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REFERENCE TO RELATED APPLICATIONS
The present application is a continuation in part of U.S. patent application Ser. No. 07/569,568 filed Aug. 20, 1990, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a device designed to save water in toilets and urinals that develop a leak.
BACKGROUND OF THE INVENTION
Conservation has become an issue of growing concern. As such, great efforts have been made to limit the waste of natural resources such as water. One area in which water waste has been scrutinized is in toilet use.
The focus of preventing water wasted in the use of toilets has until now been on the use of less water per flush. Persons have widely been advised that they can use less water by placing a brick, a full jug of water, etc. in the toilet tank to limit the volume of water which is used per flush. Also, toilets are in use, generally on a commercial basis, based on a pressure system which have no tank but work with a pressure build-up to allow water flow when the handle is pulled. Additionally, new toilets have been developed which work with reduced amounts of water to complete the flushing action.
However, a leaking toilet will waste water at a rate dependent on the flow rate of the leak, regardless of how little water is used on a per flush basis. This is because toilets regulate the amount of water which exits the system and will allow water to flow through the system anytime the water valve exiting the system is open or leaks. This situation is complicated in tank toilet systems wherein the flapper valve which sits at the bottom of the tank to prohibit water flow is degraded by water, ultimately causing a leak.
It is estimated that leaking toilets are one of the largest sources of wasted water. This problem is especially significant in rental apartments, offices or warehouses where the occupant does not see the water bill and does not have an interest in fixing a leak quickly.
Therefore, it is an object of the present invention to provide a toilet water regulation device which limits the amount of water that enters the system regardless of the water existing the system.
It is a further object of the invention to provide a regulation device which can be adjusted to predetermine the amount of water which will enter the system per flush.
It is another object to provide a regulation device which can be placed in a standard toilet tank or within standard pressure systems that is simple in its mechanism and has few working parts to limit the need for service or replacement.
SUMMARY OF THE INVENTION
These and other objects are achieved with a toilet water regulation device associated with the water inlet of a flush toilet system utilizing a tank comprising inlet valve means on the water inlet, said valve means having a water flow inlet, a water outlet divided into divergent outlets, turbine means placed in line with the water flow from one of said divergent outlets and the other of said divergent outlets directed to the tank, activation means which causes the inlet valve means to open and valve operation means cooperating with said turbine means to hold the inlet valve means open and close the inlet valve means after approximately a predetermined number of revolutions of the turbine means relating approximately to a predetermined amount of water passing over the turbine means, further comprising adjustable valve means cooperating with at least one of the divergent outlets to control water flow passing through the divergent outlet directed to the turbine means whereby the more water passing over the turbine means, the faster the turbine means will rotate and the less water will pass through the inlet valve means and into the tank before the inlet valve means closes.
The turbine means can be any type such as a propeller type, paddle fan, ferris type, wind mill type or curved turbine. The turbine can be sealed and a housing is preferred to cover the turbine and limit water splashing from the turbine when water is directed to the turbine.
The inlet valve can be any type including hydraulic, water pipe, washerless, diaphragm, carburator type, arm type, gate, slide type, screw type, spring type, water pressure type, "V" type, electric or air valves or limit switches used on worm gears or straight rods. However, the preferred valves are O-ring or ball valves having a water inlet, a push pin, an O-ring or ball which cooperates with said push pin and seats in an O-ring or ball seat due to water pressure from the inlet to prohibit water flow and a water outlet. The valve works so that when the pin is depressed, water flows through the valve and when the pin is extended, the O-ring or ball seats and water flow is prohibited.
The valve operation means preferably comprises a cam cooperating with said turbine means having a high portion, a low portion and a drop off point from said high portion to said low portion. The cam cooperates with the valve so that when the cam rotates across the drop off point the valve is changed from the open position to the closed position and water flow stops.
The cam is preferably associated with a round gear having teeth on at least a portion thereof, the teeth of said round gear cooperating with a worm gear associated with the turbine. When the teeth of the round gear are engaged by the worm gear, and water turns the turbine, the turbine turns the worm gear and the worm gear turns the round gear. The turning round gear turns the cam about the high portion of the cam. When the turbine turns a predetermined number of times, relating to a predetermined amount of water which passes over the turbine, the cam turns past the drop off point and the valves shuts off.
The cam can be fixedly attached concentrically to the round gear, with teeth missing from the round gear to allow activation of the device, or pivotably concentrically or non-concentrically attached to the round gear with teeth about the entire round gear. A concentrically or non-concentrically mounted cam associated with a gear having teeth around the entire perimeter necessarily includes means to allow movement of the cam without movement of the gear. Furthermore, straight gears can be used in the system, as can jack type gears, or the cam can be unattached to the gears when utilizing a system such as that which is used in garage door openers. The gears can also be set-up similar to the timing gears of a pool or sprinkler shut-off pump.
Various sized gears can be used with the embodiments to vary the amount of water flowing over the turbine necessary to turn the cam past the drop off point. Also, additional gears can be placed between the turbine and the gear with which the cam is associated to vary the revolutions of the turbine necessary to turn the cam past the drop off point. All such changes would be known to the skilled artisan in the gearing art.
The preferred method of regulating the amount of water needed to close the valve is found in the use of divergent water outlets from the inlet valve wherein one outlet directs water over the turbine and another goes directly to fill the system. One of the divergent outlets would have a separate adjustable valve, such as preferably a ball valve, or any of the types of inlet valves set forth above which can be set to a predetermined water flow, to directly or indirectly regulate water flow through the divergent outlet directed to the turbine. The more water that passes over the turbine, the faster the turbine turns and the faster the valve closes.
For example, since the water inlet into the system is constant, an adjustable valve reducing the flow to the divergent outlet not going to the turbine increases the flow over the turbine, speeding the time it takes to close the valve, so less water will enter the system before the valve closes. Similarly, increasing the water flow through an adjustable valve associated with the divergent outlet not going to the turbine causes less water to go over the turbine, taking longer for the valve to close and allowing more water into the system.
The gears of the system, including the turbine, cam and intermediate gears used, are made of plastic, nylon or stainless steel. The O-ring is preferably made of silicone for a lasting seal.
The activation means is preferably the same handle which is used to open the flapper valve in the bottom of the tank to release the water in the tank, or to activate the flush action in a pressure system with an extension which causes the cam to rotate to its high position, causing water flow. As such, the device can be installed in the tank of any standard toilet utilizing a tank or in the standard pressure systems currently in use.
The device is preferably produced on a backing wall or plate and preferably includes a housing enclosing at least the turbine to limit water splashing from the turbine as water flows over it. The device can be placed directly on the tube of the tank toilet on which the float valve currently in use is mounted, for ease of installation.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings, in which like reference characters represent like parts, are included to help understand the invention, and not to limit the invention, wherein:
FIG. 1 is a perspective view of one embodiment of the device of the present invention;
FIG. 2A is a front plan view of the O-ring valve of the first embodiment of the present invention;
FIG. 2B is a side cross-sectional view of the O-ring valve through line B--B of FIG. 2A;
FIG. 3A is a front elevational view of the turbine of the first embodiment of the present invention;
FIG. 3B is a side elevational view of the turbine with worm gear concentrically attached thereto;
FIG. 4A is a front elevational view of the second worm gear;
FIG. 4B is a side elevational view of the second worm gear;
FIG. 5A is a front elevational view of the round gear of the present invention with the cam attached;
FIG. 5B is a side elevational view of the round gear of the present invention with the cam attached;
FIG. 6 is a perspective view of a second embodiment of the present invention wherein the cam is non-concentrically attached to the round gear;
FIG. 7A is a front view of the round gear and cam of the second embodiment;
FIG. 7B is a side plan view of the round gear and cam of the second embodiment;
FIG. 8 is a perspective view of a two gear embodiment;
FIG. 9 is a plan view of the device of the first embodiment with activation means and housing to cover the turbine;
FIG. 10 is a perspective view of another embodiment of the cam and gear assembly allowing movement of the cam without rotation of the gear;
FIG. 11A is a front elevational view of a turbine housing;
FIG. 11B is a side elevational view of the turbine housing of FIG. 11A;
FIG. 12 is a perspective view of activation means for beginning water flow in the present invention; and
FIG. 13 is a perspective view of the configuration of the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, and specifically FIG. 1, the preferred embodiment of the water regulator device 2 of the present invention comprises a turbine 4 having a worm gear 5 attached, a second worm gear 6 and a round gear 8 having a cam 10 thereon. The cam 10 engages an O-ring inlet valve 12 which opens and closes in accordance with the position of the cam 10 in relation to the inlet valve 12. The inlet valve 12 regulates water flow from a water inlet 14, such as a pipe or tube leading from a water supply to the inlet valve 12.
The O-ring inlet valve 12 (shown in FIGS. 2A and 2B) comprises an inlet 14, an O-ring 16, and O-ring seat 18, a push pin 20 and an outlet 22. The outlet 22 preferably includes three divergent outlet lines 24, 26 and 28. The first line 24 feeds the overflow in a standard tank, the second line 26, goes to the bottom of the tank to help fill the tank with water more quietly and the third line 28 ends adjacent to the turbine 4 when the valve 12 opens and the water thereafter runs into the tank. However, it is understood that the first line 24 which feeds the overflow is not necessary to the invention.
When the water supply is connected to the O-ring valve 12, the pressure of the water forces the O-ring 16 to seat against the valve seat 18 and stop the water flow. The water pressure against the O-ring 16 causes the pin 20 to be extended unless an external force depresses the pin 20. Sufficient pressure against the pin 20 to depress the pin 20 pushes the O-ring 16 from the O-ring seat 18 and allows water to flow, through the water outlet 22.
The cam 10 on the round gear 8 works in cooperation with the push pin 20 of the inlet valve 12. The pin 20 is in proximity with the cam 10 so that the pin 20 is depressed and extended by the high and low points of the cam 10 respectively. For example, the low point 30 of the cam 10 allows the pin 20 of the valve 12 to remain fully extended, whereby the O-ring 16 seats in valve seat 18 and prevents water flow. When the cam 10 is in its low position 30 with relation to the pin 20, the device is in its ready position and will not allow water to pass through the inlet valve 12 regardless of the water level in the tank.
However, when the pin 20 is engaged by the high phase of the cam 10, from the beginning of the high portion 32 to the drop off point 34, the cam 10 depresses the pin 20 to the point where the O-ring 16 moves from the O-ring seat 18 and allows water to flow through the outlet 22.
In the embodiment shown in FIG. 1, with the cam 10 shown in FIGS. 5A and 5B, the round gear 8 has teeth missing at a strategic location across a specific portion of the perimeter determined by the position of the cam 10 in relation to the pin 20 of the inlet valve 12. The teeth are missing from the perimeter of the round gear 8 from a point beginning relative to when the pin 20 moves across the drop off point 34 of the cam 10, where the pin 20 is allowed to extend and water flow stops. At that point, the last of the teeth of the round gear 8 must have moved off of the worm gear 6.
The teeth on the round gear 8 start again at a point when the high point 32 pushes in the pin 20 and allows water flow so that the turning turbine 4 turns the worm gear 6 and the teeth of the round gear 8 engage the turning worm gear 6. The space provided by the missing teeth is necessary in the embodiment with the cam 10 concentrically and fixedly attached to the round gear 8 to allow the cam 10 to turn from the low point 30 to the high point 32 upon activation without interference from teeth on the round gear engaging the worm gear 6.
To activate the device 2, the activation means shown in FIG. 9, comprising an extension 50 which turns on a pivot 52 to rotate a projection 54 on the cam 10, as well as the round gear 8 attached thereto, moves the cam 10 to the beginning of the high portion 32, depressing the pin 20 and allowing water to flow. The missing teeth of the round gear 8 allows the cam 10 to rotate without interference of the teeth of the round gear 8 engaging the worm gear 6.
As stated above, the teeth of the round gear 8 strategically begin again, and engage the worm gear 6 again, when the pin 20 engages the beginning of the high portion 32 of the cam 10. At this point, the water begins to flow through the valve 12 and out lines 24, 26 and 28. The flow from the line 28 which passes over the blades 36 of the turbine 4 causes the turbine 4 to revolve at a rate proportional to the amount of water passing over it.
A weight 42 is strategically located on the cam 10, or round gear 8, so that when the device 2 is activated the round gear 8 is ensured to rotate sufficiently so that the teeth of the round gear 8 engage the teeth of the worm gear 6. The weight 42 should be at a point just before the top of the cam 10 (i.e. 11:30 o'clock) when the pin 20 is extended at the low point 30 of the cam 10.
In another embodiment, shown in FIG. 6, the cam 10 is non-concentrically attached to the round gear 8 and no teeth are missing from the round gear 8 (see FIGS. 7A and 7B). Activation means, including an extension 50 which engages a projection 54 on the cam 10 moves the cam 10 to its high point 32 by pivoting the cam 10 on its attachment axis 44, with a stop 46 included to prevent the cam 10 from pivoting too far. To prevent the cam 10 from pivoting too far a slot 45 can be used on the cam 10 in which a second attachment 47 to the round gear 8 is placed. The throw of the attachment in the slot 45 limits excessive rotation of the cam 10.
When the cam 10 is pivoted so the high point 32 depresses the pin 20 water flow turns the turbine 4, thereby rotating the round gear 8 so the cam 10 turns through its high phase. As with the previous embodiment, a strategically placed weight 42 can be used to ensure that the cam 10 rotated on its axis 44 remains with its high point 32 depressing the pin 20 until the turbine 4 rotates the round gear 8 sufficiently to rotate the cam 10. The weight 42 in this embodiment, however, must be placed in line with the attachment axis 44.
In this embodiment, the low portion 30 of the cam 10 is shorter so that the cam 10 need only be pivoted a short distance, equivalent to the throw of the slot 45, for the high point 32 to depress the pin 20 and begin the water flow.
In yet another embodiment, shown in FIG. 10, the cam 10 can pivot about a concentric axis 64 without movement of the round gear 8, having teeth about the entire perimeter thereof, through the use of a shaft 66 fixedly attached to the cam 10 which travels in a slot 68 in the round gear 8. Movement of the cam 10 shown in FIG. 10 in a clockwise direction moves the shaft 66 in the slot 68 to a point where the cam 10 pushes in the pin 20 of the valve 12, described above. Excessive rotation of the cam 10 is limited by the length of the slot 68. When water flowing turns the gear 8 to the point that other end of the slot 68 catches up with the shaft 66, the cam 10 turns as above.
It is understood that the embodiment of FIG. 10 can alternatively use a shaft 66 fixedly attached to the round gear 8 which cooperates with a slot 68 in the cam 10.
The turbine 4 and attached worm gear 5 are best shown in FIGS. 4A and 4B. As the turbine 4 turns with water passing over it, it turns the worm gear 5, attached concentrically about the axis of the turbine 4. The teeth of the worm gear 5 are in constant engagement with the teeth of an end gear 38 attached concentrically about the axis of the second worm gear 6. Rotation of the turbine 4, therefore, causes rotation of the second worm gear 6.
The teeth of the worm portion 40 of the second worm gear 6 engage the teeth of the round gear 8, to rotate the round gear 8 and cam 10 across the high portion of the cam 10 (i.e. from the beginning of the high portion 32 to the drop off 34). At the drop off point 34 the pin 20 is forced out by the water pressure, the O-ring 16 seats, water stops flowing and the turbine 4 stops spinning.
The use of an intermediate worm gear 6 is not essential to the invention, wherein the worm gear 5 attached concentrically to the turbine 4 can directly engage the teeth of the round gear 8, as shown in FIG. 8. However, the use of the second worm gear 6 is preferred for regulating the timing relating to the number of rotations of the turbine 4 necessary for a full rotation of the cam 10.
Alternatively, elimination of the intermediate worm gear 6 may require a larger round gear 8 to provide proper timing, as described below, when used in a standard tank system. Although the device 2 of FIG. 8 is shown with the cam 10 non-concentrically attached to the round gear 8, it is understood that it can be concentrically attached with missing teeth or concentrically attached using a shaft and slot arrangement, as described above.
The turbine 4, worm gear 5, end gear 38, second worm gear 6, round gear 8 and cam 10 can be made of any suitable material including plastics, nylon, stainless steel, polyesters, etc., with plastic or nylon being preferred. Suitable for this use is DELRIN plastic. The preferred gears are 32 pitch, the round gear having either 54 or 60 teeth, with 11 or 12 teeth removed for the first embodiment.
The housing of the inlet valve 12 can also be made of plastic or any other suitable material. The O-ring 16 can be made of rubber or other suitable material and is preferably made of silicone to ensure long life.
The device 2, if not just the turbine 4, preferably has a housing 60 to limit water splashing off of the turbine 4 when water is flowing through the inlet valve 12 and divergent outlet 28. The housing 60 necessarily has an opening or outlet 72 to allow the water passing over the turbine 4 to enter the system, and is preferably made of plastic, plexiglass or a like material.
A preferred housing structure is shown in FIGS. 11A and 11B. The housing 60 is generally shaped to conform to the turbine 4 with an inlet 70 for access of divergent outlet line 28 ending in a channel 71 for properly directed flow over the turbine 4, and a water outlet 72 which directs the water from the turbine 4 to the bottom of the tank (not shown) to fill the tank. The outlet 72 preferably includes one or more vent holes 74 for easy flow of water out the outlet 72. The housing 60 also has a sealed opening (not shown) through which the worm gear 5 passes to allow for contact with the end gear 38, but does not allow water to escape.
The handle means used to activate the flush action of the toilet or urinal is used to rotate the cam 10 to activate the present device 2. Therefore, in the tank system, the handle which lifts the flapper valve at the bottom of tank to let water flow out of the tank also raises the extension 50 and turns the cam 10 to the high portion 32, allowing water to flow through the inlet valve 12. As shown in FIG. 9, the extension 50 which cooperates with the handle has an engagement portion 56 about a pivot 52 which engages a projection 54 on the cam 10 or round gear 8.
As seen in FIG. 9, the extension 50 has several holes 58 to allow proper engagement with the handle means by wire, chain 76, etc. When the handle means is activated the extension 50 is lifted and the engagement portion 56 moves about the pivot 52 to push the projection 54 around, moving the cam 10 to its high point 32.
Alternatively, as shown in FIG. 12, the end 88 opposite engagement with a chain 76 attached to extension 50 travels in a slot 78 having two stops in arm 80. The opposite end of arm 80 engages a stud 82 on the cam 10. When the chain 76 is pulled the extension 50 pivots on pivot 84 secured to a fixed plate 90 and the opposed end 88 presses down on the stop bottom 86, preferably rounded, of the slot 78 to pull down the arm 80 attached to stud 82 on the cam 10, thereby rotating the cam 10 to start the water flow. The throw of the extension 50 is sufficient to move the cam 10 from its low position 30 to its high position 32.
A preferred configuration of the present invention is shown in FIG. 13 mounted on a plate member 90.
The device 2 works as follows. When the device 2 is in its ready position the pin 20 of the inlet valve 12 is extended within the low point 30 of the cam 10, the O-ring 16 is seated in the O-ring seat 18 due to water pressure of the water from the valve inlet 14.
The device 2 is activated by the flush activation means of the toilet, which rotates the cam 10 to the beginning of the high point 32 of the cam 10. The high point 32 of the cam 10 depresses the pin 20 of the valve 12, allowing water to flow through the inlet valve 12.
The water flows through the valve outlet 22 and through divergent outlet lines 24, 26 and 28. The water flowing through the first line 24 goes to the overflow, as is standard in most toilets, the second line 26 goes to the bottom of the tank to quietly fill the tank, and the third line 28 is directed to just above the blades 36 of the turbine 4 to turn the turbine 4.
The water flow from line 28 turns the turbine 4 and the worm gear 5 attached thereto. The worm gear 5 attached to the turbine 4 turns the end gear 38 of the second worm gear 6, thereby turning the worm portion 40 of the second worm gear 6. The teeth of the worm portion 40 engage the teeth of the round gear 8, thereby turning the cam 10 across its high portion (i.e. from the beginning of the high portion 32 to the drop off point 34). While the cam 10 is moving across its high portion it holds the pin 20 in and allows water to flow from the inlet valve 12.
When the gears rotate to the point that the pin 20 passes the drop off point 34 and is allowed to extend, the pressure from the water at the water inlet 14 closes the inlet valve 12 by seating the O-ring 16 in the O-ring seat 18 and the water flow stops. The absence of water flow also stops the turbine 4 and all subsequent gears from rotating.
Since the gearing of the device 2 works with the volume of water passing over the turbine 4 on a timing theory, the amount of water to pass through the valve 12 on a per flush basis can be regulated in a number of ways. This is important where use of the device 2 would eliminate the need for a float valve in a standard toilet tank.
One way to regulate the volume of water going through the inlet valve 12 is to change the size or number of the gears between the turbine 4 and the cam 10. For example, the larger the round gear 8, the longer it will take for the cam 10 to make a full rotation and the longer the pin 20 will be depressed, allowing more water to flow. Similarly, a smaller round gear 8 will allow less water to flow.
The preferred method of regulating the volume of water, however, is to put a regulating device, i.e. an adjustable valve 48, on one or both of the lines 24 and 26 or on line 28 to regulate the flow of water over the turbine 4. For example, the less water that flows through lines 24 and/or 26, the more water will flow through line 28 and the faster the turbine 4 will spin. Likewise, when more water is allowed to flow through line 28 the faster the turbine 4 will spin. The faster the turbine 4 spins, the less time it will take for a full rotation of the cam 10, the less water will pass through the valve 12.
Similarly, the more water that passes through lines 24 and 26, through closing or reducing water flow through a valve (not shown) on line 28 or opening or increasing water flow through a valve 48 on line 26 and/or a valve (not shown) on line 24 the less water passes over the turbine 4. The less water over the turbine 4 the slower the rotation of the gears and the more water will pass into the tank through the combined flow through lines 26 and 28 before the cam 10 allows the pin 20 to extend and flow through the inlet valve 12 to stop.
Of course, when the device 2 is installed in a tank system and there is a leak in the flapper valve, the tank will empty but water will not flow into the tank due to the device 2. Therefore, when flushing the toilet the handle will have to be activated twice, once to fill the tank with water and another time to flush.
While the invention has been described in detail and with reference to several specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. For example, a straight gear may be used between the turbine 4 and the cam 10, or gear means without teeth, causing rotation by contact or belts. Such obvious variations, however, are covered by the invention, limited only by the appended claims.
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A toilet water regulator device which prohibits water flow into the toilet system after a predetermined amount of water has entered the system comprising a valve at the water inlet to the system, said valve having a water outlet to the system, wherein the flow of water through said valve is controlled by turbine means associated with the water outlet of the valve and the amount of water predetermined necessary to fill the tank is controlled by adjustable valve means.
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BACKGROUND
Various embodiments of the present invention relate to a toy projectile or dart and a method of making the toy projectile or dart.
Darts or toy projectiles have been used in toy guns or other toys to provide an enhanced play factor to the toy guns or toys. As with any toy projectile it is desirable to provide the same with a blunt soft end as well as certain characteristics that allow for durability and continued use.
Accordingly, it is desirable to provide a toy dart or toy projectile that is easy to manufacture and have robust characteristics as well as providing for the aforementioned safety factures.
SUMMARY OF THE INVENTION
In one embodiment, a toy projectile is provided, the toy projectile having: an elongated dart body secured to a tip assembly, the tip assembly comprising: a tip insert secured to a forward end of the elongated dart body and a tip secured to the tip insert, wherein the tip comprises a styrene ethylene butylene styrene copolymer (SEBS rubber) tip.
In another embodiment, a toy projectile is provided, the toy projectile having: an elongated dart body; a tip assembly, secured to the forward end of the elongated dart body, the tip assembly comprising: a tip insert and a tip portion insert molded thereto, the tip insert having a plurality of annular features extending from an exterior surface of the tip insert, wherein at least one of the plurality of annular features is covered by the tip portion when it is insert molded onto the tip insert and wherein at least one other of the plurality of annular features is only covered by a forward portion of the elongated dart body when it is secured to tip assembly.
In yet another embodiment, a method of securing a SEBS rubber tip to an extruded dart body is provided. The method including the steps of: forming a tip assembly by inserting a tip insert into a die of an injection molding machine, wherein the tip insert has a central opening extending therethrough and a plurality of features extending from an exterior surface of the tip insert; insert molding a SEBS rubber material wherein the die of the injection molding machine is configured to allow a portion of the SEBS rubber material to extend into a portion of the central opening and cover some of the plurality of features extending from the exterior surface of the tip insert; removing the tip assembly from the injection molding machine; and securing a forward end of an extruded dart body to at least one of the plurality of features of the tip insert that is not covered by the SEBS rubber material.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 is a view of a dart or projectile in accordance with an exemplary embodiment of the present invention;
FIG. 2A is an enlarged portion of FIG. 2 ;
FIG. 2B is a cross-sectional view of the dart or projectile along the lines 2 A- 2 A of FIG. 1 ;
FIGS. 3A and 3B are front and rear perspective views of the dart or projectile illustrated in FIG. 1 in accordance with an exemplary embodiment of the present invention;
FIGS. 4 and 5 are side views of the dart or projectile in accordance with an exemplary embodiment of the present invention;
FIG. 4A is a view along lines 4 A- 4 A of FIG. 4 or a rear view of the dart or projectile of FIG. 1 in accordance with an exemplary embodiment of the present invention;
FIG. 4B is a view along lines 4 B- 4 B of FIG. 4 or a front view of the dart or projectile of FIG. 1 in accordance with an exemplary embodiment of the present invention;
FIG. 6 is a view of a tip assembly constructed in accordance with one non-limiting exemplary embodiment of the present invention;
FIG. 7 is a cross-sectional view of an insert constructed in accordance with one non-limiting exemplary embodiment of the present invention;
FIG. 8 is a cross-sectional view a tip assembly constructed in accordance with one non-limiting exemplary embodiment of the present invention;
FIG. 9 is a flowchart illustrating a method or process for forming a dart or projectile in accordance with one non-limiting exemplary embodiment of the present invention;
FIGS. 10 and 11 illustrating an apparatus for trimming a tail or rearward end of the dart or projectile;
FIG. 12 illustrates an apparatus for securing an extruded dart body to a tip assembly;
FIG. 13 illustrates a dart or projectile formed in accordance with an alternative exemplary embodiment of the present invention; and
FIGS. 13A-13D portions of the dart or projectile illustrated in FIG. 13 .
Although the drawings represent varied embodiments and features of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to illustrate and explain exemplary embodiments the present invention. The exemplification set forth herein illustrates several aspects of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION
Referring now to the FIGS. and in particular FIGS. 1-5 , a dart or projectile 10 constructed in accordance with an exemplary embodiment of the present invention is illustrated. Dart or projectile 10 has an elongated tubular body portion 12 which has a forward end or front end 14 and a rearward end 16 . Rearward or rear end 16 has an opening 17 that extends into opening 19 of the elongated tubular body portion 12 . Secured to the forward end 14 is a tip assembly 18 . Tip assembly 18 has a tip portion 20 and a tip insert 22 . The tip portion 20 is secured to a first portion of the tip insert 22 and a second portion of the tip insert is secured to the forward end 14 of the elongated tubular body portion 12 .
Accordingly, tip insert 22 provides a means for securing the tip 20 to the forward end 14 of the elongated tubular body portion 12 . In one exemplary embodiment, tip insert 22 is configured to have an inner opening 24 extending therethrough. In addition, an exterior surface 26 of the tip insert 22 is configured to have a plurality of features or annular rings 28 extending away from the exterior surface 26 of the tip insert 22 . In one embodiment, the plurality of features or annular rings 28 provide securement features to which the tip 20 and the forward end 14 are secured thereto. Still further, the plurality of features or annular rings also provide a plurality of grooves 30 located between the annular rings. The features or annular rings 28 as well as the grooves 30 located therebetween provide a mechanism for rigidly securing the forward end 14 to the tip assembly 18 . In one implementation and as the material of forward end 14 is pushed between annular rings 28 and then cooled, an interlock of the tip assembly 18 and the tubular body portion 12 is formed.
FIG. 6 illustrates a tip assembly 18 formed in accordance with one non-limiting exemplary embodiment of the present invention. FIG. 7 is a cross-sectional view of the tip insert 22 formed in accordance with one non-limiting exemplary embodiment of the present invention while FIG. 8 is a cross-sectional view of the tip insert 22 with the tip 20 secured thereto. As illustrated, the plurality of features or annular rings 28 provide securement features to which the tip 20 and the forward end 14 are secured thereto. Still further, the plurality of features or annular rings 28 also provide a plurality of grooves 30 located between the annular rings. In accordance with one embodiment, the height or distance of the annular rings 28 may vary. In addition, a rearward end 32 of the tip insert 22 maybe formed with a flange portion 34 which provides additional rigidity to the tip insert and/or tip assembly and in particular to the area that is secured to the forward end 14 of the elongated dart body 12 .
In accordance with one non-limiting exemplary embodiment, the tip insert 22 is formed from the following material TPR Thermoflex ME1385 via an injection molding process. Of course, other equivalent materials for forming the tip insert are considered to be within the scope of exemplary embodiments of the present invention. In one non-limiting exemplary embodiment, the core part or tip insert 22 , was shot at a temp of 225° C. and the shot pressure was 65 bar for a cycle time of 40 seconds. Of course, other temperatures, times and pressures greater and less than the aforementioned values are considered to be within the scope of various embodiments of the present invention.
