical on articles of manufacture as fabricated. Without having to determine the metallurgical microstructure of the article, one may surface treat the article to insure resistance to corrosive atmospheres which would be detrimental to sensitized stainless steels.
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A body of sensitized stainless steel is afforded passivity for exposure to a corrosive environment by an integral surface region of normalized stainless shell formed in situ by laser beam scanning.
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RELATED APPLICATION
[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 60/677,243, filed May 3, 2005, the disclosure of which is incorporated herein by reference as if set forth in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to cleaning products and, more particularly, to cleaning products for wiping surfaces.
BACKGROUND OF THE INVENTION
[0003] Cleaning wipes have been used for a variety of purposes, including body cleaning, cleaning of hard surfaces, cleaning dishware, flatware, pots and pans, etc. Conventional cleaning wipes may contain various compounds to accomplish their intended purpose. For example, cleaning wipes may include inverse emulsions (i.e., water-in-liquid) to clean infants. Cleaning wipes may also include waxes to polish and clean furniture, soaps and detergents to clean hands, counter tops, floors, and the like. Cleaning wipes may also include ammonia to clean glass surfaces. Alcohol and various other biocides may be included to disinfect a variety of surfaces.
[0004] Conventional cleaning wipes are typically soft and may not work well in applications where some amount of scrubbing is necessary to clean a surface. In addition, conventional dry cleaning wipes may not be capable of picking up hair and other large particles (e.g., dirt particles, etc.), even after being electrostatically charged. As such, there is a need for improved cleaning wipes that can scrub surfaces and that can pick up hair and other large particles.
SUMMARY OF THE INVENTION
[0005] In view of the above discussion, methods of making wipes capable of picking up hair and other large particles are provided. According to some embodiments of the present invention, a method of making a wipe includes bonding a layer of netting material to a substrate, and subsequently stretching the bonded layer of netting material and substrate such that strands of the netting material break and extend outwardly from the substrate to form teeth. The netting material may be bonded to the substrate in any of various ways including, but not limited to, chemical bonding, thermal bonding, ultrasonic bonding, and/or physical bonding. The bonded layer of netting material and substrate may be stretched in the machine direction (MD) and/or in a cross direction (CD) that is transverse to the MD.
[0006] According to some embodiments of the present invention, stretching the bonded layer of netting material and substrate includes passing the bonded layer of netting material and substrate through a pair of ring rolls, wherein each ring roll comprises a plurality of teeth and corresponding grooves that extend about the circumference thereof, and wherein the teeth of each ring roll intermesh with the grooves of the other ring roll.
[0007] According to some embodiments of the present invention, stretching the bonded layer of netting material and substrate includes passing the bonded layer of netting material and substrate through a pair of calendar rolls, wherein a surface of one roll is smooth, wherein a surface of the other roll has a pattern engraved thereon, and wherein the layer of netting material contacts the roll having the surface with the engraved pattern.
[0008] According to some embodiments of the present invention, stretching the bonded layer of netting material and substrate includes passing the bonded layer of netting material and substrate through a pair of calendar rolls, wherein a surface of each roll is smooth.
[0009] According to some embodiments of the present invention, one or both of the netting material and substrate may be impregnated with one or more chemical ingredients. Such chemical ingredients may include, but are not limited to, cleaning solutions, soaps, antiseptics, surfactants, tackifying agents, antimicrobial agents, detergents, bleaches, polishes, and facial cleansers.
[0010] According to some embodiments of the present invention, one or both of the netting material and substrate may be electrostatically charged.
[0011] According to some embodiments of the present invention, a method of making a wipe includes stretching a layer of netting material via ring rolls or calender rolls such that strands of the netting material break and extend outwardly to form teeth, and then bonding the layer of netting material to a substrate such that the strands extend outwardly from the substrate. The layer of netting material and substrate may be stretched in the MD and/or in a CD that is transverse to the MD. The netting material may be bonded to the substrate in any of various ways including, but not limited to, chemical bonding, thermal bonding, ultrasonic bonding, and/or physical bonding. Various articles including, but not limited to, mops, scrub brushes, cloths, may incorporate one or more wipes according to some embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which form a part of the specification, illustrate key embodiments of the present invention. The drawings and description together serve to fully explain the invention.
[0013] FIG. 1 is an enlarged portion of a wipe, according to some embodiments of the present invention.
[0014] FIG. 2 is a side section view of the wipe of FIG. 1 and illustrates broken strands in the netting material extending outwardly to form teeth.
[0015] FIG. 3 is an enlarged plan view of a portion of the wipe of FIG. 2 .
[0016] FIGS. 4A, 4B , 4 C, 4 D are respective side views of a wipe, according to some embodiments of the present invention, that illustrate that the number of teeth formed via ring rolling increases with the depth of engagement of the ring rolls.
[0017] FIG. 5 is a perspective view of a ring roll incremental stretching system that can be utilized in accordance with some embodiments of the present invention.
[0018] FIG. 6 is an enlarged cross-sectional view of the teeth on the opposing rolls of the ring roll incremental stretching system of FIG. 5 .
[0019] FIGS. 7A-7B illustrate an index pattern engraved on a ring roll according to embodiments of the present invention.
[0020] FIG. 8 is a graph that illustrates hair pick-up capability of several wipes, according to embodiments of the present invention.
[0021] FIG. 9 is a graph that illustrates the correlation between abrasiveness of a wipe and depth of engagement of ring rolls used in stretching the wipe, according to some embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. 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 so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0023] Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity. Broken lines illustrate optional features or operations unless specified otherwise.
[0024] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms โaโ, โanโ and โtheโ are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms โcomprisesโ and/or โcomprising,โ when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term โand/orโ includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as โbetween X and Yโ and โbetween about X and Yโ should be interpreted to include X and Y. As used herein, phrases such as โbetween about X and Yโ mean โbetween about X and about Y.โ As used herein, phrases such as โfrom about X to Yโ mean โfrom about X to about Y.โ
[0025] Unless otherwise defined, all terms (including 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. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.
[0026] It will be understood that when an element is referred to as being โonโ, โattachedโ to, โconnectedโ to, โcoupledโ with, โcontactingโ, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, โdirectly onโ, โdirectly attachedโ to, โdirectly connectedโ to, โdirectly coupledโ with or โdirectly contactingโ another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed โadjacentโ another feature may have portions that overlap or underlie the adjacent feature.
[0027] Spatially relative terms, such as โunderโ, โbelowโ, โlowerโ, โoverโ, โupperโ and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of a wipe in use or operation in addition to the orientation depicted in the figures. For example, if the wipe in the figures is inverted, elements described as โunderโ or โbeneathโ other elements or features would then be oriented โoverโ the other elements or features. Thus, the exemplary term โunderโ can encompass both an orientation of โoverโ and โunderโ. A wipe may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms โupwardlyโ, โdownwardlyโ, โverticalโ, โhorizontalโ and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.
[0028] It will be understood that, although the terms โfirstโ, โsecondโ, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a โfirstโ element, component, region, layer or section discussed below could also be termed a โsecondโ element, component, region, layer or section without departing from the teachings of the present invention. The sequence of operations (or steps) is not limited to the order presented in the claims or figures unless specifically indicated otherwise.
[0029] According to embodiments of the present invention, a wipe with an abrasive surface is manufactured by bonding netting material to a substrate, such as a nonwoven structure, and then ring rolling the composite. Ring rolling breaks the netting material such that unbonded netting material pieces extend outwardly to form โteethโ that are abrasive to the touch. The surface is quite aggressive, and can scrub or abrade, or alternatively, can be made from softer polymer, and give a soft brush like surface that is very effective for cleaning and holding debris. It is important that the netting material break quickly and efficiently under the stretching stress load. Alternatively, the netting can be configured with an embossed or molded โnotchโ to facilitate breaking.
[0030] Applications include floor wipes, pet wipes, wipes to be used in beautician shops, barber shops, etc. Moreover, the teeth may be oriented at an angle to enhance the ability to pick up hair and large particles.
[0031] According to embodiments of the present invention, netting material can be bonded to a substrate such that bond points substantially bond/trap machine direction (MD) netting material lines. Upon stressing in the cross direction (CD) via ring rolling, netting material lines in the CD direction break, and reorient to a more vertical or โZโ direction, thereby creating raised pieces/parts (i.e., forming teeth) that can abrade, catch hair, etc.
[0032] According to other embodiments of the present invention, net structures can be bonded to a substrate such that bond points substantially bond/trap CD direction net lines. Upon stressing in the MD direction via ring rolling, net lines in the MD break, thereby creating raised pieces/parts (i.e., forming teeth) that can abrade, catch hair, etc. According to other embodiments of the present invention, stressing in the MD and CD directions in combination can be performed to produce teeth.
[0033] According to some embodiments of the present invention, bonding a layer of netting material to a substrate may include embedding at least a portion of a layer of netting material within a substrate. According to some embodiments of the present invention, bonding a layer of netting material to a substrate may be performed by chemical bonding, thermal bonding, ultrasonic bonding, physical bonding, or some combination thereof. Adhesive bonding may include inserting an adhesive, an adhesive powder, an adhesive web, an adhesive net, or an adhesive film between a substrate and netting material.
[0034] Referring to FIG. 1 , an enlarged portion of a wipe 10 , according to some embodiments of the present invention, is illustrated. The illustrated wipe 10 includes a layer of netting material 12 bonded to a substrate 14 .
[0035] Hatch marks 16 are bond points. The illustrated layer of netting material 12 includes a first set of strands 12 a that extend along a first direction in spaced-apart, generally parallel relationship, and a second set of strands 12 b that extend between and interconnect with the first set of strands in adjacent, spaced-apart relationship. The illustrated sets of strands 12 a , 12 b are substantially co-planar, but need not be. Netting material of various configurations many be utilized in accordance with embodiments of the present invention without limitation.
[0036] FIG. 2 is a side section view of the wipe 10 of FIG. 1 and illustrates some of the strands in the netting material 12 being broken and extending outwardly to form โteethโ 18 after being ring rolled (described below). The teeth 18 may be broken strands from the first set 12 a and/or broken strands from the second set 12 b , depending on the direction in which stretching occurs via ring rolling (i.e., in the MD and/or in the CD).
[0037] FIG. 3 is an enlarged plan view of a portion of the wipe 10 of FIG. 2 illustrating broken strands from the second set 12 b.
[0038] According to embodiments of the present invention, the formation of teeth 18 increases as the engagement of the ring rolls is increased. FIGS. 4A, 4B , 4 C, 4 D are respective side views that illustrate teeth formed via ring rolling. It is clear from FIGS. 4A-4D that the highest depth of engagement of the ring rolls produces the most teeth 18 . In FIG. 4A , the depth of engagement of the ring rolls is 0.010 inch. In FIG. 4B , the depth of engagement of the ring rolls is 0.020 inch. In FIG. 4C , the depth of engagement of the ring rolls is 0.030 inch. In FIG. 4D , the depth of engagement of the ring rolls is 0.040 inch. As depth of engagement of the ring rolls increases, the number of teeth produced increases.
[0039] Netting material, according to embodiments of the present invention, can be made from many base raw materials including, but not limited to, thermosetting and thermoplastic materials including, but not limited to, polyolefins, nylons, polyesters, and ethylene vinyl acetate, and the like and blends thereof. The netting material basis weight can range from 15 to 200 gsm with a boss count ranging in MD and CD directions from 3 strands/inch to 100 strands/inch. (Boss count is the number of strands per inch in a net). A preferred netting material is the DELNETยฎ brand net produced by Delstar Technologies Inc., Middletown, Del. However, other types of netting materials may be utilized, as well.
[0040] Netting materials can be attached to the surface of a substrate or can be embedded in the substrate. Netting materials can be bonded or stabilized in a variety of methods including chemically, thermally, ultrasonically and/or physically.
[0041] An alternative netting composite may be comprised of a ring rolled netting material, subsequently adhered to another substrate via adhesive lamination, thermal bonding, etc.
[0042] The netting material construction may have a soft side made of layers of nonwoven, woven, paper, film, foam or the like. The non-abrasive material may include an absorbent material such as rayon, pulp, super absorbent polymers, etc. to assist in wiping up spills and excess liquid. Alternately, a wipe may have an abrasive side on both surfaces of the wipe with a soft, spongy, or absorbent center material.
[0043] The soft side material, as well as the netting material, may be coated on one or both sides with a tackifying agent so as to enhance large particle/hair pick up capabilities of the wipe.
[0044] Additionally, according to some embodiments of the present invention, a wipe may be impregnated with cleaning solution, antiseptic, surfactant, antimicrobial, detergent, bleach, polish, facial cleanser, or any other active chemical ingredient.
[0045] According to some embodiments of the present invention, a wipe may be electrostatically charged to enhance dust and large particle pick-up capabilities. For example, either or both of the netting material and substrate may be electrostatically charged. An electrostatic charge may be applied to either or both of the netting material and substrate either before or after bonding the netting material to the substrate.
[0046] Substrate material to which netting material is bonded, according to embodiments of the present invention, may include, but is not limited to, woven material, knit material, netting material, nonwoven material, paper material, film material, sponge material and foam material. It is important that the material used as the support structure be stretchable, and have an โelongation at breakโ that is higher than the netting.
[0047] An exemplary wipe construction is a 1.5 osy polypropylene net (style number RO412-1 OPR) made by Delnet with a boss count of 40 strands/in the MD and of 13 strands/in in the CD direction that has been thermally bonded to 1 to 3 layers of 60 gsm 50% PP/50% Rayon spunlaced nonwoven fabric. The structure is then ring rolled at 0.030โณ depth of engagement. The net strand size in the MD direction is approximately 250 microns and the strand size in the CD direction is approximately 500 microns. Other possible constructions are listed in Table 1 below and can be combined with a or without tack finish, soap, detergent, cleaning solution, antiseptic, surfactant, antimicrobial, detergent, bleach, polish, facial cleanser. Structures can also be electrostatically charged to enhance hair pick up.
TABLE I Top Bottom Layer Mid layers Layers net Nonwoven net Film Nonwoven net nonwoven/flim airlaid nonwoven/flim net nonwoven/film paper nonwoven/film net nonwoven/flim foam nonwoven/film net Foam net Paper nonwoven/film net Airlaid nonwoven/flim net woven fabric net Sponge net Nonwoven Net net woven fabric Net
[0048] According to other embodiments of the present invention, the abrasiveness of spunbond netting material can be enhanced by stressing the fibers to break and cause them to stand up. This may occur with or without thermal bonding the spunbond netting material to another layer.
[0049] According to embodiments of the present invention, one method for forming breaks in netting material is to pass the netting material through the nip formed by an incremental stretching system or ring rolls employing opposed pressure applicators and having 3-dimensional surfaces which, at least to a degree, are complementary to one another. Stretching of the netting material may be accomplished by other methods known in the art including, but not limited to, tentering, bow rolls, or even by hand. However, to achieve even strain levels across structures, an incremental stretching system, such as disclosed herein, is preferred.
[0050] An exemplary ring roll incremental stretching system is illustrated in FIG. 5 and includes incremental stretching rollers 100 , 102 . The incremental stretching roller 100 includes a plurality of teeth 104 and corresponding grooves 106 which extend about the entire circumference of roller 100 . Incremental stretching roller 102 includes a plurality of teeth 108 and a plurality of corresponding grooves 110 . The teeth 104 on roller 100 intermesh with or engage the grooves 110 on roller 102 , while the teeth 108 on roller 102 intermesh with or engage the grooves 106 on roller 100 .
[0051] Referring to FIG. 6 , the degree to which the teeth 104 , 108 on the opposing rolls 100 , 102 intermesh is referred to herein as the โdepth of engagementโ or โDOEโ. The teeth in one roll can be offset by one-half pitch from the teeth in the other roll, such that the teeth of one roll mesh in the valley between the teeth in the mating roll. The offset permits intermeshing of the two rollers when the rollers are in operative position relative to one another. According to some embodiments, the teeth of the respective rollers are only partially intermeshing.
[0052] In the illustrated embodiment, the teeth 104 , 108 on each roller 100 , 102 are generally triangular-shaped, but may have various configurations. According to embodiments of the present invention, the apex of the teeth 104 , 108 may be slightly rounded, if desired for certain effects in the finished web. The โpitchโ refers to the difference between the apexes of the teeth 104 , 108 . The pitch may be between 0.02 to about 0.40 inches, and is preferably between about 0.05 and 0.20 inches. The height or depth of the teeth 104 , 108 is measured from the base of each tooth to the apex of each tooth, and is preferably equal for all teeth. The height of the teeth 104 , 108 may be between about 0.10 to 1.50 inch, and is preferably about 0.25 inches and 0.50 inches.
[0053] Ring rolling can be performed with MD ring rolls, CD ring rolls, alternating sections of ring rolls and no ring rolls, and alternating sections of MD and CD ring rolling. Interdigitating rolls are described in U.S. Pat. No. 4,368,565, which is incorporated herein by reference in its entirety. The incremental stretching of nonwoven to film laminates is described in U.S. Pat. No. 4,285,100 to Schwarz, which is incorporated herein by reference in its entirety.
[0054] Applications for embodiments of the present invention include multipurpose wipes (car wipes for paint preparation, kitchen and bathroom wipe, shop wipe, floor wipe, laundry wipe, grooved surface wiper, etc.); cosmetic wipes (wipes for exfoliation, a pumice stone alternative, alternative back scratcher, etc.); hooks (general hygiene area, floor wipe attachment, โfelt friendโ attachment, rug on rug skid prevention, disposable to semi-durable car mat, etc.). Embodiments of the present invention can be applied in garden and landscape areas as a tree wrap to deter deer/animals, as a garden vegetable wrap to deter bugs from climbing up stalks, as a landscape fabric in which the teeth would aid in holding mulch and prevent wood chips from moving away from a designated area. In pet areas, embodiments of the present invention can be used as a disposable scratching post as well as a cat mat in which to remove extraneous kitty litter off of cat paws and to retain litter near a litter box.
[0055] Other applications for embodiments of the present invention include non-skid rug pads for kitchen and hardwood floors, non-slip surfaces for chair pads and other upholstery items.
EXAMPLE 1
[0056] One layer of DELNETยฎ brand polypropylene netting material was thermally bonded to 2 layers of 60 gsm 50% polypropylene/50% Rayon spunlace. The structure was made using a thermal calendar containing one smooth roll and one roll engraved with an index pattern as illustrated in FIGS. 7A-7B . A sample was made at 410 psi, 100 ft/min, an engraved roll temperature of 270ยฐ F. and a smooth roll temperature of 340ยฐ F. The net was oriented toward the engraved roll where as the spunlace faced the smooth roll.
[0057] In an effort to decrease stiffness of the structure and enhance abrasiveness, the sample was run between a set of ring rolls. Structure abrasion was enhanced by netting strands in the CD direction that broke and stood on end to create a more abrasive surface.
[0058] The netting material was bonded to a PP spunbond/airlaid structure, to a bicomponent airlaid and to a PP spunbond-meltblown-spunbond (SMS) construction. This composite was ring rolled at 0.050โณ depth of engagement and 0.060โณ pitch to create the enhanced abrasion.
[0059] Base net structure was ring rolled at various depths of engagement from 0.010โณ to 0.070โณ. Throughout this application such samples will be described as CTx-033104c9 to indicate ring rolling to x/100โณ and base sample. For example, CT1-033104c9 is sample 033104c9 ring rolled 0.010โณ.
[0060] Net structures were also made using a diamond thermal bonding pattern. Breaking and raising of the teeth after ring rolling was also observed.
EXAMPLE 2
[0061] Abrasive net structures, according to embodiments of the present invention, were observed to have excellent large particle/hair pick-up capabilities, as compared with conventional wipes before the addition of an electrostatic charge.
[0062] A test method was developed to quantify the hair pickup characteristics of a ring-rolled net composite according to embodiments of the present invention. The composite was comprised of a 1.5 osy PP DELNETยฎ brand net, R0412-10PR, thermally bonded to two layers of 60 gsm PP/rayon [50/50] spunlace, using the index pattern. The composite was ring-rolled using laboratory equipment, using various depths of engagement (DOE). The DOEs included 0.010โณ, 0.020โณ, 0.030โณ, and 0.04โณ. The ring-rolled composites were cut to a sample size of 4โ
โณร5 3/16โณ. The following hair was used: New York Queen Collection, 100% human hair, top grade, supreme yaki, fine, straight hair.
[0063] Thirteen inch (13โณ) full length hair was separated and laid onto a metal lab bench. More hair was laid down than any of the test samples could pick up. Ring-rolled and non-ring-rolled samples were rubbed over the hair to determine how much each sample would hold. The hair-containing sample was lifted off the lab bench for ten seconds to let any loose hair fall back to the bench top. The hair that remained attached to the sample was pulled off and weighed. The test was repeated with different lengths of hair. The test was also performed using a full size Swifferยฎ Wet Jet pad that was dry. The following results set forth in Table 2 were generated:
TABLE 2 CT1- CT2- CT3- CT4- Swiffer 033104c9 033104c9 033104c9 033104c9 Hair Wet Jet 033104c9 DOE = DOE = DOE = DOE = Length Pad DOE = 0โณ 0.010โณ 0.020โณ 0.030โณ 0.040โณ [in] [grams] [grams] [grams] [grams] [grams] [grams] 0.25 0.06 0 0.6 0.6 1.3 1.8 1 0.23 0 0.6 0.4 0.9 1 3 0.04 0 0.2 0.4 0.8 1.2 6 0.02 0 0.6 0.5 1 1.1 13 0.02 0 0.3 0.3 0.3 0.5 Pad 11.5โณ ร 4โ
โณ ร 5 3/16โณ Size 5.5โณ Area 63.25 21.4 (in2)
The non-ring-rolled net did not pick up any amount of any length of hair. In general, as the ring-roll DOE increased, the amount of hair picked up increased due to the formation of teeth. As compared to the net composites in FIG. 8 , the current floor wipe pad performed poorly in terms of hair pick-up.
EXAMPLE 3
[0064] Net structures, according to embodiments of the present invention, were found to have excellent abrasion without damaging Teflon, paint and metal surfaces.
[0065] A test method was developed to quantify the level of abrasiveness that ring-rolling of the net composite created. A 6 station Nu Martindale Abrasion and Pilling Tester was used in the test. The non-ring-rolled composite, along with the ring-rolled composites (0.010, 0.020, 0.030, and 0.040โณ DOEs) were set up to abrade a 100% PP nonwoven, using 160 cycles and 9 kPa.
[0066] When the abrading was completed, it was observed that the PP nonwoven abraded with the non-ring-rolled composite had very few raised fibers. The nonwoven abraded with the 0.010โณ DOE ring-rolled composite had a small amount of raised fibers. The remaining samples had a significant amount of raised fibers, by visual inspection.
[0067] Table 3 illustrates the abrasion of the PP nonwoven by the abrasive samples, as measured by PP nonwoven weight loss after abrading.
TABLE 3 Ring- roll Abraded DOE material [in] [mg] 0 0 0.01 5.9 0.02 27.4 0.03 62.8 0.04 40.5
Abrasiveness versus ring roll DOE is illustrated in FIG. 9 . The PP nonwoven abraded with the non-ring-rolled sample did not lose any weight after abrading. The nonwoven abraded with ring-rolled samples had much more abrasion, shown by more weight loss. To the touch, the net composite ring-rolled at 0.040โณ DOE felt significantly more abrasive than the material ring-rolled at 0.030โณ DOE. At 0.040โณ DOE, the bond points in the example net construction began to weaken, causing the net to separate from the nonwoven. The weakening bond would lessen its effectiveness when abrading surfaces. With the improvement of bonding, the nonwoven exposed to the 0.040โณ DOE ring-rolled composite could have a higher value than the nonwoven exposed to the 0.030โณ DOE sample.
EXAMPLE 4
[0068] A ring-rolled net composite was tested for abrasive resiliency after weight exposure. A 4โ
โณ by 5 3/16โณ sample was placed on a lab bench under a 15 lbs weight for approximately 24 hours (0.7 psi). The sample felt just as abrasive after the weight was removed as it did before the weight was applied. This would be a good simulation to the force used to wipe floors, appliances, kitchenware and counters.
EXAMPLE 5
[0069] Along with abrasiveness and large particle pick up, drapability also improved with ring rolling. A 4โณ by 7โณ sample was cut in MD and CD and a Thwing Albert handleometer was used to test stiffness/drapability. As shown in the Table 4 below, stiffness decreased by 30% in the MD and 900% in the CD as ring rolling was increased to 0.040โณ.
TABLE 4 Handleometer measurements Ring-roll DOE MD CD [in] [g] [g] 0 151.4 82.1 0.01 151.5 50.9 0.02 151.5 41.7 0.03 141.4 38.5 0.04 116.9 9.2
[0070] The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to is be included therein.
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Wipes capable of picking up hair and other large particles, and methods of making same, are provided. A wipe includes a layer of netting material bonded to a substrate, and subsequently stretched via ring rolls such that strands of the netting material break and extend outwardly from the substrate to form teeth. The wipe may be impregnated with one or more chemical ingredients, such as cleaning solutions, soaps, antiseptics, surfactants, tackifying agents, antimicrobial agents, detergents, bleaches, polishes, and facial cleansers. The wipe may be electrostatically charged.