In accordance with one non-limiting exemplary embodiment, the tip 20 is formed from a styrene ethylene butylene styrene copolymer (SEBS rubber) or more particularly the following material TPR Thermoflex ME1927 via an injection molding process. Of course, other equivalent materials for forming the tip are considered to be within the scope of exemplary embodiments of the present invention. In one non-limiting exemplary embodiment, the tip part was shot at a temp of 225° C. and the shot pressure was 50 bar for a cycle time of 60 seconds. Of course, other temperatures, times and pressures greater and less than the aforementioned values are considered to be within the scope of various embodiments of the present invention.
In accordance with one non-limiting exemplary embodiment, the elongated tubular body portion 12 is formed from an extrusion process wherein the tubular body portion is formed from a polyethylene which in one embodiment comprises 60% LDPE and 40% HDPE. Of course, other equivalent materials and combinations thereof are considered to be within the scope of exemplary embodiments of the present invention.
Referring now to FIG. 9 a flowchart 40 illustrating one non-limiting method for forming the dart or projectiles 10 is provided. At box 42 at least one or a plurality of tip inserts 22 are formed by the aforementioned injection molding process. Simultaneously, previously or afterwards at least one or a plurality of elongated tubular dart body portion 12 are formed by an extrusion process at step 44 . During this step or process the tubular body portion 12 is formed from an extrusion machine wherein an elongated member is extruded from the aforementioned materials and once cooled, the extruded member is cut into the desired lengths for use as tubular body portion 12 .
At step 46 , the rear end or tail end 16 of the elongated tubular dart body portion proximate to opening 17 is trimmed to have a curved or rounded surface 48 (see at least FIG. 1 ). Once trimmed, the elongated tubular body portion 12 is ready to be secured to the tip assembly 18 . In an alternative embodiment step 46 may be eliminated.
At a step 50 , the molded tip insert 22 is inserted into an injection molding machine wherein the tip portion 20 is insert molded onto a portion of the tip insert 22 as described above and illustrated in the attached FIGS. Once this process is complete, the tip assembly 18 is now formed.
After conclusion of the process at step 50 , the form tip assemblies 18 are now secured to the elongated body portions 12 via a heat treating process which occurs at step 52 .
Referring now to FIGS. 10 and 11 , an apparatus 54 for use in the trimming step 46 is illustrated. Apparatus 54 has a plunger 56 onto which the extruded elongated body 12 is placed and an end portion 58 of plunger 56 has corresponding rounded ends which form the rounded ends or end 48 of the elongated body portion 12 when plunger 56 is moved towards a copper plate or other of material 70 which is heated in order to manipulate or trim the extruded elongated body 12 to have a trimmed end or rounded surface 48 .
FIG. 12 illustrates an apparatus 72 for use in step 52 wherein the elongated body 12 with the tip insert inserted into a forward end 14 of the elongated body 12 is placed between a pair of rollers 74 which rotate the same. A heated copper roller assembly or other equivalent material 76 applies heat and pressure to the forward end 14 of the elongated body such that portions of the same are now pushed into the grooves 30 of tip insert 22 so that the elongated body 12 is now secured to the tip assembly 18 and the dart or projectile 10 is formed.
Referring now to the FIGS. 13-13D an alternative exemplary embodiment of the present invention is illustrated. Here the tip insert 22 and the tip portion 20 have alternative configurations. In this embodiment, after the insert molding process the tip 20 or material used to form tip 20 extends completely through the central opening 24 of the tip insert 22 and is received within the central opening of the elongated tubular body 12 . In addition and in this embodiment, the forward end 14 of the elongated body 12 is formed onto features 28 and groove 30 as well as a portion of tip portion 20 . Of course, numerous other configurations are considered to be within the scope of exemplary embodiments of the present invention and the above embodiments are merely examples of various embodiments of the present invention.
As used herein, the terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. In addition, it is noted that the terms “bottom” and “top” are used herein, unless otherwise noted, merely for convenience of description, and are not limited to any one position or spatial orientation.
The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity).
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A toy projectile and method of making the toy projectile is provided herein. The toy projectile having: an elongated dart body secured to a tip assembly, the tip assembly comprising: a tip insert secured to a forward end of the elongated dart body and a tip secured to the tip insert, wherein the tip comprises a styrene ethylene butylene styrene copolymer (SEBS rubber) tip.
| 1
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an arc-tangent calculation method, particularly to a low-latency and divider-free arc-tangent calculation structure and a calculation method thereof.
[0003] 2. Description of the Related Art
[0004] The arc-tangent function is expressed by
[0000]
tan
-
1
(
y
x
)
.
[0000] The calculation method thereof normally needs a divider, and the division result is used to find a corresponding angle from a lookup table. However, the divider is bulky, needs complicated hardware, and occupies considerable area.
[0005] In 1959, Volder published in IEEE a related paper “The CORDIC Trigonometric Computing Technique” that calculates the angle of an arc-tangent function without using any divider, wherein the coordinate system is divided into two parts, and wherein the part where the angle exists is determined. Next, the determined part is further divided into sub-parts again, and the sub-part where the angle exists is determined. The abovementioned dividing process is repeated until the angle is precisely defined. However, the prior art consumes too much time and greatly reduces the system efficiency.
[0006] Accordingly, the present invention proposes a low-latency arc-tangent calculation structure and a calculation method thereof to overcome the abovementioned problems. The architecture and embodiments thereof will be described in detail below.
SUMMARY OF THE INVENTION
[0007] The primary objective of the present invention is to provide a low-latency arc-tangent calculation structure and a calculation method thereof, wherein the coordinate system is divided into a plurality of parts, and wherein the part where the angle exists is determined to exclude the other part irrespective of the angle, whereby the quantity of lookup calculations is greatly reduced.
[0008] Another objective of the present invention is to provide a low-latency arc-tangent calculation structure and a calculation method thereof, wherein the divider is exponentially converted into a subtractor, whereby is reduced calculation time and hardware complexity.
[0009] To achieve the abovementioned objectives, the present invention proposes a low-latency arc-tangent calculation structure, which is used to work out an arc-tangent value of the ratio of an X-axis value I to a Y-axis value Q, and which comprises two lookup tables; two multiplexers respectively determining the order that the X-axis value I and the Y-axis value Q enter into the lookup table, and determining the signs of the comparison results of the second lookup table; at least one comparator determining the signs and magnitudes of the X-axis value I and the Y-axis value Q; a control unit determining the sector where the point corresponding to the X-axis value I and the Y-axis value Q exists; a shift encoder determining a shift angle according to the output of the comparator; and an adder adding the shift angle output by the shift encoder to the output of the multiplexer.
[0010] The present invention also proposes a low-latency arc-tangent calculation method, which comprises steps: using a comparator to determine the signs and magnitudes of an X-axis value I and a Y-axis value Q; using two absolute generators to generate the absolute values of the X-axis value I and the Y-axis value Q; using a first lookup table to obtain the logarithms of the X-axis value I and the Y-axis value Q, and using a second lookup table to obtain the result of exponentiation with the base being the Euler's number and the exponent being the difference of the two logarithms, and obtain an angle corresponding to the arc-tangent value of the exponentiation result; using a control unit to determining the sector where the point corresponding to the X-axis value I and the Y-axis value Q exists; using a multiplexer to determine the sign of the output of the second lookup table according to the output of the control unit; using a shift encoder to determine a shift angle according to the output of the comparator; and adding the output of the shift encoder to the output of the multiplexer.
[0011] Below, the embodiments are described in detail to make easily understood the objectives, technical contents, characteristics and accomplishments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a diagram schematically showing an arc-tangent calculation structure according to one embodiment of the present invention;
[0013] FIG. 2 is a flowchart of a low-latency arc-tangent calculation method according to one embodiment of the present invention; and
[0014] FIG. 3 is a diagram schematically showing that a coordinate system is divided into eight sectors to calculate the arc-tangent value of a point (I i , Q i ) according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention proposes a low-latency arc-tangent calculation structure and a calculation method thereof, wherein the present invention divides a coordinate system into a plurality of sectors, based on the characteristic of the arc-tangent function, and wherein the present invention completely replaces division operations with subtraction operations via logarithmic and exponential transformations, and wherein the present invention finds out the sector where the angle exists, whereby the calculation time is greatly reduced.
[0016] In one embodiment, the X-Y coordinate system is equally divided into eight sectors, and each sector has an angle of 45 degrees. In such a case, the arc-tangent function can be expressed by Equation (1):
[0000]
θ
i
=
tan
-
1
(
Q
i
I
i
)
=
{
tan
-
1
(
lo
g
Q
i
-
lo
g
I
i
)
+
0
°
,
where
I
i
>
Q
i
&
{
sign
(
I
i
)
,
sign
(
Q
i
)
}
=
{
+
,
+
}
-
tan
-
1
(
lo
g
I
i
-
l
og
Q
i
)
+
90
°
,
where
I
i
<
Q
i
&
{
sign
(
I
i
)
,
sign
(
Q
i
)
}
=
{
+
,
+
}
tan
-
1
(
lo
g
Q
i
-
lo
g
I
i
)
+
180
°
,
where
I
i
>
Q
i
&
{
sign
(
I
i
}
,
sign
(
Q
i
)
}
=
{
-
,
-
}
-
tan
-
1
(
l
o
g
I
i
-
lo
g
Q
i
)
+
270
°
,
where
I
i
<
Q
i
&
{
sign
(
I
i
)
,
sign
(
Q
i
)
}
=
{
-
,
-
}
-
tan
-
1
(
lo
g
Q
i
-
l
og
I
i
)
+
360
°
,
where
I
i
>
Q
i
&
{
sign
(
I
i
)
,
sign
(
Q
i
)
}
=
{
+
,
-
}
tan
-
1
(
lo
g
I
i
-
lo
g
Q
i
)
+
270
°
,
where
I
i
<
Q
i
&
{
sign
(
I
i
)
,
sign
(
Q
i
)
}
=
{
+
,
-
}
-
tan
-
1
(
lo
g
Q
i
-
l
og
I
i
)
+
180
°
,
where
I
i
>
Q
i
&
{
sign
(
I
i
)
,
sign
(
Q
i
)
}
=
{
-
,
+
}
tan
-
1
(
lo
g
I
i
-
lo
g
Q
i
)
+
90
°
,
where
I
i
<
Q
i
&
{
sign
(
I
i
)
,
sign
(
Q
i
)
}
=
{
-
,
+
}
(
1
)
[0017] Refer to FIG. 1 a diagram schematically showing an arc-tangent calculation structure for working out an angle corresponding to the arc-tangent value of a ratio of an X-axis value I to a Y-axis value Q. The structure comprises two absolute-value generators 10 and 10 ′, a first multiplexer 12 , a first lookup table 14 , a register 16 , a subtractor 18 , a second lookup table 20 , a complementer 22 , a second multiplexer 24 , an adder 26 , a sign comparator 28 , a numerical comparator 30 , a control unit 32 and a shift encoder 34 .
[0018] The two absolute-value generators 10 and 10 ′ respectively generate the absolute values of the X-axis value I and the Y-axis value Q, and send the absolute values to the first multiplexer 12 and the numerical comparator 30 . The first multiplexer 12 determines the order of absolutely X-axis value I and absolutely Y-axis value Q go to the first look up table 14 according which number is smaller. The first look up table 14 works out the logarithms of the X-axis value I and the Y-axis value Q. The worked out logarithms are stored in the register 16 . The subtractor 18 calculates the difference between the logarithms of the X-axis value I and the Y-axis value Q. The second lookup table 20 includes an exponentiation lookup table and an angle lookup table. From the second lookup table is obtain the exponentiation result of the abovementioned difference. Further from the second lookup table is obtained an arc-tangent value (an angle) corresponding to the exponentiation result. The complementer 22 adds a minus sign to the output of the second lookup table 20 . Suppose that the output of the second lookup table 20 is a positive value. After the complementer 22 adds a minus sign to the positive value, the positive value is converted into a negative value. Thereby, the second multiplexer 24 simultaneously receives a positive input and a negative input. The second multiplexer 24 calculates to determine whether to output a positive value or a negative value. The sign comparator 28 and the numerical comparator 30 respectively determine the signs and magnitudes of the X-axis value I and the Y-axis value Q. The X-axis value I and the Y-axis value Q are directly sent to the sign comparator 28 before being processed by the absolute-value generators 10 and 10 ′. The X-axis value I and the Y-axis value Q are sent to the numerical comparator 30 after being processed by the absolute-value generators 10 and 10 ′. The two comparators 28 and 30 may be regarded as a single comparator. The control unit 32 determines the sector where a point corresponding to the X-axis value I and the Y-axis value Q exists. In one embodiment, the coordinate system is divided into eight sectors each having an angle of 45 degrees. The shift encoder 34 determines the shift angle according to the outputs of the sign comparator 28 and the numerical comparator 30 . The adder 26 adds the shift angle output by the shift encoder 34 to the output of the second multiplexer 24 .
[0019] Refer to FIG. 2 for a flowchart of a low-latency arc-tangent calculation method. In Step S 10 , input an X-axis value I and a Y-axis value Q. In Step S 12 , use two absolute-value generators to respectively generate the absolute values of the X-axis value I and the Y-axis value Q. In Step S 14 , use a first look up table to convert the absolute values of the X-axis value I and the Y-axis value Q into the logarithms thereof (log I and log Q), store the logarithms in a register, and use a subtractor to calculate the difference of the logarithms (log Q−log I). According to the absolutely value of Q and I, it can be either log Q−log I or log I−log Q. In Step S 16 , find out an exponentiation result e log Q−log I of the logarithm difference (log Q−log I) from a second lookup table, and find out an angle corresponding to the arc-tangent value of the exponentiation result from the second lookup table. Both the exponentiation result and angle are positive values. A complementer adds minus signs to the positive values to obtain two negative values. The positive and negative values are input to a second multiplexer.
[0020] On the other hand, after the values of the X-axis value I and the Y-axis value Q are input in Step S 10 , use a comparator to determine the signs and magnitudes of the X-axis value I and the Y-axis value Q in Step S 18 . In the embodiment shown in FIG. 1 , a sign comparator is used to determine the signs of the X-axis value I and the Y-axis value Q, and a numerical comparator is used to determine whether the magnitude of the X-axis value is smaller or greater than that of the Y-axis value. In the present invention, the coordinate system is divided into a plurality of sectors, for example, eight sectors each having an angle of 45 degrees. In Step S 20 , use a control unit to determine the sector where a point corresponding to the X-axis value I and the Y-axis value Q exists. In other words, determine the magnitudes of ∥I i ∥ and ∥Q i ∥, and {sign(I i ), sign(Q i )}. Thereby, the second multiplexer can determine the sign of the arc-tangent value and whether to add a minus sign to tan −1 shown in Equation (1) according to the magnitudes of ∥I i ∥ and ∥Q i ∥, and {sign(I i ), sign(Q i )}. Similarly, a shift encoder determines the shift angle according to the magnitudes of ∥I i ∥ and ∥Q i ∥, and {sign(I i ), sign(Q i )}. Then, in Step S 22 , add the shift angle output by the shift encoder to the output of the second multiplexer to obtain the arc-tangent value of (I i , Q i ).
[0021] Refer to FIG. 3 a diagram schematically showing a coordinate system divided into eight sectors according to one embodiment of the present invention. In this embodiment, each sector has an angle of 45 degrees. The eight sectors are respectively the first, second eighth, seventh, third, fourth, sixth and fifth sectors in counterclockwise sequence from the positive X axis. Below is demonstrated how to calculate the angle corresponding
[0000]
tan
-
1
(
Q
i
I
i
)
.
[0000] From the position where the point (I i , Q i ) is located in the coordinate system, it is known that ∥I i ∥<∥Q i ∥ and that I i has a positive value and Q i has a negative value, i.e. {sign(I i ), sign(Q i )}={+, −}. Therefore, the point (I i , Q i ) is located in the sixth sector. Thus, the shift angle is 270 degrees, and the angle corresponding to
[0000]
tan
-
1
(
Q
i
I
i
)
[0000] has a value of tan −1 (e log|I i |−log|Q i | )+270°.
[0022] In conclusion, the present invention proposes a low-latency arc-tangent calculation structure and a method thereof, which replaces a divider with a subtractor to reduce calculation time and decrease the area occupied by hardware. In the present invention, the coordinate system is divided into a plurality of sectors, whereby the corresponding angle can be worked out with only two lookup tables, and whereby the invention can further reduce calculation complexity and promote system efficiency.
[0023] The embodiments described above are only to exemplify the present invention but not to limit the scope of the present invention. Any equivalent modification or variation according to the spirit of the present invention is to be also included within the scope of the present invention.
|
The present invention provides a low-latency arc-tangent calculation structure and a calculation method thereof. The arc-tangent calculation structure comprises two lookup tables, a subtractor, a sign comparator, a numerical comparator and a shift encoder. The present invention divides the coordinate system into a plurality of sectors for simplifying the lookup tables. The first lookup table is used to perform logarithmic transformation so as to replace a divider with a subtractor. The second lookup table integrates an exponentiation table and an angle table to translate the output of the subtractor into arc-tangent value θ. Then, θ is shifted to a correct angle according to the output of the shift encoder.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATION
This application is a Divisional of U.S. Ser. No. 10/001,012 filed Nov. 30, 2001 now U.S. Pat. No. 6,875,603. Priority is claimed based on U.S. Ser. No. 10/001,012 filed Nov. 30, 2001, which claims priority to Japanese Patent Application No. 2000-364370 filed on Nov. 30, 2000.
PRIORITY INFORMATION
This application claims priority to Japanese Application Serial No. 364370/2000, filed Nov. 30, 2000.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for detecting biopolymers capable of detecting the presence of biopolymers such as DNA, RNA and protein in a sample and measuring an existing amount or a concentration thereof, and to a cartridge used for the detection.
As technologies for detecting DNA, such technology has been generally used, in which DNA is modified with a radioactive material, a fluorescence dyestuff or the like by use of technologies of RI (radioactive isotope), fluorescence or the like and excited by a stimulus from the outside for detection of response by luminescence. Also an electric charge detecting method for electrochemically determining DNA based on an oxidation-reduction potential by use of an intercalating agent, which is specifically bonded to a duplex of DNA, has been devised. Further, there is a method of using a surface plasmon resonance phenomenon as a method without modification and the like. With respect to a method of fixing DNA to an electrode, there is a method of utilizing an action that a monolayer of free thiol radicals located on the end of DNA is self-organized on the surface of gold using a thiol modified DNA probe.
In conventional DNA detecting technologies, methods of using RI or fluorescence have been needed to modify DNA.
SUMMARY OF THE INVENTION
An apparatus for detecting biopolymers in accordance with the present invention includes: a voltage supply unit for placing electric voltage between two electrodes of a cartridge which stores biopolymers between the electrodes; a holding unit for holding the cartridge; an irradiation unit for irradiating light onto the cartridge held by the holding unit; and a light receiving unit for receiving the light irradiated by the irradiation unit onto the cartridge held by the holding unit.
The voltage supply unit can selectively supply alternating current voltage and direct current voltage so that biopolymers can be attracted to one electrode or both electrodes.
The holding unit can two-dimensionally move the cartridge on a plane perpendicular to an optical axis of the light irradiated by the irradiation unit so that the presence of a biopolymer on each location in the cartridge can be detected.
Since the irradiation unit can irradiate light having a specified single wavelength, sensitivity for detecting can be improved.
The apparatus for detecting biopolymers further includes an arithmetic unit for calculating an existing amount, a base length, a concentration, a hybridization ratio and a hybridization amount of a biopolymer from a quantity of light received by the light receiving unit so that various kinds of feature amounts for the biopolymer can be determined.
The apparatus for detecting biopolymers further includes a heater which applies heat to the electrodes of the cartridge for disassociating biopolymers hybridized in the cartridge to single strands, so that each presence of a complementary strand biopolymer and a non-complementary strand biopolymer can be detected.
Also, a cartridge in accordance with the present invention includes: a pillar-shape base unit capable of accommodating a biopolymer solution, the base unit having a first electrode on the inside of a bottom face, transparent sides at least in a portion and a top face opened; and a cap unit which has a second electrode on the outside of a bottom face and is inserted in the base unit from the top face to the middle of the base unit to be fixed.
Since biopolymer probes are fixed on the first electrode or the second electrode, a complementary strand biopolyiner and a non-complementary strand biopolymer can be separately detected.
Further, the cross section of the pillar-shape base unit is a square and the cross section of the cap unit is a round shape. Therefore, since a light incident plane is a plane surface, it is possible to suppress light scattering and easily insert the cap unit into the base unit.
Also, the cartridge further includes a solution reservoir on an upper portion of the base unit for collecting a biopolymer solution overflowed from said pillar-shape portion to prevent the solution from flowing out so that it is possible to prevent the solution from flowing out to the outside.
In the apparatus for detecting of the present invention, a sample DNA is injected between electrodes facing each other. In this technology, since an existing amount of DNA can be physically measured, a concentration thereof and the like can be also determined. Further, by applying an external force by an electric field between the facing electrodes to attract single strand probe DNA fixed on the surface of the electrode and non-hybridized sample DNA to the electrode where the probe DNA is not fixed, it becomes possible to detect a gene without washing.
Further, by use of this method, clearer results can be obtained since both of reacted one and non-reacted one are targeted for the measurement.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a structure of an apparatus for detecting biopolymers according to one embodiment in the present invention.
FIG. 2 is a view showing a structure of a cartridge according to one embodiment in the present invention.
FIG. 3 is a general view showing an apparatus for detecting biopolymers according to one embodiment in the present invention.
FIG. 4 is a schematic view showing a structure of an apparatus for detecting biopolymers using plate-shape cartridges.
FIGS. 5A and 5B are views showing a plate-shape cartridge in detail.
FIG. 6 is a general view showing an apparatus for detecting biopolymers using the plate-shape cartridges.
FIG. 7 is a view showing behaviors of DNA when direct current voltage is applied.
FIG. 8 is a view showing behaviors of DNA when alternating current voltage is applied.
DETAILED DESCRIPTION
Hereunder, referring to drawings, preferred embodiments will be described in details.
FIG. 1 is a schematic view showing a structure of an apparatus for detecting biopolymers according to one embodiment of the present invention. The apparatus includes an optical system to measure optical energy and the like, such as absorbance, transmittance and reflectance, and an optical system to detect a modified part when DNA is modified with an organic material or an inorganic material, such as a fluorescent material and a radio active material.
The optical system to measure optical energy and the like, such as absorbance, transmittance and reflectance, includes a laser, an optical source, a slit, a filter, a diffraction grating, a light receiving unit and the like. A controller 3 is connected to a computer 1 having a display 2 . Light generated from a laser and optical source 4 controlled with the controller 3 is passed through an optical source slit 6 after wavelength selection with a filter 5 . The light is passed through an incidence slit 7 and converted to have wavelengths of 260 nm and 280 nm at a diffraction grating 8 . Further, the light is passed through an ejection filter 10 placed just before a cartridge 11 , the details of which are shown in FIG. 2 ). Optical energy is decreased in the cartridge 11 depending on an existing amount of DNA since DNA absorbs the light. That is, optical energy after the decrease is obtained at a light receiving unit 12 . Any desired measurement location can be selected using an XY stage 13 , and reading can be conducted in a scanning manner. Analysis of the result is carried out with the computer 1 , and a distribution of the DNA existing amount can be determined by measuring how much the quantity of optical energy received at the light receiving unit is decreased from incident light at some place. The transmittance is obtained as a ratio of a quantity of light to that in the case of no presence of DNA under the condition that the cartridge 11 is fully filled with the solution. The reflectance is, in the same manner, obtained as a ratio of a quantity of reflected light to that in the case of no presence of DNA. In order to measure this reflectance, an optical system to receive the reflected light is needed. The absorbance is obtained by subtracting transmittance from reflectance. Temperature inside the cartridge can be controlled by a cartridge fixed portion 14 provided with an electric heater that is connected to a power source 15 . Thus, the temperature during reaction or measurement can be controlled, and the reactivity at each temperature, such as a dissociation temperature for single strands, for example, can be measured.
The optical system to detect a modified part when DNA is modified with an organic material or an inorganic material, such as a fluorescent material or a radio active material, includes a laser, a light source, a pinhole, a lens and the like. Light generated from a laser and light source 16 is condensed with a lens 22 after passing through a filter 21 for wavelength selection and is passed through a pinhole 23 at the focal point. The light passed through the pinhole 23 is again condensed with the lens 24 having the focal point at a measuring portion. The light indicating a material excited by the condensed light is advanced to the lens 24 and is advanced through a polarized beam splitter 17 to a light receiving unit 18 side. The light having a selected wavelength by passing through a filter is passed through a pinhole 19 at the focal point to reach the light receiving unit 18 . A distribution of modified parts is analyzed based on signals from the light receiving unit 18 .
FIG. 2 is a view showing a structure of a cartridge according to one embodiment of the present invention. A cartridge 11 includes a cap unit and a base unit 27 . In the cap unit 25 , at a top face thereof, an inner cylinder 25 b having a bottom face opened and a smaller cross section is coaxially joined to an outside pillar 25 a having a bigger cross section. An electrode 26 is provided on the outside of the whole bottom face of the inner cylinder 25 b . The base unit 27 has a round shape electrode 28 on the inside of the bottom face of a hollow square pillar 27 a having a square cross section. A top face of the square pillar 27 a is opened so that a DNA solution is injected and the cap unit 25 can be inserted. Further, a solution reservoir 27 b is provided on an upper portion of the square pillar 27 a to prevent the DNA solution from flowing out to the outside when some of the DNA solution overflows from the square pillar 27 a . With respect to the cartridge 11 , there are ones where DNA probes are fixed to both electrodes, DNA probes are fixed to one of the electrodes and DNA probes are fixed to neither electrode. The cartridge 11 is inserted into a cartridge insertion portion of the apparatus. The apparatus has electrodes to generate an electric field in the cartridge 11 so that direct current voltage and/or alternating current voltage supplied from a power source can be placed between the electrodes in the cartridge 11 .
Detection is carried out by measuring optical energy such as absorbance, transmittance and reflectance of light having a wavelength of 260 nm. The measurement is carried out by comparison in a plurality of ranges or scanning in a tiny range. Based on a distribution of the obtained optical energy such as absorbance, transmittance and reflectance, a distribution of DNA existing between the electrodes can be obtained to determine an existing amount, a concentration, a hybridization ratio, a hybridization efficiency of DNA and the like.
FIG. 7 is a view showing DNA behaviors when direct current voltage is applied. When direct current voltage is applied between an electrode 71 and an electrode 72 , DNA is drawn in a direction of the electric field and attracted to one of the electrodes, electrode 72 in this case. For this reason, when probe DNA 73 is fixed on the electrode 71 and direct current voltage applied between the electrodes after hybridization reaction, complementary strand sample DNA 75 , which was hybridized, is fixed to the electrode 71 to be prolonged, but non-complementary strand sample DNA 76 , which was not hybridized, is attracted to the electrode 72 side to be a shrunk state. By measuring the DNA amount at each location in this state, the amount and the base length of the hybridized complementary strand sample DNA 75 and the amount of the non-complementary strand sample DNA 76 , which was not hybridized, can be determined. Specifically, the base length can be determined by measuring where the end of DNA is prolonged and exists.
FIG. 8 is a view showing DNA behaviors when alternating current voltage is applied. When alternating current voltage is applied between an electrode 77 and an electrode 78 , DNA is drawn, in a prolonged state, from the location before the application of voltage to the closer electrode at some range of frequency and voltage, 1 MHz and 106 V/m in the present apparatus. In the present embodiment, a sample DNA 79 existing at a location closer to the electrode 77 becomes elongated at the location closer to the electrode 77 . A sample DNA 80 existing at a location closer to the electrode 78 becomes elongated at the location closer to the electrode 78 . By separately and repeatedly using direct current voltage and alternating current voltage as voltage applied to the cartridge 11 , it is possible to control the location of DNA. In the present apparatus, direct current voltage is applied between the electrodes at each of the stage of attracting DNA between electrodes at the time of injection of a sample, the stage of attracting sample DNA to the probe side before hybridization reaction and the stage of separating sample DNA forming a duplex with the probes and non-reacted sample DNA after hybridization reaction. Alternating current voltage is applied when DNA is stretched in a separated state at the time of measuring the base length and the like.
FIG. 3 is a general view of the apparatus for detecting biopolymers according to one embodiment of the present invention. A rotary cartridge inserting part 30 is provided in the main unit 29 of the apparatus. The plurality of cartridges 11 are loaded thereon, and a cover unit 31 of the apparatus is closed. Therefore, DNA detection can be continuously conducted by automatically changing the cartridges 11 to be subjected to the measurement.
FIG. 4 is a schematic view showing a structure of the apparatus for detecting biopolymers using a plate-shape cartridge, the details of which is shown in FIG. 5 . An optical system to measure optical energy and the like, such as absorbance, transmittance and reflectance, includes a laser and a light source, a slit, a filter, a diffraction grating, a light receiving unit and the like. Light generated from a laser and light source 35 , after wavelength selection with a filter 36 , is passed through a light source slit 37 . The light is passed through an incident slit 38 and converted to have wavelengths of 260 nm and 280 nm with a diffraction grating 39 . Further, the light is passed through an ejection slit 41 placed just before the cartridge. Optical energy is decreased in a plate-shape cartridge 42 depending on an existing amount of DNA since DNA absorbs the light. That is, optical energy after the decrease is obtained at a light receiving unit 45 . Any desired measurement location can be selected using an XY stage 43 , and reading can be conducted in a scanning manner. Analysis of the result is carried out with a computer 32 , and a distribution of the DNA existing amount can be determined by measuring how much the quantity of optical energy received at the light receiving unit 45 is decreased from incident light at some place.
An optical system to detect a modified part when DNA is modified with an organic material or an inorganic material, such as a fluorescent material or a radio active material, includes a laser and a light source, a pinhole, a lens and the like. Light generated from a laser and light source 47 is condensed with a lens 49 after passing through a filter 48 for wavelength selection and is passed through a pinhole 50 at the focal point. The light is turned to the plate-shape cartridge 42 with a reflecting mirror 51 and is again condensed with the lens 53 having the focal point at a measuring portion. The light indicating a material excited by the condensed light is advanced to the lens 53 and is advanced through a polarized beam splitter 52 to a light receiving unit 56 . The light having a selected wavelength by passing through a filter 54 is passed through a pinhole 55 at the focal point to reach the light receiving unit 56 . Analysis of the distribution of modified parts is conducted with a computer 32 based on signals from the light receiving unit 56 . Temperature inside the cartridge can be controlled by a cartridge fixed portion 44 provided with an electric heater that is connected to a power source 46 . Thus, the temperature during reaction or measurement can be controlled, and the reactivity at each temperature, such as a dissociation temperature for single strands, for example, can be measured.
FIGS. 5A and 5B are views showing a plate-shape cartridge in details. A plate-shape cartridge shown in FIG. 5A has a structure, in which storing ditches 59 having micro widths and depths are provided on a plate, and electrodes 57 and 58 are provided on the both sides of each of the storing ditches 59 . When the absorbance, the transmittance and the like are measured, a transparent bottom face is needed. As for the measurement, optical energy such as absorbance, transmittance and reflectance and the like is measured. The conventional detection by fluorescence can be carried out.
FIG. 5B is a view showing plate-shape cartridges having gel. By putting gel 65 in the middle of the storing ditches and heating electrodes 61 and 62 , it is possible to conduct a time lag measurement. Single-strand DNA probes are fixed to one electrode 61 beforehand and a sample DNA solution is injected in each of wells 63 located on the side of the electrode 61 , to which the probes are fixed, for hybridization reaction. Measurement is performed for non-reacted sample DNA by conventional electrophoresis. When DNA and modified materials in gel portion 65 have completely flowed out into the well 64 located on the side of the electrode 62 facing the electrode 61 , the electrode 61 is heated to dissociate DNA existing around the electrode 61 to single strands, and the measurement is again performed by conventional electrophoresis. By this way, it is possible to determine a base length distribution and an existing amount of complementary strand DNA and a base length distribution and an existing amount of non-complementary strand DNA in the sample DNA.
In the measurement and the detection, it is possible to use unmodified sample DNA, but it is possible to obtain higher sensitivity by modifying DNA with an organic material or an inorganic material, such as a fluorescent dyestuff, for excitation from an outside stimulus.
FIG. 6 is a general view of the apparatus of detecting biopolymers having plate-shape cartridges. A plurality of plate-shape cartridges 42 are loaded in a main unit 66 of the apparatus so that the electrodes of the cartridge are connected to be in contact with one electrode 67 and the other electrode 68 . The cartridges are scanned in one time with a scanning part 69 . Usually, hybridization or electrophoresis is conducted while a lid 70 is closed.
Note that the present invention is not limited to the embodiment mentioned above.
In the embodiment mentioned above, the cross section of the cartridge is a square, but other shapes such as a hexagon may be acceptable. It is desirable that the cartridge has transparent and parallel planes in order to avoid scattering of light passing therethrough.
Moreover, dissociation temperature for single strands of DNA can be determined by varying temperature of the electrodes and by measuring an amount of hybridized DNA or non-hybridized DNA at each temperature.
In accordance with the present invention, the presence and an existing amount or a concentration of a biopolymer such as DNA, RNA and protein and the like in a sample can be simply determined.
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Provided is an apparatus for detecting biopolymers (DNA) capable of total analysis including non-reacted samples without complicated operations such as washing.
A DNA probe is fixed to one of electrodes and direct current voltage is placed between the electrodes, so that it becomes possible to separate complementary strand sample DNA and non-complementary strand sample DNA. By analyzing from a ratio in the whole reaction system, it is possible to obtain clearer results. Further, by using electrophoresis by gel together, it is possible to separate reacted samples and non-reacted samples to perform measurements therefor in the same reaction field.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of British patent application number 0818466.5, filed Oct. 8, 2008, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hub for a wind turbine.
2. Description of the Related Art
Current large-scale horizontal axis wind turbines have tower head weights (including the rotor, nacelle and drive train) of the order of 120 to 200 metric tonnes. There is an increasing trend for larger diameter turbines and the weight of the tower head is increasing approximately as the cube of the diameter of the turbine. The rotor itself (made up of the hub and blades) accounts for roughly 30% of the tower head weight. Approximately 60% of this is attributed to the blades while 40% is attributable to the hub.
U.S. Pat. No. 4,029,434 discloses the blade mounting for a windmill. The root of the blade extends into the hub where it is supported by a journal bearing assembly and a combined journal and thrust bearing assembly which allow the blade to rotate about its axis. The combined journal and thrust bearing assembly must be built around the root once the root is in situ. Further, the blade root bears directly against the two bearings and therefore must have a circular cross section. The mounting is suitable for a windmill in the 1970s (which would have had a rotor diameter of less than 20 m), but is not suitable for a modern day wind turbine blade, the blade length of which could be in order of magnitude greater than the blade contemplated by U.S. Pat. No. 4,029,434.
U.S. Pat. No. 4,668,109 discloses a bearing assembly for a wind turbine. The bearing is a sealed unit which has an outer cylinder which is bolted to the hub by an array of bolts. Within the cylinder is a shaft which is supported on a pair of bearings. A wind turbine blade terminates in a flange which is bolted by an array of bolts to a flange which is integral with the shaft. The bearing has an expansive pressure ring which is arranged to apply equal compressive force to the bearings so that the pressure is maintained as the bearing wears. The bearing is designed to be suitable for a small scale wind turbine. The manner in which the bearing is connected makes it unsuitable for a modern day large wind turbine. In particular, the requirement for two arrays of bolted joints, one at either end of the bearing would make the joint too heavy to be scaled up to the size required for a modern day turbine. Its use in a modern large scale wind turbine blade would only make the problems referred to below with regard to the plurality of bolts worse.
The current design of a conventional wind turbine rotor is shown in FIGS. 1 to 3 . The rotor comprises a hub 1 which is a large, heavy and typically cast metallic structure. Three blades 2 are attached to the hub, one of which is shown in FIG. 1 . The hub has a rotor axis 3 about which the rotor rotates and the blades are rotatably mounted so as to be rotatable about a pitch axis 4 each driven by a pitch motor (not shown). For each blade, the hub is provided with an annular pitch bearing 5 which supports the blade 2 so as to allow it to rotate about the pitch axis. The pitch bearing typically has an outer race 6 and an inner race 7 with a pair of ball sets 8 inbetween.
Current art large wind turbines use two types of general blade design, those with a structural spar bonded inside an aerodynamic shell and those with the stiffening structure within the aerodynamic shell. In both cases the main structural elements of each blade are terminated at the hub end in what is known as a root structure. This is the last piece of blade structure (typically 3-8 m in length) at the proximal end of the blade. This root structure takes all of the bending loads out of the blade and into a cylindrical shape ready for transfer to the hub via the pitch bearing.
The root end of the blade has a number of bolt attachment points 9 (typically 60 to 80) around the circumference of the root. These take the form of holes 10 into which threaded steel inserts 11 are bonded. A plurality of bolts 12 are inserted through the inner race 7 and into the inserts 11 to hold the blade 2 in place.
The current design has a number of shortcomings.
The rotor mass is significant both in terms of the load on the drive train and also the tower head mass. This has a significant effect, particularly for large turbines, on the dynamic interaction between the rotor and the tower. For off-shore installations, a large tower head mass is one of the significant problems with cost-effective deployment of the technology in this environment.
The inserts 11 are very difficult to produce with a high degree of repeatability. These are one of the most highly loaded points on the blade structure yet this relies on a number of secondary bonds where very high performance adhesive is used to bond the metallic studs to the composite root component.
In addition, the inserts are typically metallic and can cause problems due to differences in thermal expansion coefficient relative to the composite root structure, as well as difficulties in bond adhesion to the steel insert. Additionally, thicker sections of composite are needed at the root end of the blade to reduce flexural mismatch with the metallic inserts. This leads to the root end of the blade being heavy.
The pitch bearing also has to take the full flapwise (M Flap in FIG. 3 ) and edgewise (M Edge ) bending moments of the blade. It also has to take the axial load (F Axial ) caused by centrifugal and gravitational loading as well as radial flap-wise (F Flap ) and edgewise (F Edge ) loads. This means that the bearings are large diameter, expensive and heavy components in order to be able to cope with the large and varied forces. A number of pitch bearings have failed in use under these loads.
The large diameter required for the pitch bearing for the reasons set out above means that the root end of the blade needs to be made thicker (larger diameter) than is desirable for aerodynamic performance, thereby decreasing the efficiency of the blade.
The assembly of the blade onto the hub requires accurate torquing of a large number of bolts in order to achieve adequate fatigue resistance at the bolts and to avoid distortion of the pitch bearing. This is a time-consuming process which must be carried out with great care if problems are to be avoided.
SUMMARY OF THE INVENTION
The present invention provides an interface between the hub and the wind turbine blades which addresses at least some of the shortcomings set out above.
According to a first aspect of the present invention, there is provided a wind turbine rotor comprising a hub and a plurality of blades, the hub comprising a plurality of sites, each having a pair of spaced apart annular bearings for receiving a respective wind turbine blade, each blade having a spar extending along a substantial portion of the length of the blade and protruding from the proximal end of the blade, the spar protruding into and being rotatably received within the respective spaced apart bearings and being fixed to the hub.
Rather than terminate the blade and provide a bulky circular root end, the present invention takes the approach of extending the spar into the hub and supporting the hub and the spar rotatably in a pair of spaced apart bearings.
This means that instead of one large bearing taking the full bending moment of the blade perpendicular to the plane of rotation, there are now two smaller bearings taking the bending moment out of the blade within the plane of rotation of each bearing. Not only does this provide a load situation which is more suitable for a bearing (in plane of bearing rotation as opposed to perpendicular to plane of bearing rotation) but also allows the loads on each bearing to be further reduced by increasing the separation of the bearings. Therefore the load on each bearing is reduced and is in a direction that the bearing is more able to support, leading to a smaller and more reliable bearing arrangement. Ultimately this leads to reduced bearing cost and increased reliability when compared to the prior art. It also allows the means by which the blade is fixed to the hub to be simplified reducing or eliminating the need for a thick root end to accommodate the array of bolts.
Preferably, the spacing between bearings is at least 1 m and more preferably at least 1.5 m. Preferably, the rotor has a rotor diameter (i.e. the diameter of the circle swept by the blades) of at least 45 m.
The blade may still be connected to the hub using the bonded insert and bolt connection of the prior art. In view of the additional support provided by the bearings referred to above, the size of the hub connection could be reduced to some extent, thereby leading to some benefits. However, preferably, each spar is fixed to the hub at a location radially inwards of the distal end of the distal bearing.
By contrast, in the conventional design, the blade abuts against the distal end of the bearing such that there is no overlap. As soon as the blade begins to overlap with the bearings, the bending loads on the blade begin to reduce as they are taken up by the bearings. This facilitates the fixing of the blade to the hub as whatever fixing is used is required to bear less load.
Preferably, each spar is fixed to the hub at a location radially inwards of the proximal end of the proximal bearing. This maximises the advantage referred to above as, beyond the proximal end of the proximal bearing, the bending moments on the blade have reduced to zero. The fixing between the blade and the hub is then only required to support the axial force on the blade (FAxial) caused by the gravitational and centrifugal loading. This fixing can therefore be greatly simplified as compared to the multiple bolts and steel inserts of the prior art.
Preferably, the blade is supported by a pin inserted through a hole in the blade proximally of the proximal bearing, the pin abutting against a proximal face of the proximal bearing to support the axial loads.
The rotor hub can be made predominantly from composite material. The only metallic pieces may be the pitch bearings and the bearings and supports for the rotor shaft attachment. The section of hub the between the two bearings essentially replaces what was the ‘root structure’ of PCT/GB2008/002571. In this section the root has predominantly more unidirectional material on the faces which are taking the highest blade loads (typically the flapwise parts) and predominantly more multiaxial material on the faces which are taking the highest shear loads (typically the edgewise parts). This variation in the laminate structure can be replicated in this section of the hub allowing for optimal use and orientation of different fibre types and arrangements and this is now a preferred route in this case. Also, the need for metallic inserts can be avoided by moving the fixing proximally of the bearings, thereby removing the need make the blade thicker at the root end. These considerations alone provide a reduction of around 25% of the hub and root mass.
Preferably, the spar and bearings are configured to allow each blade to be slid into and out of the hub along the respective axis of rotation of the blade. This provides a simple way of assembling the blades to the hub.
The present invention also extends to a method of assembling a wind turbine according to the first aspect of the invention, the method comprising assembling the hub with the pair of annular bearings at each site; inserting the spar of each blade into its respective pair of annular bearings; and fixing each blade to the hub.
The method is an improvement on the prior art as it allows for a much simpler fixing between the blade and the hub, particularly if the spar is fixed to the hub radially inwards of the proximal end of the proximal bearing and ideally using the pin.
The method also offers the possibility of fixing a hub to a wind turbine tower and subsequently assembling the wind turbine according to the above method. At present, the fully assembled rotor is lifted onto the tower. This is a complex process using very expensive cranes to move a heavy, physically large and reasonably delicate component into place. If the hub can be put in place before the blades are attached, it is a much simpler task to lift the individual blades into place either using a more basic crane, or a winch at the top of the tower.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a schematic cross-section of a prior art rotor;
FIG. 2 is a cross-section through the part labelled as 11 in FIG. 1 ;
FIG. 3 is a schematic perspective of a rotor showing the various loads on the rotor;
FIG. 4 is a cross-section through a rotor of a first example in a plane perpendicular to the axis of rotation of the rotor;
FIGS. 4A-4C are cross-sections of the blade through lines A-A, B-B and C-C respectively;
FIG. 5 is a perspective view of the hub and blade prior to insertion of a blade into the hub;
FIG. 6 is a view similar to FIG. 5 showing the blade inserted into the hub;
FIG. 7 is a view similar to FIG. 4 showing various bearing types;
FIG. 8 is a view similar to FIG. 4 showing a first pin connection;
FIG. 9 is a view similar to FIG. 4 showing a second pin connection;
FIG. 10 is a view similar to FIG. 4 showing a third pin connection; and
FIG. 11 is a view similar to FIG. 4 showing a second example of a rotor and blade.
DETAILED DESCRIPTION
Throughout this specification, the term distal refers to a part towards the radially outermost edge of the rotor (i.e., towards the tips of the blade), while the term proximal refers to the radially innermost part of the rotor (i.e., towards the centre of the hub).
The various forces acting on the blade are shown in FIG. 3 which is described in the introduction and will therefore not repeated here.
The rotor comprises a hub 20 to which three blades 21 (only one of which is shown in FIG. 4 ) are attached. The blade is shown is attached in a first port 22 and it will be readily understood that the two remaining blades are attached in identical fashion at remaining ports 23 , 24 .
The rotor is rotatable about the main axis 25 . Each of the blades is rotatable about a pitch axis 26 by a respective pitch motor (not shown) in order to optimise the angle of the blade for the prevailing wind conditions.
Each blade comprises an outer shell 27 which extends to the tip of the blade in order to form the outer profile of the blade. A spar 28 , as best shown in FIG. 5 extends substantially to the tip of the blade and protrudes from the proximal end of the shell 27 .
The cross-sectional structure of the spar may be of any type known in the art. However, preferably, the spar is assembled from a plurality of beams (in this case four) arranged side-by-side as shown in FIGS. 4A-4C . In this case, each of the beams is a box beam comprising a pair of shear webs 29 of multiaxial material with a spar cap 30 of uniaxial material at the top and bottom ends. Core material may be inserted between adjacent webs 29 at certain locations if this is necessary to prevent buckling.
Each port within the hub is provided with a pair of bearings, namely an outer bearing 31 and an inner bearing 32 . The outer bearing 31 has an inner race 33 and an outer race 34 while the inner bearing 32 has an inner race 35 and an outer race 36 . A number of different bearing configurations are shown in FIG. 7 . The bearing may be a spherical bearing shown in FIG. 7A which has only sliding contact between the two races. There may be a single ball race 51 ( FIG. 7B ) or a single roller race 52 in which the rollers are cylindrical and are orientated approximated 45 o to the axis 26 ( FIG. 7C ). Alternatively, there may be a pair of ball races 53 ( FIG. 7D ) or three races of rollers 54 arranged their axes parallel to axis 26 ( FIG. 7E ). Other known bearing configurations may also be used.
The outer bearing 31 is provided with a pair of bearing ribs 37 which are dimensioned so as to abut with the inner surface of the inner race 33 and also with the radially outermost surfaces of the spar 28 to firmly support the spar 28 within the inner race 33 .
The spar 28 has a reduced cross-sectional area 38 at its distal end and the diameter of the inner bearing is correspondingly smaller as is apparent from FIG. 4 . Also, at this point, the spar cap 30 has terminated and the upper end of the edges of the shear webs 29 fit closely with the inner wall of inner race 35 as shown in FIG. 4A . In a similar manner to the outer bearing 31 , the inner bearing 32 also has a pair of bearing ribs 39 which provide a tight fit with the spar 28 but are considerably smaller than the bearing webs 37 of the outer bearing. The spar 28 projects proximally of the inner bearing 32 and is provided an aperture 40 which receives a retaining pin 50 . The pin is a friction fit, but could be secured in other ways. In order to allow the blade to be removed the pin may be a radially expanding bolt. The retaining pin 50 has a diameter of 50 mm to 60 mm and is long enough to project at least behind the pair of bearing ribs 39 and preferably also behind the inner race 35 .
An alternative mounting of the retaining pin 50 is shown in greater detail in FIG. 8 .
In this example, a bearing collar 51 is pinned to the inner race by a plurality of pins 52 to project proximally of the inner race. As shown in Section A-A and B-B the pin 50 passes through the full width of the spar 28 via holes in the shear webs 29 and is supported at either end in the bearing collar. Thus, the load is transferred from the spar, via the pin 50 , then to the inner race 35 by a combination of the abutment with the bearing collar 51 and the load transmitted by the pins 52 . The load is then supported in the hub via any bearing rollers/balls if present to the outer race 36 . It should be noted that it has always been necessary to support the blade on the bearings, for example, as shown in FIG. 2 . However, loading requirements on each bearing can be greatly reduced by providing two separate bearings and by reducing the total loads supported by the bearings.
Of the loads shown in FIG. 3 , the axial load FAxial is borne by the pin bearing against the proximal end of the inner bearing. Only the radial bearing load MTorque is borne by the bearings, and even then, this is split between the inner and outer bearings. As the bearings are spaced apart, they are able to take out the bending moments on the blade itself (M Flap ) and (M Edge ). These bending moments and the shear loads F Edge and F Flap are transmitted to the bearings only as radial loads and can therefore be supported by the bearing ribs and inner races. This compares very favourably with the significant out-of-plane loads applied to the large pitch bearing in a conventional hub.
A second pin connection configuration is shown in FIG. 9 . This is similar to that of FIG. 8 , except that a second bearing collar 53 is attached to the proximal end of the other bearing 31 via a plurality of pins 54 as shown in Section C-C and D-D. The pin connection to the outer bearing 31 is similar to the connection for the inner bearing 32 . In this case, the pin 55 also passes through the bearing ribs 37 . By supporting the load on two pins 50 , 55 , the axial load transmitted to each bearing is reduced.
A third configuration of pin connection is shown in FIG. 10 . In this case, a single retaining pin 56 is provided mid-way between the two bearings 31 , 32 . A pair of axially extending bearing links 57 extend along the spar 28 between the two bearings 31 , 32 so as to transmit the axial loads to the inner races 33 , 35 of the two bearings. Within each bearing, the link 57 abuts against the bearing rib 37 , 39 by transmitting the load to the inner races. The bearing rib and bearing link may be integral with one another as shown, or may be separate components.
FIG. 11 shows a second example of a rotor and blade configuration. This example most closely resembles the prior art arrangement shown in FIG. 1 and the same reference numerals have been used to designate the same components. In this case, the distal bearing 5 corresponds to the annular pitch bearing 5 of the prior art. However, rather than terminating at this point, a spar 70 which projects from the distal end of the blade 2 extends into the hub and into an inner bearing 71 supported on an annular boss 72 within the hub. The blade 2 may be connected to the hub 1 simply through the distal bearing 5 in a conventional manner. Alternatively, it may additionally be connected at the distal bearing 71 , for example, using a pin as described above. Indeed, any of the pin joints disclosed above may be used.
Even if there is no additional support for the blade 2 beyond that provided by the conventional pitch bearing 5 , the loads on this bearing are still reduced by virtue of the additional support provided to the blade by the inner bearing 71 . If the spar 4 has some additional fixing, this further reduces the load on the outer bearing.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A wind turbine rotor comprising a hub and a plurality of blades. The hub comprises a plurality of sites, each having a pair of spaced apart annular bearings for receiving a respective wind turbine blade. Each blade has a spar extending along a substantial portion of the length of the blade and protrudes from the proximal end of the blade. The spar protrudes into and is rotatably received within the respective spaced apart bearings and is fixed to the hub.
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The research leading to this invention was supported by the National Science Foundation under a Presidential Young Investigator Award, NSF ECS No. 8351837.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the enhancement of gas, liquid or solid combustion reactions and/or to driving gas, liquid, or solid combustion chemical reactions.
2. Discussion of the Background
Combustion reactions are found in many different areas. Combustion reactions are found in the generation of power, for example, in internal combustion engines, turbines, jet engines, in fossil fueled electric utility plants, etc. Combustion reactions are also found in pollution control, for example, in the burning of pollutants produced by industrial processes.
Combustion reactions are however unfortunately not perfectly efficient. This results in loss of part of the energy contained in fuels, or in incomplete pollution control. There are also limits on how lean a fuel-air mixture can be reliably ignited and burned.
Increased flame speed can increase the efficiency of combustion reactions and reduce pollution. As an example, in an internal combustion engine, higher flame speed in lean mixtures could lead to a higher efficiency, better fuel economy, and reduced pollution.
Many different approaches are being pursued to increase combustion efficiency, including increasing turbulence, 1 increasing the concentration of free radicals, 2 ,3 applying electric fields, 4 and microwaves. 5 Other approaches involve enhanced ignition such as plasma jet, 6 torch, 7 and laser ignition. 8 ,9 The direct injection of energetic particles, i.e., electrons, ions or neutral particles into a combustion chamber to stimulate combustion, to the inventor's knowledge, has however never been disclosed in the literature.
Numerous processes, including chemical and mechanical manufacturing processes, generate undesired pollutants. The optimal method of pollution control is to enhance the chemical reaction in such a way as to prevent the pollutants from being generated since such pollutants are difficult to deal with after they have been generated. Unfortunately, in most cases, this has so far not been possible.
Proposals have been made to filter effluent gases to remove pollutants, for example, by using a dust collector. Such approaches suffer from the fact that filtration systems are expensive, the filtration systems used are frequently incapable of completely removing the pollutants from effluent gases, and even if the pollutant is removed from an effluent gas, the problem of disposing of the pollutant remains.
It has been proposed that filtration of pollutants can be improved by irradiating effluent gases causing the polymerization of SO x and/or NO x contaminants contained therein to facilitate their removal. See Higo et al in U.S. Pat. Nos. 4,596,642 and 4,507,265. This approach however does not solve the problem of pollutant disposal since the SO x and/or NO x solids and/or mists collected still have to be disposed of. The Higo et al approach is also not fully satisfactory for the additional reason that the main object of both of these patents is to provide a complicated geometry to recover the polymerized pollutants.
Another area which has received attention is the development of systems promoting desired reactions. This is discussed for example by Matovich in U.S. Pat. Nos. 3,933,434 and 4,042,334. These two U.S. patents note that it would be useful to be able to carry out high temperature chemical reactions which heretofore have been impractical or only theoretically possible. A reactor is provided by these patents which utilizes radiation coupling as a thermal heat source. The reactor disclosed which uses electromagnetic radiation to heat a reaction is reportedly able to provide a thermal power density to the reaction site in excess of 10 4 watts cm -2 .
The reactor provided by U.S. Pat. Nos. 3,933,434 and 4,042,334 addresses high temperature chemical reactions, and more specifically pyrolysis reactions. This reactor provides an annular envelope containing an inert fluid which is substantially transparent to radiation. At least one reactant is passed through the core of the envelope along a predetermined path substantially coincident with the envelope axis, with the reactants being confined within this envelope. After reactant flow has started, radiant energy is directed through the envelope to coincide with at least a portion of the path of the reactants. This causes the absorption of a sufficient radiant energy in the core to raise the temperature of the reactant to a level required to initiate the desired chemical reaction.
In using this reactor, heat is supplied by radiation coupling rather than by convection and/or conduction. The configuration of this reactor permits that the temperature of the reactant stream be independent of both the temperature of the reactor wall and the conditions of the reaction stream. Its disclosed application resides in promoting pyrolysis reactions, e.g., transforming methane to carbon and dihydrogen.
This reactor uses electromagnetic radiation having a wavelength of from 100 microns to 10 -2 microns for heating a reaction without actually modifying it. It is based on using electromagnetic radiation which limits the power density available to influence the reaction, and the configuration of the reactor provided precludes adaptation to various other areas where reaction enhancement would be useful.
Matovich discloses that the term "radiation" used in his patents is intended to encompass all forms of radiation, including high-energy or impacting nuclear particles. However, Matovich states that he knows of no manner in which high-energy or impacting nuclear particles can be used in accordance with his invention, and rather that black body or other electromagnetic radiation, particularly of wavelengths ranging from about 100 microns of 0.01 microns, should be used in his reactor. Matovich's system therefore uses electromagnetic radiation, and, only provides a method for directing heat onto a pyrolysis reaction. It does not provide a system for modifying and/or enhancing chemical reactions, and no combustion processes are mentioned in these patents.
There is therefore a strongly felt need for a method which would permit modifying and/or enhancing combustion processes so that these processes can be controlled and/or rendered more efficient with concomittant pollution control. Such a method would have applications in enhancing the combustion of materials, such as, fuel in internal combustion engines, electricity generation, controlling pollution, and driving reactions which are otherwise not possible.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a novel process for modifying or enhancing combustion reactions.
It is another object of this invention to provide a process for driving combustion reactions which otherwise do not occur.
It is another object of this invention to provide a process for igniting a combustible gaseous, liquid, or solid substance or mixture.
The inventor has now discovered that these objects and other objects which will become apparent from a reading of the description of the invention given here below are all satisfied by subjecting a combustion reaction, either immediately or during the combustion process, to particle beam radiation. The particle beam radiation used can be an electron beam, an ion beam, a neutral particle beam, or a combination of these. Each of these beams must have an energy of from 10 -2 eV to 10 7 eV and a current of from 10 -7 Amperes to 10 7 Amperes.
This invention also provides a novel injector plug/spark plug which can be used to either modify a chemical combustion reaction or drive a combustion reaction which is otherwise not possible. This injector plug/spark plug is designed to provide both the spark needed to initiate and maintain the combustion reaction and a stream of particles which are injected directly into the combustion process.
This invention also provides a novel injector plug. This particle beam injector plug provides a particle beam. It can be used in place of or in addition to a conventional spark plug. When used in conjunction with a conventional spark plug, the spark plug ignites the gaseous mixture while the particle beam injector plug injects a particle beam into the combustion chamber to promote more rapid flame speed.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures.
FIG. 1 illustrates an apparatus configuration for carrying out the present invention.
FIG. 2 provides cathode voltage and injected beam current for a typical febetron electron beam accelerator pulse.
FIG. 3 provides combustion data for lean mixture of 30 Torr C 2 H 4 and 710 Torr air (equivalence ratio Φ=0.6). Upper photo - Oscilloscope traces for combustion with spark ignition alone:
(a) OH line emission intensity at 309 nm;
(b) Pressure transducer signal (2 atm/ div );
Time scale: 10 ms/ div .
Lower photo - Oscilloscope traces for combustion with electron beam injection 1 ms after the spark.
(c) OH line emission intensity at 309 nm;
(d) Pressure transducer signal (2 atm/ div )
Time scale: 10 ms/ div .
FIG. 4 illustrates pressure risetime (measured from time of spark to pressure peak) as a function of fuel-air equivalence ratio Φ. Stoichiometric mix at Φ=1 corresponds to 48 Torr C 2 H 4 and 692 Torr air.
FIG. 5 illustrates results obtained for flame front position transverse to electron beam direction, measured with laser schlieren photography. Data is for a lean mixture with 30 Torr C 2 H 4 and 710 Torr air (Φ=0.6). From the slope of the lines, the flame speed was determined to be 403 cm/ s with electron beam injection, and 268 cm/ s without electron beam injection.
FIG. 6, provides a schematic illustration of an
electron beam injector plug used in accordance with the invention.
FIG. 7 illustrates one of the experimental apparatus configuration used by the inventor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a method for driving a combustion reaction by means of an electron beam, a ion beam, or a neutral particle beam. In this document, the terms electron beam, ion beam and neutral particle beam will be collectively referred to as "particle beam."