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CROSS REFERENCE TO CO-PENDING APPLICATION
[0001] This application claims the benefit of priority of provisional patent application Ser. No. 60/819,566 filed on Jul. 10, 2006, the entire contents of which are incorporated herein.
TECHNICAL FIELD
[0002] The present disclosure generally relates to heating and cooling systems and, more specifically, to those that either provide better comfort by minimizing hot and cold spots in the controlled environment and/or conserve energy usage of the HVAC system.
BACKGROUND
[0003] The design and construction of homes and other structures creates a condition whereby it is substantially difficult to provide even heating and cooling from room to room and, in some cases, within a particular room. Modern and legacy heating and cooling (HVAC) systems have never been designed to overcome the diversity of architectural design and the diversity of construction techniques both new and old. The resulting situation is one that leaves certain rooms either colder (cold spots) or warmer (hot spots) than what the home owners set at the thermostat. This is often times exacerbated by thermostats that are located in either a cold spot or a warm spot. This makes it problematic to achieve proper temperature control everywhere in the house or structure.
[0004] The HVAC industry provides few solutions to this dilemma. One such solution is a flow booster that consists of a fan that is mounted in-line to a particular duct. This fan increases flow of the heated or cooled air to a particular room when the main system blower fan is operating. This is an inexpensive solution that can be installed in a โdo-it-yourselfโ fashion; however, it often results in a particular room becoming over-cooled or over-heated as there is no thermostatic control of the booster fan. Another more costly solution is a multi-zone HVAC system. These systems usually consist of multiple furnaces and air conditioners. Typically, multiple units are installed as a result of heating and cooling capacity rather than to provide comfort or energy efficiency. Additionally, these HVAC systems and thermostatic control must be installed by a contractor and continue to provide potentially uneven heating and cooling control as each zone typically consists of multiple rooms.
[0005] Therefore, there is an unaddressed need for a product that provides room-to-room temperature control which provides whole house temperature consistency at an affordable price. Additionally, there is an unaddressed need for such system to be easily installed in a do-it-yourself fashion and for there to be an option to relocate the home's thermostat to a more suitable location for consistent temperature control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The various features, advantages and other uses of the present heating and cooling control apparatus will become more apparent by referring to the following detailed description and drawings in which:
[0007] FIG. 1 is a system diagram of a remote and relocated thermostat for a HVAC control system utilizing wireless communication means;
[0008] FIG. 2 is a system diagram of a remote and relocated thermostat for a HVAC control system utilizing hard wired communication means;
[0009] FIG. 3 is a system diagram of a remote and relocated thermostat based apparatus that utilizes two remote and relocated thermostats for a HVAC control system; one for a hot room and one for a cold room;
[0010] FIG. 4 is a system diagram of an aspect of the apparatus that utilizes three or more relocated thermostats for a HVAC control system;
[0011] FIG. 5 is a system logic diagram for a two room system in a heating mode;
[0012] FIG. 6 is a system logic diagram for a two room system in a cooling mode;
[0013] FIG. 7 is a system logic diagram for a three or more room system in a heating mode;
[0014] FIG. 8 is a system logic diagram for a three or more room system in a cooling mode;
[0015] FIG. 9 is a front view of a receiver for a two room system; and
[0016] FIG. 10 is a front view of a receiver for a three or more room system.
DETAILED DESCRIPTION
[0017] In addition to the drawings above, this description describes multiple aspects of a removed and relocated thermostat system as illustrated in the above referenced drawings. However, there is no intent to limit this disclosure to a single aspect onto the multiple aspects that are disclosed herein. On the contrary, the intent is to cover multiple alternatives, modifications, and equivalents included within the spirit and scope of this disclosure and as defined by the appended claims.
[0018] This disclosure describes several means for relocating an otherwise fixed thermostat location for a heating, ventilating, and cooling system (HVAC system). The apparatus allows an individual to relocate the central thermostatic control of a heating or cooling system to a room or location different from that where it was originally located in the structure. In some cases, the current location of the thermostatic control system is not desirous due to it being in a hot or cold zone of the structure. In one aspect, the Move-a-Thermostat apparatus consists of a receiver that is mounted in the location of the current thermostat and connected to the control wire that leads to the heating and cooling devices. Additionally, there is a transmitting thermostat that includes the main temperature selection control. This apparatus interacts with the receiver by hardwire or wireless means. This apparatus is illustrated in FIGS. 1 and 2 .
[0019] In another aspect, the apparatus provides for two transmitting thermostats to be located one in a typically warm room and one in a typically cold room. Both thermostats transmit to the single receiver which is to be placed in the location of the original, removed and replaced thermostat. The receiver allows the user to select one thermostat (room) or the other or to select both. If the user selects both, he/she is able to provide priority to one or the other by means of a dial or switch. This may also be administered by a programmable receiver unit. This apparatus is illustrated in FIGS. 3 , 4 , 5 , and 6 .
[0020] In another aspect, the apparatus provides for three or more transmitting thermostats to be located in any or all of the rooms of the environment. All of the thermostats transmit to the single receiver which is to be placed in the location of the original, removed and replaced thermostat. The receiver allows the user to select one, any two, or all of the thermostats to be active. If the user selects more than one, he/she can assign priority to each thermostat by means of a dial or switch. An algorithm determines whether heating or cooling should be called for. This may also be administered by a programmable receiver unit. This apparatus is illustrated in FIGS. 7 , 8 , 9 , and 10 .
[0021] Throughout the following description the term โroomโ will be understood to have its conventional meaning as well as to encompass an area or zone covering one or more rooms whose temperature is being controlled.
[0022] FIGS. 1 and 2 illustrate the basic system. In this system, the receiver 12 replaces the originally installed thermostat which is discarded and not employed in the system. A new remote thermostat 11 is then installed in a location that is desirous in terms of providing thermostatic data to achieve the user's objectives (energy efficiency, evenness of temperature throughout the dwelling, imperviousness to sunlight/open doors/etc.). The remote thermostat 11 transmits binary data (call for heating or not/call for cooling or not) to the receiver 12 by either wireless means 13 or by hardwired means 14 . The remote thermostat 11 may include a housing with a dial or digital display of a desired set temperature for the surrounding room, the existing temperature as sensed by a temperature sensor or thermocouple mounted in the thermostat housing, as well as a rotatable dial or input members, such as pushbuttons to allow the set temperature to be increased or decreased as desired by the user and/or to select heating, cooling, ventilation or off modes. The temperature sensor output can be used solely by the thermostat 11 in order to generate or cease the call for heating or cooling or the output may be transmitted by the thermostat 11 as part of the temperature related binary data signal.
[0023] The thermostat 11 may actually embody an existing type of thermostat with appropriate dials, digital display and pushbuttons with the addition of a transmitter for wireless operation and a processor which is capable of providing digital binary data to the transmitter specifying the set temperature and the sensed or existing temperature so as to create a demand or trigger signal for heating or cooling for the room. The processor or control circuitry mounted within the thermostat housing may also provide a thermostat I.D. to prevent miscommunication with other wireless devices in the room or other thermostats, as described hereafter, which may transmit temperature-related data to the single receiver 12 . The processor or control circuitry is capable of arranging the temperature-related digital data in the proper order or packet format required for a particular wireless or hardwired communication protocol.
[0024] The thermostat housing is capable of being mounted by various means, such as mechanical hangers or fasteners, double-backed tape, adhesive, etc., to a wall surface to enable the thermostat 11 to be located on any wall surface in a room and then moved to a different location if accurate temperature readings are not obtained.
[0025] If the receiver 12 receives a signal from the remote thermostat 11 to call for heating/cooling, the receiver 12 or a signal generator in the receiver 16 generates the appropriate signal and transmits this signal to the furnace/air conditioner 16 through the original wires that the old, removed and replaced thermostat used. If the remote thermostat 11 communicates to the receiver 12 by wireless means 13 , there are many known to those skilled in the art and include, but are not limited to, Bluetooth technology, RF communication, and infrared transmission. FIGS. 1 and 2 show that the remote thermostat 11 is powered by means of a battery power supply 15 . Those skilled in the art of thermostatic devices know that there are other powering means available such as hard wired systems, solar, and others.
[0026] FIGS. 3 , 4 , 5 , and 6 describe a two thermostat system. Typically, the two thermostat system is configured such that one remote thermostat 21 is located in a typically warm room and another remote thermostat 22 is located in a typically cold room. It will be understood that the terms โwarm room, โhot room,โ and โcold roomโ are used as relative temperature indications as the terms โhot roomโ and โcold roomโ may be only a few degrees different in temperature.
[0027] In terms of transmission of data, this system works in the same way that the single thermostat system does except that the transmitting thermostats 21 , 22 transmit not only the binary data for need for heating/cooling but also: 1) the actual temperature of its environment (T), and 2) the set and desired temperature (S). The receiver 27 receives this data and applies a logic sequence and algorithm to determine whether heating or cooling should be called for.
[0028] FIG. 6 shows the front panel of one design configuration of the receiver 27 for a two room system. This receiver 27 has buttons 30 and 31 . These buttons 30 and 31 , are for the user to make a selection. The user may select one or the other, or both of the remote thermostats 21 and 22 . If only the hot room is selected and the system is in heating mode, FIG. 4 , steps 102 through 105 , depict the logic and operation of the system for the heating mode. When the receiver 27 receives signal 104 from the hot room remote thermostat 21 , the receiver 27 calls for heating by generating and sending a signal 105 . There is a similar sequence of operations if only the cold room button 31 is selected; these are described in FIG. 4 , steps 106 through 109 . FIG. 5 also similarly depicts these same logic steps if the system is set to cooling mode. Alternatively, the user may decide to select both the hot room button 30 and the cold room button 31 . In this scenario, the priority dial 32 becomes active.
[0029] The priority dial 32 may be rotatable over a pre-set output range of values or magnitudes, such as 0.1 to 1.0 units over an approximate 300ยฐ range of rotation. Full left rotation of the priority dial 32 can cause the priority dial or associated circuitry, such as a potentiometer, to generate an appropriate signal equal to a low-priority i.e.; โ0.1โ, while a full rightward rotation of the priority dial 32 can generate a high-priority output i.e., โ1.0โ, for the selected hot room or cold room.
[0030] For example, when both the hot room and cold room buttons 30 and 31 are selected, the priority dial 32 may be rotated to the full right-most position to indicate 100% priority for the hot room control with respect to the cold room control. Alternately, one of the rooms, such as the hot room, for example, may be selected by the setting of the priority dial 32 as a percentage of the full range of motion or output magnitude of the priority dial 32 , i.e., 75% with the related magnitude or value being (25%) provided as the priority of the cold room. For example, with the priority dial 32 set at 75% towards the hot room thermostat settings and output receive priority over the related cold room settings on a factor of 3:1.
[0031] Further, separate priority dials 32 may be provided for each of the hot room and the cold room to provide individual priority settings between 0% and 100%.
[0032] The priority dial 32 allows the user to determine which thermostat 21 or 22 takes precedence and by how much it does so. Also in this scenario, steps 110 and 111 of FIG. 4 determine whether or not the receiver 27 calls for heating or, in steps 210 and 211 of FIG. 5 , for cooling. Steps 110 and 210 employ an algorithm based on data inputs (T, S, binary trigger (Tr) from the thermostats 21 , 22 and the position of the priority dial 32 ) to determine the action for heating or cooling. One version of this algorithm for heating mode 110 is as follows:
[0033] T h =Hot Room Temperature
[0034] T c =Cold Room Temperature
[0035] S h =Hot Room Set Temperature
[0036] S c =Cold Room Set Temperature
[0037] TR h =Trigger Hot Room Thermostat (1=call for heat, 0=not calling for heat)
[0038] TR c =Trigger Cold Room Thermostat (1=call for heat, 0=not calling for heat)
[0039] PD=Setting on the priority dial (0.1-1.0, 0.1 for cold/1 for hot)
[0000] ฮ h =S h โT h
[0000] ฮ c =S c โT c
[0040] IF (TR h =1 AND TR c =1) THEN Trigger for Heating, ELSE - - -
[0041] IF (TR h =0 AND TR c =0) THEN No Trigger, ELSE - - -
[0042] IF (ฮ h โง0 AND ฮ h โงPD*ฮ c ) THEN, Trigger for Heating, ELSE - - -
[0043] IF (ฮ h <0 AND |ฮ h |โงฮ c /PD) THEN, Trigger for Heating, ELSE No Trigger.
[0044] Similarly, one version of the algorithm for cooling mode 210 is as follows:
[0045] IF (TR h =1 AND TR c =1) THEN Trigger for Cooling, ELSE - - -
[0046] IF (TR h =0 AND TR c =0) THEN No Trigger, ELSE - - -
[0047] IF (ฮ h โฆ0 AND ฮ h โฆPD*ฮ c ) THEN, Trigger for Cooling, ELSE - - -
[0048] IF (ฮ h >0 AND ฮ h โง|ฮ c |/PD) THEN, Trigger for Cooling, ELSE No Trigger
[0049] Those skilled in the art of programming such devices understand that these algorithms and logic are just one version or example and describe a linear relationship between the position of the priority dial 32 and the outcome of the algorithm. Many other versions are possible including, but not limited to, non-linear relationships, such as logarithmic, exponential, quadratic and others.
[0050] FIGS. 7 , 8 , 9 , and 10 depict a system with two or more or a plurality of thermostats 41 , 42 , and 43 ; with a three-thermostat system being shown only for simplicity. In terms of the transmission of data, this system works in every way that the two thermostat system does.
[0051] FIG. 10 shows the front panel of one example of a design configuration of the receiver 50 for a three room system. This receiver 50 has buttons 44 , 45 and 46 . These buttons 44 , 45 and 46 , are for the user to make a selection. The user may select any one, any combination of two, or all of the thermostats 44 , 45 , and 46 . If only the one room with one thermostat 44 , 45 , or 46 is selected and the system is in heating mode, FIG. 8 , steps 302 through 305 , depict the logic and operation of the system for the heating mode. If the receiver 50 is receiving signal 304 from the active room remote thermostat 41 in room 44 , the receiver 50 calls for heating by generating and sending a signal 305 . FIG. 9 also similarly depicts these same logic steps if the system is set to cooling mode.
[0052] Alternatively, the user may decide to select two or more thermostats to be active. In this scenario, priority dials 47 , 48 , or 49 become active. The priority dials 47 , 48 , 49 allow the user to determine which thermostat 41 , 42 , or 43 takes precedence and by how much it does so. The priority dials 47 , 48 and 49 operate in the same manner as the priority dial 32 in that each is rotatable over a maximum range of rotation, such as 300ยฐ and by itself or in combination with suitable circuitry, generates an output signal ranging between 0.1% for a full left rotation of any of the dials 47 , 48 , and 49 up to 100% of maximum output value at a full right rotation position of any of the dials, 47 , 48 and 49 , by example.
[0053] In this manner, any one or any combination of two or all of the priority dials 47 , 48 , and 49 may be made active when any one or combination of two or all three of the room buttons 44 , 45 , and 46 are depressed. Any of the dials 47 , 48 , and 49 can be set by the user at position corresponding to an output value between 0 and 100 to determine the priority of control provided by the associated thermostat.
[0054] Also in this scenario, steps 306 and 307 of FIG. 8 determine whether or not the receiver 50 calls for heating or for cooling by steps 406 and 407 of FIG. 9 . Steps 306 and 406 employ an algorithm based on data inputs (T, S, binary trigger (Tr) from the thermostats 41 , 42 and 43 , and the position of the priority dials 47 , 48 , and 49 ) to determine the action for heating or cooling. One version of this algorithm for heating mode 306 is as follows:
[0055] Definitions same as above
[0056] PS=Priority Setting
[0057] PD 1 =Priority Dial Setting Thermostat 1 (1-100)
[0058] PD 2 โPriority Dial Setting Thermostat 2 (1-100)
[0059] PD 3 =Priority Dial Setting Thermostat 3 (1-100)
[0000]
PD
1
=PD
1
+PD
2
+PD
3
[0000] PS 1 =( PD 1 /PD t )*100 (for purposes of simplifying the algorithm, this is assigned to the PS of the highest value)
[0000] PS 2 =( PD 2 /PD t )*100 (as above, this is assigned to the PS with the middle value)
[0000] PS 3 =( PD 3 /PD t )*100 (as above, this is assigned to the PS with the lowest value)
[0000]
F
1
=PS
2
/PS
1
[0000]
F
2
=PS
3
/PS
1
[0000]
F
2
=PS
3
/PS
2
[0060] IF (TR 1 =1 AND TR 2 =1 AND TR 3 =1) THEN Trigger for Heating, ELSE - - - IF (TR 1 =0 AND TR 2 =0 AND TR 3 =0) THEN No Trigger, ELSE - - -
[0061] IF (ฮ 1 โง0 AND ฮ 2 โง0 AND (ฮ 1 โงF 1 *ฮ 2 OR ฮ 1 โงF 2 *ฮ 3 OR ฮ 2 โง 3 *ฮ 3 ) THEN, Trigger for Heating, ELSE - - -
[0062] IF (ฮ 1 <0 AND ฮ 2 <0 AND (|ฮ 1 |โงฮ 2 /F 1 OR |ฮ 1 |โงฮ 3 /F 2 OR |ฮ 2 |โงฮ 3 /F 3 ) THEN, Trigger for Heating, ELSE No Trigger.
[0063] Similarly one version of the algorithm for cooling mode 406 , is the following:
[0064] IF (TR 1 =1 AND TR 2 =1 AND TR 3 =1) THEN Trigger for Cooling, ELSE - - -
[0065] IF (TR 1 =0 AND TR 2 =0 AND TR 3 =0) THEN No Trigger, ELSE - - -
[0066] IF (ฮ 1 โฆ0 AND ฮ 2 โฆ0 AND (ฮ 1 =F 1 *ฮ 2 OR ฮ 1 โฆF 2 *ฮ 3 OR ฮ 2 โฆF 3 *ฮ 3 ) THEN, Trigger for Cooling, ELSE - - -
[0067] IF (ฮ 1 >0 AND ฮ 2 <0 AND (ฮ 1 โง|A 2 |/F 1 OR ฮ 1 โง|ฮ 3 |/F 2 OR ฮ 2 โงฮ 3 /F 3 ) THEN, Trigger for Cooling, ELSE No Trigger.
[0068] Those skilled in the art of programming such devices understand that these algorithms and logic are just one version or example and describe a linear relationship between the position of the priority dials 47 , 48 and 49 and the outcome of the algorithm. Many other versions are possible including, but not limited to, non-linear relationships, such as logarithmic, exponential, quadratic and others.
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A method and system for easily relocating a thermostat for a heating and/or cooling system is used to enable a more suitable location for the efficient control of heating or cooling. The thermostat system utilizes a selectively placable transmitting thermostat that communicates with a receiver that is installed in place of the original, removed thermostat and connects by the existing original thermostat wiring to the HVAC units. In another aspect, multiple transmitting thermostats communicate with a single receiver which accepts thermostatic and other data. The receiver is configured to allow the user to select which one or more of the thermostats are made active. If multiple thermostats are activated, the user can select the priority assigned to each.
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CROSS-REFERENCE TO RELATED INVENTIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/329,404, filed Jan. 10, 2006, which is a continuation-in-part of U.S. application Ser. No. 11/177,009, filed Jul. 7, 2005, the disclosures of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to fall protection devices and systems which are attached to roofs or other structures under construction. More particularly, this invention relates to fall protection devices and systems which are mounted on trusses or rafters of structures under construction or to the roofs of existing structures. This invention also relates to fall protection devices and systems for above-ground floors or decks under construction.
[0004] 2. Description of the Background Art
[0005] The Occupational Safety and Health Act mandates that every trade who must build or stand on a roof surface should have fall protection. At the very minimum a slide guard should be in place to protect the worker. The minimum slide guard is described as a two by four nominal dimension member secured on its edge to the roof below the worker to arrest his possible slide. Many trades must stand on a sloped roof to accomplish their work. Tradesmen include framing carpenters and roofers. For multi-storied structures, other tradesmen may include window installers, house wrap installers, siding installers, exterior trim carpenters, soffit installers, lathers and stucco crews.
[0006] In practice, the framing carpenter installs a slide guard on the roof surface, but it is often promptly removed when the framing is finished since it becomes an obstacle to some subsequent trades. Moreover, the guards are seldom replaced. There therefore exists a need to overcome the shortcomings of conventional fall protection devices.
[0007] Prior art fall protection devices include stanchions which attach to a truss below the roof line and to the fascia to dip down below the fascia and then up above the roof. Thus, the prior art cannot be employed in buildings designed with no fascia. Further, even though the buildings are designed with fascia, damage may occur where the fascia is the finished product. Still further, where the roofing requires a metal eave drip to the fascia to be installed before roofing, the connection to the fascia may have to be removed, thus rendering the prior art inoperable. Finally, the prior art cannot be properly attached until the fascia is constructed. Hence, there has existed a need for a fall protection device that does not require a mechanical attachment to fascia.
[0008] Representative prior art include U.S. Pat. Nos. 6,345,689; 5,221,076; 5,353,891; 5,573,227; 5,570,559; 4,666,131; 5,067,586; 4,669,577; 3,901,481; and 4,359,851.
[0009] Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the fall protection art.
[0010] Another object of this invention is to provide a fall protection system that attaches to a roof truss at a single point in such a manner as to extend below the fascia and return up above the roof surface such that the carpenters may attach the stanchions prior to hoisting the trusses onto the roof-bearing walls, or immediately thereafter, and then install the guardrails such that the workers are protected throughout the entire construction process.
[0011] Another object of this invention is to provide a fall protection system having various constructions for connecting the J-shaped stanchions to a roof truss, optionally including a separate attachment bracket that may be pre-installed onto the truss during fabrication of the truss at the factory to which the J-shaped stanchion is then removably connected during assembly on the job site.
[0012] Another object of this invention is to provide a fall protection system which is economical to manufacture while supporting the minimum impact of two hundred pounds (200 lbs.) required by OSHA for a slide guard or guard rail.
[0013] Another object of this invention is to provide a fall protection system including a J-shaped stanchion that is extendible to allow additional rows of guard rails to be installed.
[0014] Another object of this invention is to provide a fall protection system for reroofing a structure.
[0015] Another object of this invention is to provide a combination fall protection/catwalk system along the edge of a structure such as an above-ground floor.
[0016] The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
[0017] For the purpose of summarizing this invention, one embodiment of this invention comprises a fall protection system including a J-shaped stanchion which attaches to a roof truss (or rafter) in such a manner as to enable the entire girth of the roof truss overhang (or rafter) to be the sole support for the stanchion. The J-shaped stanchion is designed to exceed the 200 pound minimum impact currently required by OSHA for a slide guard or guardrail. The J shape of the stanchion is configured to extend below the fascia and return up above the roof surface. During assembly, a plurality of stanchions is attached along the roof line. Horizontal fall protection guardrails are then connected to the upstanding stanchions thereby providing fall protection for workers. Notably, the single point of attachment to the trusses along the roof line allows the carpenters to attach the stanchions prior to hoisting the trusses onto the roof bearing walls. As soon as the trusses are properly braced, the guardrails can be hoisted and installed. Furthermore, the trusses may optionally be fabricated with a separate attachment bracket to which the J-shaped stanchion is removably connected. This feature of the preferred embodiment has the potential of protecting workers during the entire construction process of the structure which involves working on the roof. When all workers are safely off the roof, the stanchions may be easily removed and reused.
[0018] Another embodiment of this invention comprises a truss plate affixed to the upper surface of a roof being reroofed, allowing the J-shaped stanchion to then removably attached to the truss plate.
[0019] Another embodiment of this invention comprises a catwalk bracket affixed to the wall of a structure, to support a catwalk plank and the J-shaped stanchion
[0020] The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
[0022] FIG. 1 is a perspective view of the fall protection system of the invention including a J-shaped stanchion guardrail member and attachment bracket;
[0023] FIG. 2 is a side view of FIG. 1 attached to a truss of a building with a square cut fascia;
[0024] FIG. 3 is a side view of FIG. 1 attached to a truss of a building with a plumb cut fascia;
[0025] FIG. 4 is a perspective view of three stanchion guardrail members shown in FIG. 1 attached to the trusses of a building with the horizontal guardrail installed;
[0026] FIG. 5 is a perspective view of another embodiment of a the fall protection system of the invention with a removable extended stanchion;
[0027] FIG. 6 is a perspective view of another embodiment of the fall protection system of the invention with a permanent extended stanchion;
[0028] FIG. 7 is a perspective view of a lock bracket that may be employed in combination with the fall protection system of the invention to more securely lock the attachment bracket to the truss;
[0029] FIG. 8 is a perspective view of the fall protection system of the invention shown in phantom with the lock bracket mounted in position on the attachment bracket for locking the attachment bracket into position with the truss;
[0030] FIG. 9 is a side elevational view of another embodiment of the invention employing another type of coupler allowing a stanchion extension composed of a plank to be connected to the end of the stanchion; and
[0031] FIG. 10 is a perspective view of another embodiment of the fall protection system of the invention having an attachment bracket composed of a center web with a multiplicity of punched barbs extending therefrom (preferably on both sides), that dig into the truss when the attachment bracket is installed;
[0032] FIG. 11 is a perspective view of another embodiment of the fall protection system of the invention having an attachment bracket with pointed upper members to facilitate insertion between the rafter and the already-installed plywood;
[0033] FIG. 12 is a perspective view of another embodiment of the invention in which the attachment bracket is removably connected to the J-shaped stanchion allowing the attachment bracket to be first installed to the truss, the truss erected, and the J-shaped stanchion connected thereto;
[0034] FIG. 13 is a perspective view of an attachment bracket of another embodiment of the fall protection system of the invention having a multiplicity of barbs formed in its center web for connection to the truss;
[0035] FIG. 14 is a perspective view of an attachment bracket of another embodiment of the fall protection system of the invention particularly designed to be pre-installed at the during factory fabrication of the truss;
[0036] FIG. 15 is a perspective view of a J-shaped member employed as a support for another device such as a satellite dish;
[0037] FIG. 16 is a perspective view of a J-shaped member having a hook at its end which may be employed for supporting objects such as Christmas ornaments, plants, etc.;
[0038] FIG. 17 is a perspective view of a J-shaped member having an upstanding member serving as a flag pole;
[0039] FIG. 18 is a side view of a J-shaped member which may be employed as a support for an object such as a basketball hoop;
[0040] FIG. 19 is a top perspective view of a roof truss bracket that is intended to be nailed on the roof to be reroofed;
[0041] FIG. 20 is bottom perspective view of FIG. 19 ;
[0042] FIG. 21 is a perspective view of a J-shaped stanchion having a J-shaped truss attachment bracket with a T-bar that removably engages into the roof truss bracket.