Ion beams which can be used in accordance with the present invention include, for example, beams of the following ions: H + , H 2 + , H 3 + , H - , H 2 - , He + , O + , O 2 + , O 2 +2 , O - , O 2 - , O 2 -2 , N + , N 2 +2 , N - , N 2 -2 , ionized air, C + , CO + , Ar + , CH 3 + , C 2 H 2 + , higher ionization states of these ions, etc., ionized organic compounds, including ionized hydrocarbons of the formula (C n H 2p+2 ) +m , where n is an integer of from 1 to 15, p is an integer of from 1 to 15, and m is an integer of from 1 to 5, and mixtures of these.
It must be recognized that many of these ions originate from materials which take part, or can take part in the combustion reaction. In one preferred embodiment of this invention one can accordingly inject into a combustion reaction a stream of at least one ion or neutral particle which is one of the reactants in the combustion reaction. Thus one may inject into the combustion reaction H + , O 2 + (including higher ionization states thereof), O + (including higher ionization states thereof), and ionized fuel molecules, including ionized hydrocarbon molecules.
Neutral particles which can be used in accordance with the present invention include the following: H.sup.., H 2 , H 3 .sup.., He, Ar, O.sup.., C.sup.., N 2 , CH 4 , C 2 H 2 , and any fuel molecules which can be driven into the combustion reaction. These include hydrocarbon compounds of formula (C n H 2p+2 ).sup.. q, where n is an integer of from 1 to 15, p is an integer of from 1 to 15, and q is 0 or an integer of from 1 to 5.
The particle beam of the present invention should be injected into the combustion reaction in a manner which will permit exposure of a maximum volume of reactants to the particle beam. To achieve this, the energy level of the particle beam, the current level of the particle beam, and the geometry of the combustion chamber can all be appropriately modified to maximize exposure of the combustion reaction to the particle beam.
It is known that the higher the energy of a beam, the further this beam will travel through a given atmosphere. Thus for two identical beams distinguished only by the fact that one beam is at a higher energy level, the higher energy beam will travel further through a given atmosphere.
It is also known that the density of the atmosphere influences particle beam travel. A particle beam having a specific energy will travel progressively shorter distances as the density of the atmosphere increases.
Thus, if the combustion reaction is taking place in a dense atmosphere and high penetration of this atmosphere is desired, a high energy beam should be used. By contrast, if the combustion reaction is taking place in a low density atmosphere and the particle beam is to travel only a short distance, then a lower energy beam is preferable.
It is also known that the amount of ionization in a gas is proportional to the current of the particle beam. Thus, if a high level of ionization is desired, a higher current should be used.
Adjustments which can be made include variation of the beam energy (voltage) in order to achieve an electron or particle beam range in the gas which maximizes the particle beam energy deposition in the gas while minimizing the electron beam energy deposition in the chamber walls. The optimal beam energy will therefore be a function of the gas density, gas pressure, and chamber dimensions. Particle beam current and duty cycle (or repetition rate) can be adjusted to achieve the optimal combustion enhancement or rate of chemical reaction One skilled in this art can vary these parameters to obtain optimum results.
The particle beam used in the present invention can be either injected into the combustion process to affect all of the reactants present in this combustion process, or, alternatively, the particle beam can be injected into one of the reactants prior to entry of this reactant into the combustion chamber. Thus, the particle beam of the present invention can be advantageously used to treat either the oxygen-containing component of the combustion process or the fuel being combusted.
The particle beams used in accordance with the present invention must possess an energy range of from 10 -2 eV to 10 7 eV. Preferably, these particle beams have an energy range of from 1 to 10 5 eV, and most preferably an energy range of from 10 to 10 4 eV. The current of these particle beams ranges from 10 -7 Amperes to 10 7 Amperes. Preferably a current range of from 10 -3 Amperes to 10 4 Amperes, and most preferably a current range of from 1 to 10 4 Amperes is used.
When the particle beam is administered in cycles having a very short pulse length (or duty cycle) it is best to use currents in the higher range given above. Thus with pulses of less than 100 microseconds it is preferably to use currents in the range of from 1 to 10 7 Amperes.
With intermediate length pulses, for example pulses having a pulse length of from 100 milliseconds to 100 microseconds, currents falling in the center of the current ranges is preferably used. With these intramediate length pulses, currents of from 10 -2 to 10 2 Amperes are preferably used.
With longer pulses or continuous administration of the particle beam, lower currents are advantageously used. Thus with pulses having a duration of from 10 0 milliseconds to continuous pulses, it is advantageous to use currents of from 10 -7 to 10 2 Amperes.
The most advantageous use of current in this invention therefore depends on the pulse mode. The strength of the current used should be chosen as described above as a function of the nature of the pulse which can be short, long or continuous.
The particle beam driven reactions provided by the present invention occur at a more rapid reaction rate. The particle beam can also change the reaction chemistry, resulting in the production of different products from the reaction.
Although combustion reactions are frequently given simplistic explanations in which only the molar ratios of reactants and products are compared, in fact, combustion processes are very complicated. For example, an ethylene oxidation mechanism having over 100 individual reaction steps has been proposed. See J. A. Sell, "CO 2 and Excimer Laser Ignition of Ethylene/Air Mixtures," G.M. Research Report No. PH-1274, Oct. 30, 1985.
In contrast to earlier attempts, such as the one proposed by Matovich discussed above, which were concerned with directing heat onto a reaction using electromagnetic radiation, the inventor has discovered that injecting a particle beam into a combustion reaction affects the balance of various neutral and ionized species present in combustion reactions. The particle beam thus modifies and/or enhances the combustion reaction to provide a more efficient process. The present invention modifies the molecular nature of the combustion process, instead of applying more heat to the combustion process.
Previous methods used for driving chemical reactions were based on heating the reactants in a reaction vessel. Processes for promoting combustions reactions used burners, spark plugs alone, or high powered laser beams. In contrast to earlier attempts to modify reactions using electromagnetic radiation, instead of applying heat (thermal) radiation onto a combustion reaction, the present invention treats a combustion reaction with a particle beam. This particle beam affects the ionization, dissociation, etc. of the reactants and intermediates in a combustion process. The present invention thus modifies the nature of the combustion process.
The Matovich invention relies on thermal heating of the reactants whereas the present invention uses ionization, dissociation, free radical generation, increases in vibrational/rotational energy, and metastable states to increase the flame speed and reaction rate. The particle beams in the present invention include electrons as well as ions and neutral beams of numerous elements and molecules including (as discussed above), but not limited to: H, H 2 , He, O, O 2 , C, A, C x H y , and metal or catalytic ions or neutral molecules. Thus, an important distinction between this invention and Matovich is that, while Matovich's invention included nuclear radiation, it does not include atoms and molecules which may participate in the reaction as fuel, oxidant, or catalyst.
One advantage of using the particle beam provided by the present invention to drive the reaction relates in part to the fact that the large instaneous power of the particle beam increases the ionization, formation of radicals, dissociation, generation of metastable states, and increased vibrational energy in the reactants, thereby increasing the rate of reaction. The particle beam driven reaction provided by the present invention can be used to reduce certain types of pollution by changing the products of a given chemical reaction.
The present invention has applications in the chemical industry. It can be used to drive chemical reactions more rapidly or to drive chemical reactions which can not proceed under normal conditions. The present invention can also be used to increase the efficiency and reduce the pollution of fossil fuel fired combustion processes.
The chemical reactions which can be modified or enhanced in accordance with the present invention are many and varied. Combustion reactions are, of course, the oxidation of organic materials to produce various carbon oxides and water. For example, the combustion of ethylene in air and in an oxygen/argon mixture can be illustrated as follows:
stoichiometric combustion of ethylene (C 2 H 4 )
in air:
C.sub.2 H.sub.4 +3O.sub.2 +3(3.76)N.sub.2 →2CO.sub.2 +2H.sub.20 +11.28N.sub.2
in argon+O 2
C.sub.2 H.sub.4 +3O.sub.2 +3(3.76)Ar→2CO.sub.2 +2H.sub.2 O+11.28Ar
As shown by the above equations, ideally the combustion of organic compounds produce carbon dioxide and water. Incomplete combustion provides lower oxides of carbon, including carbon monoxide. Particularly inefficient combustion processes produce carbon black which evidences very inefficient combustion. The present invention addresses specifically this problem and makes any such combustion process occur more rapidly, especially with a lean fuel-air ratio, providing high fuel efficiency and reduced pollution.
The organic materials which can be burned in accordance with the present invention include all organic materials, including hydrocarbons, which are used, or which can potentially be used, as fuel materials. These materials can of course be present as gases, liquids, solids, or mixtures of these at standard atmospheric pressure and temperature. These include coal, diesel oil, kerosene, gasoline fractions, and lower hydrocarbons, e.g., C 1-15 hydrocarbons, thus including methane. Specific example of fuels which will work is this invention include natural gas, propane, ethylene, ethane, methane, butane, acetylene, other gases, as well as automobile fuels, jet fuels, electricity generator fuels, etc. Examples of applications of this invention include coal or natural gas fired electricity generating plants in which much less fuel would be used with a corresponding decrease in particulate emissions.
In some cases no spark plug is needed. For example in a diesel engine a spark plug is not required, so particle beam, e.g., electron beam, injection can be used by itself to improve the fuel economy and to reduce the particulate emissions.
The ratio of dioxygen to combustible organic material which can be used in accordance with the present invention can be varied widely. Particle beam injection permits more reliable combustion and faster flame speeds over a wider range of fuel-air mixtures than can be achieved with simple spark ignition. A faster flame speed is also achieved at stoichiometric fuel-air ratios.
Specific fuel-air ratios which can be used range from φ of 0.3 to 3, where the stoichiometric (or molar) ratio is defined as φ=1. The best effect occurs with lean mixtures at φ=0.5 to 0.6 although other lean mixtures up to stoichiometric also work very well. A primary advantage of the present invention is that the injection of a particle beam into a combustion reaction provides for reliable combustions of leaner mixtures of oxygen and fuels.
As illustrated in FIG. 4, with ethylene, the highest modification of the combustion reaction is observed in accordance with the present invention when either an excess of oxygen or an excess of combustible organic material is present in the combustion chamber. The present inventor has discovered however that this phenomena is only observable with ethylene. With other fuels, even a stoichometric mixture of oxygen and fuel provides the advantageous results of the present invention.
FIG. 1 schematically illustrates an apparatus which can be used to modify and/or enhance reactions in accordance with the present invention. As can be seen from this Figure, an electron beam, ion beam or the neutral particle beam generator is situated adjacent a combustion chamber. The particle beam produced by the generator may be passed through a screen or foil and directed into the reactor chamber, where it modifies and/or promotes the combustion reaction in accordance with the invention.
In a commercial device for energy production the combustion reaction either moves a piston or heats a working fluid which surrounds the vessel. These are not shown in the schematic illustration of FIG. 1. In a combustion plant or chemical reactor a means of regulating the flow of reactants into the chamber is provided. The type of accelerator used depends upon the application.
A continuous or repetitively pulsed particle beam accelerator, e.g., an electron beam accelerator, can be used in the case of a continuous process, such as burning of fossil fuels in an electric utility plant. Such an accelerator is made of a high voltage rectifier circuit which can be either full wave rectified or half wave rectified.
In the case of an internal combustion engine preferably a repetitively pulsed particle beam, e.g., an electron beam, is injected at a given time during each cycle in which ignition and burning of the fuel takes place. Such an electron beam could be generated by a capacitive discharge system, a Marx generator circuit, pulse line generator, or an inductive discharge system. These types of electron beam generators are commercially available from a number of companies, including Hewlett Packard Co. of McMinnville, Oreg., or Pulse Sciences Inc. of San Leandro, Calif., and others. It must be noted however, that where convenient, a continuous particle beam can also be used in this application of the invention.
A number of existing technologies can be employed for the generation and acceleration of ion and neutral beams. Ion sources could consist of duoplasmatrons, duopigatrons, electron cyclotron ion sources, or radio frequency sources. The high voltage accelerator for ion beam acceleration could be a Van De Graaff, Marx generator, Cockroft-Walton (ladder circuit), or high voltage rectifier.
When combustion reactions are being treated in accordance with the present invention, a spark plug can be installed in the combustion chamber to initiate the combustion reaction.
In an advantageous embodiment of this invention, such a spark plug may be designed to include both the means for initiating the combustion reaction and for subjecting the combustion reaction to the particle beam. Such a plug is referred to as an injector plug/spark plug.
The operation of simple spark plugs by themselves is well known. See for example U.S. Pat. No. 4,514,656. Spark plugs, in operation, have different characteristics which are matched to the operating characteristics of the internal combustion engine, and used to which the engine is put--for example whether it is used to drive an automotive vehicle of the passenger car type, a motorcycle, truck, or if the combustion engine is used for small applications, such as chain saw or a lawnmower.
The present invention provides an injector plug/spark plug which has the dual function of initiating and maintaining the combustion reaction in accordance with well known spark plug functions, and additionally emits a particle beam into the combustion reaction to advantageously enhance and/or modify the combustion process. This spark plug/injector plug can be designed to increase electron emission. It can be designed to have an electrode (cathode) containing a material having a low work function. Such low work function materials include LaB 6 , barium oxide, calcium oxide or strontium oxide. The electrode of the injector plug/spark plug, can alternatively be coated with LaB 6 , barium oxide, calcium oxide or strontium oxide, or a combination of these.
If the electrode contains the low work function material, it contains this material in an amount of 1 to 20% by weight, preferably 5 to 15% by weight. If the electrode is coated, the thickness of the coat is from 1 micron to 1 mm, preferably 10 microns to 0.1 mm.
In still another preferred embodiment of this invention, this injector plug/spark plug is designed to enhance heating of the plug to still further enhance electron emission into the combustion process.
The components of the injector plug/spark plug, aside from the low work function materials, can be well known materials usable in making spark plugs.
As shown in FIG. 6, an electron beam injector plugged in accordance with the present invention comprises a metal housing (1), a means for securing the housing in an engine block (2), an insulating body (3) secured in the metal housing and formed with a central opening. This electron beam injector plug further comprises a high voltage electrode (4) centrally extending through the opening in the insulating body, a cathode means (5) in communication with the high voltage electrode means (4), and an anode screen or foil (6) adjacent to the high voltage cathode means.
Two spark plugs may also be used with this invention; a normal spark plug and a particle beam emitting plug. An electron beam injector spark plug is illustrated in FIGS. 6. It comprises: (a) a cathode (which may be based on thermionic emission, field emission or explosive emission), and (b) an anode foil or screen through which the electron beam passes into the reaction chamber. The foil may separate a vacuum in the cathode region from the reactants in the chamber. A voltage is applied to the cathode either continuously or in a pulsed mode. This causes an electron beam to be injected through the foil or screen into the reaction or combustion chamber.
The cathode of the injector plug of this invention is made of a material having a low work function. This includes LaB 6 or a tungsten matrix coated with LaB 6 barium oxide, calcium oxide, or strontium oxide. The anode foil can be made of tungsten, tantalum, steel, titanium or a metallized plastic foil. The screen is made of the same material as the anode.
The insulator can be made of a material known in this art which possesses characteristics suitable to permit it to function as an insulator at high temperatures. For example, alumina can be used. The metal housing can be made of steel, and the high voltage electrode can be made of copper or brass. The metal housing and the high voltage electrode are made of materials known in this art.
Other features of the invention will become apparent in the course of the following descriptions of exemplary embodiments which are given for illustration of the invention and are not intended to be limiting thereof.
In the experiment reported here, data is presented in which injection of a high current electron beam 10 has been demonstrated to dramatically alter the rate of presssure rise, flame speed, and spectroscopic emission in the combustion of both lean and rich ethylene-air mixtures.
The experimental configuration is depicted in FIGS. 7 and 2. The electron beam is generated by a field emission cathode 11 on a Febetron generator with peak parameters: V p =400 kV, I P =1 kA, and full width pulselength=300 ns. A perforated metal screen supports the 0.025 mm thick Ti anode foil which is evacuated on the cathode side and undergoes a pressure pulse of several atmospheres from the combustion in the chamber on the opposite side. The anode foil and metal screen reduce the injected current to about 200 A. The interaction chamber is an aluminum cross of circular cross section with an inside diameter of 8.26 cm and a length of 22 cm giving a chamber volume of 1.19 liter. Quartz windows are located at the sides and end of the chamber. A spark plug and piezoelectric pressure transducer are located at the top of the chamber.
Several diagnostics were used to monitor the combustion process. Chamber pressure was measured with a pressure transducer and preamplifier fed into an oscilloscope. Line emission from the 309 nm OH line was measured with a linepass filter coupled to a photomultiplier tube which was oriented transverse to the electron beam. For flame front measurements, schlieren photography with 2-dimensional resolution was performed transverse to the direction of the electron beam injection by means of a pulsed ruby laser diagnostic described in Refs. 12 and 13. Also, emission spectra were observed both during and after the spark by a 0.275 m spectrograph coupled to a gated optical multichannel analyzer.
The experimental procedure was as follows. Fuel and air were mixed for 30 seconds by a small fan located inside the chamber. This mixture was ignited by a conventional spark ignition system; after a 1 msec delay, the electron beam was injected. This permitted a direct comparison of the modification of combustion parameters by the electron beam.
It should be noted that direct ignition of the mixture by the electron beam did not occur in these experiments. This is undoubtedly due to the low energy density deposited into the gas by the electrons. The pressure rise was undetectable (<1 Torr) when the electron beam was injected into an unignited mixture. Thus the electron beam caused negligible temperature increase in the mixture.
FIG. 3 presents pressure signals and OH-emission data for combustion of a lean mixture with versus without electron beam injection. These measurements indicate that the combustion process was more rapid with electron beam injection. FIG. 4 presents a plot of pressure risetime versus equivalence ratio, (where Φ=1 corresponds to the stoichiometric fuel-air ratio of 48 Torr C 2 H 4 and 692 Torr air). The data show about a 50% decrease in pressure risetime as a result of electron beam injection into lean and rich mixtures, but very little effect near the stoichiometric fuel-air ratio. For the cases where the pressure risetime was reduced, the OH-emission risetime and decay-time were also reduced and the magnitude of the peak pressure was increased by 10% to 20%. The pressure risetime data was also more reproducible in these cases. The increase in combustion rate was observable with electron beam injection as early as 15 ms before the spark ignition and as late as 15 ms after the spark ignition. This more rapid combustion is similar to that observed in laser 8 ,9 and plasma jet 6 ,7 ignition. Electron beam injection increased the level of pressure oscillations measured by a microphone (at 1-2 kHz) during the pressure-rise and caused a loud squeal on these shots.
Laminar flame propagation was observed using schlieren photographs of the flame front at various times after ignition. In FIG. 5, the distance between the flame front and the spark plug tip is shown as a function of time for a lean mixture with versus without electron beam injection. For this mixture, the propagation velocity of the flame front was clearly increased by electron beam injection. Electron beam injection appears to enhance the flame speed by up to 50% for lean mixtures (FIG. 5) and 40% for rich mixtures (not shown). Even larger increases in flame speed have been measured fr electron beam injection into other gases, e.g., methane, ethane, propane, butane, even at stoichiometric ratios In shots with electron beam injection the flame front was slightly elongated transverse to the beam direction compared to nearly spherical flame expansion without the electron beam. This suggests that the flame was propagating more rapidly in the region of the electron beam axis, where the electron beam current density was highest.
In conclusion, the injection of a 300 ns electron pressure, flame speed, and spectroscopic emission data over timescales exceeding 10 ms.
PUBLICATIONS CITED IN THE TEXT
1. Proceedings of the International Conference on Fuel-Air Explosions, edited by J. H. S. Lee and C. M. Guirao.
2. R. Hickling, General Motors Research Report EM-478 Sept. 30, 1980.
3. T. M. Sloane and J. W. Ratcliffe, General Motors Research Laboratories Publication GMR-4404, July 11, 1983.
4. H. C. Jaggers and A. von Engel, Combustion and Flame, 16, 275 (1971).
5. C. S. Maclatchy, R. M. Clements, and P. R. Smy, Combustion and Flame, 45, 161 (1982).
6. P. L. Pitt and R. M. Clements, Combustion Science and Technology, 30, 327 (1983).
7. P. L. Pitt, J. D. Ridley, and R. M. Clements, Combustion Science and Technology, 35 277 (1984).
8. R. Hickling and W. R. Smith, Society of Automotive Engineers Paper No. 740114.
9. J. A. Sell, General Motors Research Report GMR-5247, Oct. 30, 1985.
11. M. L. Brake, R. M. Gilgenbach, R. F. Lucey, Jr., K. Pearce and T. Repetti, Appl. Phys. Lett., 49, 696 (1986).
12. L. D. Horton and R. M. Gilgenbach, Phys. Fluids, 25, 1702 (1982).
13. L. D. Horton and R. M. Gilgenbach, Appl. Phys. Lett., 43, 1010 (1983).
14. D. W. Koopman and K. A. Saum, J. Appl. Phys., 44, 5328 (1973).
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A process for modifying or enhancing a combustion reaction by injecting a particle beam into the combustion reaction, is disclosed.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of application Ser. No. 13/137,568 filed Aug. 26, 2011, entitled Access Port Seal.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to plugs in general and in particular for plugs located in insulated coverings to provide access to an interior thereof.
[0004] 2. Description of Related Art
[0005] In many industries, it is frequently necessary to access pipes or other conduits to conduct inspection, maintenance and the like. One difficulty that arises with such pipes and conduits is that they are often insulated to protect the contents of the conduit from adverse weather and the like. In particular, in the oil and gas industry, it is common to provide insulation around such pipes with a sheath of protective sheet metal therearound.
[0006] Conventionally, when it has been necessary to provide access to a pipe or the contents thereof which have an insulating layer therearound, a hole has been cut in the sheet metal and the insulation removed from that region to form a cavity for access to the pipe. After the maintenance, inspection or the like has been performed on the pipe, insulation is reinserted into the cavity and a new layer of sheet metal secured over the hole to provide a patch in the original sheet metal. Problematically, such a patch has been unsatisfactory at providing the original level of insulation and protection of the pipe from adverse weather. In particular, such sheet metal patches have been known to leak when subjected to rain or melting snow.
[0007] The compromised insulation and protective sheath poses a problem for the insulation under the patch as well as the surrounding region as the insulation typically used for such applications is of a fiberglass batting or other fibrous material. Such materials are known to be intolerant of becoming wet, and being prone to compacting when damp. Such compacting of the insulation impairs the ability of the insulation to adequately insulate the pipe in that location as well as any surrounding regions which also become wet.
[0008] An additional difficulty of such patches are that once they are installed, any subsequent removal thereof for future maintenance of inspection will increase the size of the screw holes thereby further increasing the ability of water to enter the insulation.
SUMMARY OF THE INVENTION
[0009] According to a first embodiment of the present invention there is disclosed an apparatus for sealing an opening in a metal sheath surrounding an insulated pipe, the apparatus comprising a waterproof body locatable within the opening, the body having a periphery therearound and a groove located within the periphery, the groove being sized and shaped to closely and sealably receive an edge of the opening therein and a flexible securing means extending from the waterproof body.
[0010] The body may be formed of a material selected from the group consisting of neoprene, rubber, silicone and closed cell foam. The body may be elongate with substantially parallel sides. The body may be circular.
[0011] The groove may have a constant radius. The groove may have a radius of less than ½ inch. The groove may be located in the middle of the peripheral edge. The apparatus may further comprise a leading surface of the peripheral edge extending from the groove by a distance greater than a trailing surface of the peripheral edge. At least one of the leading and trailing surfaces peripheral edge may be rounded.
[0012] The strap may be securable to the sheet metal. The strap may be integrally formed with the body. The apparatus further comprise a gasket securable to an edge of the opening in the sheet metal wherein the gasket is locatable within the groove of the body. The gasket may comprise a base ring. The strap may be securable to the base ring. The base ring may be integrally formed with the strap and the body.
[0013] 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
[0014] In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,
[0015] FIG. 1 is a perspective view of an insulated pipe having a hole cut in the insulation for access to the pipe.
[0016] FIG. 2 is a perspective view of an apparatus according to a first embodiment of the present invention applied to the hole in the pipe.
[0017] FIG. 3 is a cross-sectional view of the apparatus of FIG. 2 as taken along the line 4 - 4 in FIG. 3 .
[0018] FIG. 4 is a cross-sectional view of the apparatus of FIG. 2 located within a hole in pipe insulation as taken along the line 5 - 5 in FIG. 2 .
[0019] FIG. 5 is a perspective view of an apparatus according to a further embodiment of the present invention applied to the hole in the pipe.
[0020] FIG. 6 is a cross-sectional view of the apparatus of FIG. 5 located within a hole in pipe insulation.
DETAILED DESCRIPTION
[0021] Referring to FIG. 1 , an opening through pipe insulation is shown generally at 10 . The pipe 8 is surrounded by an insulating layer 12 and a sheath layer 14 . The opening is defined by an opening edge 16 having top and bottom straight edges, 18 and 20 , respectively, and first and second arcuate portions therebetween, 22 and 24 , respectively. As illustrated, the opening 10 may be located within an elbow portion 6 of the pipe and pipe insulation, however it will be appreciated that the opening may also be located within a straight portion 4 or at any other location desired by a user.
[0022] With reference to FIG. 2 , the apparatus comprises a plug body 30 sized and shaped to be sealably received within the opening 10 . The body comprises a member having front and rear surfaces, 32 and 34 , respectively, extending between top and bottom edges 36 and 38 and first and second side arcuate ends, 40 and 42 , respectively. Although the body 30 is illustrated and described as having an elongate shaped, it will be appreciated that other shapes may be utilized as well, such as, by way of non-limiting example, circular as illustrated in FIG. 5 , oval, rectangular, square, triangular, octagonal or irregular. Additionally, although the body 30 is illustrated as being adapted for insertion into an elbow portion 6 , it will be appreciated that the body may be adapted for fitting into a straight portion 4 or other section of the sheath member 14 . For use in the straight portion 4 , the body may have a straight profile whereas for an elbow portion 6 , the body 30 may have a curved profile as illustrated matching or otherwise corresponding to the curvature of the intended section of the sheath layer 14 . According to a further embodiment of the present invention, a gasket 60 may be provided around opening edge 16 of the opening as will be further described below.
[0023] Turning now to FIG. 3 , the body 30 is illustrated in cross section. The body 30 has a thickness between the front and rear surfaces 32 and 34 which may be selected to be any suitable thickness for properly sealing the opening 10 . By way of non-limiting example, the body may have a thickness of between ½ and 2 inches (12 and 51 mm) with a thickness of approximately 1 inch (25 mm) having been found to be particularly useful. The top and bottom edges 36 and 38 and first and second sides 40 and 42 of the body define a periphery thereof. It will be appreciated that the top and bottom edges 36 and 38 are sized and shaped to correspond to the top and bottom edges 18 and 20 of the opening 10 and the first and second sides 40 and 42 are sized and shaped to correspond to the first and second arcuate portions 22 and 24 of the opening. In particular, it will be appreciated that a user may cut the opening 10 to correspond to the plug body 30 and in some instances may be provided with a cut template (not shown) to guide them in cutting the appropriate sized and shaped opening according to known methods.
[0024] As illustrated in FIG. 3 , the periphery of the body 30 is defined by the top and bottom edges 36 and 38 and first and second sides 40 and 42 and has a substantially constant profile. The body 30 also includes a groove 44 extending around the periphery and dividing the periphery into a leading and a trailing edge, 46 and 48 , respectively. The leading edge 46 is disposed between the front surface 32 and the groove 44 and the trailing edge 48 is disposed between the groove and the rear surface 34 of the body 30 . As illustrated, the leading and trailing edge may be rounded although it will be appreciated that other profiles may also be utilized as well, such as by way of non-limiting example, chamfered, beveled or routed. As illustrated, the groove 44 may have a semi-circular cross section having a radius generally indicated at 50 of up to ½ inch (12 mm) with a radius of ¼ inch (6 mm) having been found to be particularly useful although other profiles may be utilized as well, such as, by way of non-limiting example, v-notched, arcuate, rectangular or a slot. Optionally, a strap 52 or other suitable connector may be provided for connecting the body 30 to the sheath layer 14 wherein the strap 52 is secured between the body 30 and an inner surface of the sheath layer 14 by any known means, such as, by way of non-limiting example, screws welding adhesives or the like. As illustrated in FIG. 4 , the strap 52 may be separate from the body 30 or may be integrally formed therewith as illustrated in FIG. 5 .
[0025] The body 30 may be formed of any suitable waterproof material, such as by way of non-limiting example, neoprene, natural or synthetic rubber, silicone or closed cell foam. The body 30 may be formed of any known suitable method, such as by way of non-limiting example, casting, machining, utilizing a router or molding.
[0026] The gasket 60 may be of any suitable type and in one embodiment may have an outer radiused surface 62 and an inner slot. The outer radiused surface is sized to be sealably engaged within the groove 44 and may therefore have an outer radius of up to ½ inch (12 mm), such as by way of non-limiting example, Edge Trim sold as product ID WRE10B34 by Edge Lok Inc. of Buena Park Calif. The gasket may also include an inner slot 64 sized to be relieved over an edge of the sheath layer 14 . The gasket may be provided as a roll which may then be cut by a user or may optionally be provided as part of a kit with a length selected to fully surround a hole as cut according to a provided template.
[0027] Optionally, as illustrated in FIGS. 5 and 6 , the gasket may comprise a base ring 80 which is securable to the inside of the opening edge 16 . The base ring 80 may be formed integrally with the body and strap 30 and 52 or may be formed separately therefrom and the components secured together with fasteners or the like. The base ring comprises a top flange 82 having a plurality of fastener bores 84 extending therethrough. An inner cylinder 88 extends away from said top flange 82 by a distance sufficient to provide an inner mounting surface 86 . The top flange 82 and cylinder 88 have an inner passage 85 therethrough corresponding to the diameter or size and shape of the body 30 . Although the embodiment illustrated in FIGS. 5 and 6 is illustrated as circular, any other outline as set out above may also be utilized. The inner passage 85 includes an annular ridge 90 inside of the top flange 82 sized to correspond to and be engaged within the groove 44 of the body so as to retain the body therein. As illustrated in FIG. 6 , the base ring 80 may be secured within the opening edge 16 proximate to the outside of the sheet metal 14 . Thereafter, fasteners 94 may be passed through the bores 84 to secure the base ring to the sheet metal layer 14 .
[0028] In operation a user may cut an opening 10 , optionally with the use of a provided template matched to the body 30 through the sheath layer 14 and insulating layer 12 surrounding a pipe 8 . Thereafter the cut out insulation and sheath layer opening portions may be removed to provide access to the pipe for maintenance, inspection and the like. After the user has completed their activities requiring access to the pipe 8 , the removed insulation or replacement insulation, generally indicated at 13 in FIG. 4 may then be replaced within the opening. The gasket 60 may then be installed over the edge of the sheath layer and the body 30 inserted such that the gasket 60 is sealably received within the groove as illustrated in FIG. 4 . If future access is required to the pipe 8 , the body 30 and replacement insulation 13 may be removed to provide access thereto and thereafter reinserted into the opening 10 .
[0029] 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 an opening in an insulated covering comprises a waterproof body locatable within the opening, the body having a periphery therearound and a groove located within the periphery, the groove being sized and shaped to closely and sealably receive an edge of the opening therein and a flexible securing means extending from the waterproof body.
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BACKGROUND INFORMATION
The present invention relates to hard disk drives. More specifically, the invention relates to a system and method for edge blending hard drive head sliders.
FIG. 1 provides an illustration of a typical hard disk drive. Hard disk drive storage devices typically include a rotating disk 101 mounted for rotation by a spindle motor (not shown). A slider 102 , supported by a suspension arm 103 , ‘flies’ over the surface of the magnetic disk 101 at a high velocity, reading data from and writing data to concentric data tracks 104 on the disk 101 . The slider 102 is positioned radially by a voice coil motor 105 .
FIG. 2 shows a more detailed view of a head slider 102 flying over the surface of a magnetic disk 101 as is typical in the art. Modern head sliders 102 float over the surface of the disk 101 on a cushion of air. If the ‘flying height’ is too great, the head 201 on the head slider cannot properly read from and write to the disk 101 . If it is too small, there is an increased chance of a head crash.
If a head slider 102 contacts the surface of the disk while it is at operational speed, the result can be a loss of data, damage to the head slider, damage to the surface of the disk 101 , or all three. One of the most common causes of head crashes is a contaminant getting wedged in the microscopic gap between head 102 and disk 101 . Head sliders 102 are typically ceramic for durability and corrosion resistance. A ceramic slider is durable due to its hardness. The tradeoff, however, of ceramic's hardness is its brittleness. When a row bar is cut into individual sliders 102 (explained below), the ceramic crystal array causes the slider 102 edges to crack easily. Loose chips of ceramic material may be found on the cutting surface edge corners even after solvent cleaning. Also, after cutting a row bar into individual sliders, a high point is often left on the cut slider surface. This is known as ‘edge jump’. Edge jump is believed to be from the stress applied to the cut edge of the slider 102 . A deformation layer 301 is created by the pressure created by the cutting process. (See FIG. 3 ).
FIG. 3 illustrates the problems related to particle contamination and edge jump as is typical in the art. The problems concerning loose chips 302 and edge jump 301 can cause hard drive head crashes. A loose chip 302 may fall from the slider and contaminate the interface between the slider 102 and disk 101 . An edge jump 301 can affect a slider's anti-shock performance negatively. If the HDD gets a physical impact while operating, a location of edge jump may contact and damage the disk 101 .
It is therefore desirable to have a system and method for edge blending hard drive head sliders that avoids the above-mentioned problems, as well as having additional benefits.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 provides an illustration of a typical hard-disk drive.
FIG. 2 shows a more detailed view of a head slider flying over the surface of a magnetic disk as is typical in the art.
FIG. 3 illustrates the problems related to particle contamination and edge jump as is typical in the art.
FIG. 4 illustrates a head parting jig as is typical in the art.
FIG. 5 illustrates an edge blending jig according to an embodiment of the present invention.
FIG. 6 illustrates the attachment of a head blending jig to a head blending machine according to an embodiment of the present invention.
FIG. 7 illustrates portions of lapping tape inserted between individual head sliders mounted to an edge blending jig in a standby configuration and in two edge blending configurations according to an embodiment of the present invention.
FIG. 8 provides a more detailed illustration of lapping tape partially wrapping a slider's edge to perform edge blending according to an embodiment of the present invention.
FIG. 9 provides a detailed view of an individual slider mounted to an arm of an edge blending jig with lapping tape partially wrapping a slider edge for edge blending according to an embodiment of the present invention.
FIG. 10 illustrates an edge blending machine according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 4 illustrates head parting jig as is typical in the art. As is illustrated in FIG. 4 a , a slider row bar 401 is typically bonded to multiple arms 402 of a head parting jig 403 . As is illustrated in FIG. 4 b and described further below, the row bar is cut into individual head sliders 102 by a slider parting tool (not shown).
FIG. 5 illustrates an edge blending jig according to an embodiment of the present invention. As illustrated in FIG. 5 a , in one embodiment, a slider row bar 501 is bonded to multiple arms 502 of the edge blending jig, whereupon the row bar is separated into individual head sliders 102 by a slider parting tool (not shown). One advantage of this jig design is that imperfections on the edges of the sliders 102 (such as edge jump) can be detected by viewing the sliders from behind 505 and observing the uniformity of gaps between the sliders 102 .
FIG. 6 illustrates the attachment of a head blending jig 601 to a head blending machine according to an embodiment of the present invention. In one embodiment, the edge blending jig 601 is coupled to a support assembly 602 of the head blending machine by a pair of pins 603 .
FIG. 7 illustrates portions of lapping tape inserted between individual head sliders mounted to an edge blending jig in a ‘standby’ configuration and in two edge blending configurations according to an embodiment of the present invention. As illustrated in FIG. 7 a , in one embodiment, lapping tape 701 covered with an abrasive, such as diamond powder (e.g., of a grade between 0.1 microns and 3.0 microns), is inserted between sliders 102 . FIG. 7 a shows the edge blending assembly in a ‘standby’ configuration with the sliders 102 out of contact with the lapping tape 701 . FIG. 7 b shows the edge blending assembly configured to partially wrap the lapping tape 701 across one of the edges of each slider 102 on the edge blending jig 601 according to an embodiment of the present invention. In this embodiment, the lapping tape is positioned by an adjustable series of rollers (described below) to be stretched across the slider edges at a predetermined tension force (e.g., less than 0.8 kilograms). In this embodiment, the edge blending jig 601 is directionally oscillated 702 by the edge blending assembly to cause relative motion between the sliders 102 and the lapping tape 701 (e.g., at a frequency of at least 1 cycle per second and at an amplitude between 10 millimeters and 40 millimeters). FIG. 7 c shows the edge blending assembly configured to partially wrap the lapping tape 701 across the opposite edge of each slider 102 according to an embodiment of the present invention. In this embodiment, the edge blending assembly is configured to stretch the lapping tape 701 across the opposite edge of each slider to complete the edge blending process. As explained below, in one embodiment, the process of edge blending is performed submerged in lubricant.
FIG. 8 provides a more detailed illustration of lapping tape partially wrapping a slider's edge to perform edge blending according to an embodiment of the present invention. In one embodiment, a first angle (α) is formed between a face 802 of the slider 102 and the lapping tape 801 , and a second angle (β) is formed between the opposite face 803 of the slider 102 and the lapping tape 801 (α and β being between 102 degrees and 90 degrees, for example).
FIG. 9 provides a detailed view of an individual slider mounted to an arm of an edge blending jig with lapping tape partially wrapping a slider edge for edge blending according to an embodiment of the present invention. In one embodiment, after a row bar is bonded to multiple arms of an edge blending jig 901 (by, e.g., epoxy) and cut into individual mounted sliders 102 (such as by a diamond cutting wheel), lapping tape 902 is inserted between the sliders 102 and the edge blending assembly is configured to wrap the lapping tape 902 around an edge of the slider 102 under a predetermined amount of tensile force. As stated above, in this embodiment, the slider 102 is directionally oscillated to achieve relative motion between the slider 102 and the lapping tape 902 .
FIG. 10 illustrates an edge blending machine according to an embodiment of the present invention. In one embodiment, an edge blending jig with mounted sliders is coupled to a jig support 1001 and mounted in the edge blending machine. In this embodiment, a top platform 1002 , containing lapping tape rollers 1003 , is attached to a base unit 1004 , supporting the edge blending jig. In this embodiment, portions of lap tape 1005 are positioned and kept in alignment by a series of guide arms 1006 . In this embodiment a spring mechanism 1007 , which is adjusted by a tension adjustment knob 1008 , is utilized to maintain the appropriate tensile force for the portions of lapping tape 1005 . Maintaining appropriate lapping tape tension is important to prevent lapping tape 1005 breakage or dislodging of sliders from the edge blending jig arms.
In this embodiment, another adjustment knob 1009 is utilized to move the lapping tape portions relative to the sliders (on the edge blending jig) to shift the relative position to partially wrap the slider edges appropriately (to provide the appropriate angles of α and β. In this embodiment, the process of edge blending is performed with the edge blending assembly submerged in lubricant. In this embodiment, a reservoir 1010 is filled above the level of the sliders with a lubricant (such as a mixture of de-ionized (DI) water and oil) before edge blending.
In one embodiment, rubber tape is used instead of the lapping tape with the reservoir 1010 filled with a diamond slurry. In this embodiment, the diamond particles travel on the rubber tape as an abrasive to smooth the slider edge's surface. Also, in an embodiment, a cleaning process could be performed after edge blending, wherein the lapping tape 1001 is replaced with rubber tape and the reservoir 1010 is filled with a cleaning solution. The slider would be oscillated with respect to the rubber tape in the cleaning solution to clean any debris left on the sliders after the edge blending process.
Although several embodiments are specifically illustrated and described herein, it will be appreciated that modifications and variations of the present invention are covered by the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention.
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A system and method are disclosed for edge blending hard drive head sliders by oscillating abrasive lapping tape across the edges of multiple sliders simultaneously. Lapping tape is inserted between each of a number of head sliders bonded to a edge blending jig of an edge blending assembly. The edge blending assembly is adjusted to cause the lapping tape to partially wrap an edge of each slider. The head sliders are edge blended by the relative movement between the sliders and the lapping tape.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of U.S. Provisional patent application No. 61/685,281 filed Mar. 15, 2012.
BACKGROUND
[0002] Field of the Invention
[0003] This invention relates to a painters tool used for storing, holding and dispensing paints in an improved manner. In particular the invention relates to an improved low profile receptacle apparatus and system to carry paint from one location to another without spillage and to disperse paint to a brush or painting tool.
[0004] Discussion of Prior Art
[0005] A paint palette is a tool typically used by an artist and is used to provide a hand held platform typically made of wood or plastic on which the artist dabs acrylic paint for use when painting.
[0006] Typically, this is used only for artist painting upon a canvas and designed for the use of thicker acrylic paint that can be applied in dabs. This system works well for an artist painting in acrylics but a typical artist palette would not be suitable for someone painting a house.
[0007] While the artist palette will not generally work for a typical house painter it could offer a painter a useful way and tool to move paint from one location to another without spillage.
[0008] Unfortunately, if a mixture of house paints were to be applied to a painters palette the results would lead to paint running and mixing together. Additionally the typical house paint would not easily remain on the palette if the palette were tilted.
[0009] In general, the prior art for painter tools designed to provide a palette tool or like has attempted to create paint palettes by focusing on producing small paint cavities or keeping paint retained within a sponge or a similar material.
[0010] Other prior art has utilized porous materials on which dabs of paint are placed, but still utilize a water retentive means such as a sponge material to keep the paint from drying out. None of these system allows for easy storing and are not designed to retain the paint between extended uses.
[0011] Although these types of systems are adequate to maintain the paint dabs in a useable condition for short periods of time, they have a tendency to dry the paint from the top of the sponge, thereby necessitating the user to add water or oil to the palette in order to maintain the paint in a useable condition.
[0012] Additionally, house paint is often stored between uses for extended periods of time and typically needs to be transported to the various locations about a house wherein an artist palette typically remains in an art room.
[0013] Prior art has not shown us a useful means for transporting and storing or viewing paint colors while in storage. Additionally, Prior art has not provided a truly useful painters tool that allows a painter a truly powerful tools to speed up the painting process in a neat and effective way.
[0014] Thus, there exists a need for a tool that can be used by painters comprising a paint palette system that can maintain paint in a moist and useable condition and also dispense paint to the paintbrush in a simple fashion while being easy to transport and store.
SUMMARY OF THE INVENTION
[0015] The paint palette system is a new system and tool long needed by painters and fills a need for both professional and non-professional painters. The invention provides an improved way to move paint around the house or up a ladder without spillage.
[0016] The paint palette system allows the painter to focus on painting and not on accidental spills or worrying where the paint bucket is located or accidentally knocking over a paint can. Focus can be on painting.
[0017] The paint palette system is so mess free that a child can paint without spilling paint. In testing the paint palette system the product was loaded with paint and thrown on a rooftop without any loss of paint or spillage.
[0018] The paint palette tool system allows for easy storage and reuse of paint. The complete paint palette tool system can be easily stored for extended periods of time in commercially available seal type plastic bags. It can be easily stored and the paint color can be easily viewed when needed again.
[0019] The paint palette tool system allows for the painter to worry less about mess and more about painting. The paint palette system allows for less trips to the paint can to reload the paintbrush. The paint palette system also saves the painter clean up and painting time.
[0020] A painter can now climb a ladder to paint a roof or elevated area without handling full cans of paint. A painter can even take two or more colors to remote locations without worrying about multiple cans.
[0021] The paint palette system offers a unique tool with many add-ons for holding a brush, squeegee or other tools and its novel design offers many improvements for painters and simplifies the painters' life.
[0022] Accordingly, several objects and advantages of the disclosed invention are provided including but not limited to an improved system or process wherein a house painter or like professional can paint in a more efficient and faster way.
[0023] Other objects and advantages of the invention include providing an apparatus for paint containment and dispensing that is spill proof and easily transported, as well as an apparatus that is easily manageable, carried and sealed for an extended time.
[0024] Additionally, the invention discloses an apparatus that can be easily held while transporting paint up and down a ladder and will retain paint even when tipped at an angle. The invention is also a low profile containment apparatus that allows it to be taken into very tight places and stored easily.
[0025] Another new and unique advantage of the invention is that multiple colors can be used together without the paints mixing and it can also be set upon a high pitch roof and will not slide off or spill the contained paint.
[0026] The apparatus can be tilted at a high degree and be turned upside down onto a drop cloth for an extended period of time to prevent air from drying the contained paint.
[0027] When in use, the system will not drip paint on unprotected surfaces. When used outside the apparatus can be held at any angle away from the sun to shield the paint from drying while painting outdoors, It can also be used to shield the sun out of the painters' eyes without spilling the contained paint.
[0028] The invention retains paint and will not spill or drip even when turned upside down and will additionally keeps paint from being blown off the brush in windy conditions. This is due to less excess paint to remove from the brush.
[0029] Because of the improved design of the invention the brush is loaded with paint in an improved fashion and the brush, roller, or other painting tools become easier to use and better disperses the paint. Less paint is wasted.
[0030] Paint storage also becomes easier, due to the low profile. The whole palette system can be contained in a commercially available plastic bag allowing for extended storage times between uses and additionally the clear plastic allows for ease of viewing paint colors stored.
[0031] Additionally, use of the apparatus minimizes the use of drop cloths because of its spill resistant design. Further objects and advantages of the invention will become apparent from consideration of the drawings and ensuing description.
[0032] Certain accessories may also be added to the invention as described and may include a strap across the base of the container so that a user may slide their hand between the strap and the container base. Other accessories may include a Squeegee, covering means and add-on attachments for managing a paint brush or other tools.
[0033] The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon the consideration of the following detailed description of the invention.
DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a top plan view;
[0035] FIG. 2 is a right end view, the opposite side bring a mirror image:
[0036] FIG. 3 is a bottom plan view;
[0037] FIG. 4 is an end view taken from FIG. 3 , the opposite side being a mirror image;
[0038] FIG. 5 is an exploded perspective view;
[0039] FIG. 6 is an assembled perspective view;
[0040] FIG. 7 is a sectional view taken from FIG. 1 ;
[0041] FIG. 8 is a sectional view taken from FIG. 1 ;
[0042] FIG. 9 is an exploded perspective view showing a second embodiment.
DESCRIPTION OF THE INVENTION
[0043] FIG. 1 shows a top plan view of the basic embodiment of the paint palette tool system invention 10 wherein the main body of the invention comprises an open-top circular structure container 20 comprising an open receptacle 30 constructed of a semi-rigid plastic material.
[0044] In the preferred embodiment the invention 10 has several fitting components including a semi-rigid outer structure comprising an open low profile structure designed for complementary receiving a snap-in removable liner 60 constructed of a thinner and lighter plastic material.
[0045] Plastic liner 60 shall be designed to receive and have affixed within its interior a cut and formed bristle fabric 70 fitted within the interior cavity 80 of the liner 60 Shown in FIG. 5 . In the preferred embodiment bristle fabric 70 is a formed cavity that is securely fitted and affixed to the interior side of removable liner 60 as shown in FIG. 1 and FIG. 6 . FIG. 8 shows a sectional view of formed bristle fabric 70 .
[0046] Formed bristle fabric 70 is a commercially available paint retaining material typically used on paint application devices and is a fabric like material comprising a short bristle filament or like material.
[0047] The bristle fabric 70 may also be know as paint pad material may be a flocked material, acrylic canvas pad, open cell foam material, a memory foam, sponge, woven carpet or similar like materials.
[0048] In the preferred embodiment the formed bristle fabric 70 may have an adhesive backing for quick assembly and attachment. In a second embodiment shown in FIG. 9 the bristle fabric is supplied in a die cut sheet form. A fitted circular section 78 is affixed to the interior of the bottom of the interior cavity 80 and a matching cut strip 75 is affixed to the interior of the outer edge of the liner 60 .
[0049] Additionally, in a second embodiment, a pair of extended wall sections 82 may be added to the sidewall 50 and shaped accordingly to support a brush handle from sliding, shown in FIG. 9 . Raised sidewall 82 placed at a ninety degree angle from liner snapping means 60 .
[0050] Although the preferred embodiment allows for a liner component 60 fitted into the open top circular structure 20 . The invention 10 may be used without a liner 60 and bristle fabric 70 may be applied directly into the open receptacle 30 . The liner 60 allows for more functionality and easier cleaning.
[0051] Said receptacle 30 shall be preferably constructed of a semi rigid plastic or like material comprising a substantially flat bottom base 40 with enclosing sidewalls 50 Shown is FIG. 3 . Sidewalls 50 preferably formed in a concave shape or similar shape as best seen in FIG. 3 .
[0052] Sidewalls 50 shall be rigid and may be outwardly inclined or angular in shape with complementary design features for securely receiving and fitting liner 60 . Sidewall 50 may in some embodiments have a guide rigid 140 that may be used for additional add-on tools such as a paint squeegee 150 .
[0053] The open receptacle 30 shall have a centrally mounted opening 90 in the central base of the bottom section in embodiments that require a liner 60 for ease in removing said liner 60 . In embodiments without the liner 60 a opening is not required.
[0054] The flat bottom base 40 shall be constructed of a rigid material and may have on the exterior bottom side extruded design features to better grip a surface that may include extruded feet or gripping ridges. The bottom 40 may additionally be slightly depressed in reference to sidewalls 50 .
[0055] Some embodiments of the invention may include formed attachment means for attaching brushes, tools, and other utility items that may be used by an amateur or commercial painter and feature attachment opening 100 shall be included on the invention 10 for future features,
[0056] The invention 10 shall also have a handle means 110 extending across the length of the flat bottom base 40 and shall be affixed by a plurality of fastening support extrusions shown in FIG. 4 and FIG. 8 .
[0057] In one embodiment, handle 110 may be threaded thru a complementary receiving ring 130 as shown in FIG. 8 . Handle adjustable options may include D-Ring, strap adjustment connectors or Velcro adjustment means.
[0058] In other embodiments, handle 110 may not be adjustable and be affixed directly to the flat bottom base 40 and may be affixed by a glued, snaps, fastening commercially available hardware. Handle 110 may also be removable for replaceable as required.
[0059] Handle 110 shall be constructed of a flexible material and may be made of a durable cloth fabric or like material. In other embodiments a flexible plastic or rubber like material may be used. Handle 110 may also include metal or plastic ends for secure attachment to handle receiving connections (Not Shown).
[0060] Said handle 110 shall be designed to easily facilitate handling and transportation. Additionally, said handle may also act as a gripping component and keep the invention from sliding off a steep incline such as a roof or like surface.
[0061] In use the invention 10 is utilized by pouring paint into the open receptacle 30 and then sliding the users hand between the strap handle 110 and flat bottom base 40 . The paint palette system 10 may then be used to dispense paint to a paint brush or like tool, The paint palette system may be used at any angle and has been tested while upside down without paint spillage.
[0062] The paint palette system 10 in the preferred embodiment includes a small attached paint squeegee 150 that helps pull all the paint from the bristle fabric The squeegee 150 may also be used as a hard paint separator.
[0063] In use the paint palette system 10 may have multiple colors of paint in the open receptacle 30 or liner 60 and the paint colors will not run together. In use it has also been discovered that multiple brushes can also be carried using the strap handle 110 .
[0064] In between uses, the paint palette system 10 may be easily stored in a readily available 1½ gallon salable plastic bag (Not Shown) and may be easily stacked when multiple palette systems are used.
[0065] Additionally, multiple liners 60 may be stored in plastic bags and may be interchangeably inserted into the open receptacle 30 in cases wherein many different paint colors are utilized and this offers the user a simpler way to view and use multiple colors
[0066] In some embodiments a plastic divider means be inserted into the liner 60 and may be used to better separate paint colors or materials that may be utilized. The paint palette system may additionally be used for other materials besides paints where a hard divider is required to keep separate material apart such as glue and paint.
[0067] Although applicant has described applicant's preferred embodiment of this invention, it will be understood that the broadest scope of this invention includes such modifications as diverse shapes and sizes and materials. Such scope is limited only by the below claims as read in connection with the above specification. Further, many other advantages of applicant's invention will be apparent to those skilled in the art from the above descriptions and the below claims.
[0068] From the foregoing, it will be apparent that the present invention provides for a novel and improved means for filter inspection and whereas the present invention has been described in a particular fashion, it should be understood that other and further modifications apart from those shown or suggested herein may be made within the scope of the invention.
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A paint palette system for holding and dispersing paint wherein the a painter can pour paint into a low profile receptacle for later removal with a paintbrush or like tool, wherein a disposed and removable paint retaining fabric retains the paint in a drip-less and mess free fashion wherein paint can be transported and stored in an improved manner allowing for a faster and more efficient painting effort.
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REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a Continuation of U.S. application Ser. No. 15/227,285 filed on Aug. 3, 2016, which is a Continuation of U.S. application Ser. No. 14/326,774 filed on Jul. 9, 2014 (now U.S. Pat. No. 9,503,127 issued on Nov. 22, 2016). The contents of the above referenced matters are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] Data deduplication removes redundancy while erasure coding adds redundancy. Data deduplication represents an original set of symbols in a smaller set of code symbols while erasure coding represents an original set of symbols in a larger set of code symbols. Thus, conventionally there has been no reason to use deduplication and erasure coding together.
[0003] Data that is stored or transmitted may be protected against storage media failures or other loss by storing extra copies or by storing additional redundant information. One type of redundancy-based protection involves using erasure coding. Erasure coding creates additional redundant data to produce code symbols that protect against ‘erasures’ where data portions that are lost can be reconstructed from the surviving data. Adding redundancy introduces overhead that consumes more storage capacity or transmission bandwidth, which in turn adds cost. The overhead added by erasure code processing tends to increase as the protection level provided increases.
[0004] While erasure codes increase data storage requirements by introducing additional redundancy, data deduplication seeks to reduce data storage requirements by removing redundancy. Data deduplication seeks to remove redundancy within a data set by representing an original set of symbols in a smaller set of code symbols. By representing data with a reduced number of code symbols, data storage space and communication capacity use are improved, which may in turn reduce cost.
[0005] The lack of redundancy in deduplicated data causes some unique data identified during deduplication to be less protected than others with respect to storage media failure or other loss. Over time, some unique data may become more or less valuable than other unique data. For example, one piece of unique data may be used to recreate hundreds of documents while another piece of unique data may only be used to recreate a single document. While loss of the unique data that is used for one document would be bad, the loss of the unique data that is used in the hundreds of documents may be worse. In some cases, the loss of the unique data used to recreate even a single document may be catastrophic when the data concerns, for example, user authentication or system security.
[0006] To enhance data protection, different approaches for storing redundant copies of items have been employed. Erasure codes are one such approach. An erasure code is a forward error correction (FEC) code for erasure channels. The FEC facilitates transforming a message of k symbols into a longer message with n symbols so that the original message can be recovered from a subset of the n symbols, k and n being integers, n>k. The symbols may be individual items (e.g., characters, bytes) or groups of items. The original message may be, for example, a file. The fraction r=k/n is called the code rate, and the fraction k′/k, where k′ denotes the number of symbols required for recovery, is called the reception efficiency or coding overhead. Optimal erasure codes have the property that any k out of the n code word symbols are sufficient to recover the original message (e.g., coding overhead of unity). Optimal codes may require extensive memory usage, CPU time, or other resources when n is large. Erasure coding approaches may seek to create the greatest level of protection with the least amount of overhead via optimal or near optimal coding. Different types of erasure codes have different efficiencies and tradeoffs in terms of complexity, resources, and performance.
[0007] Erasure codes are described in coding theory. Coding theory is the study of the properties of codes and their fitness for a certain purpose (e.g., backing up files). Codes may be used for applications including, for example, data compression, cryptography, error-correction, and network coding. Coding theory involves data compression, which may also be referred to as source coding, and error correction, which may also be referred to as channel coding. Fountain codes are one type of erasure codes.
[0008] Fountain codes have the property that a potentially limitless sequence of code symbols may be generated from a given set of source symbols in a manner that supports ideally recovering the original source symbols from any subset of the code symbols having a size equal to or larger than the number of source symbols. A fountain code may be optimal if the original k source symbols can be recovered from any k encoding symbols, k being an integer. Fountain codes may have efficient encoding and decoding algorithms that support recovering the original k source symbols from any k′ of the encoding symbols with high probability, where k′ is just slightly larger than k (e.g., an overhead close to unity). A rateless erasure code is distinguished from an erasure code that exhibits a fixed code rate.
[0009] Storage systems may employ rateless erasure code technology (e.g., fountain codes) to provide a flexible level of data redundancy. The appropriate or even optimal level of data redundancy produced using a rateless erasure code system may depend, for example, on the number and type of devices available to the storage system. The actual level of redundancy achieved using a rateless erasure code (EC) system may depend, for example, on the difference between the number of readable redundancy blocks (e.g., erasure code symbols) written by the system and the number of redundancy blocks needed to reconstruct the original data. For example, if twenty redundancy blocks are written and only eleven redundancy blocks are needed to reconstruct the original data that was protected by generating and writing the redundancy blocks, then the original data may be reconstructed even if nine of the redundancy blocks are damaged or otherwise unavailable.
[0010] An EC system may be described using an A/B notation, where B describes the total number of encoded symbols that can be produced for an input message and A describes the minimum number of the B encoded symbols that are required to recreate the message for which the encoded symbols were produced. By way of illustration, in a 10 of 16 configuration, or EC 10/16, sixteen encoded symbols could be produced. The 16 encoded symbols could be spread across a number of drives, nodes, or geographic locations. The 16 encoded symbols could even be spread across 16 different locations. In the EC 10/16 example, the original message could be reconstructed from 10 verified encoded symbols.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various example systems, methods, and other example embodiments of various aspects of the invention. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.
[0012] FIG. 1 illustrates an example of protecting unique chunks produced by a data deduplication system using erasure code redundancy.
[0013] FIG. 2 illustrates another example of protecting unique chunks produced by a data deduplication system using erasure code redundancy, where unique chunks are grouped together before being provided to an erasure coding system.
[0014] FIG. 3 illustrates a file segmented into parts and deduplicated before erasure coding.
[0015] FIG. 4 illustrates a file segmented into parts that have been deduplicated and had erasure correction parities added.
[0016] FIG. 5 illustrates grouping chunks before erasure coding.
[0017] FIG. 6 illustrates an example method associated with protecting a data deduplication system using erasure code redundancy.
[0018] FIG. 7 illustrates an example method associated with manipulating a generator matrix used by an erasure encoder to protect data produced by a data deduplication system.
[0019] FIG. 8 illustrates an example apparatus for protecting a data deduplication system using erasure code redundancy.
[0020] FIG. 9 illustrates an example apparatus for protecting a data deduplication system using erasure code redundancy.
[0021] Prior Art FIG. 10 illustrates an example set of systematic erasure codes.
[0022] Prior Art FIG. 11 illustrates an example set of non-systematic erasure codes.