[0043] FIG. 22 is a cross-sectional view of the roof truss bracket and J-shaped truss attachment bracket removably assembled together;
[0044] FIGS. 23A&B are a top perspective views of a combination fall protection/catwalk bracket that is intended to be nailed to the wall of the above-ground floor and tied to the floor by a tie strap, to which a catwalk plank may then be mounted thereon and to which the J-shaped stanchion may then be removably connected;
[0045] FIGS. 24A&B are bottom perspective views of FIG. 23 ;
[0046] FIG. 25 is an exploded perspective view of the combination fall protection/catwalk bracket being affixed to the wall of the structure;
[0047] FIG. 26 is a perspective view of the J-shaped stanchion having an attachment bracket for connection to the combination fall protection/catwalk bracket;
[0048] FIG. 27 is an exploded perspective view of the attachment bracket of the J-shaped stanchion being connected to the combination fall protection/catwalk bracket;
[0049] FIG. 28 is a perspective view of a pair of J-shaped stanchions affixed to the wall of an above-ground floor showing the manner in which the catwalk plank is inserted into position on top of the upper plate and under the edge plate of the combination fall protection/catwalk bracket; and
[0050] FIG. 29 is a perspective view of the assembled combination fall protection/catwalk system of the inventions with the guard rails installed.
[0051] Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] Referring to the drawing of FIG. 1 , a J-shaped stanchion 1 includes a truss attachment bracket 2 in a preferred J shape comprised of center web 2 C to which an upper rear flange 2 A, upper front flange 2 B and lower flange 2 D, formed of flat stock steel are secured by weld 16 . The J-shaped formed of square stock tubing and bent 180 degrees is preferably affixed to the lower flange 2 D by weld 16 . Also preferably, two slide arrest guardrail brackets 3 , formed of flat stock steel and bent so as to accept a nominal 2โฒ.times.4โณ plank (or higher) horizontal slide arrest guardrail 5 (see FIG. 4 ) is affixed to the stanchion 1 by weld 16 on the upper portion thereof above the roof line at its side 17 to face roof-ward.
[0053] Referring next to FIG. 2 , the stanchion 1 and the attachment bracket 2 are shown mounted to a structure or building 15 with square cut fascia 6 . The attachment bracket 2 is preferably fastened by nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent to either side of the truss 11 . Where nails, bolts, screws, bolts, and their fastener equivalents are used to secure the attachment bracket 2 to the roof truss 11 , they are inserted through the orifices 4 in the center web 2 C of the attachment bracket 2 and into the adjacent truss 11 .
[0054] Stanchions 1 are respectively installed on respective roof trusses 11 along the horizontal roof edge 18 . The strength of this attachment is due to the envelopment of the roof truss 11 between the upper rear flange of attachment bracket 2 A, the upper front flange of attachment bracket 2 B and the lower flange of attachment bracket 2 D adjacent the center web 2 C causing the entire truss 11 to react as one with stanchion 1 on impact. The lower portion of the stanchion 1 is bent 180 degrees from its end 17 such that the guardrail brackets 3 are perpendicular to the plane of the roof regardless of the roof pitch.
[0055] Referring next to FIG. 3 , the stanchion 1 and the attachment bracket 2 are shown mounted to a structure or building 15 with plumb cut fascia 6 . Note that the J shape of the stanchion 1 provides adequate clearance for the fascia 6 .
[0056] Referring next to FIG. 4 , the stanchions 1 are installed along horizontal roof edge 18 and then the guardrails 5 are installed into the respective guardrail brackets 3 . As shown, when two stacked guardrail brackets 3 are employed on the stanchion 1 , the guardrails 5 overlap adjacent guardrails 5 at their ends.
[0057] Referring next to FIG. 5 , the stanchion 1 is extendable by a removable stanchion extension 1 A coupled to the stanchion by a coupler 20 . Guardrail brackets 19 , similar in construction to brackets 3 , comprise flat stock steel bent so as to accept a nominal 2.times.4 plank (or higher) slide arrest guardrail 5 (see FIG. 4 ), and are welded 16 to the upper portions of the extension 1 A to face roof-ward.
[0058] FIG. 6 illustrates an alternative embodiment of the invention illustrated in FIG. 5 in which the stanchion extension 1 A is integrally formed with the stanchion 1 .
[0059] Referring now to FIG. 7 , the invention also comprises a lock bracket 21 composed of a strip of steel bent in a generally L-shaped configuration. The shorter leg 21 A of the L-shaped configuration comprises an inwardly turned end 22 that defines space 23 between it and the balance of the shorter leg 21 A.
[0060] As shown in FIG. 8 , the lock bracket 21 is dimensioned to be installed after the attachment bracket 2 is mounted to the truss 11 whereby the lock bracket 21 more securely holds the attachment bracket 2 in position. More particularly, as shown in FIG. 8 , once the attachment bracket 2 is affixed to the end of the truss 11 with, for example, nails through orifices 4 , the space 23 of the lock bracket 21 allows it to be slid onto the lower flange 2 D from the inward side of the mounting bracket 2 to the underside of the lower flange 2 D with the end 22 overlapping one side thereof When slid downwardly to meet the stanchion 1 , the 2.times.6 plank of the truss 11 is captured between the web member 2 C and the longer side 21 B of the L shape of the lock bracket 21 . The lock bracket 21 fully captures the truss 11 to prevent any loosening of the fasteners that secure the attachment bracket 2 to the truss 11 .
[0061] Referring now to FIG. 9 , in lieu of the stanchion extension 1 A previously described above, another type of extension may comprise a wood plank 25 such as a 2.times.4 plank which is coupled to the end of the stanchion 1 by a tubular coupler 26 that conforms at its one end to the outer circumference of a nominal sized plank 25 and its other end to the upper end of the stanchion 1 . As shown in FIG. 9 , the horizontal guardrails 5 may be connected to the stanchion extension 25 by conventional nailing 27 or other techniques for fastening wood components.
[0062] The operation of the preferred embodiment of the invention is as follows. Referring to FIG. 3 , the stanchion 1 is attached only to the rafter, roof truss, or roof member 11 and is attached up to two inches from horizontal roof edge 18 . The attachment bracket 2 is comprised of the upper rear flange 2 A, the upper front flange 2 B, the securing plate 2 C, and the lower flange 2 D. Working in concert with its comprised parts, the attachment bracket 2 , envelopes the girth of rafter, roof truss, or roof member 11 , and once stanchion 1 is attached at securing plate 2 C, by means of nailing, and or screwing, welding, strapping, gluing, bolting, or any known equivalent, no additional points of attachment are necessary. Since this is the only necessary connection to the rafter, roof truss, or roof member 11 , it becomes evident that the ideal location for this connection is on the ground before the rafter, roof truss, or roof member 11 is hoisted onto the wall 14 . Ground level installation has many advantages. The installation can be more precise, is easy to install, and due to the firm footing of ground level installation, the occurrences of injury from heights (ladders, scaffolding, lift equipment, etc.) is eliminated. Lock bracket 21 may be installed while still on the ground or after the trusses are hoisted and seated on the wall 14 .
[0063] The lock bracket 21 may be tethered to the attachment bracket 2 by a chain or other member to minimize the possibility of it being lost and inadvertently not used. Furthermore, to assure that the lock bracket 21 may not slide off, a headed stop pin 24 may be inserted into a hole in the lower plate 2 D to block the lock bracket 21 from being removed. The stop pin 24 may likewise be tethered to the attachment bracket 2 to prevent inadvertent loss or nonuse.
[0064] Ground level installation of the fall protection device stanchion 1 greatly reduces the work time involved in assembly, and allows the system to be substantially assembled prior to the workman being in peril Immediately after the rafter, roof truss, or roof member 11 is hoisted onto structure 15 , the horizontal slide arrest guardrail 5 can be hoisted up and secured. Therefore, fall protection can be in position prior to the installation of the first sheathing/roof decking and if used until all roof operations are complete, it will provide the absolute time maximum uninterrupted fall guard protection possible.
[0065] The process of ground level installation, although preferred, does not limit the attachment of the fall protection stanchion 1 in other situations, such as existing structures, or in conventional framing, i.e., framing in which the construction of the structure must be built in the field, on the job site, such as hips, dormers, or any other roof or balcony configuration as is known to one of ordinary skill in the art. Such alternative attachments may require the use of additional equipment (ladders, scaffolding, lift equipment, etc.).
[0066] Optional dimensions of attachment bracket 2 are available to accommodate other nominal sizes of rafters, roof trusses, roof members 11 , or for any architecturally specified size rafter, roof truss, or roof member 11 .
[0067] Once stanchion 1 is properly attached to the rafter, roof truss, or roof member 11 , and the rafter, roof truss, or roof member 11 is properly affixed to building 15 and the slide arrest guardrails 5 are installed, a continuous barrier around the perimeter of the roof is formed. Such guardrails 5 may be composed of a nominal 2.times.4 or greater wood plank, a metal member, a crossbar, a rope, a strap, mesh netting or any known equivalent. The slide arrest guardrail 5 may be strung or inserted through the slide arrest guard bracket 3 and may be optionally fixed in place by means of nailing, screwing, welding, strapping, gluing, or bolting the strap to the bracket 3 , such nails, screws, bolts and equivalents, passing through the orifices 4 in the bracket 3 .
[0068] The stanchions 1 are secured to adjacent manufactured rafter, roof trusses or roof member 11 at horizontal roof edge 18 , they extend down below the fascia 6 location and up above the horizontal roof edge 18 where the 2.times.4 wood plank, metal member, crossbar, mesh netting or any known equivalent, horizontal slide arrest guardrail 5 is attached to the guard rail bracket 3 by means of nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent and thus becomes the barrier which a sliding workman would contact thus preventing the workman from sliding off of the roof.
[0069] This fall protection device stanchion 1 attaches directly to the truss tail, and does not touch the fascia 6 ; therefore there is no interference with the process of snapping a line from the first rafter, roof truss, or roof member 11 , to the last rafter, roof truss, or roof member 11 , for the purpose of determining which horizontal roof edges 18 , do not line up. At this point the roof edge 18 can be saw cut straight for a square cut 6 , or plumb cut 6 , fascia without interference from the fall protection device stanchion 1 , thus allowing the attachment of the fascia 6 . Due to the encompassing features of the attachment bracket 2 , fascia optional architecture (open design with no fascia) still allows continuous fall protection for workman.
[0070] The continuous row of the J shaped stanchions 1 mounted along the horizontal roof edge 18 , allows a useful area in their inner radii for the temporary support of long stock materials, (i.e., fascia stock material or sub fascia stock material) thus providing a safer environment for the installation of the fascia 6 . Once the fascia 6 is attached and horizontal slide arrest guardrail 5 is properly fastened by nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent; the sheathing process may begin. Therefore the safety of workers is enhanced even before stanchion 1 begins providing fall protection.
[0071] Depending on the pitch and or overall size of a roof, OSHA requires additional slide guards at specific intervals going up the roof. As the sheathing or roofing progresses the stanchion 1 can be used as a brace against which a grid of additional 2.times.4 supports and slide guards can be constructed with minimal or no penetration of the roofing surface.
[0072] The fall protection device stanchion 1 remains attached to the rafter, roof truss, or roof member 11 thus allowing all trades which may have to work on the roof surface, such as framers, roofers, plumbers, HVAC, electricians, window installers, siding installers, soffit installers, etc. to complete all work necessary while assuring continuous fall protection for all workman.
[0073] The attachment bracket 2 encompasses the rafter, roof truss, or roof member overhang 11 , in such a manner as to allow the girth of the rafter, roof truss, or roof member 11 to support the fall protection device stanchion 1 . This strong connection is suitable for attachment of additional devices such as stanchion extensions with additional guard rails, proprietary or others, and may be fastened by means of nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent.
[0074] The fall protection device stanchion 1 attaches only to the rafter, roof truss, or roof member 11 and therefore does not interfere with the exterior finishes such as siding, lath, stucco, paint, trim, or other exterior claddings.
[0075] The fall protection stanchion 1 becomes suitable for additional devices such as bracket arm extensions 21 with additional nets, rope, cables, straps or any known equivalents. Additional ropes, cables, straps, harnesses or any known equivalent may be attached tied, strapped, clamped or any known equivalent to the fall protection stanchion 1 or harness ropes may be placed over the crown of the roof to a stanchion on the opposing side for support of the workers on the roof.
[0076] The fall protection stanchion 1 can be used to support any number of other devices such as Jacob's ladders, swings, swinging scaffolds, roof jacks, safety harnesses (for workman and materials) ropes, pulleys, beams, and cables upon which to hang lights, drapes or any known equivalent.
[0077] The attachment bracket 2 is preferably double-sided and can be used on either side of any given roof truss, rafter, or roof member 11 . Furthermore, the fall protection system is economical, has little or no moving parts, is sturdy, requires nominal if any maintenance, and provides value far beyond the cost to build install and maintain. Lastly, the device easily and safely removed and is fully reusable.
[0078] Referring now to FIG. 10 , as noted above, the attachment bracket 2 may be affixed to the end of the truss 11 by any suitable means. As shown in FIG. 10 , one method may comprise forming a multiplicity of barbs 30 in the center web 2 C, preferably extending on both surfaces thereof to engage into the surface of the truss 11 during assembly. Due to the engagement of the barbs 30 into the wood of the truss 11 , the attachment bracket 2 is firmly secured to the truss 11 .
[0079] It is noted that in some applications, it may be desirable to have the J-shaped stanchion removably connected to the attachment bracket 2 . For example, as shown in FIG. 12 , the attachment bracket 12 may comprise a boss 34 formed on the underside of the lower flange 2 D which comprises a configuration and is properly dimensioned to fit into the tubular stanchion 1 . Aligned holes 36 and 38 formed in the stanchion 1 and the boss 34 allows a fastener 40 to be inserted therethrough to removably interconnect the bracket 2 to the stanchion 1 . During installation, the attachment bracket 2 may be installed to the end of the truss 11 whereupon the truss may then be hoisted onto the wall and, once secured; the stanchion 1 may then be connected to the bracket 2 by means of the boss 34 and fastener 40 . The removability of the stanchion 1 from the bracket 2 allows more convenient installation and erection of the fall protection system of the invention.
[0080] FIG. 13 illustrates still another method for attaching the attachment bracket 2 to the end of a truss 11 . More specifically, a plurality of barbs 30 are punched into the center web 2 C so as to engage into the wood of the truss 11 as described previously in connection with FIG. 10 . The embodiment of FIG. 13 , however, comprises a one-sided bracket, as opposed to the double-sided brackets described above. This one-sided bracket 2 is particularly adaptable to be installed at a truss factory during the fabrication of the truss itself. Indeed, it is contemplated that brackets 2 would be customarily installed at the fabrication plant during fabrication of the trusses whereupon, on the job site, the trusses would be erected onto the walls and the stanchions 11 then connected to the brackets by means of the removable connection composed of the boss 34 and fastener 40 that engages through hole 38 .
[0081] FIG. 14 illustrates still another embodiment of a one-sided bracket 2 intended to be factory-installed during fabrication of the trusses. More particularly, in this embodiment, in lieu of the center web 2 C, the bracket 2 includes two upstanding webs 2 W, each having inwardly facing barbs 30 . During assembly, the truss 11 is placed within the U-shaped channel formed by the lower flange 2 D and the upstanding flanges 2 W whereupon the barbs 30 of the upstanding flanges 2 W are then pressed into the wood of the truss 11 for assuring a secure connection.
[0082] As noted above, the attachment bracket 2 may be factory-installed or installed on the job site. In either case, the attachment bracket 2 with a removable connection may be used as a way of removably connecting modified stanchion members 42 to the attachment bracket 2 via the boss 34 and fastener 40 that engages into corresponding holes 36 and 38 . More particularly, as shown in FIG. 15 , the stanchion member 42 may comprise a support for a satellite dish 44 . In FIG. 16 , it is seen that the stanchion member 42 may be provided with an ornament hook 46 for connecting Christmas ornaments, plants, or any other object along the roof line of the structure. Indeed, the hook 46 with its bracket 46 B may be directly connected to the boss 34 . In FIG. 17 , it is seen that the stanchion member 42 may be fitted with a flag pole 48 for supporting a flag, pennant or other object 50 . Finally, FIG. 18 illustrates a stanchion member 42 having an elongated length to which is mounted a conventional basketball assembly 52 having a backboard 52 rigidly connected to the stanchion member 42 by brackets 54 .
[0083] Without departing from the spirit and scope of the invention it should be appreciated that FIGS. 15 through 18 are exemplary and that stanchion member 42 may be used to support many other objects along the roof line of a structure.
[0084] It is noted that in re-roofing applications, the roofing plywood is already nailed to the trusses 11 and therefore, it would be difficult to force the upper rear and front flanges 2 A and 2 B therebetween. Accordingly, in order to facilitate forcing the flanges 2 A and 2 B between the roofing plywood and the truss 11 , as shown in FIG. 11 , the ends of the upper rear and front flanges 2 A and 2 B may comprise points 32 and be beveled. In this manner, the points 32 along with their bevels form a web shape that can be more easily driven between the roofing plywood and the truss 11 .
[0085] Referring now to FIGS. 19-22 , another embodiment of the fall protection system 100 of the invention is designed for reroofing applications. More particularly, in typical reroofing applications the existing shingles (e.g., asphalt or concrete shingles) are removed. Likewise, the underlayment (e.g., felt underlayment) is removed; thereby leaving exposed the plywood roof. Any damaged plywood may be replaced with new sheets of plywood. Flashing/drip edges along the roof's edges are commonly left in place and reused (although any damaged flashing or drip edges may likewise be removed and replaced). New shingles are then installed.
[0086] It should be appreciated that fall hazards exist during reroofing applications. In order to minimize such hazards, the fall protection system 100 of the invention may be installed before the reroofing process begins.
[0087] More specifically, the fall protection system 100 comprises a roof truss plate 110 preferably having a generally elongated rectangular plate 112 (e.g., steel) and having opposing transverse members 114 welded to the end of the elongated rectangular plate 110 . A bottom plate 116 interconnects the opposing transverse members 114 to form an opened box construction.
[0088] The open box construction forms a rectangular socket for removably receiving a corresponding T-bar 120 welded to a J-shaped bracket 122 formed at the lower end of a stanchion 124 .
[0089] During installation, the existing roof shingles along the edge 128 of the roof 130 are peeled back (or removed altogether) allowing elongated rectangular plates 112 to be installed along the roof edge 128 in a generally spaced-apart configuration. More specifically, each of the elongated rectangular plates 112 is aligned down the roof line with the opposing transverse members 114 extending over the edge 128 of the roof 130 (and over the roof's drip edge 131 ). Each of the elongated rectangular plates 112 includes a plurality of holes 132 allowing the roof truss plate 110 to then be nailed to and therefore permanently affixed to the plywood of the roof 130 .
[0090] After the plurality of the roof truss plates 110 are affixed along the edge 128 of the roof 130 , the T-bar 120 of the J-shaped bracket 122 may be slipped sideways into the end of the box enclosure formed by the end of the elongated rectangular plate 112 , opposing transverse members 114 and bottom plate 116 , whereupon the stanchion 124 is prevented from tilting in any direction and is thereby held rigidly but removably in an upright position.
[0091] In accordance with one aspect of the invention, because roof gutters 134 are typically mounted to the fascia 136 of the roof 130 underneath the drip edge 131 , the J-shaped brackets 122 are preferably configured and dimensioned to fit within configuration of the gutter 134 . When configured and dimensioned in this manner, the roof truss plates 110 may be nailed to the roof 130 and the T-bar 120 slipped into the box structure as described above without having to remove the gutters 134 (see cross-sectional view of FIG. 22 ).
[0092] Once all the stanchions 124 are installed, guard rails 138 (shown in phantom) may be installed in the stanchions' guard brackets 140 to interconnect the stanchions 124 and thereby provide fall protection. Workers on the roof may then safely begin removing the balance of the shingles (and the underlayment) and installing the new roof. It is noted that since the new shingles are installed from roof's edge upwardly and thereby cover the elongated rectangular plate 112 of the roof truss plate 110 , the plate 112 is preferably provided with nail access cut-outs 142 to provide less obstructions while nailing shingles. The roof truss plates 110 are intended to be permanently left in place once the roof 130 is completed. Nevertheless, when fall protection is no longer needed, the stanchions 124 may be readily removed by simply taking down the guard rails 138 and then for each stanchion 124 , sliding its T-bar 120 out from the box enclosure formed by the end of the elongated rectangular plate 112 , opposing transverse members 114 and bottom plate 116 .
[0093] Referring now to FIGS. 23-29 , another embodiment of the invention comprises a combination fall protection/catwalk bracket 150 that is intended to be nailed to the wall 152 of an above-ground floor 154 (e.g., a deck) to provide fall protection around the perimeter of the above-ground floor 154 while at the same time providing a catwalk allowing workers to work around the floor 154 without walking on it (e.g., to allow painting of the floor 152 out to the edge).
[0094] The fall protection/catwalk bracket 150 comprises a generally L-shaped backplate 156 whose longer leg portion 156 L comprises a plurality of holes 156 LH formed therethrough for rigidly connecting it to the wall 152 of the floor 154 by fasteners 158 (e.g., screws or nails). The shorter leg portion 156 S extends outwardly from the floor 154 to form a lip (as described in more detail below the lip extends over a plank 160 forming the catwalk). The shorter leg portion 156 S may also comprise plurality of holes 156 SH formed therethrough for rigidly connecting it to the plank 160 by fasteners 158 (e.g., screws or nails).
[0095] The fall protection/catwalk bracket 150 further comprises a T-shaped web member 162 composed of a center web 162 C extending downwardly from a transverse top web 162 T. The T-shaped web member 162 is welded at its ends to the longer leg portion 156 L of the L-shaped backplate 156 to extend outwardly therefrom.
[0096] The upper surface of the top web 162 T of the T-shaped web member 162 functions as a platform on which the plank 160 may rest to form the catwalk. The center web 162 C of the T-shaped web member 162 functions as a mounting plate to which a generally J-shaped bracket 164 of stanchion 166 may be removably connected (see FIG. 26 ).
[0097] In one embodiment, J-shaped bracket 164 comprises a generally U-shaped configuration composed of generally parallel side members 1645 extending upwardly from opposing sides of a bottom member 164 B. A pair of blind slots 164 BS are formed inwardly from the ends of the bottom member 164 B.
[0098] The center web 162 C of the T-shaped web member 162 comprises downwardly extending tabs 162 CT that are dimensioned to fit into the respective blind slots 164 BS of the bottom web 164 B when the opposing parallel side members 162 S straddle the center web 162 C. Once extended into the slots 164 BS, the tabs 162 CT may be locked into position by fasteners 158 (e.g., nails or screws) inserted into holes 162 H.
[0099] It is noted that segments of angle iron 168 may be welded to the opposing sides of the center web 162 C to take up the play between the opposing parallel side members 162 S and the center web 162 C, thereby minimizing the wobbling of stanchion 166 . It is also noted that for roofing fall-protection applications, a plurality of holes 164 H are formed through the side members 1465 allowing the J-shaped bracket 164 to be connected directly to the roof truss or to a factory-installed bracket such as those described above.
[0100] During installation, as best shown in FIG. 5 , a plurality of combination fall protection/catwalk brackets 150 are affixed spaced-apart about the peripheral wall 152 of the above-ground deck or floor 154 by the fasteners 158 . For added securement, a slot 174 may be formed in the longer leg portion 156 L close to the bend in the L-shaped backplate 156 so as to be in approximate alignment with the surface of the floor 154 . A nail strap 170 may then be folded over a conventional nail 172 and then inserted into the slot 174 and nailed to the upper surface of the floor 154 .
[0101] Once all the stanchions 166 are connected to their respective combination fall protection/catwalk brackets 150 , the planks 160 may be slid into position onto top web 162 T and under the lip of the shorter leg portion 1565 of the backplate 156 , and fasteners 158 installed. Guard rails 176 may be installed in the stanchions' guard brackets 178 to interconnect the stanchions 166 . As the work on the floor 154 is underway, full fall protection is provided along with a catwalk allowing the workers to work around the floor 154 without stepping on it.