DETAILED DESCRIPTION
[0023] Example apparatus and methods combine data deduplication with erasure coding to reduce the amount of data that is erasure coded while adding protection for unique data produced by data deduplication. Since not all unique data may have the same value—whether real or perceived—to a deduplication system, example apparatus and methods account for varying levels of importance of unique data. Varying levels of importance are accounted for by dynamically adapting erasure code generation approaches.
[0024] Example apparatus and methods may identify redundancy policies to be employed based on attributes of unique data produced by a deduplication system. For example, an erasure code approach may provide greater protection to unique data that has a higher value. The value may be determined from some attribute of the unique data (e.g., reference counts). The redundancy policies may identify, for example, M/N policies that control the number of erasure code symbols generated and the distribution of those symbols. In one embodiment, M and N may be manipulated based on an attribute of the unique data. In one embodiment, the amount of additional information (e.g., parity) that is added to create an encoded codeword symbol may be a function of an attribute of the unique data. In one embodiment, the size of an erasure code symbol (e.g., number of bits, number of bytes) may be a function of an attribute of the unique data. In one embodiment, while N erasure code symbols may be generated, example apparatus and methods may control how many of the N erasure code symbols are stored based on an attribute of the unique data. The erasure code symbols may be stored on a single device or may be distributed between two or more devices. The number of devices to which erasure code symbols are distributed may also be a function of an attribute of the unique data.
[0025] Example apparatus and methods may vary the erasure code approach for certain data over time. For example, as certain data becomes more valuable, the number of erasure code symbols used to protect that data may be increased. Conversely, as other data becomes less valuable, the number of erasure code symbols used to protect that data may be decreased. Conventional systems, if it were even possible to try to modify them to try be adaptive over time, would be required to compute entirely new sets of erasure codes. Unlike conventional systems, new erasure code symbols may be computed and added to existing codes without computing entirely new sets of erasure codes. Additionally, unlike conventional systems, some erasure code symbols may be deleted, either physically or logically, without having to compute new erasure code symbols.
[0026] Rateless erasure codes may be well-suited for this application of adaptively varying erasure code protection over time based on a property (e.g., value, reference counts) of the data being protected. When rateless erasure codes are employed, additional rateless erasure code symbols (e.g., parities) may be generated and stored as data value increases (e.g., number of references goes up). The additional rateless erasure code symbols may be generated using the same generator matrix that was used to generate the original rateless erasure codes. The original rateless erasure codes do not need to be deleted or overwritten.
[0027] As data value decreases (e.g., number of references goes down), some original rateless erasure code symbols may be deleted, either logically or physically. An erasure code symbol may be logically deleted by, for example, erasing a pointer value in memory. Logically erasing an erasure code symbol rather than physically erasing the erasure code symbol may reduce stress on data storage devices (e.g., disk drives) that are used to store erasure codes.
[0028] Different types of erasure coding and data deduplication may combine in different ways. Systematic erasure codes do not incur a decode penalty when reading back data that has not encountered any erasures (e.g., no data has been corrupted or lost) since some of the encoded symbols are actually just the plaintext symbols from the original message. When no data has been lost, decoding can be avoided, which helps performance. Rateless erasure codes handle large data objects well, are flexible for adapting to different levels of protection, and are reliable against random, distributed errors. Thus, example apparatus and methods may employ systematic erasure codes, rateless erasure codes, or even systematic rateless erasure codes. Other forms of erasure codes may also be employed.
[0029] Variable-length, block-level data deduplication exhibits superior performance in some deduplication applications. For example, variable-length, block-level data deduplication quickly adapts to a data stream and synchronizes to data segments that have occurred elsewhere regardless of whether data has been inserted or removed. Variable-length, block-level data deduplication can be performed ‘in-line’ where all data does not need to be seen first or may be performed in post-processing. While variable-length, block-level deduplication is described, other types of deduplication may be combined with various forms of erasure coding.
[0030] Prior Art FIG. 10 illustrates an original message 1000 that has sixteen symbols S 1 , S 2 , . . . S 16 (k=16) and that reads “original message”. While the symbol size is one character, different symbol sizes may be employed. Message 1000 is provided to erasure encoder 1010 . Erasure encoder 1010 uses a generator matrix 1020 to produce erasure code symbols 1030 . In this example, erasure encoder 1010 produces systematic erasure code symbols EC 1 , EC 2 , . . . ECn (n>k). The systematic erasure code symbols include EC 1 . . . EC 16 (EC 1 . . . ECk), which correspond directly to S 1 . . . S 16 (S 1 . . . Sk). In this embodiment, at least EC 1 . . . EC 16 may be the same size as S 1 . . . S 16 . For example, if the symbols S 1 . . . S 16 are one byte each, then the symbols EC 1 . . . EC 16 may also be one byte each. The systematic erasure code symbols also include EC 17 . . . ECn (ECk+1 . . . ECn), which do not correspond to any of S 1 . . . Sk. In one embodiment, ECk+1 . . . ECn may be parity information. In another embodiment, ECk+1 . . . ECn may be other information that facilitates recreating the original message.
[0031] The original message 1000 can be recreated from any 16 of the systematic erasure code symbols EC 1 . . . ECn. If EC 1 . . . ECk are available, then original message 1000 can be recreated without performing erasure code decoding. If any of EC 1 . . . ECk are not available, then original message 1000 can still be recreated but erasure code decoding would be necessary. If original message 1000 became more important, additional erasure code symbols (e.g., ECn+1 . . . ECn+y) may be computed using the same generator matrix. If original message 1000 became less important, then some of erasure code symbols EC 1 . . . ECn may be logically or physically deleted.
[0032] Prior Art FIG. 11 illustrates an original message 1100 that also has sixteen symbols S 1 , S 2 , . . . S 16 (k=16) and that reads “original message”. While the symbol size is one character, different (e.g., larger) symbol sizes are likely to be employed. Message 1100 is provided to erasure encoder 1110 . Erasure encoder 1110 uses a generator matrix 1120 to produce erasure code symbols 1130 . In this example, erasure encoder 1110 produces non-systematic erasure code symbols EC 1 , EC 2 , . . . ECn (n>k). EC 1 , EC 2 , . . . ECn do not correspond directly to any of S 1 . . . S 16 as was the case for systematic erasure codes 1030 ( FIG. 10 ). Instead, EC 1 , EC 2 , . . . ECn are the result of processing symbols S 1 . . . S 16 with the matrix 1120 as controlled by erasure encoder 1110 .
[0033] FIG. 1 illustrates a system 100 that combines data deduplication and erasure coding. Data 110 is provided to a parser 120 . Parser 120 produces chunks C 1 . . . Ca. There may be duplicate chunks in C 1 . . . Ca. The chunks C 1 . . . Ca are provided to a deduplicator 130 . Deduplicator 130 may consult and update metadata 132 and an index 134 to produce unique chunks U 1 . . . Ub.
[0034] Unique chunks U 1 . . . Ub are provided to erasure code generator 140 . Erasure code generator 140 produces erasure code symbols EC 1 . . . ECc based, at least in part, on information stored in generator matrix 142 . Unique chunks U 1 . . . Ub are protected by erasure codes and they are recoverable from erasure code symbols EC 1 . . . ECc. In one embodiment, a rateless erasure code approach is employed to facilitate a complementary relationship between erasure coding and variable length data deduplication. The complementary relationship facilitates accounting for unique chunks having different values to the deduplication system. Rateless erasure codes, systematic erasure codes, systematic rateless erasure codes, or other erasure codes may be produced.
[0035] Erasure code symbols EC 1 . . . ECc are provided to an erasure code distributor 150 . Erasure code distributor 150 may distribute erasure code symbols EC 1 . . . ECc to a number of different storage devices DS 1 . . . DSd. While a storage system is illustrated, different embodiments may combine data deduplication with erasure coding in a communication system or other system. Data 110 may be, for example, a file, an object, a block, a stream, a binary large object (BLOB), or other item.
[0036] By performing deduplication before erasure coding, only unique data is encoded, which reduces the time required to perform erasure coding. By performing erasure coding after deduplication, unique chunks are protected by some redundancy, which facilitates mitigating the risk of removing redundant data. Protecting unique chunks using erasure coding may have the technical effect of allowing the use of less expensive (e.g., RAID-5, near line storage) storage systems instead of more expensive (e.g., RAID-6, enterprise storage) storage systems.
[0037] In one embodiment, using a rateless erasure code approach facilitates selectively and adaptively varying the level of data protection (e.g., erasure code approach) for different pieces of unique data. In one embodiment, the value of the unique data may be measured by the number of references to the unique data. For example, a segment of shared data that is present in several files may have more references to it and thus may be treated as being more valuable than a segment of shared data that is used in fewer files and thus has fewer references. While reference counts are described, other value measures may be employed (e.g., the number of bytes in the original file or unique data). Thus, the number (c) of erasure code symbols EC 1 . . . ECc that are produced, the characteristics (e.g., size, composition) of the erasure code symbols EC 1 . . . ECc that are produced, the distribution of the erasure code symbols EC 1 . . . ECc that are produced, the type of erasure encoding (e.g., rateless, systematic), or other erasure code attributes may be manipulated based on an attribute (e.g., importance, size, number) of the unique chunks U 1 . . . Ub. Since the attribute (e.g., importance, size, age) of the unique chunks may vary over time, in one embodiment, the number of erasure code symbols used to protect a unique chunk may be updated upon determining that the attribute has changed. For example, as reference counts to a chunk increase, the number of erasure code symbols used to protect the chunk may be increased.
[0038] Although a storage system is illustrated, example apparatus and methods may also be employed with a communication system. For example, metadata that tracks unique segments may be maintained at both a sender and a receiver. The metadata may be maintained for different periods of time to accommodate different history durations. Unique segments and the metadata (e.g., recipes) associated with recreating larger data objects (e.g., files) from the unique segments may be encoded by a transmitter and provided to a receiver. In one embodiment, the recipes may be encoded and provided, which prompts a receiver to identify segments that are desired, which in turn prompts encoding and providing the erasure code symbols for the desired segments.
[0039] FIG. 2 illustrates another example of system 100 where unique chunks U 1 . . . Ub are protected by erasure code symbols EC 1 . . . ECc. In this example, the unique chunks U 1 . . . Ub are grouped together by grouper 135 into group Gp 1 before being provided to erasure code generator 140 . Having larger inputs to erasure code generator 140 may facilitate improving certain erasure code properties. For example, rateless codes incur less overhead penalty with larger block lengths and only have linear time complexity operation.
[0040] FIG. 3 illustrates a file 300 that has been segmented into segments segment 1 . . . segment 6 . The segments segment 1 . . . segment 6 are provided to a deduplication apparatus or method 310 . Deduplication apparatus or method 310 produces four unique chunks, chunk 1 . . . chunk 4 . There may be different numbers of reference counts to the different unique chunks. The chunks may have different chunk-level probabilities {p 1 , P 2 . . .p 4 }. The segments may have the same or different user-defined attributes (e.g., value metrics, size).
[0041] FIG. 4 illustrates that the segments segment 1 . . . segment 6 may be characterized by different failure probabilities {P 1 , P 2 . . . P 6 }. After deduplication, the reconstruction quality profile for a segment may change based, for example, on reference counts or other metadata. The reference counts are illustrated using a bipartite graph in which the graph connections 410 establish which segment contains which chunk in a storage pool of chunks. The set of probabilities {P 1 , P 2 . . . P 6 } may induce different chunk-level probabilities {p 1 , p 2 . . . p 4 }. In one embodiment, chunk-level probabilities may then be constrained to satisfy an example set of inequalities:
[0000] 1−(1− p 1 )(1− p 3 )<= P 1
[0000] 1−(1− p )(1 −p 2 )(1 −p 3 )<= P 2
[0042] Note that even if P i are the same, the p j can still be different. Based on {P 1 , P 2 . . . P 6 } and the set of inequalities, chunk level recovery can be guaranteed by calculating the appropriate set {p 1 , p 2 . . . p 4 }. An erasure coding mechanism can be manipulated to protect these chunks at a level appropriate to the chunk-level probability requirements. Different erasure coding approaches can be applied to different chunks having different chunk-level probability requirements. For example, chunk 1 has more connections (e.g., 4) than any other chunk in the pool. In an example parity based systematic EC approach, more parity may be allocated for chunk 1 in the erasure coding phase. The amount of parity par 1 allocated for chunk 1 may be larger than the amount of parity par 2 allocated for chunk 2 , the amount of parity par 3 allocated for chunk 3 , or the amount of parity par 4 allocated for chunk 4 . The amount of parity allocated for a chunk may be proportional to an attribute (e.g., number of connections) of the chunk. More generally, variable size chunks having varying sensitivity to loss may be protected using different numbers of parity symbols in a systematic erasure code approach. Even more generally, chunks having different attributes may be protected differently by controlling attributes of an erasure coding approach. The attributes of an erasure coding approach (e.g., number of parity symbols employed) may vary over time as the attribute of the chunk (e.g., number of connections) varies over time.
[0043] FIG. 5 illustrates the segments segment 1 . . . segment 6 and the unique chunks chunk 1 . . . chunk 4 of FIG. 3 . In one example that uses rateless codes, example apparatus and methods may keep the rateless codeword length above a certain threshold by grouping the unique chunks before erasure coding. Recall that rateless codes incur less overhead penalty with larger block lengths and only have linear time complexity operation. Thus, in one embodiment, deduplicated chunks chunk 1 . . . chunk 4 may be grouped together (e.g., concatenated) by grouper 500 to produce a single data item to be encoded by erasure encoder 510 . In one embodiment, erasure encoder 510 may use a rateless erasure code process. In one embodiment, when deduplicated data exceeds a threshold size, example apparatus and methods may control erasure encoder 510 to use code words that are larger than a threshold size to facilitate accounting for random failures and thus improve performance of the storage network.
[0044] The grouped chunks are encoded by erasure encoder 510 to generate a desired number of EC symbols. Erasure encoder 510 builds EC symbols EC 1 . . . ECn from the group as processed in light of generator matrix 512 . To meet desired protection guarantees (e.g., probabilities {p 1 , p 2 . . . p 4 }) the rateless encoder algorithm applied by erasure encoder 510 may be controlled. In one embodiment, a graph defining the properties of the rateless code would make more connections with the higher valued content in the concatenation to increase recoverability of that higher valued content. In one embodiment, node/edge probability distributions realized as non-zero entries in the generator matrix 512 representation of an encoding graph may be manipulated to allow error probabilities less than or equal to {p 1 , p 2 . . . p 4 }. More generally, attributes of erasure codes produced by erasure encoder 510 may be controlled by manipulating the generator matrix 512 employed by the erasure encoder 510 . For example, the composition of an erasure code (e.g., number of connections between a portion of the message and an erasure codeword) can be controlled by the construction of the generator matrix 512 , which can be manipulated by attributes (e.g., desired probabilities p 1 . . . p 4 ) of unique chunks.
[0045] Some portions of the detailed descriptions herein are presented in terms of algorithms and symbolic representations of operations on data bits within a memory. These algorithmic descriptions and representations are used by those skilled in the art to convey the substance of their work to others. An algorithm, here and generally, is conceived to be a sequence of operations that produce a result. The operations may include physical manipulations of physical quantities. Usually, though not necessarily, the physical quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. The physical manipulations create a concrete, tangible, useful, real-world result.
[0046] It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, or numbers. It should be borne in mind, however, that 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, it is to be appreciated that throughout the description, terms including processing, computing, and determining refer to actions and processes of a computer system, logic, processor, or similar electronic device that manipulates and transforms data represented as physical (electronic) quantities.
[0047] Example methods may be better appreciated with reference to flow diagrams. For purposes of simplicity of explanation, the illustrated methodologies are shown and described as a series of blocks. However, it is to be appreciated that the methodologies are not limited by the order of the blocks, as some blocks can occur in different orders or concurrently with other blocks from that shown and described. Moreover, less than all the illustrated blocks may be required to implement an example methodology. Blocks may be combined or separated into multiple components. Furthermore, additional or alternative methodologies can employ additional, not illustrated blocks.
[0048] FIG. 6 illustrates a method 600 associated with protecting a data deduplication system using erasure code redundancy. Method 600 may include, at 610 , accessing a message produced by a data deduplication system. The message may be, for example, a unique chunk, a collection (e.g., grouping, concatenation) of unique chunks, or other data. The data deduplication system may be, for example, a variable-length, block-level system. Other types of deduplication systems (e.g., fixed length) may also be employed. Accessing the message may include receiving the message as a parameter in a function call, reading the message from a memory, receiving a pointer to the message, or other electronic data processing action.
[0049] Method 600 may also include, at 620 , identifying a property of the message. The property may be, for example, the importance of the message to the data deduplication system. The importance of the message may be user-assigned or may be derived from, for example, the number of items that reference the message. The importance of the message may vary over time, therefore, in one embodiment, portions of method 600 may be repeated or values produced by method 600 may be recalculated.
[0050] Method 600 may also include, at 630 , generating W erasure code symbols for the message. The erasure code symbols are generated according to an X/Y erasure code policy, where W, X and Y are numbers (e.g., integers). W is greater than or equal to X, meaning that at least X erasure code symbols will be produced. W is less than or equal to Y, meaning that not all Y possible erasure code symbols may be produced. Unlike conventional systems where W, X, and Y are fixed, in method 600 , W, X or Y depend, at least in part, on the property (e.g., importance) of the message. In one embodiment, W, X, or Y are directly proportional to the property. For example, as the importance of the message increases, W, X, or Y may also increase. Over time, as the importance of the message increases or decreases, W, X, or Y may be increased or decreased and additional erasure code symbols may be generated and stored or some original erasure code symbols may be deleted.
[0051] Conventional methods typically have fixed erasure code symbol sizes. Method 600 is not so limited. In one embodiment, the size of an erasure code symbol in the W erasure code symbols is a function of the size of the message. For example, as the message size increases, the size of an erasure code symbol may increase.
[0052] Once the erasure code symbols have been created, they may be stored to add back the redundancy created by the erasure code approach to protect the message. Thus, method 600 may also include distributing members of the W erasure code symbols to Z different data stores according to a distribution policy. Z is a number and may be less than or equal to Y. For example, in a 10/16 policy, the erasure code symbols that are produced may be distributed to a number Z of devices, and the number Z may depend, at least in part, on the property.
[0053] Method 600 may use different types of erasure codes. For example, method 600 may use systematic erasure codes, rateless erasure codes, or other types of erasure codes. In one embodiment, the systematic erasure codes may be at least partially parity based. In this embodiment, the amount of parity generated by the X/Y erasure code policy depends, at least in part, on the property. For example, for more important messages there may be more parity symbols produced while for less important messages there may be fewer parity symbols produced.
[0054] How X, Y, or Z are chosen may depend on user configuration. The user may define rules that relate the property to a configurable attribute (e.g., X, Y, Z). In one embodiment, a relationship between the property and the X/Y erasure code policy is controlled, at least in part, by a user-defined rule. For example, a user may mandate that for messages with less than three references that a 10/14 policy be employed while for messages with three or more references that a 10/16 policy be employed. In another embodiment, a relationship between the property and the X/Y erasure code policy is controlled, at least in part by an automated rule. For example, the automated rule may cause Y to be set to a first value if the number of references for the message is in the bottom half of all reference counts for all messages encountered and may cause Y to be set to a second value if the number of references is in the top half of the reference counts encountered.
[0055] FIG. 7 illustrates an example method 700 . Method 700 includes, at 710 , accessing unique data produced by a data deduplication system. Accessing the unique data may include reading from a file, reading from a device, receiving a network data communication, receiving a pointer to data, or other actions.
[0056] Method 700 also includes, at 720 , identifying a property of the unique data. The property may be, for example, an importance of the unique data. The importance may be derived from, for example, a reference count to the unique data. The property may also be, for example, an amount that a user is willing to spend to protect the data. In one embodiment, the property may be an intrinsic value of the unique data including, for example, the number of symbols in the unique data, the symbol size in the unique data, the age of the unique data, or other values.
[0057] Method 700 also includes, at 730 , manipulating a generator matrix representation of an encoding graph associated with an erasure encoder. The manipulating may be based on the property. Manipulating the generator matrix may include controlling a number of non-zero elements in the generator matrix or controlling the value of one or more non-zero elements in the generator matrix. For example, a generator matrix may be an N×K matrix of values that are used to produce erasure code symbols from symbols in an input message. N or K may be selected based on the property. For systematic erasure codes, the upper portion of the matrix may be an identity matrix.
[0058] In one embodiment, the property of the unique data is a probability of failure associated with the unique data. In this embodiment, the number of non-zero elements as well as the number of rows N in the generator matrix may be controlled to cause erasure codewords produced by the erasure encoder to account for chunk level probability requirements associated with the unique data. In one embodiment, the value of one or more non-zero elements in the generator matrix may be controlled to cause erasure code symbols produced by the erasure encoder to account for chunk level probability requirements associated with the unique data.
[0059] The generator matrix may be manipulated to cause erasure code symbols to have different properties. For example, manipulating the generator matrix may control, at least in part, the size or composition of an erasure codeword produced by the erasure encoder. The composition of an erasure codeword may in turn control, at least in part, the relevance of an erasure codeword to a selected portion of the unique data. For example, in a rateless erasure code approach, chunks having higher probability requirements may have more connections to an erasure codeword while chunks having lower probability requirements may have fewer connections to an erasure codeword. This enables adapting the erasure code according to the recoverability requirements of different chunks.
[0060] Method 700 may also include, at 740 , generating erasure codewords from the unique data based, at least in part, on the generator matrix. Generating erasure codewords may include mathematically oversampling the unique data with values in the generator matrix.
[0061] The following includes definitions of selected terms employed herein. The definitions include various examples and/or forms of components that fall within the scope of a term and that may be used for implementation. The examples are not intended to be limiting. Both singular and plural forms of terms may be within the definitions.
[0062] References to “one embodiment”, “an embodiment”, “one example”, “an example”, and other similar terms, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, though it may.
[0063] “Computer component”, as used herein, refers to a computer-related entity (e.g., hardware, firmware, software in execution, combinations thereof). Computer components may include, for example, a process running on a processor, a processor, an object, an executable, a thread of execution, and a computer. A computer component(s) may reside within a process and/or thread. A computer component may be localized on one computer and/or may be distributed between multiple computers.
[0064] “Computer-readable storage medium”, as used herein, refers to a non-transitory medium that stores instructions and/or data. A computer-readable medium may take forms, including, but not limited to, non-volatile media, and volatile media. Non-volatile media may include, for example, optical disks, magnetic disks, and other disks. Volatile media may include, for example, semiconductor memories, dynamic memory, and other memories. Common forms of a computer-readable medium may include, but are not limited to, a floppy disk, a flexible disk, a hard disk, a magnetic tape, other magnetic medium, an ASIC, a CD, other optical medium, a RAM, a ROM, a memory chip or card, a memory stick, and other media from which a computer, a processor or other electronic device can read.
[0065] “Data store”, as used herein, refers to a physical and/or logical entity that can store data. A data store may be, for example, a database, a table, a file, a data structure (e.g. a list, a queue, a heap, a tree) a memory, a register, or other repository. In different examples, a data store may reside in one logical and/or physical entity and/or may be distributed between two or more logical and/or physical entities.
[0066] “Logic”, as used herein, includes but is not limited to hardware, firmware, software in execution on a machine, and/or combinations of each to perform a function(s) or an action(s), and/or to cause a function or action from another logic, method, and/or system. Logic may include, for example, a software controlled microprocessor, a discrete logic (e.g., ASIC), an analog circuit, a digital circuit, a programmed logic device, or a memory device containing instructions. Logic may include one or more gates, combinations of gates, or other circuit components. Where multiple logical logics are described, it may be possible to incorporate the multiple logical logics into one physical logic. Similarly, where a single logical logic is described, it may be possible to distribute that single logical logic between multiple physical logics.
[0067] “Object”, as used herein, refers to the usage of object in computer science. From one point of view, an object may be considered to be a location in a physical memory having a value and referenced by an identifier.
[0068] An “operable connection”, or a connection by which entities are “operably connected”, is one in which signals, physical communications, or logical communications may be sent or received. An operable connection may include a physical interface, an electrical interface, or a data interface. An operable connection may include differing combinations of interfaces or connections sufficient to allow operable control. For example, two entities can be operably connected to communicate signals to each other directly or through one or more intermediate entities (e.g., processor, operating system, logic, software). Logical or physical communication channels can be used to create an operable connection.
[0069] “Signal”, as used herein, includes but is not limited to, electrical signals, optical signals, analog signals, digital signals, data, computer instructions, processor instructions, messages, a bit, or a bit stream, that can be received, transmitted and/or detected.
[0070] “Software”, as used herein, includes but is not limited to, one or more executable instructions that cause a computer, processor, or other electronic device to perform functions, actions and/or behave in a desired manner. “Software” does not refer to stored instructions being claimed as stored instructions per se (e.g., a program listing). The instructions may be embodied in various forms including routines, algorithms, modules, methods, threads, or programs including separate applications or code from dynamically linked libraries.
[0071] “User”, as used herein, includes but is not limited to one or more persons, software, logics, applications, computers or other devices, or combinations of these.
[0072] FIG. 8 illustrates an apparatus 800 that includes a processor 810 , a memory 820 , and a set 830 of logics that is connected to the processor 810 and memory 820 by an interface 840 . In one embodiment, the apparatus 800 may be a stand-alone device connected to a data communication network. In another embodiment, apparatus 800 may be integrated into another device (e.g., deduplication apparatus) or system (e.g., object storage system).
[0073] The set 830 of logics may include a first logic 832 that produces a set of n erasure code symbols for a message received from a data deduplication system. The message may be, for example, a unique chunk, a collection (e.g., concatenation) of unique chunks, or other data to be protected. The message has k symbols. n and k are numbers and n>k. Unlike conventional systems, n is a function of a first attribute of the message.
[0074] The first attribute may describe, for example, an importance of the message to the data deduplication system. The importance may be determined by the number of references to the message, by a user-defined value assigned to the message, by a cost to replace the message, or in other ways. The first attribute may also describe, for example, the size of the message, an amount to be spent protecting the message, an age of the message, or other properties. The value of the first attribute may vary over time.
[0075] The apparatus 800 may also include a second logic 834 that selectively stores members of the n erasure code symbols on z different data storage devices. z is a function of a second attribute of the message. The second attribute may also describe, for example, the importance of the message or another property of the message (e.g., size, age, cost to replace, user-assigned value). The value of the second attribute may vary over time.
[0076] Different types of erasure codewords may be produced. In one embodiment, the type of erasure codewords produced is a function of the first attribute. The erasure codes may be, for example, systematic erasure codes, rateless erasure codes, or other erasure codes. In one embodiment, the size of an erasure code symbol is a function of the size of the k symbols. For example, message symbols that are sixteen bytes wide may yield erasure code symbols that are twenty bytes wide. In different embodiments the size of the erasure code symbol may be the same as the size of the k symbols or may be different than the size of the k symbols. In one embodiment, the composition of an erasure code symbol is a function of the first attribute or the second attribute. The composition of the erasure code symbol may allocate a certain amount of the erasure code symbols to a certain portion of the message and may allocate another amount of the erasure code symbols to another portion of the message.
[0077] FIG. 9 illustrates another embodiment of apparatus 800 . This embodiment includes a third logic 836 . The third logic 836 may adapt how n is selected as a function of the first attribute. For example, over time, a metric that measures overall redundancy in a system may report that apparatus 800 is producing redundancy above a threshold level. In this case, n may be reduced for certain values of the first attribute. In another example, a metric that measures overall resource usage for storing data may report that apparatus 800 is only consuming half of the available resources. In this case, n may be increased for certain values of the first attribute.
[0078] This embodiment also includes a fourth logic 838 . The fourth logic 838 may adapt how z is selected as a function of the second attribute. For example, over time, a failure rate for the z devices on which erasure code symbols are being stored may be tracked. If the failure rate is above a certain threshold, then z may be increased to decrease the impact of any single failure.
[0079] In one embodiment, the first logic 832 or the second logic 834 may be controlled to recalculate n or z for a message upon determining that the first attribute or the second attribute for the message has changed more than a threshold amount.
[0080] While example systems, methods, and other embodiments have been illustrated by describing examples, and while the examples have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the systems, methods, and other embodiments described herein. Therefore, the invention is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Thus, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims.
[0081] To the extent that the term “includes” or “including” is employed in the detailed description or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim.
[0082] To the extent that the term “or” is employed in the detailed description or claims (e.g., A or B) it is intended to mean “A or B or both”. When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995).
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Example apparatus and methods combine erasure coding with data deduplication to simultaneously reduce the overall redundancy in data while increasing the redundancy of unique data. In one embodiment, an efficient representation of a data set is produced by deduplication. The efficient representation reduces duplicate data in the data set. Redundancy is then added back into the data set using erasure coding. The redundancy that is added back in adds protection to the unique data associated with the efficient representation. How much redundancy is added back in and what type of redundancy is added back in may be controlled based on an attribute (e.g., value, reference count, symbol size, number of symbols) of the unique data. Decisions concerning how much and what type of redundancy to add back in may be adapted over time based, for example, on observations of the efficiency of the overall system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
Millions of surgeries are performed each year under local anesthesia and/or intravenous (IV) sedation in freestanding ambulatory surgery centers. In any procedure, the patient is often faced with significant distress and anxiety which can lead to many problems. In addition to the physiologic changes caused by anxiety and pre-procedural stress, the patient's ability to follow pre-op instructions is often compromised. This can be of a particular problem in patients such as diabetics who are often confused about which medicines and how much of each they should or should not take in the pre-op period. This, coupled with the fact that patients often need to refrain from eating or drinking (nothing by mouth or Latin: Nil Per Os or NPO) for an extended period of time prior to the procedure, can lead to problems such as significant and symptomatic hypoglycemic episodes.
Minor medical emergencies in a non-hospital, office-based environment can pose challenges. Often, in the stable and fully conscious patient with mild hypoglycemia, a glucose-rich Per Os (by mouth, Latin: Per Os or PO) drink is administered. Such intervention is practical in these mildly affected patients where a more acute intervention is not necessary.
In a more acute situation where quick reversal of hypoglycemia is required, dextrose may be administered via IV access. However, the option of IV administration would take some time to prepare and push even in the event that an IV is already in place. Intervention with IV dextrose alone would likely be slower than optimal or desirable in those patients who do not already have IV access.
Intervention in the form of the application of a sugar-rich substance such as cake icing to the buccal or sublingual mucosa is often advocated and a possible option in the event that an IV is not accessible or if dextrose infusion is not immediately available. This option, in addition to having no data supporting its efficacy, has other problems as well. Application should only be used in a fully conscious and alert patient due to the risk of pulmonary aspiration. There is also a dependence on patient compliance even in the conscious persons. If the sugar is swallowed, there would be a significant delay in the effects on blood glucose levels. Another problem is the delay necessary for the sugar, in the form of sucrose, to be broken down by sucrase in the oral cavity prior to being able to be transported transmucosally as glucose.
If the above treatments are not administered without delay, a patient, particularly those with brittle (labile) diabetes, may become comatose due to hypoglycemic brain injury. In certain situations this can lead to a persistent vegetative state without any expected neurologic improvement. Quick and acutely effective sources of glucose, administered expeditiously during crashing could be the difference between life and death. Of additional importance, the dose of dextrose required to effect a change in the blood glucose of an individual is approximately 5 to 15 grams—necessitating the ability to deliver a large dextrose payload.
The problem and risk of hypoglycemic episodes for the diabetic is not limited to the medical or dental office, however, and constant access to a source of rescue glucose is crucial. It is not uncommon for physicians to recommend that these individuals keep a tube of cake icing or other glucose rich substance on their person for quick application in such events. As enumerated earlier, the use of either cake icing or PO forms of rescue glucose pose significant problems and are suboptimal for these same reasons.
Hypoglycemia of the newborn and hypoglycemia associated with severe systemic illness is a significant health problem worldwide, particularly in the undeveloped world. Hypoglycemia can be closely linked to a significant proportion of the two hundred and twenty-five thousand (225,000) yearly malarial deaths in African children under the age of five (5) years. The preferred treatment in most cases is correction via IV dextrose infusions. Problems with this treatment are plentiful in the undeveloped areas that are poor both in terms of monetary and human capital. Delay to infusion can be caused by many reasons. Most health care facilities do not have the supplies. Families of the sick are given prescriptions for needed supplies/medications and they must go and find not only the money to buy these supplies but a pharmacy that has the supplies available prior to returning to the hospital for initiation of treatment. Additionally, it can be hard to obtain IV access in a small, acutely ill (dehydration, shock, unconscious) child. IV access carries other risks, including pain, risk of blood-borne pathogen transmission, and possible local or systemic infection associated with venous catheterization.
The correction of hypoglycemia by placing a spoon full of granulated table sugar (sucrose) under the tongue has been studied in this population by the medical community and the results were promising when compared to IV dextrose infusion. Problems with this very basic method, however, included early swallowing of the loose, granulated sugar by the children which resulted in treatment failure. Additionally, table sugar is sucrose and must be broken down to glucose and fructose by sucrase in the oral cavity prior to transport transmucosally.
Hypoglycemia is of immediate concern in the person found by healthcare workers to be unconscious due to an unknown cause. Classically, such a patient is always treated, immediately on arrival in the emergency department, with an intravenous administration of a three drug combination including dextrose, thiamine, and naloxone. The decision to administer these drugs is a reflexive decision (i.e. all unconscious patients with a significantly and abnormally depressed mental status, without a clear or known cause for such, are reflexively administered this “coma cocktail.”) If such a transmucosal dosage-form were possible, under the reflexive direction of a proper protocol, it would allow for the administration of the classic cocktail constituents by emergency medical services providers immediately upon arrival to the scene and long before IV access or reaching the hospital emergency department.
Long-distance athletes have a need to obtain hydration, electrolytes, and carbohydrates during the episodes of intense and prolonged exertion that they often put themselves through. Many different carbohydrate formulations, predominantly meant to be consumed orally, have been developed to target this population. A popular embodiment involves a gel-type formulation that is stored in a small pouch and meant to be consumed at some time period during the extended physical exertion. Targeting the PO route with these carbohydrate loads have multiple unwanted side effects—all of which have to do with the normal gastrointestinal physiology. Stimulation of the gastrointestinal tract with a load of carbohydrate, causes increased neuronal activity to the area leading to increased peristalsis which combined with the decreased blood supply to the bowels during strenuous exertion produces the common sensation of gastrointestinal uneasiness or queasiness after consuming the product. The next step in physiology is an increased shunting of blood away from the muscles needing this perfusion to the splachnic circulation towards the bowels. Athletes also describe the subjective feeling of a vague central heaviness.
Prior art, with regard to oral, transmucosal drug delivery does not describe a method by which large payloads of active pharmaceutical agent, on the order of grams, can be delivered systemically. The prior art of dosage form fabrication for oral transmucosal drug delivery describes gels, tabs, patches, sprays. It lacks in having not described a form by which large payloads (on the order of multiple grams) can be delivered systemically through the mucosa of the oral cavity. It has also not described anatomic delivery forms for oral application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the parts of the oral cavity (prior art).
FIG. 2 illustrates a three-dimensional anatomic form of the bilateral lingual vestibular space in accordance with an exemplary embodiment of the invention.
FIGS. 3A and 3B illustrate cross-sectional areas of a pharmaceutical dosage-form molded in a three-dimensional anatomic form of the bilateral lingual vestibules in accordance with an exemplary embodiment of the invention.
FIG. 4A through 4D illustrates handles and supportive substrates for use in bilateral lingual vestibular transmucosal pharmaceutical dosage-form and delivery systems in accordance with an exemplary embodiment of the invention.
FIG. 5A through 5C illustrates embedded supportive substrates in molded bilateral lingual vestibular transmucosal pharmaceutical dosage-form and delivery systems in accordance with an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Described herein is a transmucosal dosage-form for delivery to the oral cavity substances in a large payload, on the order of 5+ grams, in order to deliver therapeutic amounts of substances systemically. Substances may be, but are not limited to pharmaceuticals and other active agents. A transmucosal dosage-form for delivery of dextrose, thiamine, and naloxone (i.e. the “coma cocktail”), would allow for immediate administration by a health care worker upon encountering an unconscious patient without the delay of starting an IV. The problem is that there was previously no method of such a transmucosal dosage-form of any one of these drugs, much less all three in a dosage adequate to accommodate the amount of pharmaceutical payload necessary to deliver therapeutic amounts of these drugs systemically. Further, by the description herein, we describe a transmucosal dosage-form for delivery to the oral cavity of agents which may be used for delivery of dextrose for treatment of hypoglycemia without fear of aspiration.
A bilateral lingual vestibular mucoadhesive, transmucosal dosage-form and delivery system for pharmaceutical payload delivery can provide a quick, easy, and safe means of treatment, even in patients whose consciousness is questionable, with the capacity to deliver large pharmaceutical payloads. In one embodiment pharmaceutical payloads of 5 to 10 grams could be delivered by the system. A polymeric mucoadhesive carrier matrix, serving as one possible type of a supportive substrate, binds the pharmaceutical payload to the mucosal tissue in the lingual vestibules to overcome the displacing forces created by salivary flow in the area and combat the risk of treatment failure due to premature patient swallowing or patient aspiration. By using a general or anatomical shape, the dosage-form is also physically secured in the lingual vestibular region by the lingual frenulum and the tongue to hold it against the thin mucosa overlying the dense vasculature of the floor of the mouth and ventral tongue, preventing it from migrating. The retention of the dosage-form can be further enhanced by the addition of a handle, its purpose serving both to aid insertion and allowing for external control of the dosage-form position once placed. The pharmaceutical payload may be an active pharmaceutical agent, a medicament, and/or other active or passive substances.
In one embodiment, there is an embedded supportive substrate to which a pharmaceutical payload is molded or otherwise adhered. In such an embodiment the supportive substrate may be partially or substantially enclosed within the pharmaceutical payload. The pharmaceutical payload may be molded, formed, or otherwise shaped into either a general or a specific anatomical shape to fit the lingual vestibular space. In one embodiment, the shape is anatomical to fit the potential space formed by the bilateral lingual vestibules. In another embodiment the dosage-form payload is formed into a generally cylindrical or rectangular shape which is curved along the center so that the ends are substantially parallel forming a “U” like shape. In another embodiment, the dosage-form is shaped to fit a unilateral lingual vestibular space of either the left or right side. Such a dosage-form could be used alone, in pairs, or in conjunction with another dosage-form containing a different combination of active pharmaceuticals. One skilled in the art would appreciate that other forms could be utilized in accordance with the teachings herein.
In another embodiment the supportive substrate forms the structure of at least a generally anatomical shape designed in a manner to fit into the lingual vestibule. In such an embodiment the supportive substrate may be semi-permeable and impregnated with a pharmaceutical payload. As an alternative, in such an embodiment, the supportive substrate may be coated in a pharmaceutical payload. One skilled in the arts would appreciate other configurations for mating the pharmaceutical payload to the supportive substrate in a manner consistent with an exemplary embodiment of the invention.
A pharmaceutical dosage-form may be comprised of any active pharmaceutical agent which may be administered in a transmucosal manner. Many such pharmaceutical agents benefit from avoidance of the degradation, delay, and/or unpredictability of passing through the gastrointestinal track before finding its way into other of the body systems. Examples of such pharmaceutical agents include, but are not limited to: Dextrose, Thiamine, Naloxone, Alanine, Terbutaline, and Arginine.
A pharmaceutical dosage-form may further be comprised of agents that enhance the transmucosal transportation of an active agent (permeation enhancers). Examples of such permeation enhancers include, but are not limited to: bile salts such as sodium cholate, sodium glycocholate, sodium glycodeoxycholate, taurodeoxycholate, sodium deoxycholate, sodium lithocholate chenocholate, chenodexoycholate, ursocholate, ursodeoxy-cholate, hyodeoxycholate, dehydrocholate, glycochenocholate, taurochenocholate, taurochenodeoxycholate. Others include sodium dodecyl sulfate (“SDS”), dimethyl sulfoxide (“DMSO”), sodium lauryl sulfate, salts and other derivatives of saturated and unsaturated fatty acids, surfactants, bile salt analogs, derivatives of bile salts, capsaicin, histamine, or any other additives which may positively augment the transmucosal absorption of the active pharmaceutical payload. Once skilled in the art would appreciate that different permeation enhancers would be used depending on the active agents used in a particular dosage-form and a particular patient target.
A pharmaceutical dosage-form may further be comprised of components which aid in binding the payload to the mucosal tissue in an effort to avoid migration and maximize transmucosal transportation. These mucoadhesives or mucoretentive polymers or compounds may serve to form the supportive substrate of the dosage-form or may serve as a component of the substance payload itself. Such mucoadhesives may be natural, and/or synthetic in the form of polymers and/or reservoirs with tissue adhesives. Examples include, but are not limited to: chitosan, mucilage, hydrogel, sodium alginate, sodium carboxymethylcellulose, guar gum, xanthum gum, hydroxyethylcellulose, karya gum, methylcellulose, polyethylene glycol (PEG), retene, tragacanth, Poly(acrylic acid), Polycarbophil, carbopol, polyox, chitosan-cysteine, chitosan-thiobutylamidine, chitosan-thioglycolic acid, poly (acrylic acid)-cysteine, poly (acrylic acid)-cysteamine, carboxymethylcellulose-cysteine, alginate-cysteine, polaxamer. In an alternative embodiment, a plurality of active pharmaceutical agents, payload enhancers, and/or flavor enhancers may be combined in the dosage-form to act synergistically. One skilled in the art would appreciate that the composition of the dosage-form may contain various permutations of the above in varying percentages depending on the intended treatment, the targeted patient type, and the specific condition.
The preferred embodiment is a bilaterial lingual vestibular dosage-form and delivery system comprised of an anatomic three-dimensional matrix formed by the combination, in solutions, of a mucoadhesive compound, active substance/agent payload(s), and any additional modifying compounds such as permeation enhancers which is formed to the approximate anatomical shape of the bilateral lingual vestibules. The achievable payload allowed by fabricating a dosage-form and delivery system that targets the bilateral lingual vestibules can be as high as 5-10 grams in an average patient Further, fabricating the dosage-form in an anatomic shape of the lingual vestibule aids in maximizing the mucosal surface area engaged by active pharmaceutical agent thereby optimizing speed and amount of transmucosal payload transportation. The bilateral lingual vestibular delivery system may further comprise a fixed or detachable handle apparatus which could be used to place and secure the device in the oral cavity, specifically the lingual vestibule of a patient experiencing a hypoglycemic episode, particularly in a situation where altered conscious makes normal PO delivery unsafe due to the danger of aspiration; or where timing, lack of equipment, or lack of expertise makes the use of IV delivery unviable; and other methods would not yield delivery of a sufficient sized payload for transmucosal uptake into the systemic circulation.
Through an indirect impression technique, it is possible to model an anatomic negative representation of the bilateral lingual vestibules. This is best achieved through the proper use of an elastomeric impression material, such as a polyvinyl siloxane rubber base. This negative representation of the bilateral lingual vestibules is then used to create the reciprocal positive form which can be accomplished using a material, such as die stone, which has a working state that is fluid and a final, set state that is solid and stable. From this solid positive representation of the bilateral lingual vestibules, a mold, for subsequent dosage-form production, can then be fabricated using a material of choice. With this exact negative mold of the targeted lingual vestibule, an anatomic lingual vestibular dosage-form can be fabricated. In one embodiment, the dosage-form of the delivery system is comprised of an active pharmaceutical agent(s) and permeation enhancer(s) combined within a polymeric, mucoadhesive matrix which is produced in the form of the bilateral lingual vestibules via the fabrication processes enumerated above. Additionally, it is possible to commercialize an anatomically-shaped dosage-form by generalizing the dosage-form size in production so that the dosage-forms are subsequently applied to patients based on the patient's sex and/or size, and/or other physical attributes. Averages of the general anatomic curvatures of the bilateral lingual vestibules, obtained via the above enumerated impression procedures, can guide scaling of the dosage-forms in production to fit differing sized individuals. One skilled in the art would appreciate that such a shape may be approximated by several other methods which would suit the requirements embodied within this disclosure.
Employing an alternative embodiment, athletes having a need to obtain hydration, electrolytes, and carbohydrates during the episodes of intense and prolonged exertion may avoid the gastrointestinal uneasiness, queasiness, and vague central heaviness that accompany normal PO route carbohydrate loads. The ability to transport sufficiently larger payloads of dextrose, for instance, transmucosally in the oral cavity via a mucoadhesive delivery form/device allows for systemic effects without stimulating the unwanted gastrointestinal physiology. The primary payload (ie dextrose) could additionally be accompanied by adjunct constituents to maximize athletic performance (ie alanine, arginine, electrolytes, etc.)
As a matter of definition with respect to the descriptions within this document, the lingual vestibules are bordered: superiorly by the ventral surface of the tongue, laterally by the mucosa covering the mandible, inferiorly by the floor of the mouth, and medially by the root of the tongue posteriorly. Anteromedially, at the midline of the mouth, the right and left lingual vestibules are continuous. Posteriorly the lingual vestibule is bordered by the oropharynx.
Referring to FIG. 1 , one finds an illustration of the parts of the oral cavity ( 100 ) illustrated to aid one in understanding the descriptions given herein. Shown are the familiar parts of the mouth, specifically the lips ( 110 ), the teeth ( 120 ), and the tongue ( 130 ). The parts of the tongue ( 130 ) are the body of the tongue ( 131 ), the apex of the tongue ( 132 ), the dorsum of the tongue ( 133 ), the ventral of the tongue ( 134 ) and the deep lingual vasculature ( 137 ). One can clearly see that the body of the tongue ( 131 ) is rooted to the floor of the oral cavity by the lingual frenulum ( 140 ) between the sublingual papilla ( 150 ), in line with the apex of the tongue ( 132 ). Sublingual glands and a dense array of superficial vasculature (not illustrated) are covered by the sublingual mucosal covering ( 160 ).
FIG. 2 illustrates a three-dimensional anatomic form of the bilateral lingual vestibules in accordance with an exemplary embodiment of the invention. This three-dimensional anatomic mold of the lingular vestibular shape ( 200 ) has an anterior ( 210 ) and a posterior ( 220 ). The anatomical lingular vestibular mold's ( 200 ) shape is substantially mirrored along a midline plane which runs from the anterior ( 210 ) to the posterior ( 220 ) and extends from the superior ( 230 ) of the mold ( 200 ), which approximates the ventral surface of the tongue ( 134 ) to inferior ( 240 ), which approximates the floor of the mouth, where the sublingual mucosal covering ( 160 ) and sublingual papilla ( 150 ) are located. A left lingual vestibular flange ( 260 ) is shaped to occupy the space of the lingual vestibular region to the left of the lingual frenulum ( 140 ) and extending to the posterior of the oral cavity. A right lingual vestibular flange ( 250 ) is shaped to occupy the space of the lingual vestibular region to the right of the lingual frenulum ( 140 ) and extending to the posterior of the oral cavity. The left lingual vestibular flange ( 260 ) and the right lingual vestibular flange ( 250 ) are continuous at the midline on the anterior side ( 210 ) creating a void along the posterior ( 220 ). When the anatomical mold of the lingual vestibular shape ( 200 ) is placed in the oral cavity ( 100 ), the void will be occupied by the lingual frenulum ( 140 ) and the root of the tongue, and thus the mold will be held to the floor of the mouth by the body of the tongue ( 131 ), thus preventing slippage. Also illustrated is the location of the cross section ( 3 A, 3 B) from which FIGS. 3A and 3B were derived.
FIG. 3A illustrates a cross-sectional area of a bilateral lingual vestibular dosage-form molded in a three-dimensional anatomic form of the bilateral lingual vestibules in accordance with an exemplary embodiment of the invention. For reference, the superior/ventral tongue ( 230 ) and the inferior/floor of the mouth ( 240 ) are indicated. From the area shown, a cross section of the left lingual vestibular flange ( 260 ) is seen on the left of the figure, and a cross section of the right lingual vestibular flange ( 250 ) is seen on the right of the figure. The embodiment illustrated is constructed from a semi-permeable substrate structure ( 270 ), such as a mucoadhesive polymeric matrix, which is impregnated with a active substance/agent payload (not illustrated) which may be liquid, gaseous, or semi-solid in form. Such a payload would migrate from the supportive substrate ( 270 ) across the mucosal coverings into the vasculature and thus enter the patient's system.
FIG. 3B illustrates a cross-sectional area of a hollow supportive substrate filled with a pharmaceutical payload and mucoadhesive polymer formed in a three-dimensional anatomic form of the lingual vestibular space in accordance with an exemplary embodiment of the invention. One skilled in the arts would appreciate that a pharmaceutical payload which possesses mucoadhesive properties may not require the addition of mucoadhesive polymer to serve the same purpose. For reference, the superior/ventral tongue ( 230 ) and the inferior/floor of the mouth ( 240 ) positions are indicated. From the area shown, a cross-section of the left lingual vestibular flange ( 260 ) is seen on the left of the figure, and a cross-section of the right lingual vestibular flange ( 250 ) is seen on the right of the figure. The embodiment illustrated is constructed from a hollow supportive substrate ( 280 ) which contains a pharmaceutical payload ( 290 ) which may be solid, or semi-solid in form. Such a payload would dissolve, melt, or in some other manner break-down or degrade to release at least the active pharmaceutical agents across the mucosal coverings into the vasculature and thus enter the patient's system. In this embodiment the bottom of the supportive substrate ( 280 ) is shown as open to the sublingual mucosal covering ( 160 , not illustrated). In other embodiments the supportive substrate ( 280 ) may be more substantially closed with only minor openings to allow the pharmaceutical payload ( 290 ) to be released. In other embodiments the supportive substrate ( 280 ) may be open in other areas to direct the pharmaceutical payload to other parts of the oral cavity ( 110 ).
FIG. 4A illustrates a handle attached to a three-dimensional anatomic form of the lingual vestibular space in accordance with an exemplary embodiment of the invention. The handle ( 400 ) is attached to a pharmaceutical delivery form which is an anatomic representation of the potential space formed by the bilateral lingual vestibules ( 200 ). In this embodiment, the handle is a flat tab-like structure which is affixed by a clip or band connected to the anterior joint between the left and right lingual vestibular flanges ( 260 and 250 , not indicated)
FIG. 4B illustrates a handle connected to an embedded supportive substrate in a three-dimensional anatomic form of the lingual vestibular space in accordance with an exemplary embodiment of the invention. The handle ( 410 ) is attached to a pharmaceutical delivery form which is an anatomic representation of the potential space formed by the bilateral lingual vestibules ( 200 ). In this embodiment the handle ( 410 ) is a string or band-like structure which is attached to more string or band like material ( 420 ) which is embedded in a moldable pharmaceutical payload ( 450 ). The pharmaceutical payload ( 450 ) illustrated is a three-dimensional shape formed to the potential space of the bilateral lingual vestibular shape. Other shapes could be used to produce other embodiments.
FIG. 4C illustrates a supportive substrate with attached handle for use in a lingual vestibular pharmaceutical delivery system in accordance with an exemplary embodiment of the invention. In the embodiment shown, a handle ( 410 ) is a string or band-like material which is attached to a U shaped flexible rod ( 430 ) which forms an internal structural support for the pharmaceutical delivery system. In the embodiment shown the U-shaped flexible rod is formed from a sheet material which has been gathered and twisted. The material from the handle ( 410 ) has been tied to the approximate middle of the rod ( 430 ). The two ends of the rod ( 430 ) are then bent such that the first end and the distal end are approximately parallel to one another.
FIG. 4D illustrates a supportive substrate with attached handle for use in a lingual vestibular pharmaceutical delivery system in accordance with an exemplary embodiment of the invention. The molded supportive substrate ( 440 ) is formed from a substantially flat material formed into a “U” shape. The material may be further comprised of a surface texture which enhances the bonding of the pharmaceutical payload to the supportive substrate. The material has a plurality of openings ( 443 ) passing through the main body in several locations so that the formed pharmaceutical payload ( 290 , not illustrated) can be attached above and below and joined through the openings to secure it to the supportive substrate ( 440 ). A rounded ridge, bead, or lip ( 445 ) is formed at the edge of the body. This helps to further secure the pharmaceutical payload ( 290 , not illustrated) to the supportive substrate ( 440 ) and prevents sharp edges which may harm a patient's delicate oral tissue. A handle ( 400 ′) is formed form the same material as the supportive substrate and is angled to be offset from the main body such that the main body may be situated in the lingual vestibule of a patient, and the handle may protrude from the oral cavity through the mouth. In the illustration, the handle is joined to the base of the “U” shape so that it would project directly from the front of the face. One skilled in the art would appreciate that such a handle could be of varying shapes and attached in varying ways to the main body. Further a handle could be angled to project from the side of the mouth at varying angles and still be in accordance with the teaching herein.
FIG. 5A illustrates an embedded supportive substrate in a molded pharmaceutical payload system in a three-dimensional general form of the bilateral lingual vestibular space in accordance with an exemplary embodiment of the invention. Illustrated is a handle ( 400 ′) attached to a supportive substrate ( 440 , not visible) which is embedded in a moldable pharmaceutical payload ( 460 ). The pharmaceutical payload ( 460 ) in this embodiment has a general shape of a long cylinder which is curved near the middle into a general “U” shape to fit into the bilateral lingual vestibules.
FIG. 5B illustrates an embedded supportive substrate in a molded pharmaceutical payload system in a three-dimensional general form of the bilateral lingual vestibules in accordance with an exemplary embodiment of the invention. Illustrated is a handle ( 400 ′) attached to a supportive substrate ( 440 , not visible) which is embedded in an anatomically moldable pharmaceutical payload ( 470 ). The pharmaceutical payload ( 470 ) in this embodiment has a semi- anatomical shape to fit into the bilateral lingual vestibules. One skilled in the art would appreciate that a perfect fit or custom mold, while an option, is not absolutely necessary due to the pliable nature of the oral tissue. Therefore several general sizes could be used to fit patients with different characteristics.
FIG. 5C illustrates an embedded supportive substrate in a molded pharmaceutical payload system in a three-dimensional general form of the lingual vestibular space in accordance with an exemplary embodiment of the invention. Illustrated is a handle ( 410 ) formed from a string or band type material and attached to a supportive substrate ( 430 , not visible) which is embedded in a moldable pharmaceutical payload ( 460 ). The pharmaceutical payload ( 460 ) in this embodiment has a general shape of a long cylinder which is curved near the middle into a general “U” shape to fit into the lingual vestibule. One skilled in the art would appreciate that other shapes for the cross-sectional areas of the pharmaceutical payload ( 460 ) could be used in accordance with the teachings herein.
The diagrams in accordance with exemplary embodiments of the present invention are provided as examples and should not be construed to limit other embodiments within the scope of the invention. For instance, heights, widths, and thicknesses may not be to scale and should not be construed to limit the invention to the particular proportions illustrated. Additionally some elements illustrated in the singularity may actually be implemented in a plurality. Further, some element illustrated in the plurality could actually vary in count. Further, some elements illustrated in one form could actually vary in detail. Further yet, specific numerical data values (such as specific quantities, numbers, categories, etc.) or other specific information should be interpreted as illustrative for discussing exemplary embodiments. Such specific information is not provided to limit the invention.
The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A pharmaceutical delivery system enabling the oral transmucosal administration of active pharmaceutical agents in a situation where rapid transmucosal administration is preferred to prevent the delay and decomposition of the agents in passing through the intestinal tract. The delivery system comprises a supportive substrate with bilateral lingual vestibular flanges connected at the anterior midline to form a ‘U’ like shape for fitting in the potential space of the bilateral lingual vestibules, and further comprising a handle or tab for holding the device in the mouth of a patient with altered consciousness to prevent aspiration or premature swallowing. The pharmaceutical dosage-form is formulated and shaped to contact the mucosal tissues and may include mucoadhesive compounds, retentive compounds, and/or additional payload enhancers, such as permeation enhancers and flavor enhancers.
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BACKGROUND OF THE INVENTION
This invention generally relates to a fusing apparatus and, more particularly, to a machine for fusing the armature wires of an electric motor to a tang or slot of a commutator bar and for fusing wires to stator hooks.
Although fusing machines are widely known, more precise, efficient and economical machines are greatly needed. Existing methods for the mechanical manipulation and control of a fusing electrode as related to both armature tang fusing and stator terminal fusing include pneumatically driven slides as well as ball screw driven slides controlled by a servo motor. Pneumatics have proven to be functional but include inherent deficiencies. They are not easily adjusted for fine tuning of the fusing forces. A pressure regulator may be adjusted, which will increase or decrease the fusing force, but does not give the user an actual reading of the forces since the driving cylinder output force is not directly obtainable from the regulator gauge. Alternatively, the tension on a spring results in a non-precision change in the fusing forces.
The use of servo motors to regulate the fusing forces as shown in U.S. Pat. No. 5,063,279 to Axis USA, Inc. has also proven to be inefficient. Servo motors are excellent devices for fast, accurate positioning but they are not designed to be torque limiters. Even with external force feedback gauges it is very difficult, if not impossible, to design a control system fast enough to react to a rapidly changing force curve relating the position of a ball screw driven by a servo motor to a known, constant fusing force. Another limiting factor with a servo motor is cost. Servo systems are both expensive and costly to maintain in severe applications.
One difficulty in regulating the fusing operation is in detecting that the electrode has contacted the tang. It has been proposed to use a load cell for this purpose but the force of the tang against the electrode is so small compared to the weight of the fusing head that it is very difficult to sense tang contact with a load cell. Therefore, a need exists for an improved fusing apparatus that eliminates the problems associated with previous fusing machines, produces uniform connections, and provides for an easy, quick-change of the electrode.
SUMMARY OF THE INVENTION
The present invention is a fusing apparatus for making terminal or commutator wire connections on an armature or stator which eliminates or alleviates the problems associated with prior fusing apparatus and produces uniform connections. The fusing machine is effective to deform the tang around the wire, remove insulation from the wire, and compress the tang around the wire such that a cohesive low resistance bond is formed. In accordance with the invention, the fusing cycle is initiated by detecting a low level trigger current between the electrode and the workpiece.
In the present invention an armature is held by a spindle which is effective to rotate the armature such that tangs or slots are aligned under an electrode. A pneumatic cylinder actuates a rod connected to a fusing head. Actuation of the cylinder causes the fusing head and electrode to move into contact with the tang or slot. A low electrical potential is applied to the electrode such that upon contacting the tang with the electrode, a trigger current is generated. A fusing cycle is initiated when the trigger current is detected. The fusing cycle includes a delay (or "squeeze") during which the welding or fusing current is not initiated but the electrode continues to engage the tang and begin cold forming the tang around the wire. Following the squeeze, the welding current is gradually increased and the pressure on the electrode is regulated. As the welding current increases, the insulation burns off the wire. At this stage, the tang preferably has not closed around the wire. During the balance of the cycle, the tang is closed, the welding current increased, and the wire and tang are fused. While the term "welding current" is used herein, those skilled in the art will appreciate that in the principal embodiment of the invention the workpieces are not actually welded but rather they are merely fused.