[0102] After the work is completed, the guard rails 176 , stanchions 166 and combination fall protection/catwalk brackets 150 may be easily removed. However, it should be appreciated that the nail strap 170 , if concealed or covered over by carpeting, tile or other floor coverings, may be simply left in place permanently by pulling the nail 172 out from in between the folded-over nail strip 170 allowing the bracket 150 to be removed.
[0103] The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
[0104] Now that the invention has been described,
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In one embodiment, a fall protection system including a J-shaped stanchion that attaches to a roof truss (or rafter) in such a manner as to enable the entire girth of the roof truss overhang (or rafter) to be the sole support for the stanchion. The stanchion is designed to bend below the fascia and return up above the roof surface where successive stanchions similarly attached are connected via a fall protection guardrails providing fall protection for all workers. This single point of attachment allows the carpenters to attach the stanchions prior to hoisting the trusses onto the roof bearing walls. As soon as the trusses are properly braced, the guardrails can be hoisted and secured. In another embodiment, the disclosure includes a combination fall protection and catwalk system for above-ground floors. In another embodiment, the disclosure includes a fall protection system for reroofing applications.
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PRIORITY INFORMATION
This application is based on and claims priority to Japanese Patent Application No. 2000-339505, filed Nov. 7, 2000, the entire contents of which is hereby expressly incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to a generator arrangement for an engine, and more particularly to an improved generator cooling arrangement for a watercraft engine.
DESCRIPTION OF THE RELATED ART
Watercraft engines typically incorporate electrical generators. The generator rotor is rotated by the engine and the electricity produced is used to recharge the battery or to directly power the ignition system used to ignite the fuel/air mixture inside the cylinder of the engine. Due to the compact design and waterproofing of watercraft engines and the fact that the generator itself produces heat, dissipation of the heat within the generator is an ongoing concern in watercraft applications.
U.S. Pat. No. 6,184,599 assigned to Sanshin Kogyo Kabushiki Kaisha describes improvements in cooling generators including the use of cooling jackets and heat transfer elements.
SUMMARY OF THE INVENTION
The preferred embodiments of the present invention, while having a very compact and confined waterproof design, effectively and cost efficiently dissipate the heat created by the generator on an engine in a watercraft.
The stator armature of the generator includes a stack of plates of iron or other material having a high magnetic permeability. The individual plates are insulated from each other by a suitable dielectric. In addition, the stack includes a plate of aluminum that has substantially the same length and width dimensions. The armature coil is then wound around the entire assembly of plural iron plates and the abutting aluminum plate such that the aluminum plate is an integral part of the armature. A generally circular stator mounting bracket is also formed of aluminum. One surface of this bracket directly abuts the engine block. The opposite surface of this bracket directly abuts the aluminum plate integral with the armature stator.
The aluminum plate is thus strategically positioned between the stacked metal plates and the aluminum stator bracket in order to very effectively dissipate heat away from the metal plates of the stator. As a result, the heat produced by resistors heating of the armature coils is directly conducted from the coils and armature iron plates through the integral aluminum plate and the aluminum mounting bracket to the engine block.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will now be described with reference to the drawings of a preferred embodiment, which is intended to illustrate and not to limit the invention. The drawings comprise four figures.
FIG. 1 is a side elevational view of an outboard motor configured in accordance with a preferred embodiment of the present invention. An associated watercraft is partially shown in section.
FIG. 2 is a sectioned side view of a generator assembly.
FIG. 3 is a top sectional view taken along line 3 โ 3 of FIG. 2; and
FIG. 4 is an enlarged view of a stator assembly configured in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The Overall Construction
With reference to FIG. 1 an overall construction of an outboard motor 30 that employs an internal combustion engine 32 configured in accordance with certain features, aspects and advantages of the present invention will be described. The engine 32 has particular utility in the context of a marine drive, such as the outboard motor 30 for instance, and thus is described in the context of an outboard motor. The engine 32 , however, can be used with other types of marine drives (i.e., inboard motors, inboard/outboard motors, etc.) and also certain land vehicles, which includes lawnmowers, motorcycles, go carts, all terrain vehicles and the like. Furthermore, the engine 32 can be used as a stationary engine for some applications that will become apparent to those of ordinary skill in the art.
In the illustrated arrangement, the outboard motor 30 generally comprises a drive unit 34 and a bracket assembly 36 . The bracket assembly 36 supports the drive unit 34 on a transom 38 of an associated watercraft 40 and places a marine propulsion device in a submerged position with the watercraft 40 resting relative to a surface 42 of a body of water. The bracket assembly 36 comprises a swivel bracket 44 , a clamping bracket 46 , a steering shaft 48 and a pivot pin 50 .
The steering shaft 48 typically extends through the swivel bracket 44 and is affixed to the drive unit 34 by top and bottom mount assemblies 52 . The steering shaft 48 is pivotally journaled for steering movement about a generally vertically extending steering axis defined within the swivel bracket 44 . The clamping bracket 46 comprises a pair of bracket arms that preferably are laterally spaced apart from each other and that are attached to the watercraft transom 38 .
The pivot pin 50 completes a hinge coupling between the swivel bracket 44 and the clamping bracket 46 . The pivot pin 50 extends through the bracket arms so that the clamping bracket 46 supports the swivel bracket 44 for pivotal movement about a generally horizontally extending tilt axis defined by the pivot pin 50 . The drive unit 34 thus can be tilted or trimmed about the pivot pin 50 .
As used through this description, the terms โforward,โ โforwardlyโ and โfrontโ mean at or to the side where the bracket assembly 36 is located, unless indicated otherwise or otherwise readily apparent from the context use. The arrow Fw of FIG. 1 indicates the forward direction. The terms โrear,โ โreverse,โ โbackwardlyโ and โrearwardlyโ mean at or to the opposite side of the front side.
A hydraulic tilt and trim adjustment system 56 is provided between the swivel bracket 44 and the clamping bracket 46 for tilt movement (raising or lowering) of the swivel bracket 44 and the drive unit 34 relative to the clamping bracket 46 . Otherwise, the outboard motor 30 can have a manually operated system for tilting the drive unit 34 . Typically, the term โtilt movementโ, when used in a broad sense, comprises both a tilt movement and a trim adjustment movement.
The illustrated drive unit 34 comprises a power head 58 and a housing unit 60 , which includes a driveshaft housing 62 and a lower unit 64 . The power head 58 is disposed atop the housing unit 60 and includes an internal combustion engine 32 that is positioned within a protective cowling assembly 66 , which preferably is made of plastic. In most arrangements, the protective cowling assembly 66 defines a generally closed cavity 68 in which the engine 32 is disposed. The engine, thus, is generally protected from environmental elements within the enclosure defined by the cowling assembly 66 .
The protective cowling assembly 66 comprises a top cowling member 70 and a bottom cowling member 72 . The top cowling member 70 is detachably affixed to the bottom cowling member 72 by a coupling mechanism so that a user, operator, mechanic or repairperson can access the engine 32 for maintenance or for other purposes. In some arrangements, the top cowling member 70 is hingedly attached to the bottom member such that the top cowling member 70 can be pivoted away from the bottom cowling member for access to the engine. Preferably, such a pivoting allows the top cowling member to be pivoted about the rear end of the outboard motor, which facilitates access to the engine from within the associated watercraft 40 .
The top cowling member 70 preferably has a rear intake opening 76 defined through an upper rear portion. A rear intake member with one or more air ducts is unitarily formed with or is affixed to the top cowling member 70 . The rear intake member, together with the upper rear portion of the top cowling member 70 , generally defines a rear air intake space. Ambient air is drawn into the closed cavity 68 via the rear intake opening 76 and the air ducts of the rear intake member as indicated by an arrow 78 of FIG. 1 . Typically, the top cowling member 70 tapers in girth toward its top surface, which is in the general proximity of the air intake opening 76 . The taper helps to reduce the lateral dimension of the outboard motor, which helps to reduce the air drag on the watercraft during movement.
The bottom cowling member 72 has an opening through which an upper portion of an exhaust guide member or support member 80 extends. The exhaust guide member 80 preferably is made of aluminum alloy and is affixed atop the driveshaft housing 62 . The bottom cowling member 72 and the exhaust guide member 80 together generally form a tray. The engine 32 is placed onto this tray and can be affixed to the exhaust guide member 80 . The exhaust guide member 80 also defines an exhaust discharge passage through which burnt charges (e.g., exhaust gases) from the engine 32 pass.
The engine 32 in the illustrated embodiment operates on a four-cycle combustion principle. This type of engine, however, merely exemplifies one type of engine on which various aspects and features of the present invention can be suitably used. Preferably, the engine has at least two cylinder banks, which extend separately of each other. For instance, an engine having an opposing cylinder arrangement can use certain features of the present invention. Nevertheless, engines having other numbers of cylinders, having other cylinder arrangements (in-line, opposing, etc.), and operating on other combustion principles (e.g., crankcase compression two-stroke or rotary) also can employ various features, aspects and advantages of the present invention. In addition, the engine can be formed with separate cylinder bodies rather than a number of cylinder bores formed in a cylinder block. Regardless of the particular construction, the engine preferably comprises an engine body that includes at least one cylinder bore.
A crankshaft 82 extends generally vertically through a cylinder block 84 and can be journaled for rotation about a rotational axis 86 by several bearing blocks. Connecting rods (not shown) couple the crankshaft 82 with the respective pistons (not shown) in any suitable manner. Thus, the reciprocal movement of the pistons (not shown) rotates the crankshaft 82 .
Preferably, the cylinder block 84 is located at the forwardmost position of the engine 32 ; a cylinder head assembly 88 being disposed rearward from the cylinder block 84 . Generally, the cylinder block 84 (or individual cylinder bodies) and the cylinder head assembly 88 together define the engine 32 . Typically, at least these major engine assemblies 84 and 88 are substantially made of aluminum alloy. The aluminum alloy advantageously increases strength over cast iron while decreasing the weight of the engine 32 .
The engine 32 will also typically include a cooling system, a lubrication system and other systems, mechanisms or devices other than the systems described above.
With reference again to FIG. 1, the driveshaft housing 62 depends from the power head 58 to support a driveshaft 90 which is coupled with the crankshaft 82 and which extends generally vertically through the driveshaft housing 62 . The driveshaft 90 is journaled for rotation and is driven by the crankshaft 82 . The driveshaft housing 62 defines an internal section 92 of the exhaust system that leads the majority of exhaust gases to the lower unit 64 . The internal section 92 includes an idle discharge portion that is branched off from a main portion of the internal section 92 to discharge idle exhaust gases directly out to the atmosphere through a discharge port that is formed on a rear surface of the driveshaft housing 62 in idle speed of the engine 32 .
The lower unit 64 depends from the driveshaft housing 62 and supports a propulsion shaft 94 that is driven by the driveshaft 90 . The propulsion shaft 94 extends generally horizontally through the lower unit 64 and is journaled for rotation. A propulsion device is attached to the propulsion shaft 94 . In the illustrated arrangement, the propulsion device is a propeller 96 that is affixed to an outer end of the propulsion shaft 94 . The propulsion device, however, can take the form of a dual counter-rotating system, a hydrodynamic jet, or any of a number of other suitable propulsion devices.
Electrical Generator
A preferred embodiment of the improved electrical generator 98 is shown in FIGS. 2, 3 , and 4 .
A stator core 102 includes a plurality of radially extended armature legs 104 . These armature legs 104 are uniformly spaced in a circle and attached to an aluminum stator bracket 110 . Each of the armature legs is advantageously made up of a series of uniformly spaced plates 106 of iron or other material having a high magnetic permeability. Each plate may be insulated from its adjoining plates by a suitable dielectric to inhibit eddy currents.
By high magnetic permeability is meant sufficient permeability to provide ample electrical current. Typically this magnetic permeability will be equal to or greater than the magnetic permeability of iron.
A significant feature of the preferred embodiment of this invention is an efficient, dissipation of heat from the armature. As best shown in the enlarged view of FIG. 4, each armature leg 104 includes an aluminum heat conductive plate 108 having a high thermal conductivity abutted against the plate 106 that is closest to the armature stator bracket. Plate 108 has advantageously the same planar dimensions, i.e., length and width, as each of the iron plates 106 . However, the thickness of plate 108 may be greater or less then the plate 106 as determined by the heat conduction requirements.
By high thermal conductivity is meant superior heat dissipation properties in order to transfer heat efficiently and effectively. Typically this thermal conductivity will be greater than the thermal conductivity of iron or iron alloys. The thermal conductivity of aluminum compared to iron and other metals can be referenced in Mark's Standard Handbook for Mechanical Engineers, page 4-60, table 1.
Each of the armature legs further includes an electrical winding 112 , typically provided by a suitable number of turns of insulated wire 112 . This armature coil 112 is wound around both the stack of iron sheets 106 and the aluminum plate 108 such that the plate 108 is an integral part of the stator armature. As a result, plate 108 is close proximity to both the stack of iron sheets 106 and the coil 112 .
Aluminum heat conductive plate 108 is advantageously mounted to the aluminum stator bracket 110 of a sufficient mass designed to very effectively dissipate the generated heat from the armature legs 104 .
A cup shaped flywheel rotor 100 preferably protected by a generator cover 101 is positioned above atop the crankshaft 82 and is mounted for rotation with the crankshaft 82 . Various permanent magnets 114 are positioned around the circumference of the flywheel rotor 100 that induces by magnetic induction an electrical current through various general coils 112 . As well known in the art, this electrical current is used to charge the boat battery or batteries as well as the various electrical needs of the engine 32 and watercraft.
Bolts 116 secure each of the armature legs 104 to the stator bracket 110 . The stator bracket 110 is mounted to a through hole 118 in the engine block 84 or stationary member 120 with bolts 122 . A bearing 124 that guides and supports the crankshaft 82 is mounted within the stator bracket 110 .
The electrical resistance heating within the stator armature is transferred from the highly thermal conductive aluminum heat sink plates 108 within each of the armature legs 104 to the stator bracket 110 . Bracket 110 in turn directly abuts the engine block 84 . As a result, the armature legs 104 are maintained at a safe operating temperature. The alternate long-and-short dashed line shown in FIG. 4 illustrates the path of heat transfer from the armature legs 104 to the stator bracket 110 .
The present invention successfully satisfies both the growing demand for a compact design as well as effective heat dissipation.
Of course, the foregoing description is that of a preferred construction having certain features, aspects, and advantages in accordance with the present invention. Various changes and modifications may be made to the above described arrangements without departing from the spirit and scope of the invention, as defined by the appended claims.
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An engine includes an engine body and a generator. The engine body has a stator bracket mounted to the cylinder block. The generator incorporates a rotor flywheel and an armature assembly consisting of armature legs. Various metal plates with high magnetic permeability make up the armature legs and are securely fastened in a radial manner to the similar plate made of aluminum. The stacked armature legs surround the crankshaft and are mounted to the stator bracket. The preferred heat conduction path travels from the armature legs through the aluminum plate on onto the stator bracket in order to improve the heat dissipation of the generator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 14/577,518, filed Dec. 19, 2014, and entitled VIBRATION ISOLATION OF ELECTRONICS AND/OR COMPONENTS, which claims priority to and the benefit of U.S. Provisional Patent Application No. 61/919,402, filed Dec. 20, 2013, and entitled VIBRATION ISOLATION OF ELECTRONICS, the disclosures of which are incorporated herein by reference in their entireties.
BACKGROUND
1. The Field of the Invention
[0002] Generally, this disclosure relates to vibration isolation. More specifically, the present disclosure relates to devices, systems, and methods regarding the vibrational isolation of electronic devices and/or components.
2. Background and Relevant Art
[0003] Electronic devices and components are prevalent in consumer, commercial, and industrial settings. Electronic devices and components are used in an increasing number of applications, and therefore, are exposed to a larger variety of adverse conditions on a regular basis. Electronic devices are no longer a carefully protected commodity, expected to fail at the first exposure to adverse conditions; rather, electronics are now expected to survive situations including remote locations, challenging weather, use in and around heavy machinery, and even military operations. However, at the same time, electronics have become smaller and lighter with finer wires and much denser concentrations of components. Because the electronics are more susceptible to physical damage, and because of the greater reliance on electronics functioning in all conditions, there is an increasing need to provide a protective housing to isolate electronic components from mechanical damage, such as due to vibration.
[0004] Vibration can damage electronic components due to repeated acceleration and deceleration of the materials over long periods of time. Vibration issues for electronic systems may include cracking or degeneration of circuit contacts, loosening of electrical connections, arcing damage, false operation or โbouncingโ of relay contacts or thermostat contacts disrupting normal system operation, dust generation that may interfere with sensitive circuitry or with heat dissipation from electronics, internal stress or metal fatigue to electronic parts, head crashes on platen storage media, or even simple abrasion damage. For example, electronic components used to operate modern rock crushing equipment experience extremely harsh conditions and may serve as an approximate โworst-case scenario.โ The electronics mounted on the rock crushing equipment are exposed to nearly continual low frequency, very high amplitude vibrations that can easily shake components loose from the electronics themselves or from the surrounding housing that may then damage the sensitive electronics.
[0005] Attempts have been made in the past to isolate the on-board electronics of heavy machinery from vibration and/or harmonics. One approach has been to simply remove the electronics from the source of the vibration on the machinery (e.g., place the electronics on the ground away from the vibration source). Having a detachable assembly effectively โdecouplesโ the transmission path of the vibrations from the source of the vibrations, such as the rock crushing equipment, and the electronics housing by anchoring the electronics housing on some other surface, such as the ground. However, this detachable assembly has significant drawbacks. The electronics assembly may itself be a large component of the system and removal by hand may not be feasible, demanding additional equipment that requires time and resources to manufacture, maintain, and operate. A mechanical, hydraulic, or pneumatic system intended to decouple the electronic components from the transmission path of the vibrations may be subjected to the same harsh vibrations, thereby merely exchanging one problem for another problem as the mechanical, hydraulic, or pneumatic system intended to prevent damage to the electronic components would be susceptible to damage and need repairs, which would demand time and resources.
[0006] Furthermore, a mechanical, hydraulic, or pneumatic system implemented to remove electronic components from the heavy machinery would only be implemented if the electronic components themselves are too heavy for an operator to remove by hand, in which case the removal system would likely need to be large and heavy, itself. While adding a large, heavy electronics removal system may be a small relative change in weight to an already heavy machine, it is desirable to limit the weight added, if possible.
[0007] Additionally, a mechanical, hydraulic, or pneumatic system used to remove the heavy electronic components from the source and isolating the electronics housing, for example, against the ground requires three assumptions. First, the ground is not the source of the vibrations. In many construction, extraction, or excavation applications, the earth itself is a transmitter of the vibrations. For example, for equipment such as a thumper truck, removing the electronic components to the ground is not a viable option. Thumper trucks are used as a seismic source for seismic surveys. Seismic surveys are commonly used in the extractive industries and to research subsurface formations. A thumper truck accelerates a large mass toward the ground. The resulting impact sends a powerful shockwave through both the truck and the earth surrounding the impact location. Removal of the electronic components from the vehicle to the ground would, of course, be ineffectual in such an application. Second, the vibrations must be present only when the associated machinery is stationary. In the case of excavation equipment, such as a bulldozer or loader, vibrations are generated during motion of the machinery. For that reason, electronic components must remain on-board the machinery to allow proper operation. Third, the application for which the machinery is designed must not require transit over uneven surfaces. The electronic components are susceptible to damage even when the machinery is not in operation. Many applications require travel over rough roads or over areas that have no roads. It would be desirable to isolate electronic components from vibrations at all times.
[0008] Passive vibration isolation devices have been attempted to isolate electronic components from vibrational damage. Bushings, and in particular automotive motor mounts, have been employed, for example, in rock crushing machinery with little success. Again, the vibrations created by the machinery tend to be low-frequency, high amplitude vibrations. Therefore, any bushings would need to be soft and allow with a high amount of compliance to ensure the vibrational motion of the electronics, or alternatively the support to which the electronics mount, does not exceed the limits of the bushings. Unfortunately, having a very heavy and very costly (in the case of rock crushing machinery electronics a half-ton, $30,000 object) placed upon very soft, highly compliant mounts is undesirable.
[0009] Manufacturers have also employed spring mounts, but spring mounts require extensive damping for use in vibrational applications. Springs, undamped, will transfer the vibrations and run the risk of amplifying the vibrations when near resonance of the system. To create a system with a long period that would not resonate with the input vibrations, a manufacturer may include soft springs with a low spring constant. However, such a spring would require more distance to travel, and creates the aforementioned problem of placing a 1,000 pound (โlb.โ) object on a soft mount. To address this problem, one could add springs, which would increase the restoring force for a given displacement of the electronics housing, but as one increases the stiffness of the springs, the duration of the resonant period shortens. Therefore, damping of the system becomes necessary again.
[0010] Rock crushing equipment is not the only example, however, as much heavy machinery may generate similar vibrations that could potentially damage electronic components, such as construction equipment, excavation equipment, extraction equipment, or truck, rail, or air transport. Furthermore, consumers are increasingly harsh and demanding on their personal electronics, while simultaneously become more dependent upon them. Therefore, the hard drive in a laptop is consequently more vulnerable and more valuable.
[0011] Consumer applications may be more challenging, as the variety of conditions to which consumers subject their personal electronics may be less predictable than the conditions in which commercial or industrial machinery is operated. Consumer applications may need vibrational dampening that operates in a large range of conditions, orientations, and dimensions. For example, while the vibrations experienced by rock crushing machinery are fairly predictable in frequency, amplitude, and direction, the vibrations encountered by a consumer laptop may be due to a constant high frequency vibration of a jet turbine engine during air travel, or a single large amplitude impact such as dropping the device on the floor in an inverted position.
[0012] It is therefore desirable to vibrationally isolate the electronic components of a device cheaply and reliably from a wide range of shocks from many directions.
BRIEF SUMMARY
[0013] Implementations of the present disclosure address one or more of the foregoing or other problems in the art with devices, systems, and methods for vibrational isolation of electronic components. In particular, implementations of the present disclosure related to vibrational isolation of electronic components from input vibrations due to machinery.
[0014] In an embodiment, a vibration isolation device may comprise an isolated member that houses the electronics to be isolated from input vibrations. The isolated member may then be disposed within a support frame and suspended by elastic members connected thereto. The elastic members may comprise the same type of material or different elastic members may comprise different materials. The elastic members may be disposed on substantially opposing sides of the isolated member to prevent swaying or twisting of the isolated member and damp down oscillations of the isolated member.
[0015] In a further embodiment, the vibration isolation device may comprise a retention device such that the isolated member may be substantially fixed relative to the support frame. The retention device may comprise a pre-tensioning device that also allows for selective pre-tensioning of the elastic members during operation.
[0016] In another embodiment, the vibration isolation device may comprise an isolated member and a support frame. The isolated member may be connected to the support frame by a plurality of elastic members, with each of the elastic members applying a force to the isolated member. The force applied by each elastic member to the isolated member may be decomposed into its constituent vectors. Each elastic member may apply a force having a vector that substantially opposes the vector of a force applied by another elastic member.
[0017] In a further embodiment, the elastic members may be disposed symmetrically. In another embodiment, the elastic members may be disposed with symmetry displaying at least two reflection planes, at least three reflection planes, or inversion symmetry.
[0018] In yet another embodiment, a method of vibrationally isolating electronic components is provided. A method may comprise housing electronic components in an isolated member, the isolated member disposed within a support frame, and the isolated member connected to the support frame with a plurality of elastic members. The elastic members may be configured to apply forces having vectors at least about 90ยฐ apart. The method may further comprise applying an input vibration to the support frame and then absorbing at least a part of the input vibration.
[0019] Additional features of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such embodiments. The features of such embodiments may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such embodiments as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0021] FIG. 1A is a perspective schematic view of a vibration isolation device according to the present application in which the isolated member is supported by a partially non-elastic member and is accessible during operation, according to at least one embodiment described herein;
[0022] FIG. 1B is a perspective schematic view of a vibration isolation device according to the present application in which the isolated member is supported by an elastic member and accessible during operation, according to at least one embodiment described herein
[0023] FIG. 2 is a perspective schematic view of another vibration isolation device according to the present application in which the vibration isolation is irrespective of orientation, according to at least one embodiment described herein;
[0024] FIG. 3 is a perspective schematic view of yet another vibration isolation device according to the present application in which the vibration isolation is irrespective of orientation, according to at least one embodiment described herein;
[0025] FIG. 4 is a perspective schematic view of the vibration isolation device of FIG. 2 further comprising a retention device, according to at least one embodiment described herein;
[0026] FIG. 5 is a perspective schematic view of the vibration isolation device of FIG. 2 further comprising an extension mechanism, according to at least one embodiment described herein;
[0027] FIG. 6 is a perspective schematic view of a vibration isolation device according to the present application in which a plurality of isolated members are disposed within a support frame and connected to one another, according to at least one embodiment described herein;
[0028] FIG. 7A is a perspective view of another vibration isolation device for vibrationally isolating a plurality of electronic control housings, according to at least one embodiment described herein;
[0029] FIG. 7B is a perspective view of a vibration isolation device for vibrationally isolating a plurality of electronic control housings mounted to a rock crushing machine, according to at least one embodiment described herein; and
[0030] FIG. 8 is a flowchart illustrating a method of vibrational isolation of electronic components, according to at least one embodiment described herein.
DETAILED DESCRIPTION
[0031] One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual implementation may be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions will be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0032] When introducing elements of various embodiments of the present disclosure, the articles โa,โ โan,โ and โtheโ are intended to mean that there are one or more of the elements. The terms โcomprising,โ โincluding,โ and โhavingโ are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to โone embodimentโ or โan embodimentโ of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
[0033] One or more embodiments of the present disclosure relate to vibration isolation. More specifically, the present disclosure relates to devices, systems, and methods regarding the vibrational isolation of electronic devices or components. While the following examples may highlight applications in heavy machinery, embodiments according the present application are not so limited. Embodiments disclosed herein may be adapted for scale and forces of differing applications without deviating from the spirit or essential characteristics described herein.
[0034] The challenge of vibration isolation may require the balancing of three competing goals. First, ideal vibration isolation may allow for sufficient displacement of the isolated component such that any energy due to input vibrations may be dissipated without harsh acceleration of the isolated component. Similarly, there may be sufficient displacement capable to ensure the isolated component does not interact directly with any mounting hardware or surrounding environment, thus negating any vibration isolation. Second, ideal vibration isolation may allow for the continuous application of force such that no sudden application of force causes additional acceleration. For example, any support provided to an isolated component may avoid a discontinuous force curve. Finally, the vibration isolation may provide damping to prevent any resonance with the input vibrations.
[0035] In some embodiments, these three considerations may be sufficiently addressed by suspending an electronic component using elastic members such that the electronic component becomes an isolated member in contact with the surrounding structure exclusively by the elastic members. The elastic suspension members may connect the isolated member to a surrounding support frame such that the isolated member is freely suspended above and/or away from all surfaces. The elastic suspension members may have sufficient compliance and a relatively low elastic modulus (e.g., less than that of the support frame) to ensure that the isolated member is not subjected to high acceleration from the input vibrations on the support frame. For example, the elastic suspension members and/or elastic dampening members may comprise nitrile rubber, butyl rubber, epichlorohydrin rubber, ethylene propylene diene monomer rubber, gum rubber, polyethylene rubber, latex rubber, neoprene rubber polyurethane, santoprene rubber, styrene-butadiene rubber, silicone rubber, vinyl rubber, fluoroelastomer rubber, other elastic compound, or combinations thereof.
[0036] Elastic dampening members may be disposed around the isolated member such that the isolated member may resist swaying or resonant motion from the input vibrations. For example, the elastic members may be elastic cords, elastic straps, elastic belting strips, or elastic panels. In particular, elastic dampening members may be used in applications which require frequent transport of the isolated electronic components or for applications in which the device may be subjected to a constant vibration input for a duration sufficient to produce resonant motion. Furthermore, the elastic suspension members and the elastic dampening members may dissipate energy upon extension and contraction to damp down oscillations in the device. As used herein to describe and reference figures, like reference characters may refer to like structures.
[0037] Referring now to FIGS. 1A and 1B , a vibration isolation device 100 may comprise an isolated member 102 such as a housing configured for the housing of electronic equipment therein. The embodiments illustrated in and elements described in relation to FIGS. 1A and 1B are example combinations of such elements, but contemplated combinations should not be considered inclusive of all recited elements or exclusive of additional elements. Additional embodiments may describe additional elements, which may be combined with elements of any other embodiment described herein. The isolated member 102 may be supported by a support frame 104 that comprises at least one side support 106 and a top support 108 . The embodiments depicted in FIGS. 1A and 1B are designed to allow access to the isolated member 102 that houses the electronic components, and therefore, the support frame 104 is shown with only two side supports 106 ; however, the support frame 104 may have more than two side supports 106 .
[0038] The isolated member 102 may be suspended from the top support 108 by one or more elastic suspension members 110 . The one or more elastic suspension members 110 may include a non-elastic portion, as shown in FIG. 1A , or may connect the isolated member 102 to the top support 108 directly, as shown in FIG. 1B . An elastic suspension member 110 having a non-elastic portion, such as the chains depicted in FIG. 1A , may allow the vibration isolation device 100 to accommodate isolated members 102 of varying dimensions (e.g., isolated members 102 of differing heights) without altering the one or more elastic suspension members 110 . The one or more elastic suspension members 110 may comprise a material with an appropriate elastic modulus such that when the isolated member 102 is suspended therefrom, the isolated member 102 is suspended approximately in the center of the support frame 104 . For example, the one or more elastic suspension members 110 may comprise a material having a lower elastic modulus (i.e., a material that is more elastic) than the support frame. The one or more elastic suspension members 110 may comprise rubber, such as nitrile rubber, butyl rubber, epichlorohydrin rubber, ethylene propylene diene monomer rubber, gum rubber, polyethylene rubber, latex rubber, neoprene rubber polyurethane, santoprene rubber, styrene-butadiene rubber, silicone rubber, vinyl rubber, fluoroelastomer rubber; other elastomer compounds; textile materials; leather; metals; or combinations thereof. The equilibrium position may be the position to which the device 100 restores the isolated member 102 after application of input vibrations through the support frame 104 or any other displacement of the isolated member 102 . After displacement of the isolated member 102 , the isolated member 102 may be restored to the equilibrium position at least partially by one or more elastic dampening members 112 .
[0039] In some embodiments, the elastic dampening members 112 may apply a net zero force on the isolated member 102 such that the elastic dampening members 112 themselves will not move the isolated member 102 from the equilibrium position, but may apply a net force to the isolated member 102 when the isolated member 102 is displaced from the equilibrium position. For example, one or more of the elastic dampening members 112 may apply no force to the isolated member 102 when the isolated member 102 is in the equilibrium position, while one or more of the elastic dampening members 112 may experience a tension force, and hence apply an opposing force, when the isolated member 102 displaces from the equilibrium position.
[0040] In other embodiments, the elastic dampening members 112 may each apply a force to the isolated member 102 , the force applied by each elastic dampening member 112 having a vector component substantially opposing a vector component of a force applied by another elastic dampening member 112 . For example, one or more of the elastic dampening members 112 may experience a tension force, and hence apply an opposing force, when the isolated member 102 is in the equilibrium position. In such an example, the force applied by an elastic dampening member 112 may be at least partially balanced by an opposing force applied by another elastic dampening member 112 and/or another elastic suspension member 110 . In yet other embodiments, the elastic dampening members 112 and the elastic suspension members 110 are configured such that at least two of the elastic dampening members 112 and elastic suspension members 110 apply tension forces to the isolated member 102 having vectors at least about 90ยฐ apart. For example, two elastic dampening members 112 may be positioned between and connect the isolated member 102 and the support frame 104 . The two elastic dampening members 112 may experience tension forces when the isolated member 102 is in an equilibrium position, and a direction of the tension forces may be approximately 180ยฐ from one another.
[0041] Similarly to the elastic suspension members 110 , elastic dampening members 112 may comprise any material with an appropriate elastic modulus such that the isolated member 102 may displace within the support frame 104 without its position substantially exceeding the dimensions of support frame 104 . For example, the elastic dampening members 112 may comprises rubber, such as nitrile rubber, butyl rubber, epichlorohydrin rubber, ethylene propylene diene monomer rubber, gum rubber, polyethylene rubber, latex rubber, neoprene rubber polyurethane, santoprene rubber, styrene-butadiene rubber, silicone rubber, vinyl rubber, fluoroelastomer rubber; other elastomer compounds; textile materials; leather; metals; or combinations thereof. In some embodiments, the one or more elastic suspension members 110 may comprise the same material as the one or more elastic dampening members 112 . In other embodiments, the one or more elastic suspension members 110 may comprise different materials from the one or more elastic dampening members 112 .
[0042] In an embodiment, elastic suspension members 110 and elastic dampening members 112 may comprise elastic cords. In a further embodiment, elastic suspension members 110 and elastic dampening members 112 may comprise sheathed elastic cords, commercially known as BUNGEE cords. In embodiments with sheathed elastic cords as at least one of the elastic dampening members 112 , the sheathed elastic cords may vary in thickness or diameter. For example, in some embodiments, the sheathed elastic cords may be about one inch in diameter or may exceed one inch in diameter. In yet another embodiment, the elastic suspension members 110 and elastic dampening members 112 may comprise elastic sheets, the elastic sheets providing substantially equal force along the length of their connection to the support frame 104 and to the isolated member 102 . For example, an elastic sheet may connect the isolated member 102 along a length of one or more side supports 106 and/or top support 108 . The elastic sheet may connect the isolated member 102 to the top support along a length of the top support 108 that is a percentage of the full length of the isolated member 102 . In some embodiments, an elastic sheet may connect the isolated member 102 to a side support 106 or top support 108 along a percentage of the length of the isolated member 102 in a range having upper and lower values including any of 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, or any value therebetween. For example, an elastic sheet may connect the isolated member 102 to a top support 108 along between 50% and 100% of a full length of the isolated member 102 . In other examples, an elastic sheet may connect the isolated member 102 to a top support 108 along between 60% and 90% of a full length of the isolated member 102 . In yet other examples, an elastic sheet may connect the isolated member 102 to a top support 108 along between 70% and 85% of a full length of the isolated member 102 .
[0043] Elastic dampening members 112 may also provide a net force on the isolated member 102 such that a second equilibrium position may be created after the elastic dampening members 112 are connected to the isolated member 102 and the support frame 104 . For example, the elastic dampening members 112 may provide a net force downward from the first equilibrium position, such that the second equilibrium position is lower relative to the top support 108 . When the isolated member 102 is in an equilibrium position, the elastic dampening members 112 may experience a tension force such that each elastic dampening member 112 applies a force to the isolated member 102 . The forces applied by the elastic dampening members 112 may be balanced by other elastic dampening members 112 , by the elastic suspension members 110 , by a gravitational force (not depicted in FIGS. 1A and 1B ), or by another force. In an embodiment, the elastic dampening members 112 may be disposed with at least two planes of symmetry. For example, as depicted in FIGS. 1A and 1B , there may be two vertical planes of symmetry disposed at 90ยฐ from one another. In another embodiment, the elastic dampening members 112 may be disposed with inversion symmetry about the center of the isolated member 102 . For example, a plurality of elastic dampening members 112 may be positioned around the isolated member 102 and connecting the isolated member 102 and the support frame 104 such that each elastic dampening member 112 is in line with another elastic dampening member 112 on an opposing side of the isolated member 102 . In yet another embodiment, the elastic dampening members 112 may be disposed with at least three planes of symmetry.
[0044] With the elastic dampening members 112 under tension at the equilibrium position, an input vibration applied to the support frame 104 may displace the isolated member 102 from the equilibrium position relative to the support frame 104 and the net force on the isolated member 102 may change linearly and/or continuously. The elastic dampening members 112 may be disposed such that the isolated member 102 may displace relative to the support frame 104 without any of the elastic dampening members 112 becoming slack. A slack elastic dampening member 112 may result in a discontinuous force curve during displacement of the isolated member 102 from the equilibrium position. A discontinuous force curve may result in undesirable or unnecessary vibration in the isolated member 102 . To ensure the isolated member 102 of device 100 is restored to its equilibrium point with minimal twisting and/or swaying, the elastic dampening members 112 may further comprise upper dampening members having a modulus of elasticity greater than a modulus of elasticity of lower dampening members to generate similar forces on the isolated member 102 when a lower portion of the isolated member 102 displaces more than a upper portion. In some embodiments, the upper dampening members may differ in modulus of elasticity relative to one another.
[0045] In some embodiments, the input vibration may have a frequency greater than about 40 Hertz (Hz), such as when the device 100 is subjected to vibrations during transportation. In other embodiments, the input vibration may have a frequency less than about 40 Hz, such as when the device 100 is subjected to vibrations due to a heavy machinery motor. In yet other embodiments, the input vibration may have a frequency less than about 15 Hz, such as when the device 100 is subjected to vibrations from a rock crusher motor and/or during crushing of rock.
[0046] The restoring force after a displacement of the isolated member 102 may be at least partially dependent on the force applied by the elastic dampening members 112 . The portion of the restoring force due to the elastic dampening members 112 , when the elastic dampening members 112 are under tension at the equilibrium position, may be the net force of the elastic dampening members 112 applied to the isolated member 102 . In the embodiments depicted in the FIGS. 1A and 1B , a lateral displacement toward one of the side supports 106 may result in an increase in the force applied by one or more of the elastic dampening members 112 and an associated decrease in the force applied by one or more of the elastic dampening members 112 positioned on the opposing side of the isolated member 102 . Conversely, therefore, the transmission of force and/or energy from the support frame 104 to the isolated member 102 is lowest when the isolated member 102 remains at the equilibrium point. When input vibrations enter the device 100 at the support frame 104 , the vibrations may move the support frame 104 with little transmission of the vibrations to the isolated member 102 at the equilibrium point.
[0047] FIGS. 1A and 1B depict a vibration isolation device 100 intended for use in a mobile rock crushing machine, and therefore, the orientation of the device 100 is known and access to the isolated member 102 is necessary for the operation of the machinery. However, other embodiments of the present disclosure are possible in other applications in which access to the isolated member 102 during operation is unnecessary.
[0048] FIG. 2 depicts a vibration isolation device 200 for use in an application that may not require access to the isolated member 202 during exposure to vibrations. The embodiment illustrated in and elements described in relation to FIG. 2 are example combinations of such elements, but contemplated combinations should not be considered inclusive of all recited elements or exclusive of additional elements. Additional embodiments may describe additional elements, which may be combined with elements of any other embodiment described herein. An example of such an application may be the vibrational isolation of a โblack boxโ recorder in a transportation vehicle such as an airplane. In such an application, the vibration source may be air turbulence, vibration from taxiing across a surface, or vibration from operation of the engines or other machinery on the aircraft. Therefore, there is not a predetermined direction to the vibration, and the device 200 may be configured to vibrationally isolate the isolated member 202 from any direction.
[0049] Because the isolated member 202 may not need to be accessed during routine operation, the vibration isolation device 200 may have a support frame 204 that encompasses the isolated member 202 with support frame sides 206 surrounding all sides of the isolated member 202 . The support frame sides 206 and/or support frames 204 , which may or may not be solid sides and/or frames, may meet at frame corners 208 . For example, the support frames 204 may have apertures formed therein. The apertures may be elliptical, polygonal, otherwise shaped, or combinations thereof. In some embodiments, the elastic suspension members 210 and/or elastic dampening members 212 may connect to the corners of the isolated member 202 and the frame corners 208 . In other embodiments, the elastic suspension members 210 and/or elastic dampening members 212 may connect to another part of the support frame 204 between the frame corners 208 . In the embodiment illustrated in FIG. 2 , the elastic suspension members 210 and the elastic dampening members 212 may be the same material. The device 200 may then dampen vibrations substantially equivalently irrespective of orientation of the input vibrations or of the device 200 . In other embodiments, the device 200 may have a dominant orientation. For example, a flight recorder, while experiencing many orientations of acceleration and/or vibrations during use, may experience much greater acceleration in particular orientations. Therefore, the elastic suspension members 210 and elastic dampening members 212 may comprise different materials. Furthermore, the elastic suspension members 210 and elastic dampening members 212 may comprise different materials based on their orientation. For example, as depicted in FIG. 2 , the elastic suspension members 210 may comprise a material with a higher modulus of elasticity than the elastic dampening members 212 because the elastic suspension members 210 may be responsible for suspending the mass of the isolated member 202 , while the elastic dampening members 212 may be responsible exclusively for preventing swaying and/or motion of the isolated member 202 .
[0050] As depicted in FIG. 2 , the elastic suspension members 210 and elastic dampening members 212 are connected to the frame corners 208 and to the isolated member 202 . The elastic suspension members 210 and elastic dampening members 212 are connected to the isolated member 202 at the corners of the isolated member 202 . Connecting the elastic suspension members 210 and elastic dampening members 212 to corners of the isolated member 202 may apply a greater torque on the isolated member 202 . Therefore, the acceleration of the isolated member 202 due to the elastic suspension members 210 and elastic dampening members 212 may be fine-tuned by the placement of the elastic suspension members 210 and elastic dampening members 212 .
[0051] For example, the elastic suspension members 210 and elastic dampening members 212 , depending on orientation, may need to suspend more or less of the weight of the isolated member 202 . In an application with an isolated member 202 having a lower mass, the elastic suspension members 210 and elastic dampening members 212 may have a lower elastic modulus because they need to suspend less weight. However, decreasing the elastic modulus of the elastic suspension members 210 and elastic dampening members 212 would also affect the rate at which input vibrations are transmitted to the isolated member 202 . Moving the connection of the elastic suspension members 210 and elastic dampening members 212 with the isolated member 202 further from the center of inertia of the isolated member 202 will provide greater torque on the isolated member 202 to maintain its orientation within the support frame 204 .
[0052] FIG. 3 depicts an embodiment in which vibration isolation device 300 has an analogous isolated member 302 and support frame 304 with support sides 306 , which meet at frame corners 308 . (Support sides 306 are transparent for the purposes of FIG. 3 .) The embodiment illustrated in and elements described in relation to FIG. 3 are example combinations of such elements, but contemplated combinations should not be considered inclusive of all recited elements or exclusive of additional elements. Additional embodiments may describe additional elements, which may be combined with elements of any other embodiment described herein. However, in the embodiment depicted in FIG. 3 , the elastic suspension members 310 and elastic dampening members 312 are disposed in the center of the isolated member faces 314 and at the isolated member corners 316 , respectively. The elastic suspension members 310 and elastic dampening members 312 may have different moduli of elasticity, as well. For example, the elastic suspension members 310 may have a higher modulus of elasticity than the elastic dampening members 312 such that the elastic suspension members suspend the mass of the isolated member 302 at the isolated member faces 314 and the elastic dampening members 312 apply torque to the isolated member corners 316 . The vibration isolation device 300 depicted in FIG. 3 may have similar or identical vibration isolation properties irrespective of the orientation at which the device 300 is mounted.
[0053] Referring now to FIG. 4 , yet another embodiment of a vibration isolation device 400 is depicted. The embodiment illustrated in and elements described in relation to FIG. 4 are example combinations of such elements, but contemplated combinations should not be considered inclusive of all recited elements or exclusive of additional elements. Additional embodiments may describe additional elements, which may be combined with elements of any other embodiment described herein. For the purposes of FIG. 4 , vibration isolation device 400 is depicted having an analogous structure to device 200 shown in FIG. 2 , but may comprise an analogous structure to any of the embodiments described herein or combinations thereof. The vibration isolation device 400 may comprise an analogous isolated member 402 , support frame 404 , support sides 406 , frame corners 408 , and elastic suspension members 410 and elastic dampening members 412 . In addition, vibration isolation device 400 may comprise a retention device 418 .
[0054] As shown in FIG. 4 , the retention device 418 may comprise a deployable bracket that, in a deployed state, may limit or substantially prevent motion of the isolated member 402 . The retention device 418 may be selectively deployable or engageable to limit motion of the isolated member, for example, during transport of the device 400 , when the device 400 is not subject to input vibrations, or when movement of the isolated member 402 would be undesired. For example, if the isolated member 402 comprises components that require maintenance, it may be desirable to fix the isolated member 402 relative to the support frame 404 such that the isolated member 402 does not move while a technician attempts to perform maintenance.
[0055] The retention device 418 may be a single bracket or, as depicted in FIG. 4 , a plurality of brackets. In an embodiment, the retention device 418 may be a rigid member or a semi-rigid, resilient member. In another embodiment, the retention device 418 may be an inflatable member that may be selectively inflated to substantially occupy the space between the isolated member 402 and the support frame 404 . In yet another embodiment, the retention device 418 may comprise a flexible, inelastic member (relative to the elastic suspension members 410 and/or elastic dampening members 412 ), such as rope or chain, that may selectively connect the isolated member 402 to the support frame 404 and thereby restrict the relative movement of the isolated member 402 and the support frame 404 .
[0056] In a further embodiment, the retention device 418 may comprise a pre-tensioning device associated with the elastic suspension members 410 and/or elastic dampening members 412 . By pre-tensioning the elastic suspension members 410 and/or elastic dampening members 412 , the isolated member 402 may be subject to less displacement during transport or maintenance, such that other components may not be necessary. Additionally, the pre-tensioning device may pre-tension the elastic suspension members 410 and/or elastic dampening members 412 such that the isolated member 402 remains at the original equilibrium point, but any restoring force generated due to displacement of the isolated member 402 increases, effectively retaining the isolated member 402 without altering any geometry of the device 400 .
[0057] In a yet further embodiment, a vibration isolation device 500 may comprise a substantially analogous structure to vibration isolation device 200 as depicted in FIG. 5 , but also may comprise an analogous structure to any of the embodiments described herein. The embodiment illustrated in and elements described in relation to FIG. 5 are example combinations of such elements, but contemplated combinations should not be considered inclusive of all recited elements or exclusive of additional elements. Additional embodiments may describe additional elements, which may be combined with elements of any other embodiment described herein. Vibration isolation device 500 may comprise an analogous isolated member 502 , support frame 504 , support sides 506 , frame corners 508 , and elastic suspension members 510 and elastic dampening members 512 . In addition, vibration isolation device 500 may comprise one or more extension mechanisms 520 .
[0058] Extension mechanisms 520 may allow for greater extension of the elastic suspension members 510 and elastic dampening members 512 without approaching their elastic limits. It may be undesirable to approach the elastic limit of the elastic suspension members 510 and/or elastic dampening members 512 because near their elastic limit, the elastic suspension members 510 and/or elastic dampening members 512 will cease to behave with a linear elasticity. At which point, the elastic suspension members 510 and/or elastic dampening members 512 may no longer effectively isolate the isolated member 502 from input vibrations. Extension mechanisms 520 may allow use of longer elastic suspension members 510 and/or elastic dampening members 512 , such that displacements of the isolated member 502 remain within the linear elastic deformation range of the elastic suspension members 510 and/or elastic dampening members 512 .
[0059] As depicted in FIG. 5 , the extension mechanisms 520 may be disposed at the frame corners 508 , but may also be disposed at any point at which the elastic suspension members 510 and/or elastic dampening members 512 may connect to the support frame 504 . For example, in the depicted embodiment in FIG. 5 , the extension mechanism may be a mechanism that directs the elastic suspension members 510 and/or elastic dampening members 512 along a different direction to allow the use of longer elastic suspension members 510 and/or elastic dampening members 512 without requiring larger geometry of the device 500 . Extension mechanism 520 may allow the elastic suspension members 510 and/or elastic dampening members 512 to continue beyond the frame corners 508 and connect to a further point on the support frame 504 , such as mounting point 522 . In an embodiment, the extension mechanisms 520 may be wheels, such as those depicted in FIG. 5 . In another embodiment, the extension mechanisms 520 may comprise sliders, such as a slider comprising polytetrafluoroethylene, polyurethane, perfluoroalkoxy, fluorinated ethylene propylene, another material having a similarly low coefficient of friction, or combinations thereof configured to allow the elastic suspension members 510 and/or elastic dampening members 512 to move over its surface with low friction and, therefore, less wear on the elastic suspension members 510 and/or elastic dampening members 512 .
[0060] In an embodiment such as that depicted in FIG. 5 , extension mechanisms 520 may enable the use of elastic suspension members 510 and/or elastic dampening members 512 of two or more times the length of the elastic suspension members 210 and elastic dampening members 212 of the vibration isolation device 200 as depicted in FIG. 2 . Extension mechanisms 520 may enable vibration isolation device 500 to isolate the isolation member 502 from larger amplitude input vibrations than an embodiment without extension mechanisms 520 .
[0061] In an embodiment, the extension mechanisms 520 may direct the elastic suspension members 510 and/or elastic dampening members 512 in a different direction without inhibiting the movement of the elastic suspension members 510 and/or elastic dampening members 512 . In another embodiment, the extension mechanisms 520 may also comprise a secondary dampening mechanism. The secondary dampening mechanism may also be configured to dampen an extension or a contraction of the elastic suspension members 510 and elastic dampening members 512 past extension mechanism 520 . For example, the extension mechanism 520 depicted in FIG. 5 may have a high viscosity lubricant such that the wheel in the extension mechanism 520 turns slowly, inhibiting the movement of the elastic suspension members 510 and elastic dampening members 512 past the extension mechanism 520 .
[0062] In addition to the described embodiments, it may be desirable to isolate multiple isolated members within a single support frame. As shown in FIG. 6 , in an embodiment, a vibration isolation device 600 may incorporate a first isolated member 602 a and a second isolated member 602 b disposed inside a support frame 604 and connected thereto by a plurality of elastic suspension members 610 or elastic dampening members 612 . The embodiment illustrated in and elements described in relation to FIG. 6 are example combinations of such elements, but contemplated combinations should not be considered inclusive of all recited elements or exclusive of additional elements. Additional embodiments may describe additional elements, which may be combined with elements of any other embodiment described herein.
[0063] In an embodiment, such as that depicted in FIG. 6 , the first and second isolated members 602 a , 602 b may be connected to one another horizontally via elastic dampening members 612 to dampen the transmission of vibrations therebetween. In another embodiment, the first and second isolated members 602 a , 602 b may be orientated vertically with respect to one another or the support frame 604 . In yet another embodiment, multiple isolated members may be disposed horizontally and vertically with respect to one another forming a matrix of isolated members disposed within a support frame. For example, the matrix may have two dimensions, such as a 2ร2ร1 arrangement (corresponding to an X-Y-Z-directions convention) or a 2ร1ร2 arrangement. In a yet further embodiment, the matrix may have three dimensions, such as a 2ร2ร2 arrangement. For example, a 2ร2ร2 arrangement may form a cube of 8 isolated members that may each move at least partially independently of one another due to the elastic connections therebetween.
[0064] FIG. 7A depicts an embodiment according to the present disclosure that may be used in heavy machinery applications. FIG. 7B depicts an embodiment according to the present disclosure as applied to a rock crushing machine. The embodiment illustrated in and elements described in relation to FIGS. 7A and 7B are example combinations of such elements, but contemplated combinations should not be considered inclusive of all recited elements or exclusive of additional elements. Additional embodiments may describe additional elements, which may be combined with elements of any other embodiment described herein.
[0065] Vibration isolation device 700 includes a first isolated member 702 a and a second isolated member 702 b suspended from a support frame 704 . The support frame 704 may comprise a plurality of side supports 706 and a top support 708 . The first and second isolated members 702 a , 702 b may each be suspended from a top support 708 by elastic suspension members 710 . As shown in FIGS. 7A and 7B , elastic suspension members 710 may comprise elastic sheets that connect to a portion of or a substantially complete length of the first and second isolated members 702 a , 702 b . The first and second isolated members may also be connected to the plurality of side supports 706 and to one another by elastic dampening members 712 , which may also comprise elastic sheets that connect to a portion of or a substantially complete height and/or of the first and second isolated members 702 a , 702 b . As is also depicted in FIGS. 7A and 7B , the vibration isolation device 700 may be mounted directly to a frame of a rock crushing machine as the sensitive electronic components are now vibrationally isolated.
[0066] FIG. 8 is a flowchart depicting a method 824 for the vibrational isolation of electronic components. The method 824 may include housing 826 electronic components in an isolated member located within a support frame. The isolated member may be connected to the support frame by a plurality of elastic members, where at least two of the elastic members are configured to apply forces having vectors at least about 90ยฐ from one another. The method 824 may then include applying 828 an input vibration to the support frame and absorbing 830 at least part of the energy from the input vibration. Absorbing 830 at least part of the energy from the input vibration may include displacing the isolated member away from an equilibrium position and restoring the isolated member to the equilibrium position such that restoring the isolated member takes more time that displacing the isolated member. In some embodiments, the kinetic of the input vibration and/or movement of the isolated member may be converted into heat in one or more of the plurality of elastic members. For example, the extension and contraction of the elastic members due to the input vibration and/or movement of the isolated member may be damped by the internal friction of the elastic members, which may in turn generate heat.
[0067] In some embodiments, the input vibration may be less than 200 Hz. In other embodiments, the input vibration may be less than 100 Hz. In yet other embodiments, the input vibration may be less than 40 Hz. In yet further embodiments, the input vibration may be less than 15 Hz. The input vibration may include a plurality of vibrational modes. For example, an input vibration may include a first frequency and a second frequency. The first frequency may be about 10 Hz and the second frequency may be about 200 Hz. The 10 Hz frequency may relate to vibrations produced by rock being crushed, while the 200 Hz frequency may relate to a drive motor or feed. In some embodiments, absorbing 830 at least part of the energy from the input vibration may include reducing a first amplitude of the input vibration at or near the first frequency and reducing a second amplitude of the input vibration at or near the second frequency by different amounts. For example, absorbing 830 at least part of the energy from the input vibration may include reducing a first amplitude of the input vibration at or near the first frequency more than a second amplitude of the input vibration at or near the second frequency.
[0068] Testing of an embodiment similar to or the same as vibration isolation device 700 described in relation to FIGS. 7A and 7B indicates the efficacy of a vibration isolation device in accordance with the present disclosure. During operation of a rock crushing machine, a vibration isolation device was connected to the machine. A vibration measurement device was mounted to directly to a support frame of the vibration isolation device and to an isolated member of the vibration isolation device during. Maximum peak particle velocities (โPPVโ) were measured during operation of the rock crushing machine in three axes (longitudinal, transverse, and vertical). PPV is a measurement of the rate of movement of the sensor due to vibrations traveling through the system. It may also be thought of as a product of amplitude and frequency of the vibrations traveling through the system.
[0069] Table 1 depicts the averaged values of tests depicting the reduction in PPV and, hence, measurable vibrations transmitted to the isolated member during operation of the rock crushing machine. The vibration measurement device was rotated 90ยฐ between data collection runs to minimize any systemic variation within the vibration measurement device. The measured vibrations at the support frame may be approximately equal to the input vibrations from the rock crushing machine.
[0000]
TABLE 1
Average PPV Measurement (inches/second)
Location
Longitudinal PPV
Transverse PPV
Vertical PPV
Isolated Member
1.2315
3.7155
1.798
Support Frame
1.549
4.2905
2.8975
% Reduction
20.50%
13.40%
37.95%
[0070] Table 2 depicts the associated change in dominant frequency in measured vibration between the support frame and the isolated member. The dominant frequency (DF) may shift toward a higher frequency due to greater dampening on the lower frequency (i.e., longer duration) vibrations applied to the support frame.
[0000]
TABLE 2
Average Dominant Frequency Measurement (Hertz)
Location
Longitudinal DF
Transverse DF
Vertical DF
Isolated Member
11.25
11.15
10.1
Support Frame
9.75
8.6
6.2
[0071] The increase in frequency is associated with a decrease in amplitude indicated by the overall reduction in maximum PPV, as described. In at least one embodiment, a vibration isolation device in accordance with the present disclosure may therefore preferentially isolate low frequency vibrations. Testing data shows that while the isolated member may experience an overall reduction in the vibrational energy and/or movement relative to the input vibrations experienced by the support frame, the isolated member experiences vibrational energy that is preferentially reduced at lower frequencies, such as below 10 Hz.
[0072] The articles โa,โ โan,โ and โtheโ are intended to mean that there are one or more of the elements in the preceding descriptions. The terms โcomprising,โ โincluding,โ and โhavingโ are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to โone embodimentโ or โan embodimentโ of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are โaboutโ or โapproximatelyโ the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.
[0073] A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional โmeans-plus-functionโ clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words โmeans forโ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.
[0074] The terms โapproximately,โ โabout,โ and โsubstantiallyโ as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms โapproximately,โ โabout,โ and โsubstantiallyโ may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to โupโ and โdownโ or โaboveโ or โbelowโ are merely descriptive of the relative position or movement of the related elements.
[0075] The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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Implementations of the present invention relate to devices, systems, and methods for isolating electronic components from input vibrations. The vibration isolation device may passively isolate the housed electronics from substantially all input vibrations. The vibration isolation device may include elastic members to suspend the electronic components within a support frame such that input vibrations are unable to directly influence the electronic components.
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FIELD OF THE INVENTION
The invention relates to flocced mineral materials. More particularly, the invention relates to an improved tensile strength and heat resistant flocced fluorhectorite paper.
BACKGROUND OF THE INVENTION
Flocced mineral materials can be used to prepare high temperature resistant, water resistant materials. These non-asbestos materials can be prepared as described in U.S. Pat. No. 4,239,519 and No. 4,707,298. In particular U.S. Pat. No. 4,707,298 describes how lithium in lithium fluorhectorite can be exchanged with guanidinium ions to provide films with good flexibility and wet strength.
SUMMARY OF THE INVENTION
A heat and water resistant mineral article with improved tensile strength comprises magnesium fluorhectorite and guanidinium fluorhectorite.
A preferred composition comprises on a weight basis (a) 20 to 40% ceramic fiber, (b) 30 to 60% magnesium fluorhectorite, and (c) 20 to 50% guanidinium fluorhectorite to produce a paper which maintains structural integrity after heat treatment.
FIG. 1 illustrates the tensile strength improvement of the invention.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered that mixtures of two fluorhectorite materials give surprising and unexpected properties in fluorhectorite papers. FIG. 1 provides a graphic representation of the synergism where the strength of the mixture (10-90 to 90-10) increases relative to either component alone. As shown, the tensile strength with pure magnesium fluorhectorite is slightly higher than with pure guanidinium fluorhectorite. From FIG. 1 the peak in strength occurs with a ratio of about 60% magnesium fluorhectorite to 40% guanidinium fluorhectorite.
While not known with certainty, it is believed that the very fine particle size of the guanidinium fluorhectorite floc serves to fill in voids between the larger magnesium fluorhectorite floc in the paper, thus acting as a binder.
A starting material for preparing either magnesium fluorhectorite or guanidinium fluorhectorite is lithium fluorhectorite as prepared according to U.S. Pat. No. 4,239,519. Examples 1 and 2 of U.S. Pat. No. 4,707,298 describe the preparation of guandinium fluorhectorite. Magnesium fluorhectorite is similarly prepared using Mg ++ solutions.
Reinforcing materials useful for preparing articles according to the invention are inorganic fibers such as ceramic, mineral, or glass fibers.
A preferred reinforcement material is ceramic fiber which is available as Kaowool from Babcock & Wilcox Co.
Flocculated materials were prepared and tested as described in U.S. Pat. No. 4,707,298, which is incorporated by reference.
The invention has industrial applicability for packaging materials which must retain structural integrity after elevated temperature exposure.
The following preparations and examples illustrate the practice of the invention. Example 1 represents the best mode.
PREPARATION A
Magnesium Fluorhectorite Floc
A 10% solids lithium fluorhectorite dispersion prepared according to U.S. Pat. No. 4,239,519 was added to a 1M solution of magnesium chloride under constant agitation. The salt solution represented a greater than a 4:1 weight excess to the dispersion. During the addition, the lithium dispersion was destabilized as magnesium ions exchanged with lithium ions; thereby producing flocculated magnesium fluorhectorite. The magnesium floc was washed with deionized water until chloride free. The floc (5 to 10% solids) was broken down in a Waring blender to produce a homogeneous slurry with the following particle size distribution as determined by sieve analysis.
______________________________________12 Mesh 18 Mesh 35 Mesh 60 Mesh 200 Mesh______________________________________% Floc 0 0.3% 2.44% 73.29% 23.96%Retainedon Screen______________________________________
PREPARATION B
Guanidinium Fluorhectorite Floc
Guanidinium fluorhectorite floc was prepared as in Preparation A except that a 1M solution of guanidinium chloride was used for preparation of the slurry. The guanidinium fluorhectorite floc had much finer particle size than the magnesium fluorhectorite floc of Preparation A.
EXAMPLE 1
Fluorhectorite based papers were prepared containing 30% by weight Kaowool ceramic fibers. Preparation A, Preparation B, and combinations of both slurries plus the Kaowool were diluted to 2% solids with water and placed in a 11.5ร11.5" hand sheet mold (manufactured by Williams Apparatus Co.) and then dewatered. The sheets produced were then wet pressed and dried on a drum drier to produce papers for testing.
Tensile strength measured were determined using an Instron at 1.5 inch jaw separation and a 0.2 inch/minute crosshead speed. Table 1 contains comparative results.
TABLE 1______________________________________% Kaowool % Magnesium % Guanidinium TensileFiber Fluorhectorite Fluorhectorite (PSI)______________________________________30 70 -- 39130 44 26 55830 -- 70 302______________________________________
Table 1 illustrates the discovery that papers prepared from the combination have about twice the tensile strength of control sheets.
EXAMPLE 2
Guanidinium fluorhectorite was prepared as in Preparation B except for using a vibro cell by Sonic & Materials, Inc. after the floc was blended. Median particle size was 30.7 microns with a 1 to 192 micron distribution as measured by a Cilas Granulometer. This material was used with Preparation A to prepare additional samples to allow a determination of the theoretical curve shown in FIG. 1. Table 2 contains comparative results.
TABLE 2______________________________________% Kaowool % Magnesium % Guanidinium TensileFiber Fluorhectorite Fluorhectorite (PSI)______________________________________30 60 10 37430 50 20 49830 44 26 61130 35 35 55630 25 45 54830 15 55 426______________________________________
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A heat and water resistant paper prepared with ceramic fiber and a 90-10 to 10-90 mixture of magnesium fluorhectorite and guanidinium fluorhectorite provides improved tensile strength. The fluorhectorites are flocculated from lithium fluorhectorite by ion exchange with 1 M solution of magnesium chloride and guanidinium chloride.
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FIELD OF THE INVENTION
This invention relates generally to air conditioning apparatus and more particularly to apparatus and methods for maintenance of the water line that drains water from a pan that receives water that condenses on the evaporator coils of an air conditioning system.
BACKGROUND OF THE INVENTION
It is well known in the art to provide a receptacle such as a tray or pan beneath the evaporator coils of an air conditioner to receive water that condenses from the air as it is cooled. A drain pipe line is generally connected to a side wall of the tray to drain the condensate water as it accumulates. The drain pipe line is commonly a horizontal pipe connected to the pan followed by an elbow, then a vertical line. The vertical line generally terminates outside the building in a water trap to drain to the atmosphere. The line is commonly formed of either one inch or three quarter inch rigid pipe, but other sizes may be used. Because water may stand still in the system, various microorganisms may grow in the tray and drain pipe until they clog up the drainage system. When this occurs, water overflowing from the tray may cause considerable damage. Because the drainage system and tray are out of sight and may be relatively inaccessible, they may be neglected until damage occurs. Clearing obstructions in the drain line and routine maintenance of the drain line are now generally done by manually disconnecting the drain line and blowing out, or sucking out, obstructions. The drain line is then reconnected. A less labor intensive and convenient system would encourage routine maintenance and avoid complete blockage.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an assembly or kit for service personnel to facilitate maintenance. The kit supplies all of the necessary items that enable the service person to modify the drainage system so that it is then much easier to clean out the drain line by forcing fluids through it on this visit and on future visits. A first unit of the kit is a flexible connector adapted to fit onto the rigid pipe after a portion of the pipe line has been permanently cut away. The flexible connector is open at both ends. Each end is provided with a hose clamp to make a water-tight seal of the connector to restore the integrity of the drain line after the portion of the original pipe line has been cut away. The flexible connector may be straight to replace a straight section of drain pipe or an elbow to replace an elbow section of drain pipe. A proximal end of the flexible connector is easily disconnected from the pipe line when it is desired to clean out the line. A rigid straight connector has a first open end adapted for fluid tight insertion into the opened end of the flexible connector. The second open end of the rigid straight connector is provided with a threaded female water hose coupling. This is also termed a garden hose connector. The kit then provides the service person with four different options for clearing the drain line by providing three different fluid adapters, each of which simply screws into the female water hose coupling on the second end of the rigid connector fitted onto the flexible connector. Each fluid adapter has the male water hose connection at a first end, and the second end has one of:
1. A barbed tube for connection to a resilient tube that may supply fluid such as air or liquid to dislodge and/or wash away an obstruction or flush the drain line.
2. A compressed gas tire valve housing for delivering compressed gas.
3. A tapered funnel adapted to receive the nozzle of a wet vacuum/blower hose.
A fourth option uses a garden hose for forcing water through the line. The conventional garden hose terminates in a male water hose connection.
After the line is cleared, the rigid connector is pulled from the end of the flexible connector, after the hose clamp is loosened. The free end of the flexible connector is then forced onto the drain line and secured with the hose clamp to restore the integrity of the drain line until the next maintenance visit.
These and other objects, features, and advantages of the invention will become more apparent from the detailed description of an exemplary embodiment thereof as illustrated in the accompanying drawings, in which like elements are designated by like reference characters in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a condensate drain line of the prior art.
FIG. 2 is a side elevation view of the condensate drain line after the elbow has been replaced and maintenance completed.
FIG. 3 is a side elevation view of the condensate drain line after a vertical section has been replaced and maintenance completed.
FIG. 4 is a plan view of a kit of the invention.
FIG. 5 is a side elevation view of a portion of the condensate drain line after elbow has been replaced and ready for maintenance with barbed tube in place.
FIG. 6 is a side elevation view of a portion of the condensate drain line after a straight section has been replaced and ready for maintenance with tire valve housing in place.
FIG. 7 is a side elevation view of a portion of the condensate drain line after elbow section has been replaced and ready for maintenance with the tapered funnel in place.
FIG. 8 is a side elevation view, partially cut away, of a portion of the condensate drain line after elbow section has been replaced and ready for maintenance with a garden hose in place.
FIG. 9 is a sectional detail of a portion of FIG. 7 with nozzle in place.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now first to the drawing FIG. 1 , a prior art drain line pipe 5 is in fluid communication with side 27 of a pan 28 . The pan receives atmospheric water that condenses on the evaporator coils 29 of an air conditioning unit (not shown). The drain line 5 may have a variety of configurations and pipe sizes to fit a particular installation. It starts with an elbow 1 at the pan 28 , and connects to a vertical pipe 2 . The line terminates with a water trap 26 that empties water outside the building. Marks A-A indicate where the elbow is cut away to install a flexible elbow of the invention. Marks B-B indicate where a straight portion of the vertical pipe is cut away to install a flexible straight connector of the invention. A decision will be made to install only one of these flexible connectors, based upon the physical conditioned found by the user.
FIG. 2 illustrates the condition of the drain line pipe 5 after pipe elbow 1 has been cut away, a flexible elbow 3 has been installed, and the maintenance completed.
FIG. 3 illustrates the drain line pipe after a portion of straight pipe 2 has been cut away, the flexible straight connector 6 has been installed, and the maintenance completed.
FIG. 4 illustrates a portable maintenance kit 16 of the invention that is supplied to a person servicing air conditioning equipment. The kit supplies, within an internal volume 17 , all the special materials needed to modify an air conditioning drainage pipe system for easier cleaning. At present, most systems employ three quarter inch pipe or one inch pipe. The kit provides materials to modify those pipes. In future, items for other pipe sizes may then be included. The kit includes: a flexible elbow 3 having a hose clamp 4 at each open end, and a straight connector 6 with a hose clamp 4 , at each open end, both for three quarter inch pipe, and flexible elbow 3 w and flexible straight connector 6 w , both for one inch pipe; a rigid straight connector 7 having a first open end adapted to fit snugly into an open end of either elbow 3 or straight connector 6 , and a second open end having a threaded female water hose coupling; a rigid straight connector 7 w having a first open end adapted to fit snugly into an open end of either elbow 3 w or straight connector 6 w , and a second open end having a threaded female water hose coupling 9 ; a rigid fluid connector 10 having a first open end provided with a threaded male water hose coupling 11 and a second open end provided with a barbed tube 18 for a resilient hose; a rigid fluid connector 12 having a first open end provided with a threaded male water hose coupling 11 and a second open end provided with a tapered funnel 19 adapted for receiving a hose nozzle from a wet vacuum/blower; and a rigid fluid connector 13 having a first open end provided with a threaded male water hose coupling 11 and a second open end provided with a compressed gas tire valve housing 20 .
FIG. 5 illustrates the use of the invention preparatory to clearing the drain line with a fluid source terminating in a resilient tube, when flexible elbow 3 has been installed. The elbow 3 is released at its upper end, rotated, and rigid straight connector 7 inserted by a first end 8 into the free end of elbow 3 to make a fluid tight connection. A second end of connector 7 provides a female water hose coupling 9 . A rigid fluid connector 10 has a male water hose coupling 11 at a first end and a barbed tube 18 at a second end to receive a resilient tube to force cleaning fluid through the line from a source of fluid (not shown).
FIG. 6 is a side elevation view of a portion of the condensate drain line 2 after a straight section has been replaced by flexible straight connector 6 and ready for maintenance with tire valve housing fluid connector 13 in place.
FIG. 7 is a view of a portion of the condensate drain line after elbow section 1 has been replaced by flexible elbow 3 and rigid straight connector 7 , and ready for maintenance with the tapered funnel fluid connector 12 in place ready to receive a hose nozzle (not shown) from a wet vacuum/blower.
FIG. 8 is a view of a portion of the condensate drain line after elbow section 1 has been replaced by elbow 3 and rigid straight connector 7 , and ready for maintenance with garden hose 14 .
FIG. 9 is a sectional detail of a portion of FIG. 7 with hose nozzle 15 from a wet vacuum blower (not shown) in place on tapered funnel end 19 of fluid connector 12 . The male water hose coupling end 11 of connector 12 fits securely in the female coupling end of straight connector 7 which is sealingly engaged in the free end of flexible elbow 3 . The joint between male and female couplings is provided with a resilient washer 21 .
While I have shown and described the preferred embodiments of my invention, it will be understood that the invention may be embodied otherwise than as herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention.
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A drain pan collects condensate water from an air conditioner. A drain line includes an elbow connecting the pan to a vertical pipe that drains the condensate water to outside. The drain line must be periodically cleaned to prevent clogging. A kit and method is provided to modify the drain line so that it can then be cleaned more easily, and components are provided to facilitate the drain line cleaning process.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of Ser. No. 374,741, filed May 4, 1982, now U.S. Pat. No. 4,590,746, which is a continuation-in-part application of Ser. No. 307,283, filed Sept. 30, 1981, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to equipment and a process for wrapping a pallet load with a stretchable wrapping material in such a manner so as to achieve the tightest wrap possible without damaging the load being wrapped.
2. Description of the Prior Art
United Kingdom Pat. No. 2,059,906 discloses a stretch wrapping machine and process. An accumulator having a dancer roller which contacts the moving film, compensates for variations in speed at which the film is drawn into the object being wrapped. The dancer roller is biased against the moving film by a constant force producing element.
Several different types of stretch wrapping machines are illustrated in U.S. Pat. Nos. 4,050,221; 4,077,179; and 4,079,565, all to Lancaster et al. Other stretch wrapping machines are shown in U.S. patent applications Ser. Nos. 72,471, filed Sept. 4, 1979 to Humphrey, and 235,946, filed Feb. 19, 1981 to Humphrey et al, both of which are assigned to the same assignee as the present application. The subject matter of both of these applications is hereby incorporated by referrence.
Stretch wrapping a pallet load may be compared to stretching a rubber band around a group of objects. Presuming that there is a uniformly-shaped pallet load that has been stretch wrapped with a stretchable wrapping film tensioned to a 10 pound pull and that there are three wraps, i.e. the load has been wrapped three times around the load, then the force holding the load together are 30 pounds in both directions at each corner. At the center points of each side of the load there is no direct inward holding force although the products in the center of the load are clamped together by the adjacent outer products. There is also a diagonal force which is the resultant of the two directional forces on each corner of the load.
It must be recognized that all wrapping films relax with the result that the rubber band effect or holding power is diminished with the passing of time. The amount of tension required for a particular load must be sufficient to contain the integrity of the load which may settle, change shape or shift in transit or during storage. A shifting load alternately strecthes and relaxes the film; each time the film is stretched further, the recovery tension is reduced. Enough initial tension must be applied to the load to compensate for these subsequent.
If the extent to which the wrapping material is stretched is too great, then this will diminish its holding power. Most films produce their greatest holding force or tension when stretched during the wrapping operation between approximately 20% to 35%. If a film is stretched beyond its elastic limit, which is the point where permanent deformation occurs, the film thins out in gauge and its ability to recover and hold the load will decrease, perhaps drastically and perhaps even destroyed. For example, a wrapping film with a maximum holding power of 30 pounds when stretched to 30% stretch may have only 15 to 17 pounds holding power if stretched over 100%. If the resulting weaker film is adequate to hold the load securely then economies will result by using less film per pallet load. Otherwise, additional wraps will be required to obtain the same holding force as can be obtained by fewer of the same film stretched only 20% to 35%.
As indicated above, all stretch films relax to some extent, in varying degrees, after the load is wrapped. In addition, the wrapping films which have been stretched or prestretched more than 100% will tend to relax more than films which are stretched 20% to 35% during the wrapping process. The objective in wrapping a load with a stretchable wrapping material is to obtain the tightest wrap possible without damaging or causing collapse of the load.
The concept of prestretching the stretchable wrapping material before wrapping a load has recently emerged and has been incorporated in several commercial machines. Employing a film prestretching device makes the film longer and thinner while simultaneously increasing the yield and decreasing the load holding power or strength of the film. Since various loads, however, may need to be wrapped with film having different holding powers, prestretching enables a single type of film to be used in wrapping a plurality of different types of loads with the film then being prestretched to the extent necessary.
Whether or not a prestretching device is used, however, the film must still be stretched by applying tension on the film as it is applied to the load. This tension, which results from the load pulling the film against some restraining device during the wrapping operation, is normally necessary since it causes the stretching that provides the holding power to hold the load together. Prestretching is a separate and isolated function from stretch wrapping of the load. Whether film prestretching is done on the wrapping machine or in the film manufacturers plant, the film normally must still be further stretched during the wrapping operation.
The currently available commercial prestretching devices noramlly consist of two rubber-covered rollers which are rotated at different speeds. The speed differential is created by appropriate gears, belt drives, separate D.C. variable speed motors, separate brakes or other similar types of mechanisms. While some of the prestretching devices are powered by the load pulling the film, most of the devices are motor powered.
In the operation of the pre-stretching devices, the film passes over both rollers with the second roller rotating at a faster speed than the first roller thereby providing a stretching action on the film. If the second roller rotates twice as fast as the first, assuming there is no slippage and a minimum "necking down" of the film, the film will be stretched approximately 100%. Various speed ratios of the rollers will produce proportional percentage stretch in the film. For example, a relatively heavy gauge film (#90) may theoretically be doubled in yield (length) to wrap light loads with light tension. The original holding power of such film was 30 pounds but with 100% pre-stretching the gauge changes to #45 and the holding power is approximately 16 pounds, whcih is adequate for light loads.
Loads consisting of cartons which are easily crushed may be stretch wrapped with light gauge film under very low tension. Light gauge films are on the market in the range of 60 to 70 gauge but these films cost more per pound. The prestretching devices permit the use of lower cost heavy gauge films which may be pre-stretched to make light gauge films which are then wrapped around the load under light tension. For example, a 5000 foot roll of 100 gauge film if pre-stretched to 100% would yield 10,000 feet of 50 gauge film and wrap twice as many pallet loads which may be adequately wrapped under light tension.
There are several different types of pre-stretching systems. A first type is a non-powered system which relies upon the load pulling the film both off the roll of film and through the pre-stretching device. This system eliminates the requirement for friction brakes but considerable inertia is added to the operation of the system both due to the necessity of pulling the material off of the film roll and due to the need to rotate the rubber rollers which are geared together. In addition, the gears between the rollers must be changed in order to change the percentage of pre-stretching.
A second type of system is a powered system that employs a variable speed motor drive for each of the two rubber rollers plus a friction brake on the film roll. The two motors must attempt to maintain a speed differential under varying film demands which often leads to severe inaccuracies in the extent of pre-stretching. In addition, the friction brake adds inherent erratic behavior toward trying to maintain a constant pre-stretching.
A second type of powered system uses one power driven roll with a friction brake then being coupled to the other roller. The pre-stretching is adjustable by varying the setting of the electromagnetic brake torque of the friction brake.
In all of the above systems, however, there is still the need for additional stretching of the film to take place between the pre-stretching device and the load when actually wrapping the load. This additional stretching during the wrapping operation quite often varies in magnitude due to the uneven shape of the load, which is normally not round. The final result is that each load is still wrapped under a different stretch tension as well be further explained below.
While there are several benefits of pre-stretching, such as outlined above, there are also definite limitations to such procedures. In most stretch wrapping applications, the integrity of the unitized load depends upon the cling of one layer of film to another layer of film. In addition to keeping the tail end of the wrap from unwrapping, film cling is extremely important in spiral wrapping where the "lamination" or overlaying of one layer upon another produces considerable strength in the wrapped load. Many of the stretchable films currently on the market tend to dramatically lose their clinging ability when stretched beyond 100%. Often loads that are stretch wrapped with 120% pre-stretched film have been observed to become unwrapped in 48 hours. Other films will become too brittle and shatter like glass when excessively pre-stretched while yet other films will take a set and lose their load holding power. All films tested have demonstrated a considerable loss in strength in the transverse direction when stretched over 100%.
This inherent limitation in the extent to which it is beneficial to pre-stretch a film prior to wrapping becomes even more critical upon realizing that further variable stretching occurs during the wrapping operation itself. The rotating turntable support member rotates a load which is usually not round. This results in variable demands on the film dispensing mechanism. This becomes a particular problem where the dispensing of stretchable material does not occur at an identical rate with the demand for such material by the rotating load. This is particularly a problem where a pre-stretching device is inserted between the film roll and the load since the roll of film does not roll freely in response to the taking up of film by the load. Inherently this variable demand for film that is not synchronized with the dispensing mechanism produces an erratic tensioning of the film.
As can be seen from FIG. 8 of the drawings, which illustrates a prior art system, with a rectangular load the demand for film will vary greatly as the load is rotated. Assuming that the pallet load size is 40 inches by 60 inches when the film is wrapping the long side of the load, the effective wrapping diameter is 40 inches. At 10 rpm turntable speed, the film is drawn from the roll at 105 fpm. As the corner of the load approaches, the effective wrapping diameter becomes the diagonal dimension of 72 inches. At 10 rpm turntable speed, the film must now accelerate to 188 fpm in less than 1 second, i.e. an 80% increase in speed. Subsequent rotation of the load produces a similar decrease in speed and a series of sudden accelerations and decelerations as the load continues to be wrapped. The film speed curve abruptly changes during the wrapping operation. The inertia and momentum of the film roll constantly opposes the desired results by tightening and slackening film tension during the wrapping cycle which further enhances the degree of variance in tension of the wrapping film. In such a wrapping operation, the film tension at the corners of the load can double with the film brake turned off due entirely to the inertia of the film roll. The peak in film tension occurs just as the sharp corner of the load is presented to the film. Consequently, the tension on the film must be set well below (approximately half) the theoretical limits of the film to prevent breaking of the film.
This problem is further aggravated by the braking systems in common use today. Most of the braking systems employ some variation of a friction brake, usually electro-magnetically controlled. An electromagnetic brake has approximately 300 to 400% more torque at rest (static) than when rotating. This means in connection with the operation of the stretch wrapper that when the film tension drops off suddenly during load rotation, the film roll stops turning momentarily and the brake becomes tightly locked. As the corner of the load swings outwardly (see FIG. 8) the film tension suddenly increases and the friction brake must be jerked into rotation to reduce its braking torque to preset value. This violent action occurs just as a relatively sharp corner of the load comes around and it is one of the major causes of film breakage. This problem becomes even more pronounced with higher speeds of rotation.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved stretch wrapping machine and stretch wrapping operation.
Another object of the present invention is to provide a stretch wrapping machine for wrapping a load with a stretchable material while maintaining such material under a substantially constant tension.
A further object of a first embodiment of the present invention is to provide a stretch wrapping machine that includes a pre-stretching device and is capable of wrapping a load with a stretchable wrapping material while maintaining such material under a substantially constant tension during the wrapping operation.
Still another object of the present invention is to provide an improved stretch wrapping machine for enabling the wrapping of a load with a stretchable wrapping material and reducing the possibility of breakage of the material during the wrapping operation due to variations in tension on the stretchable material.
A still further object of the present invention is to provide an improved stretch wrapping machine for more tightly wrapping loads without crushing any portion of the load.
Still another object of the present invention is to provide an improved stretch wrapping machine capable of tightly wrapping irregularly shaped loads while maintaining a substantially constant stretch of the stretchable material.
A still further object of the present invention is to provide a stretch wrapping machine and a wrapping operation that enables the stretchable material to be pre-stretched to a greater extent without subsequently incurring a risk of film breakage during the wrapping operation.
A still further object of the present invention is to provide a stretch wrapping machine and operation that overcome those problems of prior machines discussed above.
Still another object of the first embodiment of the present invention is to provide a stretch wrapping machine that eliminates the need to use troublesome friciton brakes and provides a film dispensing system that supplies the stretchable film to the load during the wrapping operation under a substantially constant tension and compensates for speed surges resulting from uneven configuration of the load.
Another object of a second embodiment of the invention is to provide a stretch wrapping machine having a friction brake which controls the supply of film while maintaining a relatively constant tension on the film.
The above objectives are accomplished in the utilization of the stretch wrapping machine and stretch wrapping operation of the present invention wherein the stretchable wrapping material is wrapped around the pallet load while maintaining a substantially constant tension on the wrapping material. The constant tension on the wrapping material is maintained by providing a mechanism that in effect isolates the wrapping of the load and the accompanying drawing up of material by the load from the dispensing of the stretchable material from the roll of material. In this manner the tension on the stretchable material can be maintained substantially constant even though the rate at which material is taken up by the load varies due to the varying shape of the load.
In order to stretch the stretchable wrapping film being wrapped around the load, the load is rotated at a speed for drawing up film faster than the film is dispensed. In the preferred embodiment of the present invention, the film can be pre-stretched up to 300% and then further stretched during the wrapping operation to cause a total stretching of 500%.
The pallet load that is to be wrapped by the wrapping machine is placed upon a load support member. The support member then is normally rotated so as to take up the stretchable wrapping material to be wrapped around the load. Alternatively, the dispensing mechanism which holds the stretchable wrapping material can revolve around the load support member so that the load pulls off the stretchable wrapping material as the dispensing mechanism revolves. A drive mechanism provides the relative movement between the dispensing mechanism and the load support member.
A tension maintaining mechanism forming part of the wrapping machine acts to maintain the substantially constant tension on the stretchable material as the material is wrapped around the load. This tension maintaining mechanism applies a biasing force against a tension roller over which the stretchable material passes so as to maintain a constant tension on the stretchable material. The tension roller is movable with respect to the load support member. Thus as the load is rotated, if due to the configuration the load draws up the stretchable material more rapidly then the tension roller moves closer to the load support member so as to maintain the constant tension. Alternatively, as the speed at which the load draws up the stretchable material decreases, the tension roller moves away from the support member so as to pick up any slack that would otherwise occur in the stretchable material and thereby maintain the constant tension in such material.
The tension roller of the tension maintaining mechanism is attached to a pair of arms capable of swinging either towards or away from the support member so in essence the tension roller with the arms act as a "dancer". To understand the operation, returning to prior art FIG. 8, it can be seen that as the corner of the load swings outwardly it suddenly demands more film. In accordance with the present invention to compensate for such demand, the dancer of the tension containing mechanism swings forward so as to dispense surplus film stored in the dancer loop. As the short side of the load comes around thus requiring less film than the dispensing mechanism in supplying, the dancer swings away so as to store the surplus film. The biasing force on the dancer which is constant throughout arcuate swing maintains the same tension on the film in any position of the dancer.
The dispensing mechanism includes a film feed roll for drawing film off the roll of stretchable material at a constant rate thus the film feed roller acts as a governor that simply feeds the stretchable material at a constant rate. In both embodiments, a control device can be incorporated and operated in conjunction with the movement of the dancer so as to sense when the dancer moves too far in either direction. In the first embodiment when such movement of the dancer occurs, the speed of the film feed roller is adjusted by the control device to bring the system back into balance. In the second embodiment when such excess movement of the dancer occurs the braking force which is applied to the film feed roll is varied to bring the system back into balance.
In order to maintain the biasing force on the dancer and hence the tension roller that presses against the stretchable material,a constant force applying mechanism is coupled to the dancer to maintain the constant force as the dancer swings back and forth. Two possible types of mechanisms that can be used for supplying the necessary constant force to the dancer are a fluid cylinder having a self-relieving type air regulator and a Negator spring that is marketed by Hunter Spring Company. Both of these mechanisms provide a constant force regardless of displacement. A constant torque electric motor can also be used to produce constant force. If the constant force mechanism biases (or loads) the tension roller with force of 100 lbs. then the tension force on the stretchable material is 50 lbs. on the material extending from each side of the roller. The actual force applied by the fluid cylinder or spring, however would be higher since the length relationship of the linkage members between the tension roller and the force applying mechanism must be taken into consideration.
In the first embodiment, prior to actually wrapping the stretchable material around the load, it is possible to pre-stretch the material. In order to carry out such a pre-stretching operation the material is passed between a first stretching roller and a second stretching roller arranged along the path of travel of the material with the second roller rotating with a greater circumferential speed than the circumferential speed of the first stretching roller. This differential in speed creates a corresponding pre-stretching of the stretchable material. The second stretching roller of the pre-stretching mechanism can be the constant rate feed roller of the dispensing mechanism. Thus the only additional roller is a first stretching roller the speed of which is varied depending upon the extent of pre-stretching desired. In order to ensure that the pre-stretching occurs to the extent desired as determined by the speed differential between the two rollers, spring biased nip rollers can be used to clamp the stretchable material against the stretching rollers to avoid any slippage of the material during the pre-stretching operation.
In conjunction with the utilization of the constant tension mechanism of the present invention, it is possible to employ a horizontal supply mechanism that constitutes another aspect of the invention. The horizontal supply mechanism enables a much larger roll of stretchable wrapping material to be used in conjunction with a wrapping machine particularly a spiral type wrapping machine since the roll does not move up and down with the spiral dispensing carriage. With this type of wrapping machine, the film roll and the feed roller as well as the stretch roller are arranged horizontally in fixed positions so that each rotates about a fixed horizontal axis. The film as it is dispensed from the roll passes over a 45ยฐ air bar that turns the film into a vertical position just prior to being supplied to the dancer mechanism with the tension roller. Only the dancer mechanism with the tension roller and the air bar move up and down so as to supply the film to the load in spiral application. This particular mechanism provides two principal benefits. First, the mechanism eliminates the need to move the heavy weight of the film roll, stretch rollers, drive motors, controls and other associated equipment up and down on the vertical cage since all of these remain stationary. Thus a lighter, safer and more economical elevator mechanism can be used. Second, it now becomes practical to use much larger film rolls which more easily can be mounted horizontally for most packaging machines particularly on automatic machines thereby enabling, for example, up to four times as many pallet loads to be wrapped without stopping the machine or changing the rolls.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of a stretch wrapping machine in accordance with the present invention.
FIG. 2 is a diagrammatic view illustrating the operation of the stretch wrapping machine of FIG. 1.
FIG. 3 is another diagrammatic view similar to FIG. 2 illustrating the stretch wrapping machine during another stage of the wrapping operation.
FIG. 4 is a diagrammatic view of the stretch wrapping machine illustrated in FIG. 1.
FIG. 5 is a top plan view of the dispensing mechanism of the stretch wrapping machine illustrated in FIG. 1.
FIG. 6 is a front plan view of the dancer mechanism and tension roller used in the stretch wrapping machine illustrated in FIG. 1.
FIG. 7 is a perspective diagrammatic view of another embodiment of the stretch wrapping machine of the present invention.
FIG. 8 is a diagrammatic view of a stretch wrapping machine in accordance with the prior art.
FIG. 9 is a top view of the preferred form of the first embodiment which includes a motor control mechanism for the stretch rollers.
FIG. 10 is an elevational view of a modification of the embodiment of FIG. 9.
FIG. 11 is a view of a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A stretch wrapping machine 2 such as illustrated in FIG. 1 has a rotatable load support turntable 4 and a dispensing mechanism 8 both arranged on a support frame 6. Turntable 4 is capable of rotating around a central axis so that it draws off stretchable wrapping material (often referred to as film), from the dispensing mechanism with the supply roll 16.
The particular stretch wrapping machine illustrated in FIG. 1 is a spiral type wrapping machine in which the width of the wrapping material is less than the height of the load that is to be wrapped. In the operation of the spiral wrapping machine during the wrapping operation, dispensing mechanism 8 moves up and down carriage 10 as turntable 4 rotates the load to be wrapped. In this manner the load is wrapped with a plurality of overlapping wraps as the dispensing mechanism moves up and down on the carriage. This movement of the dispensing mechanism is controlled by movement of drive chain 12 which can be driven in either direction for moving dispensing mechanism 8 which is coupled to the drive chain.
Dispensing mechanism 8 includes a supply roll of the stretchable wrapping material 16 which first passes around a first roller 18 and subsequently over a feed roller 32 before being supplied to the constant tension mechanism. A motor drive 20 drives feed roller 32 which in turn drives roller 18. Alternatively motor drive 20 can be directly coupled to roller 18 and then feed roller 32 would be coupled to and driven by roller 18.
The output gear (sprocket) 23 of motor drive 20 is coupled to gear (sprocket) 25 and transfer drive shaft 26 through a drive chain 22. Transfer shaft 26 in turn rotates pulley 28 which through drive belt 24 rotates pulley 30. By properly sizing the portions over which drive belt 24 passes around pulleys 28 and 30, a desired rotating relationship between the two pulleys and hence rollers 18 and 32 can be obtained. A variable speed drive mechanism can be used between shaft 26 and shaft 31. Rotation of pulley 30 through shaft 31 rotates roller 18 at a speed having a desired relationship to the speed of roller 32.
The speed at which feed roller 32 rotates should remain at a relatively constant set level for supplying the stretchable material to the tension mechanism at a constant rate during a wrapping operation. The speed of feed roller 32 can vary under certain circumstances during a wrapping operation, however, the speed of rotation of feed roller 32 can be varied by varying the output speed of motor drive 20. This speed of rotation is controlled through control mechanism 14, which is also capable of controlling other various aspects of the operation of the stretch wrapper such as the number of wraps to be made around the load and the height to which the dispensing mechanism should travel in wrapping the load.
Gear 25 and transfer shaft 26 act as the coupling for driving roller 18 and also drives feed roller 32. Due to the difference in sizes of pulleys 28 and 30, as shown in FIG. 1, as well as in FIG. 5, feed roller 32 will rotate at a much faster speed than roller 18. The ratio of the speed of rotation of the circumferential surface of feed roller 32 as compared to roller 18 determines the extent of pre-stretching that will occur. If there is no slippage between the wrapping material and rollers 18 and 32, then the extent of pre-stretching is directly proportional to the speed differential between the two rollers. In order to prevent any slippage, both roller 18 and feed roller 32 are covered with a rubber material for firmly grasping the stretchable material as it passes around the roller. In addition, nip rollers 34 and 36 which are spring biased by mechanism 56 as shown in FIGS. 4 and 5 press the nip rollers for clamping the stretchable material against rollers 18 and 32 as the rollers rotate so as to avoid any slippage of the stretchable material.
The operation of the constant tension mechanism can be seen and is explained herein in conjunction with the diagrammatical illustrations in FIGS. 2 and 3 as well as comparison with the prior art system as illustrated in FIG. 8. As shown in FIG. 8, as load 78 rotates the speed at which the load rotates will vary. This can be seen by observing the difference in the length of the stretchable material between roller 84 and load 78 between the load positioned as shown by the solid lines and the load positioned as shown by the broken lines. If roller 80 is power driven or rollers 82 and 84 are power driven so that the quantity of material passing around roller 84 is relatively constant during the wrapping operation then the variance in the demand for film by rotating load 78 will increase the tension on the film thereby causing significant variations in the amount of stretching of the film during the wrapping operation. Even if the machine as shown in FIG. 8 supplies the film completely based upon the pulling of the material by rotating load 78, due to the inertia in pulling the various rollers the tension on the wrapping material still will vary.
In the wrapping machine and operation of the present invention, however, this variance in the demand for wrapping material by the rotating load 44 is compensated for by the constant tension mechanism so as to maintain a constant tension on the section of stretchable wrapping material 42a and 42b being supplied to and wrapped around load 44 as it rotates. As shown in FIG. 2, as load 44 rotates to a position where the speed at which the load draws up the stretchable wrapping material increases, tension roller 38 moves closer to the load by pivoting movement of dancer arms 40. As tension roller 38 moves closer, it supplies the extra material needed while the tension force that pulls upon the portion of wrapping material 42a extending to the load is maintained at a substantially constant level.
Dancer arms 40 on which roller 38 is mounted are connected to an air cylinder 52 having a self-relieving type air regulator, through a linkage arm 50 and piston rod 54. The linkage arm 50 is connected to arm 40. There can be either a single air cylinder or two cylinders, one at the top and one at the bottom. With air cylinder 52, a constant biasing force is applied to tension roller 38 for biasing such roller away from load 44 with a substantially constant force irrespective of the position of tension roller 38 and the extent to which piston rod 54 extends from air cylinder 52. Thus whether the load 44 is in the position shown in FIG. 2 or the position shown in FIG. 3 the tension on the portion of wrapping material extending to the load, 42a and 42b, respectively, is maintained at a substantially constant level. In this manner, the additional stretching of the stretchable material that takes place during the actual wrapping of the load can be maintained at a substantially constant percentage. While the tension is maintained constant during a wrapping operation, the tension can be varied from one operation to the next by regulating or adjusting the air pressure to the air regulator of the air cylinder itself or the air cylinder position with respect to tension roller 38.
The stretching during the wrapping operation is separate from the pre-stretching that occurs prior to the material passing around tension roller 38. As described above, pre-stretching of the stretchable material occurs between roller 18, which acts as a first stretching roller, and feed roller 32, which acts as the second stretch roller. To help avoid breakage in and necking down of the stretchable material during the pre-strecth operation, the stretchable material also can pass over an idler roller 48. Idler roller 46 improves the wrap around roller 18.
During the wrapping operation it is desirable to keep the geometrical angle of the film as it approaches tension roller 38 and as it leaves the tension roller substantially the same. Variations in such angles have been noted to have a negative impact upon the tension in the film thereby causing undesirable variations in the stretching of the film during the wrapping operation. For this purpose, an additional idler roller 58 can be inserted along the path of the stretchable wrapping material as it leaves tension roller 38 such as shown in FIG. 4. Roller 58 rotates about a fixed axis and hence the angle of the film approaching tension roller 38 and the film leaving tension roller 38 remains substantially the same.
Tension roller 38 is connected to a pair of dancer arms 40 at both ends of the roller such as shown in FIG. 6. The two arms are then connected to rod 60 which in turn is coupled to self-relieving air cylinder 52 through linkage member 50 and piston 54.
In a modified embodiment of the stretch wrapper of the present invention, such as shown in FIG. 7, a role of stretchable wrapping material 62 is arranged along a horizontal axis. The stretchable material as it leaves roll 62 passes over a feed roller 66 which is driven in the same manner as feed roller 32 as discussed above in connection with the embodiment of FIG. 1. The stretchable material also can pass over an intermediate roller 64 that serves as a stretch roller by being at a slower speed than roller 66 for pre-stretching the stretchable wrapping material. By rotating roller 66 at a greater circumferential speed than roller 64, pre-stretching of the stretchable wrapping material can be obtained. The stretchable wrapping material then passes around an idler roller 68 still traveling along a vertical path and subsequently is rotated by 90ยฐ as it passes around air bar 70. Air bar 70 has a plurality of openings out of which air passes so as to enable a smooth flow of the stretchable material around the air bar as the material is turned. Air bar 70 is arranged so as to extend at a 45ยฐ angle with respect to idler roller 68 so that it can properly rotate the stretchable wrapping material. The stretchable wrapping material then passes around tension roller 72 that is connected to dancer arms 74. The portion of the stretchable wrapping material 76 passing around tension roller 72 is then fed to the load for being wrapped around the load as discussed above in conjunction with the embodiments shown in FIG. 1. During a spiral wrapping operation the only elements that would move up and down along carriage 10 in the embodients shown in FIG. 7 would be air bar 70 and the tension maintaining mechanism that includes tension roller 72 and dancer arms 74.
FIG. 9 illustrates a form of the first embodiment of the invention which controls the speed of the rollers 18 and 32 (not the relative speed between the rollers) in response to movement of the dancer arms 40. In FIG. 9, the angles "a", "b" and "c" are substantially equal to each other within the path of rotation defined by the arcuate segments labeled INCREASES MOTOR SPEED, NO SPEED CORRECTION, and SLOWS MOTOR SPEED. When these angles are substantially equal, the wrapping tension is maintained substantially constant. The roller 32 of the prestretcher and the tension roller 38 define a path of approach of the stretchable wrapping material and the tension roller 38 and the roller 58 define a path of departure of the stretchable wrapping material. The linkage arm 50 is connected to arm 40. It has been found that the control of the speed of the rollers 18 and 32 in response to movement of the dancer arms 40 past angular limits 70 and 72 to increase the speed of the rollers in response to an increase in the velocity of the wrapping material at the load support and to decrease the speed of the rollers in response to a decrease in the velocity of the wrapping material at the load support helps prevent breakage of the wrapping material. Identical reference numerals are used in FIGS. 1-8 and 9 to identify like parts. In addition to the constant tension mechanism described supra with regard to FIGS. 2 and 3, the form of the first embodiment illustrated in FIG. 9 includes means for varying the velocity of the first roller 18 and feed roller 32 when the dancer arms 40 rotate past angular limits of 70 and 72. The means for varying the velocity of the rollers 18 and 32 includes a cam 74 which is fixedly mounted to the end of dancer arms 40. The rotation of the cam 74, which is produced by rotation of dancer arms 40, closes microswitches 80, 82, 84 and 86 as described, infra. The contact of microswitch 80 is closed when the dancer arms 40 rotate counter-clockwise past the angular limit 70 and the contact of microswitch 82 is closed if and when the film breaks. The closure of the contact of microswitch 80 activates a motor control mechanism 88 described infra to slow down the rotation of rollers 18 and 32 to reduce the supply of film to ultimately cause the dancer arms 40 to rotate back clockwise past angular limit 70 where no motor speed control is utilized. If the film breaks, the contact of microswitch 82 closes and causes activation of an emergency stop dynamic braking circuit which stops the motor instantaneously which drives the rollers 18 and 32. The contact of microswitch 84 is closed first when the dancer arms 40 rotate clockwise past angular limit 72 and the contact of microswitch 86 is closed manually when the dancer arms 40 are pushed against the resistance of a spring (not illustrated) to run the rollers 18 and 32 at a slow speed used only during threading of the film. The closure of the contact of microswitch 84 activates the motor control mechanism 88 described infra to speed up rollers 18 and 32 to increase the supply of film to cause dancer arms 40 to ultimately rotate counter-clockwise back past angular limit 72. When the tension roller 38 is located between angular limits 70 and 72, the motor control 88 does not cause any change in the driven velocity of stretch wrapping material passing through the prestretcher. The stretch wrapping material accumulated between the roller 32 of the prestretcher, tension roller 38 and the idler roller 58 supplies the demand for additional stretch wrapping material caused by the wrapping of a corner of a load. Additionally, the tension roller 38 biased by air cylinder 52 takes up surplus stretch wrapping material during the wrapping of a load when the demand for stretch wrapping material is decreasing. The closure of the contact of microswitch 86 only occurs manually during threading of the film when the dancer arms are pushed by an operator against the aforementioned spring bias which opposes its closure. The motor control 88 includes a motor operated potentiometer (MOP) or equivalent electronic potentiometer 92 which may be a model SS MOP-1 manufactured by Precision D Series Inc., 63 Nicholas Road of Framingham, Mass. and a regenerative DC motor controller 94 which may be a model RG 8 manufactured by Southcon of 3608 Rozzells Ferry Road, Charlotte, N.C. The output of the regenerative DC motor controller 94 is applied to motor 96 which is applied to drive 20 of FIG. 1 to vary its speed. The function of the regenerative DC motor controller 94 is to maintain the output shaft speed of the motor 94 constant independent of torque. The DC motor controlled by a regenerative controller functions as a brake to the load when the motor is being driven by the load at a speed higher than the rated speed of the controller for driving a load. The function of the motor operated potentiometer 92 or the equivalent is, upon the closure of the contacts of microswitches 80 and 84, to respectively increase and decrease the motor drive velocity for the rollers 18 and 32. The output signal which is applied from the motor operated potentiometer to the regenerative DC motor controller 94 is maintained at a constant potential upon the subsequent opening of the contacts of microswitches 80 and 84, which potential is maintained equal to the potential at the instance of opening of the contacts.
FIG. 10 illustrates schematically a second form of motor control for the rollers 18 and 32 which is proportionate to the angular position of the dancer arms 40 throughout almost the entire rotation of the dancer arms 40. In this form of motor control, a potentiometer 100 is coupled to the axis of rotation 101 of the dancer arms 40 by a slip coupling 102 and a transmission 104 which multiplies the angular rotation of the dancer arms (approximately 60ยฐ) into 300ยฐ of rotation to use the full range of commercially available rotary potentiometers. The slip coupling 102, which may be of any known design, allows for a limited degree of dead space between initial movement of the axis of rotation 101 of the dancer arms 40 and the wiper of the potentiometer 100. The potentiometer 100 functions as a means for detecting change in the velocity of the wrapping material on the load. The dead space tends to prevent over compensation of the velocity of the rollers 18 and 32 which could cause "hunting" by not introducing a change in the motor control until a change in the sign (positive to negative or visa versa) of the acceleration of the film has occurred which has produced a net velocity change of a magnitude sufficient to require correction. With reference to FIG. 10, the motor control potentiometer circuit has potentiometer 100 which is electrically coupled to a regenerative DC motor controller 94 which may be identical to the regenerative DC motor controller described supra with regard to FIG. 9. The motor controller maintains the speed of the motor substantially constant.
FIG. 11 illustrates a second embodiment of the invention which does not prestretch the film before wrapping. The same reference numerals are used in FIGS. 10 and 11 to identify like parts. The second embodiment differs principally from the first embodiment in that the film of wrapping material 16 is pulled from the film roll by the rotation of the load not illustrated which is resting on a turntable under the resistance of braking force which is applied by a film roll electromagnetic brake 110. The preferred form of brake is the magnetic particle type. Once the film 16 leaves the film roll, it contacts idler roller 112, and a constant tension mechanism, including elements 38, 40, 50, 52 and 54, which is identical to the constant tension mechanism described above with reference to the first embodiment. The film passes from roller 38 to idler roller 114 and to a load being wrapped which is not illustrated. The wiper 116 of a rheostat 114 is connected to the axis of rotation of the dancer arms 40 by a slip coupling 102 and transmission 104 which are identical to those described with reference to FIG. 10 supra. The rheostat functions as means for sensing changes in the velocity of the film being wrapped on the load and produces an output voltage which is a linear function of the velocity of the film. The position of the wiper 116 of the rheostat 114 is used to generate a signal to control the braking force applied to the film roll by the electromagnetic brake 110. The control circuit of FIG. 11 includes a source of alternating current potential 120. The alternating current is rectified by a full wave rectifier 122 which output is applied across the terminals of master control rheostat 124. The setting of the wiper 126 of the rheostat 124 determines the average braking force which is applied by the electromagnetic brake 110. The greater the resistance setting of the wiper 126, the greater average braking force which is applied by the electromagnetic brake 100. The wiper 126 is coupled to one of the two terminals of rheostat 116 which is coupled to the axis of rotation 101 of the dancer arms 40 as previously described. The remaining terminal of rheostat 114 is coupled across one of the outputs of full wave rectifier 122 which is in common with the terminal of rheostat 124. The wiper 116 of rheostat 114 is coupled to one terminal of the electromagnetic brake 110, the remaining terminal being coupled to the common terminal of the full wave rectifier 122 and the rheostats 114 and 124. As is apparent from the discussion above with reference to FIG. 10, the angular movement of wiper 116 is responsive to the movement of the dancer 40 in the manner described with reference to slip coupling 102 and transmission 104. The magnitude of the potential which is applied from the full wave rectifier 122 to the electromagnetic brake is a linear function of the combined settings of the wiper arms 103 and 112.
The operation of the electromagnetic brake control in varying the speed of rotation of the film roll is as follows. The constant tension mechanism is adjusted to create the desired tension required for wrapping of an article, the actual wrapping tension being approximately one half of the constant biasing force which has been set on roller 38. After the desired tension is set and the film has been threaded around the article to be wrapped, the master control rheostat 124 is set so that the dancer arms will move in response to changes in velocity of the wrapping film for the desired tension setting. In operation, any significant change in the velocity of the film will produce a counteracting braking force on the electromagnetic brake 100 which tends to maintain a constant tension. If the sign of the (positive to negative or visa versa) acceleration of the film changes, the slip coupling 102 will not translate any movement of the dancer arm's axis of rotation 101 to the wiper 116 of rheostat 114 until a certain magnitude of velocity change has occurred, the dead space in the slip coupling tending to reduce overcorrection in braking force which could result in hunting.
While the invention has been described in terms of its preferred embodiments, it should be understood that numerous modifications may be made to the invention without departing from its scope as defined in the appended claims.
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A wrapping machine and operation for wrapping a load arranged on a pallet with a stretchable wrapping material under a substantially constant tension during the wrapping operation. The load that is to be wrapped is arranged on a support member which can be rotated for drawing off stretchable wrapping material from a roll of such material. A dispensing mechanism holds the roll of stretchable wrapping material and dispenses the material so that it can be wrapped around the load arranged on the support member. As an alternative to the support member with the load being rotated, the dispensing member can revolve around the support member and the load so as to dispense and wrap the load with the stretchable material. During the wrapping operation, the tension on the portion of the stretchable wrapping material being wrapped around the load is maintained at a substantially constant tension. Prior to actually wrapping the load with the stretchable wrapping material, such material can be prestretched. The prestretching operation occurs at a location between the dispensing mechanism and the location at which the stretchable material is actually supplied to the load for wrapping.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit of U.S. Provisional Patent Application No. 61/428,803, filed Dec. 30, 2010, entitled COMPRESSOR TIP CLEARANCE CONTROL AND GAS TURBINE ENGINE, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to gas turbine engines and compressors, and more particularly, to compressor blade tip clearance control.
BACKGROUND
[0003] Blade tip clearance control for compressors and gas turbine engine compressors remain an area of interest. Some existing systems have various shortcomings, drawbacks, and disadvantages relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
SUMMARY
[0004] One embodiment of the present invention is a unique compressor. Another embodiment of the present invention is a unique gas turbine engine. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for blade tip clearance control for compressors and gas turbine engine compressors. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
[0006] FIG. 1 schematically illustrates some aspects of a non-limiting example of a gas turbine engine in accordance with an embodiment of the present invention.
[0007] FIG. 2 illustrates some aspects of a non-limiting example of a compressor with a tip clearance control system in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0008] For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nonetheless be understood that no limitation of the scope of the invention is intended by the illustration and description of certain embodiments of the invention. In addition, any alterations and/or modifications of the illustrated and/or described embodiment(s) are contemplated as being within the scope of the present invention. Further, any other applications of the principles of the invention, as illustrated and/or described herein, as would normally occur to one skilled in the art to which the invention pertains, are contemplated as being within the scope of the present invention.
[0009] Referring to FIG. 1 , there are illustrated some aspects of a non-limiting example of gas turbine engine 20 in accordance with an embodiment of the present invention. In one form, engine 20 is a two spool engine having a high pressure spool 24 and a low pressure spool 26 . In other embodiments, engine 20 may include three or more spools, or may include only a single spool. In one form, engine 20 is a turbofan engine, wherein low pressure spool 26 powers a propulsor 28 in the form of a turbofan (fan), referred to herein as a turbofan or a fan. In other embodiments, engine 20 may be a turboprop engine, wherein low pressure spool 26 powers a propulsor 28 in the form of a propeller system (not shown), e.g., via a reduction gearbox (not shown). In still other embodiments, engine 20 may be a marine and/or industrial gas turbine engine, e.g., for providing marine and/or land propulsion, power generation, fluid pumping and/or other work.
[0010] In one form, engine 20 includes, in addition to fan 28 , a bypass duct 30 , a compressor 32 , a diffuser 34 , a combustor 36 , a high pressure (HP) turbine 38 , a low pressure (LP) turbine 40 , a nozzle 42 A, and a nozzle 42 B. In other embodiments, there may be, for example, an intermediate pressure spool having an intermediate pressure turbine.
[0011] Bypass duct 30 is in fluid communication with nozzle 42 B. Diffuser 34 is in fluid communication with compressor 32 . Combustor 36 is fluidly disposed between compressor 32 and turbine 38 . In one form, combustor 36 includes a combustion liner (not shown) that contains a continuous combustion process. In other embodiments, combustor 36 may take other forms, and may be, for example, a wave rotor combustion system, a rotary valve combustion system, and/or a slinger combustion system, and may employ deflagration and/or detonation combustion processes. Turbine 40 is fluidly disposed between turbine 38 and nozzle 42 B. In the depicted embodiment, engine 20 core flow is discharged through nozzle 42 A, and the bypass flow is discharged through nozzle 42 B. In other embodiments, other nozzle arrangements may be employed, e.g., a common nozzle for core and bypass flow; a nozzle for core flow, but no nozzle for bypass flow; or another nozzle arrangement. Bypass duct 30 and compressor 32 are in fluid communication with fan 28 .
[0012] Fan 28 includes a fan rotor system 48 . In various embodiments, fan rotor system 48 includes one or more rotors (not shown) that are powered by turbine 40 . Fan 28 may include one or more vanes (not shown). Bypass duct 30 is operative to transmit a bypass flow generated by fan 28 around the core of engine 20 . Compressor 32 includes a compressor rotor system 50 . In various embodiments, compressor rotor system 50 includes one or more rotors (not shown) that are powered by turbine 38 . Turbine 38 includes a turbine rotor system 52 . In various embodiments, turbine rotor system 52 includes one or more rotors (not shown) operative to drive compressor rotor system 50 . Turbine rotor system 52 is drivingly coupled to compressor rotor system 50 via a shafting system 54 . Turbine 40 includes a turbine rotor system 56 . In various embodiments, turbine rotor system 56 includes one or more rotors (not shown) operative to drive fan rotor system 48 . Turbine rotor system 56 is drivingly coupled to fan rotor system 48 via a shafting system 58 . In various embodiments, shafting systems 54 and 58 include a plurality of shafts that may rotate at the same or different speeds and directions. In some embodiments, only a single shaft may be employed in one or both of shafting systems 54 and 58 . In one form, rotor systems 48 , 50 , 52 and 56 , and shafting systems 54 and 58 rotate about an engine centerline 46 . Turbine 40 is operative to discharge an engine 20 core flow to nozzle 42 A.
[0013] During normal operation of gas turbine engine 20 , air is drawn into the inlet of fan 28 and pressurized by fan rotor system 48 . Some of the air pressurized by fan rotor system 48 is directed into compressor 32 as core flow, and some of the pressurized air is directed into bypass duct 30 as bypass flow. Compressor 32 further pressurizes the portion of the air received therein from fan 28 , which is then discharged into diffuser 34 . Diffuser 34 reduces the velocity of the pressurized air, and directs the diffused core airflow into combustor 36 . Fuel is mixed with the pressurized air in combustor 36 , which is then combusted. The hot gases exiting combustor 36 are directed into turbines 38 and 40 , which extract energy in the form of mechanical shaft power to drive compressor 32 and fan 28 via respective shafting systems 54 and 58 . In addition, in some embodiments, such as in turbofan, propjet or jet configurations, turbine 40 generates a thrust output.
[0014] Referring to FIG. 2 , some aspects of a non-limiting example of compressor 32 with a tip clearance control system 60 in accordance with an embodiment of the present invention is schematically depicted. Included as part of compressor rotor system 50 are a plurality of rotating compressor blades 62 , 64 , 66 , 68 , 70 and 72 , each of which is disposed in a corresponding compressor blade stage having blades spaced apart circumferentially. In one form, compressor 32 is an axial compressor. In other embodiments, compressor 32 may be a centrifugal compressor or an axi-centrifugal compressor. In one form, compressor 32 includes a plurality of vanes 74 , 76 , 78 , 80 and 82 disposed axially adjacent to compressor blades 64 , 66 , 68 , 70 and 72 . In some embodiments, compressor 32 may not include vanes. A vane 84 is disposed downstream of blade 62 . In one form, vane 84 is considered a part of diffuser 34 . In other embodiments, vane 84 may be considered a part of compressor 32 .
[0015] Vanes 74 , 76 , 78 , 80 and 82 are mechanically supported by an inner compressor case 86 . Inner compressor case 86 is mechanically supported by an outer compressor case 88 . Outer compressor case 88 is disposed around inner compressor case 86 . Vane 84 is supported by diffuser 34 . In one form, inner compressor case 86 is formed of a plurality of ring cases, e.g., including ring cases 90 , 92 and 94 . In other embodiments, inner compressor case 86 may be a single integrally formed structure, or may be any number of structures assembled and/or joined together. Blades 62 , 64 and 66 have respective tips 96 , 98 and 100 disposed opposite inner compressor case 86 . In one form, ring cases 90 , 92 and 94 include respective abradable blade tracks 102 , 104 and 106 disposed opposite tips 96 , 98 and 100 . Other embodiments may not include abradable blade tracks, e.g., structural or non-structural materials of inner compressor case 86 may be disposed opposite blade tips 96 , 98 and/or 100 without an intervening abradable material. In various embodiments, one or more coatings and/or treatments may or may not be applied to inner compressor case 86 or portions thereof opposite blade tips 96 , 98 and/or 100 .
[0016] Tip clearance control system 60 is configured to control a clearance between the blade tips 96 , 98 and 100 and inner compressor case 86 , e.g., blade tracks 102 , 104 and 106 . In one form, in order to control tip clearance between blade tips 96 , 98 and 100 and inner compressor case 86 , e.g., blade tracks 102 , 104 and 106 , tip clearance control system 60 impinges a fluid onto inner compressor case 86 . In one form, the fluid is air. In other embodiments, other fluids may be employed in addition to or in place of air. In one form, the air is air that has been compressed by compressor 32 . In other embodiments, other sources of air may be employed. In one form, the impingement fluid is cooled prior to impingement upon inner compressor case 86 . In other embodiments, the fluid may not be cooled and/or may be heated or may be supplied without any heating or cooling, e.g., depending on the temperature of the fluid and other aspects of a particular application.
[0017] Blades 62 , 64 , 66 , 68 , 70 and 72 and vanes 74 , 76 , 78 , 80 and 82 are disposed in a compressor flowpath 108 formed in part by inner compressor case 86 , and by structures (not shown) disposed at root portions of blades 62 , 64 , 66 , 68 , 70 and 72 and vanes 74 , 76 , 78 , 80 and 82 . Vane 84 is disposed in a diffuser flowpath 110 located immediately downstream of compressor flowpath 108 .
[0018] Extending from ring case 90 is a support structure 112 . Support structure 112 extends between inner compressor case 86 and outer compressor case 88 , and supports the aft end of inner compressor case 86 . Support structure 112 is configured for radial flexibility for absorbing a thermal growth differential between inner compressor case 86 and outer compressor case 88 , e.g., resulting from tip clearance control system 60 impinging the fluid onto inner compressor case 86 . In one form, the radial flexibility is supplied by extending support structure 112 in axial directions in addition to radial directions. In other embodiments, other configurations or arrangements may be employed to provide radial flexibility. In one form, support structure 112 is attached to outer compressor case 88 via a bolted flange arrangement. In other embodiments, support structure 112 may be coupled or affixed to outer compressor case 88 via one or more other arrangements, including being integral with outer compressor case 88 .
[0019] Extending from ring case 94 is a support structure 114 . Support structure 114 extends between inner compressor case 86 and outer compressor case 88 , and supports the forward end of inner compressor case 86 . Support structure 114 is configured for radial flexibility for absorbing a thermal growth differential between inner compressor case 86 and outer compressor case 88 , e.g., resulting from tip clearance control system 60 impinging the fluid onto inner compressor case 86 . In one form, the radial flexibility is supplied by extending support structure 114 in an axial direction in addition to radial directions. In other embodiments, other configurations or arrangements may be employed to provide radial flexibility. In one form, support structure 114 is attached to outer compressor case 88 via a bolted flange arrangement. In other embodiments, support structure 114 may be coupled or affixed to outer compressor case 88 via one or more other arrangements, including being integral with outer compressor case 88 .
[0020] In one form, the fluid that is impinged upon inner compressor case 86 by tip clearance control system 60 is compressor 32 discharge air 116 that has been diffused by diffuser 34 . In one form, the air is supplied through an opening 118 in a diffuser vane 120 . Air 116 then passes through a cavity 122 defined between support structure 112 and a diffuser support structure 124 . Air 116 then passes from cavity 122 into a discharge tube 126 extending from a discharge opening 128 in outer compressor case 88 . In other embodiments, other arrangements for obtaining air 116 may be employed.
[0021] In one form, a joint 130 is formed at the interface between diffuser 34 and inner compressor case 86 . Joint 130 is configured to permit relative radial motion between inner compressor case 86 and diffuser 34 , e.g., resulting from the impingement of air 116 onto inner compressor case 86 . In other embodiments, joint 130 may be formed between inner compressor case 86 and one or more other static structures. In one form, a bellows seal 132 forms a part of joint 130 , which permits the relative radial motion while sealing the interface between inner compressor case 86 and diffuser 34 . In other embodiments, other sealing arrangements may be employed.
[0022] In one form, air 116 is cooled by a cooler 134 prior to being impinged upon inner compressor case 86 . In other embodiments, air 116 may be conditioned to any desired temperature via one or more thermal management means. In one form, cooler 134 is a heat exchanger, e.g., an air-to-air heat exchanger or an air/fuel heat exchanger. In other embodiments, other cooling schemes may be employed. In one form, cooler 134 is mounted on engine 20 and considered a part thereof. In other embodiments, cooler 134 may be mounted elsewhere.
[0023] Air 116 exiting cooler 134 is supplied to a valve 136 . Valve 136 is configured to control the flow of air 116 , and is disposed upstream of impingement openings that impinge air 116 onto inner compressor case 86 . In one form, valve 136 is configured to modulate the flow of air 116 between a maximum flow amount and a minimum flow amount. In one form, the minimum flow amount is zero flow of air 116 . In other embodiments, valve 136 may be an on/off valve.
[0024] Air 116 exiting valve 136 is passed via a supply tube 142 extending from a supply opening 144 in outer compressor case 88 into a distribution channel 146 formed between support structures 112 and 114 , outer compressor case 88 and inner compressor case 86 . In various embodiments, more than one of each of cooler 134 and valve 136 may be employed. For example, in some embodiments, a plurality of coolers 134 and valves 136 may be employed, e.g., with corresponding discharge tubes 126 and discharge openings 128 , and supply tubes 142 and supply openings 144 , respectively, spaced apart circumferentially around outer compressor case 88 . In some embodiments, such an arrangement may be employed to preferentially cool different circumferential sectors of inner compressor case 86 , e.g., to control the roundness of inner compressor case 86 during the operation of engine 20 .
[0025] Distribution channel 146 is configured to distribute air 116 from supply opening 144 to desired locations for subsequent impingement upon inner compressor case 86 . Disposed adjacent to inner compressor case 86 is a fluid impingement structure 150 having a plurality of impingement openings 152 configured to impinge air 116 onto inner compressor case 86 . Tip clearance control system 60 supplies air 116 to impingement structure 150 and impingement openings 152 via supply opening 144 and distribution channel 146 . In one form, impingement openings 152 are angled radially inward toward the center of rotation of the compressor blades, i.e., engine centerline 46 ( FIG. 1 ). In other embodiments, one or more impingement openings 152 may also be angled in one or more circumferential and/or axial directions, e.g., to direct bulk flow of air 116 in one or more desired directions. After having impinged onto inner compressor case 86 , air 116 is directed into compressor flowpath 108 via openings 160 and 162 .
[0026] In one form, fluid impingement structure 150 is an impingement plate, i.e., a plate having impingement openings 152 formed therein. In one form, the impingement plate is disposed adjacent to inner compressor case 86 , and extends circumferentially around inner compressor case 86 . In other embodiments, the impingement plate may only be disposed adjacent to one or more desired parts of inner compressor case 86 . In various embodiments, the impingement plate may be one or more flat plates and/or one or more curved plates. In other embodiments impingement structure may take other forms, e.g., an impingement tube.
[0027] Embodiments of the present invention include a compressor, comprising: a rotating compressor blade having a blade tip; a compressor case having a blade track disposed opposite the blade tip; and a tip clearance control system including a fluid impingement structure having a plurality of impingement openings configured to impinge a fluid onto the compressor case, wherein the tip clearance control system is configured to control a clearance between the blade tip and the blade track by impinging the fluid onto the compressor case.
[0028] In a refinement, the fluid is air compressed by the compressor.
[0029] In another refinement, the fluid is cooled prior to impingement onto the compressor case.
[0030] In yet another refinement, the compressor case is an inner compressor case, further comprising an outer compressor case disposed around the inner compressor case.
[0031] In still another refinement, the inner compressor case is mechanically supported by the outer compressor case.
[0032] In yet still another refinement, the compressor further comprises a support structure extending between the inner compressor case and the outer compressor case, wherein the support structure is configured for radial flexibility for absorbing a thermal growth differential between the inner compressor case and the outer compressor case resulting from impingement of the fluid onto the inner compressor case.
[0033] In a further refinement, the compressor further comprises an other support structure extending between the inner compressor case and the outer compressor case, wherein the fluid is supplied to the plurality of impingement openings via a supply opening in the outer compressor case; and wherein the support structure and the other support structure form a distribution channel configured to distribute the fluid from the supply opening to a desired location for subsequent impingement upon the inner compressor case.
[0034] In a yet further refinement, the fluid impingement structure is an impingement plate having the plurality of impingement openings therein; and wherein the impingement plate is disposed adjacent to at least part of the compressor case.
[0035] In a still further refinement, at least one of the impingement openings is angled radially inward toward the center of rotation of the rotating compressor blade.
[0036] In a yet still further refinement, the compressor further comprises a compressor flowpath, wherein the compressor is configured to discharge the fluid into the compressor flowpath after impingement of the fluid onto the compressor case.
[0037] Embodiments of the present invention include a gas turbine engine, comprising: a compressor including a rotating compressor blade having a blade tip, and a compressor case disposed opposite the blade tip; a fluid impingement structure having a plurality of impingement openings configured to impinge a fluid onto the compressor case; a combustor in fluid communication with the compressor; and a turbine in fluid communication with the combustor.
[0038] In a refinement, the gas turbine engine further comprises a tip clearance control system configured to control a clearance between the blade tip and the compressor case by impinging the fluid onto the compressor case, wherein the tip clearance control system is configured to supply the fluid to the fluid impingement structure.
[0039] In another refinement, the gas turbine engine further comprises a cooler configured to cool the fluid prior to impingement onto the compressor case.
[0040] In yet another refinement, the cooler is a heat exchanger.
[0041] In still another refinement, the gas turbine engine further comprises a valve configured to control a flow of the fluid, wherein the valve is fluidly disposed upstream of the impingement openings.
[0042] In yet still another refinement, the valve is configured to modulate the flow of the fluid between a maximum flow amount and a minimum flow amount.
[0043] In a further refinement, the minimum flow amount is zero flow of the fluid.
[0044] In a yet further refinement, the gas turbine engine further comprises: a static structure adjacent to the compressor case; and a joint configured to permit relative radial motion as between the compressor case and the static structure.
[0045] Embodiments of the present invention include a gas turbine engine, comprising: a compressor including a rotating compressor blade having a blade tip, and a compressor case disposed opposite the blade tip; a combustor in fluid communication with the compressor; a turbine in fluid communication with the combustor; and means for controlling a clearance between the blade tip and the compressor case by impinging a fluid onto the compressor case.
[0046] In a refinement, the means for controlling includes a fluid impingement structure having a plurality of impingement openings configured to impinge the fluid onto the compressor case.
[0047] 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(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as โa,โ โan,โ โat least oneโ and โat least a portionโ are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language โat least a portionโ and/or โa portionโ is used the item may include a portion and/or the entire item unless specifically stated to the contrary.
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One embodiment of the present invention is a unique compressor. Another embodiment of the present invention is a unique gas turbine engine. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for blade tip clearance control for compressors and gas turbine engine compressors. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
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