Accordingly, it is an object of the present invention to provide a fusing machine for making terminal or commutator wire connections on an armature or stator that insures precise and accurate positioning of the electrode before initiating the fusing cycle.
These and other features and advantageous of the present invention will be better understood by reference to the following detailed description, the accompanying drawings and the appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a fusing apparatus of the present invention;
FIG. 2 is a side view of the fusing apparatus of FIG. 1;
FIG. 3 is a schematic diagram of an embodiment for generating and detecting a trigger current in accordance with the invention.
FIG. 4 is a schematic cross-sectional view of an electrode contacting the tang on a commutator bar.
DETAILED DESCRIPTION
A fusing apparatus, generally designated 10 of the present invention is shown in FIGS. 1 and 2. The fusing apparatus 10 is used to make terminal or commutator wire connection on an armature 12 or stator (not shown). While the invention is illustrated for making connections to an armature, those skilled in the art will appreciate that it is useful in making similar electrical connections to a stator or other electrical device. A winding machine is used to wind the armature 12 and connect the wire 19 (FIG. 4) into an open tang 16 of commutator bar 17 or slot in a known manner. The fusing apparatus 10 is effective to deform the tang 16 around the wire 19 and compress the tang such that a cohesive low-resistance bond is formed.
The armature 12 is held by a spindle at one end and is supported in a cradle 20 on the opposite end. The spindle is connected to a servo motor 18 which is effective to rotate the armature 12, such that the tangs 16 are sequentially aligned under the electrode 22.
The fusing apparatus 10 includes a support structure 24 to which a cylinder 26 is mounted with its top portion in alignment with the electrode 22. The cylinder 26 is preferably a conventional 3-position pneumatic cylinder having, in one embodiment, a 4 inch and a 31/4 inch stroke. The cylinder 26 has a cylinder rod 28 extending from the cylinder in the direction of the electrode 22. Located at the end of the cylinder rod 28 is a floating coupling 30 which connects the cylinder rod 28 to the fusing head 34. Connected to the bottom of fusing head 34 is an electrode holder 36. Ground electrode 54 contacts the workpiece, e.g., a commutator bar, to complete a secondary circuit when the electrode contacts the workpiece. A ground electrode cylinder 55 is provided to pivot the ground electrode into and out of contact with the workpiece.
The support structure 24 includes precision linear bearings 38, 40, on which journals 42, 44 positioned on the fusing head may slide. The fusing head 34 is driven upwardly and downwardly on the bearings by the cylinder 26.
A proportional regulator 50 is provided on cylinder 26 to regulate the force applied by the electrode to the tang during the fusing step. Depending on the workpiece, as the tang and wire are heated during the fusing step, less force may be required to deform the tang. If the force on the tang is not reduced, the resistance decreases and more current passes through the workpiece, rather than creating heat, the workpiece heats less and the tang may not be adequately fused. During the fusing step, the proportional regulator 50 can be actuated to reduce the force on the cylinder side of the piston.
For some workpieces, it may be desirable to increase the force of the electrode on the piece after the squeeze. For example, in some cases if the electrode strikes the tang with a large initial force, the tang may close too quickly about the wire before the insulation can be removed and a poor contact may be formed. By striking the tang with a low initial force and increasing the force later in the cycle after the squeeze, a cleaner contact can be provided.
In another embodiment, a pair of proportional regulators may be provided, one on each side of the piston, to effect the pressure adjustments desired during the fusing cycle.
Typically the electrode 22 will have to be changed several times during an operating shift. To change the electrode, the rod 28 is withdrawn through its entire 4 inch stroke to permit access to the electrode. The quick change feature described in copending application Ser. No. 07/949,383, filed Sep. 22, 1992, may be used.
In accordance with one embodiment of the invention, the trigger current is generated by a welding control apparatus. Welding control apparatus are known in the art. One example of such apparatus is a Tru-Amp III Welding Control and Current Monitor and is commercially available from Atek Corp. and is manufactured under U.S. Pat. No. 4,721,906. Typically, welder controls with current monitors control current level responsive to a current signal generated across an air core toroid coil which surrounds a portion of the secondary circuit. The current level is controlled using a high current silicon controlled rectifier switch (SCR). In accordance with the invention, as the electrode approaches the workpiece, the SCR is activated to provide low level detection current in the secondary circuit when the electrode initially contacts the workpiece. When this current is detected in the toroid, a signal is generated which starts the weld cycle.
FIG. 3 depicts a schematic diagram of an embodiment of the present invention used with a single phase resistance welder, an air core toroid coil, which embodies the teachings of the present invention. The single phase resistance welder 60 is provided with electric power by a pair of power lines 62. A transformer 64 steps down the power line voltage and increases the electrode current which is provided to secondary circuit 66 and electrodes 68 which heat workpieces 80. The power line voltage provided to transformer 64 is controlled by SCR switch 82, drive 84 and welder control 86. Power lines 62, transformer 64 and SCR switch 82 comprise a primary circuit. An air core toroid coil 90 (also known as a Rogowski coil or belt) surrounds a portion of secondary circuit 66 and may be located at any point in secondary circuit 66. The electrode current typically has a fixed current frequency and a fixed current period. The changes in the electrode current passing through secondary circuit 66 induces an electro-magnetic force (EMF) within the toroid of air core toroid coil 90. This EMF causes a differential current signal to be generated by the coil of air core toroid coil 90 which is proportional to the rate of change of the magnetic field induced by the electrode current flowing in secondary circuit 66. Alternatively, other devices which produce a current signal can be used instead of an air core toroid coil.
The signal from the air core toroid coil 30 is fed through lines 92 and 94 to the input of processor 100. A power supply 102 supports the operation of microprocessor 100. Microprocessor 100 interfaces with the control welder controller 86 in an otherwise conventional manner except that in accordance with the invention, initiation of the fuse cycle is triggered by and timed with respect to the detection of the trigger current in the toroid.
Those skilled in the art will recognize that a variety of circuits can be used to generate and detect the trigger current. For example, a separate circuit can be established around the electrode and workpiece with its own power supply. When the fuse cycle is initiated, a relay is activated to isolate the trigger circuit from the weld current. When the cycle is complete, the relay is switched to initiate the next cycle.
The operation of the fusing apparatus preferably proceeds as follows: The 3-position cylinder advances the fusing head 34 through a 31/4 inch stroke. From this point on, all fusing head movement will be within the 3/4 inch distance representing the difference between the 4 inch and the 31/4 inch strokes of the cylinder until it is desired to change the electrode whereupon the fusing head will be withdrawn through the entire 4 inch stroke.
The proportional regulator(s) are set to provide the cold forming force required to deform the workpiece. For example, a pre-set pressure of 25 psi might correspond to a cold forming force of 45 pounds.
As the fusing head 34 and the electrode 22 are advanced by cylinder 26 through the 3/4 inch stroke, the SCR is periodically fired (e.g., each half-cycle or 16 milliseconds). Once the electrode 22 contacts the workpiece 16, the secondary circuit 66 is completed and a trigger current is detected by microprocessor 100 in toroid 90. A suitable trigger current is about 100 to 500 amps and can be established by firing the SCR at an appropriate firing angle based upon the transformer tap setting.
Once the trigger current is detected, the fusing cycle is initiated. A typical cycle begins with a squeeze during which the electrode 22 continues to move toward the workpiece and cold form it. The squeeze may run about 16 to 48 milliseconds. Thereafter, the fusing current is initiated through an upslope. An upslope is used so as not to hit the workpiece with too much current before there is good contact between the workpiece and the electrode. A suitable upslope might run from 16-64 milliseconds and increase current in proportional increments until full program current is reached.
Preferably, when fusing a wire to the tang or armature slot, as the fusing current is increased the insulation burns off the wire. This process is coordinated using the proportional regulator(s) with the advance of the electrode and the deformation of the tang such that the insulation is removed before the tang is formed around the wire. In this way, clean uniform connections are made.
Simultaneously with the detection of the trigger current or at such later time as may be desired, the proportional regulators are typically adjusted to reduce the force of the electrode against the tang. At the point where the weld begins, all the necessary cold-forming of the tang has taken place and less force is needed to complete the weld, therefore, as the weld begins, the regulators are actuated to relieve a portion of the force being applied by the cylinder.
When the fusing cycle is complete, the electrode is retracted only a sufficient distance to allow the spindle to position another tang or slot beneath the electrode. The process is then repeated for the remainder of the workpiece.
While the invention has been described with reference to a fusing operation, those skilled in the art will appreciate that the generation of a trigger current within a secondary circuit as described herein to control the start of a fusing operation also has application to welding operations. Hence, welding control and monitoring equipment such as the Atek unit referenced above can be modified to provide for the generation of and detection of a trigger current and used in any fusing or welding operation.
The preceding description has been presented with reference to a presently preferred embodiment to the invention shown in the drawings. Workers skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structure can be practiced without departing from the spirit, principles and scope of this invention.
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An apparatus for fusing a workpiece including at least two electrically conductive elements comprising:
an electrode;
means for moving the electrode into contact with said workpiece causing said electrode to contact and apply a force to said workpiece;
means for generating a trigger current upon contacting said workpiece with said electrode;
means for detecting said trigger current and initiating a welding current which fuses said elements;
and means for generating said welding current.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/839,779, filed Apr. 20, 2001, now U.S. Pat. No. 7,514,067, which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/199,350, filed Apr. 25, 2000. The entire teachings of each of these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Monoclonal antibodies (MAb), by virtue of their unique in-vitro specificity and high affinity for their antigen, have generally been considered particularly attractive as selective carriers of cancer radiodiagnostic/therapeutic agents. Several reasons underlie these expectations: (i) they show a high degree of specificity and affinity for their intended target; (ii) they are generally nontoxic; and (iii) they can transport such agents. The application of MAb in animals and humans for both tumor scintigraphic detection (labeled with 123 I, 131 I, 93m Tc, and 111 In) and therapy (labeled with the beta emitters 131 I, 186 Re, 90 Y, 165 Dy, 67 Cu, and 109 Pd; the alpha emitters 211 At, 212 Bi, and 213 Bi; or conjugated to various toxins and cytotoxic drugs) is the focus of work in many research laboratories.
In pursuing these studies, the basic assumption continues to be that MAb have a role in the radioimmunodiagnosis and radioimmunotherapy of cancer. However, while most published work on this subject has demonstrated their utility in the diagnosis and treatment of various tumors in experimental animal models, the use of radiolabeled MAb to target and treat solid tumors in cancer patients has been for the most part unsuccessful. There are at least five reasons for the results seen in humans:
1. Low tumor uptake. Thus far, most studies in humans have demonstrated that the percentage injected dose per gram of tumor (% ID/g) is extremely low. As a result, the absolute amount of the therapeutic radionuclide within the tumor is much less than that needed to deposit a radiation dose sufficiently high to sterilize the tumor.
2. High activity in the whole body. A corollary to low tumor uptake is the presence of ˜90%-99% of the injected radiolabeled MAb in the rest of the body. This has led to the deposition of high doses in normal tissues and unacceptable side effects, and a reduction in the maximum tolerated dose (MTD).
3. Slow blood clearance. In most human radioimmunotherapy trials, whole MAb (MW˜150,000 Da) have been used. The clearance of such high-molecular-weight proteins from blood and nontargeted tissues is rather slow. The resulting systemic exposure to the radioisotope thus produces high doses to the bone marrow and a lowering of the MTD.
4. Limited intratumoral diffusion. The high molecular weight of MAb also limits their ability to extravasate and diffuse through the tumor mass. As a consequence, many areas within the tumor are spared from receiving a lethal dose of radiation (i.e., the areas are either outside the range of the emitted particle or receive a sublethal dose).
5. Heterogeneity of tumor-associated antigen expression. Many studies have demonstrated that a substantial proportion of the cells within a tumor mass show reduced/no expression of the targeted antigen. This also will lead to nonuniform distribution of the radionuclide within the tumor mass and the sparing of a large number of cells within the tumor.
In an attempt to bypass some of the limitations of these unique molecules, various two-step and three-step approaches have been theorized, in which a noninternalizing antitumor antibody is injected prior to the administration of a low-molecular-weight therapeutic molecule that has an affinity/reactivity with the preinjected antibody molecule. These systems can be categorized into two major classes: MAb-directed enzyme prodrug therapy and MAb-directed radioligand targeting, details of which are known in the art.
It is clear that under ideal conditions, a radiolabeled therapeutic agent must meet the following requirements: (i) be labeled with an energetic particle emitter, (ii) be taken up rapidly and efficiently by the tumor, (iii) be retained by the tumor (i.e. very long effective clearance half-life), (iv) have a short residence within normal tissues (i.e., short effective half-life in blood, bone marrow, and whole body), (v) achieve high tumor-to-normal tissue uptake ratios, (vi) attain an intratumoral distribution that is sufficiently uniform to match the range of the emitted particles (i.e. all tumor cells are within the range of the emitted particles), and (vii) achieve an intratumoral concentration that is sufficiently high to deposit a tumoricidal dose in every cell that is within the range of the emitted particle.
SUMMARY OF THE INVENTION
The present invention relates to a method for the enzyme-mediated, site-specific, in-vivo precipitation of a water soluble molecule in an animal. The enzyme is either unique to tumor cells (i.e. only produced by tumor cells), or is produced within the specific site (e.g., tumor) at concentrations that are higher than that in normal tissues. Alternatively, the enzyme is conjugated to a targeting moiety such as an antibody. For example, an antibody-enzyme conjugate is injected into tumor bearing animals and following tumor targeting and clearance from normal tissues and organs, the water soluble substrate is injected. Owing to the negatively charged prosthetic group (e.g. phosphate) present within its molecules, the substrate is highly hydrophilic, is not internalized by mammalian cells, and should clear from circulation at a rate that is compatible with its physical characteristics (e.g. molecular weight, charge). However, being a substrate for the enzyme (pre-targeted or otherwise), this water soluble molecule loses the prosthetic group and the resulting molecule precipitates out due to its highly water-insoluble nature. The precipitated molecule is thus “indefinitely trapped” within the targeted tissue. In one of its aspects (Enzymatic Radiolabel Insolubilization Therapy, ERIT), the substrate is radiolabeled with a gamma or a positron emitting radionuclide and as such, the location of the precipitate can be detected by external imaging means (SPECT/PET). On the other hand, when the radionuclide is an alpha or a beta particle emitter, the trapped precipitated radioactive molecule will maintain the radionuclide within the targeted tumor thereby enhancing its residence time and delivering a high radiation dose specifically to the tumor relative to the rest of the body. In yet another aspect (Enzymatic Boron Insolubilization Therapy, EBIT), the substrate is conjugated to one/more boron-containing molecule and upon precipitation within its intended target, the tumor is subjected to epithermal neutrons with the subsequent alpha particle emissions (Boron Capture Therapy).
In its simplest form, therefore, the present invention is based on the conversion of a chemical (e.g. quinazolinones, benzoxazoles, benzimidazoles, benzothiazoles, indoles, and derivatives thereof) from a freely water-soluble form to a highly water-insoluble form and hence in vivo precipitation at the specific site where an enzyme (e.g. acetylglucosaminidases, acetylneuraminidases, aldolases, amidotranferases, arabinopayranosidases, carboxykinases, cellulases, deaminases, decarboxylases, dehydratases, dehydrogenase, DNAses, endonucleases, epimerases, esterases, exonucleases, fucosidases, galactosidases, glucokinases, glucosidases, glutaminases, glutathionases, guanidinobenzodases, glucoronidases, hexokinases, iduronidases, kinases, lactases, mannosidases, nitrophenylphosphatases, peptidases, peroxidases, phosphatases, phosphotransferases, proteases, reductases, RNAses, sulfatases, telomerases, transaminases, transcarbamylases, transferases, xylosidases, uricases, urokinasess) or any other species capable of carrying out such a conversion in high concentrations. Pretargeting of enzyme or its equivalent species may be achieved by making use of specific antibodies or any such specific receptor-binding ligand to the desired sites in vivo. Note that the ligand may also be a peptide or hormone, with the receptor specific to the peptide or hormone.
Alternatively, the enzyme may be produced within the tumor site by the tumor cells themselves or following gene therapy or similar means. The chemical to be injected in the second step contains any nuclide suitable for imaging and/or therapy (e.g. Boron-10, Carbon-11, Nitrogen 13, Oxygen-15, Fluorine-18, Phosphorous-32, Phosphorous-33, Technetium-99m, Indium-111, Yttrium-90, Iodine-123, Iodine-124, Iodine-131, Astatine-211, Bismuth-212, etc.).
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate preferred embodiments of the invention as well as other information pertinent to the disclosure, in which:
FIG. 1 is a graph of a time-course conversion of 1 (or Compound A) to 2 (or Compound B) following incubation in alkaline phosphatase;
FIG. 2 is an illustration of the conversion of 125 I-1 ( 125 I-labeled Compound A) to 125 I-2 ( 125 I-labeled Compound B) following incubation with ALP.
FIG. 3 is a graph of radioactivity following i.v. injection of 125 I-1 into mice.
FIG. 4 is an illustration of the biodistribution of 125 I-1 in normal mice.
FIG. 5 is an illustration of the biodistribution of 125 I-2 in normal mice.
FIG. 6 is a graph of the accumulation of radioactivity within forelimbs of mice after subcutaneous (s.c.) injection of alkaline phosphatase followed by i.v. injection of 125 I-2.
FIG. 7 is a graph depicting the retention of radioactivity within a forelimb of mice injected s.c. with 125 I-1 or 125 I-2.
FIG. 8 is an illustration of the biodistribution (24 hours) of s.c.-injected 125 I-2 in normal mice.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention describes a novel approach that serves to localize water-insoluble, radioactive molecules within the extracellular (interstitial) space of a tumor. In one embodiment of this invention, a noninternalizing monoclonal antibody (MAb) to a “tumor-specific” antigen is chemically conjugated to the enzyme alkaline phosphatase (ALP); the MAb-ALP conjugate is administered intravenously (i.v.) to tumor-bearing animals, and after MAb-ALP tumor localization and clearance from circulation (high tumor to normal tissue ratios), a water-soluble, radiolabeled prodrug (PD) that is a substrate for ALP is injected intravenously. The conjugate or prodrug may also be injected intra-arterially, subcutaneously, into the lymphatic circulation, intraperitoneally, intrathecally, intratumorally, intravesically, or is given orally.
The prodrug substrate is represented by the following formula:
R 1 -D-(O-BLOCK)
wherein BLOCK is a blocking group that can be cleaved from the remainder of the substrate by action of an enzyme, resulting in a water-insoluble drug molecule represented by the following formula:
R 1 -D-O—H
wherein D contains a minimum of 2 linked aromatic rings, and R 1 is a radioactive atom, a molecule labeled with one or more radioactive atom(s), a boron atom, or a molecule labeled with one or more boron atoms.
The radiolabel is selected from the group consisting of a gamma emitting radionuclide suitable for gamma camera imaging, a positron emitting radionuclide suitable for positron emission tomography, and an alpha or a beta particle emitting radionuclide suitable for therapy. The alpha particle emitting radionuclide may be, e.g., astatine-211, bismuth-212, or bismuth-213. The beta particle emitting radionuclide emits beta particles whose energies are greater than about 1 keV. The beta particle emitting radionuclide may be, e.g., iodine-131, copper-67, samarium-153, gold-198, palladium-109, rhenium-186, rhenium-188, dysprosium-165, strontium-89, phosphorous-32, phosphorous-33, or yttrium-90. Note also that the boron atom is suitable for neutron activation.
The BLOCK is selected from the group consisting of:
a monovalent blocking group derivable by removal of one hydroxyl from a phosphoric acid group, a sulfuric acid group, or a biologically compatible salt thereof;
a monovalent blocking group derivable by removal of a hydroxyl from an alcohol or an aliphatic carboxyl, an aromatic carboxyl, an amino acid carboxyl, or a peptide carboxyl; and a monovalent moiety derived by the removal of the anomeric hydroxyl group from a mono- or polysaccharide.
As the PD molecules percolate through the tumor mass, they will be hydrolyzed by the ALP molecules present within the tumor (MAb-ALP). The hydrolysis of PD (Compound 1, or Compound A below) leads to the formation of a water-insoluble, radiolabeled precipitate (D). It is anticipated that D (Compound 2, or Compound B below), as a consequence of its physical properties, will be trapped within the extracellular space of the tumor mass. Thus, when labeled with iodine-131 ( 131 I), a radionuclide that decays by the emission of both a beta particle (E max =610 keV; mean range=467 μm; maximum range=2.4 mm) and photons suitable for external imaging, the entrapped 131 I-labeled D molecules will serve as a means for both assessing tumor-associated radioactivity (planar/SPECT) and delivering a protracted and effective therapeutic dose to the tumor.
Enzymatic hydrolysis of radiolabeled quinzalinone prodrugs
R 1 = 123 I, 125 I, 131 I, 77 Br, 211 At etc and R 2 =H
R 1 =H and R 2 = 123 I, 125 I, 131 I, 77 Br, 211 At etc
R 1 , R 2 =Boron cage and/or H
R 3 =phosphate, sulphate, galactosyl, etc.
Radiolabeled 2-(2′-hydroxyphenyl)-4-(3H)-quinazolinone dyes are employed in the method of the present invention: These classes of compounds contain a hydroxyl group that forms an intramolecular six-membered stable hydrogen bond with the ring nitrogen and hence they are highly water-insoluble in nature. However, addition of a prosthetic group (e.g. phosphate, sulfate, sugars such as galactose or peptide) on the hydroxy group renders the molecule freely water-soluble. Furthermore, the presence of such prosthetic groups makes cell-membranes impermeable to these molecules; they are anticipated to have relatively short biological half-lives in the blood. However, when acted on by the enzyme, the prosthetic group is lost, resulting in the restoration of intramolecular hydrogen bonding, and the molecule becomes water-insoluble and precipitates.
The procedure for the synthesis of the unsubstituted quinazolinone dye (1, below), is as follows:
Synthesis of 2-(2′hydroxyphenyl)-4-(3H)-quinazolone
1.3 g anthranilamide (3) and 1.2 g salicylaldehyde (4) were refluxed in methanol. Within 30 minutes, a thick orange precipitate of the Schiff-base (5) was formed. The reaction mixture was cooled in a refrigerator and the product filtered and washed with cold methanol. The precipitate (about 1.5 g) was then suspended in 20 ml ethanol containing p-toluene sulfonic acid and refluxed for 1 hour. The progress of reaction was followed by TLC. The off-white precipitate of dihydroquinazolinone (6) was filtered off and washed thoroughly with cold ethanol. It was then suspended in 12 ml methanol containing 0.6 g dichloro-dicyanobenzoquinone and heated under reflux for 1 hour. The quinazolinone dye product (2) was isolated after cooling the reaction mixture and subsequent filtration. The pale yellow chemical was suspended in diethyl ether and stirred, filtered and washed with ether. To 100 mg of the quinazolinone dye (2) in 1 ml of dry pyridine under nitrogen in an ice bath was added 65 mg (40 μl) of POCl 3 through a syringe. After stirring at this temperature for 30 minutes, it was neutralized by the addition of 116 μl of 30% ammonia. The crude product (1) was evaporated to dryness in rotary evaporator and was partitioned between ethyl acetate and water, the organic layer re-extracted with water, and the combined aqueous extract was back extracted with ethyl acetate. Finally, the product was loaded on to a DEAE Sephacel column (10 ml) pre-equilibrated in bicarbonate form. The column was washed with 20 ml water followed by a stepwise gradient of triethyl ammonium bicarbonate buffer (pH 7.0, 0.1 M to 0.5 M, 25 ml each). Appropriate fluorescent fractions were pooled and lyophilized to dryness (yield 55%). All chemicals were characterized by NMR and elemental analysis.
In order to make use of the above chemistry for the synthesis of radiolabeled quinazolinones, halogen substituted anthranilamides that are easily converted to the tin precursors needed for the exchange labeling with radiohalogens were used. Thus, for the synthesis of 5-haloanthranilamides (9) from 5-haloanthranillic acids (7), isatoic anhydrides were used, as shown below.
Synthesis of 5-halo-anthranilamides from 5-halo-anthranilic acids
Such anhydrides are known to react with amines to furnish anthranilamides under certain controlled conditions. Since phosgene gas is not available, reaction conditions were employed using triphosgene which is a solid. 5-Halo-anthranilic acid (bromo- or iodo-) was stirred with equimolar amounts of triphosgene in dry THF at ambient temperature for 1-2 hours. The solution was filtered and diluted with hexane until it became turbid and then stored at −20° C. overnight. The precipitated anhydride (8) was filtered and washed copiously with hexane THF mixture and dried (yield ˜60%). The anhydride (dissolved in THF) was stirred in 1 M aqueous solution of ammonia (containing 1:1 THF) at ambient temperature for 25 minutes. Finally, the organic layer was evaporated under nitrogen and the product (9) was filtered and washed copiously with water followed by acetonitrile and dried in vacuo (yield ˜75%).
2-Amino-5-iodobenzoic acid (10) and triphosgene were then dissolved in dry THF and the reaction mixture stirred at room temperature for 1 hour. An off-white precipitate formed and TLC showed that compound 10 is consumed, as shown below. The precipitate was filtered, washed with cold methanol, and crystallized in acetonitrile. 1 H NMR indicated that the spectrum was an iodoisotoic anhydride (11).
Synthesis of non-radioactive ( 127 I) prodrug (15)
A solution of iodoisotoic anhydride (11) was then suspended in THF and cooled in an ice-bath. Aqueous ammonium hydroxide was added dropwise, the reaction mixture was stirred for 15 minutes at 0° C. and 30 minutes at RT, and the solvent was evaporated. The white solid obtained was characterized by 1 H NMR and identified as an iodoanthranilamide (12).
Next, Iodoanthranilamide (12) and salicylaldehyde were suspended in methanol and refluxed in the presence of catalytic amounts of p-toluene sulfonic acid (TsOH) for 30 minutes. To the pale-yellow precipitate (13) formed, 2,3-dichloro-5,6-dicyano-1,4-benzoquinone was added and the suspension was refluxed for 1 hour. The solid product was filtered, washed with cold methanol, characterized by 1 H NMR, and identified as 2-(2′-Hydroxyphenyl)-6-iodo-4-(3H)-quinazolinone.
Synthesis of Ammonium 2-(2′-Phosphoryloxyphenyl)-6-iodo-4-(3H)-quinazolinone (15).
In one method, 2-(2′-Hydroxy)-6-iodo-4-(3H)-quinazolinone (14) was added to dried pyridine at 0° C., followed by phosphorus oxychloride. Silica gel TLC indicated that the reaction was completed within 2 min. The reaction solution was neutralized to pH 7.0 by the addition of ammonium hydroxide. The solvent was evaporated and the solid product was suspended in water, filtered, and purified by chromatography. Following elution (stepwise gradient: water followed by acetonitrile-water, 2:1), a yellow solution containing UV-visible product was collected, the solvent was evaporated, and the product was characterized by 1 H and 31 P NMR and identified as compound 15.
In an alternative method, ammonium 2-(2′-phosphoryloxyphenyl)-6-tributylstannyl-4-(3H)-quinazolinone (17) was dissolved in methanol, and sodium iodide was added followed by hydrogen peroxide. A yellow precipitate formed immediately. The reaction vial was vortex-mixed and incubated for 30 minutes at 37° C. Reversed-phase silica gel TLC showed approximately 50% conversion (solvent: acetonitrile-water, 1:1). The solvent was evaporated and the product purified by chromatography. TLC (solvent: chloroform-methanol, 1:1) showed the same R f value (0.6), and proton and 31 P NMR gave the same spectra as were obtained with the known compound 15 synthesized by the route shown above.
Synthesis of compounds 18 and 15 by iododestannylation
Next, to a dioxane solution containing 14, hexa-n-butylditin and tetrakis (triphenylphosphine) palladium were added, as shown above. The reaction mixture was refluxed for 1.5 hours and progress of the reaction was followed by silica gel TLC (solvent: methylene chloride-ethyl acetate, 9:1) to test for the formation of a more nonpolar product. The solvent was evaporated, and the crude yellow solid was purified on a silica gel column (stepwise gradient: starting with hexane followed by hexane-dichloromethane, 1:1). Following solvent evaporation, a yellow fluorescent solid 2-(2′-Hydroxy)-6-tributylstannyl-4-(3H)-quinazolinone 16 was obtained as identified by 1 H NMR.
Next, to a stirred solution of 16 in dry pyridine cooled to 0° C., phosphorus oxychloride was added dropwise. The reaction mixture was stirred for 10 min at 0° C. and then quenched by the addition of ammonium hydroxide (Scheme 5). The solvent was evaporated, the crude product redissolved in methanol-acetate (1:1) and purified on a C 18 column (stepwise gradient: water followed by acetonitrile-water going from 30% to 50% acetonitrile). The solvent was evaporated and the nonfluorescent solid Ammonium 2-(2′-Phosphoryloxyphenyl) 6-tributylstannyl-4-(3H)-quinazolinone 17 was obtained as identified by 31 P NMR.
Next, three Iodo-beads were placed in a reaction vial, followed by 20 μl of 1 μg/μl solution of 17, 30 μl 0.1 M borate buffer (pH=8.3), and Na 125 I (800 μCi/8 μl of 0.1 M sodium hydroxide). After 20 minutes at room temperature, the crude reaction mixture was loaded on a Sep-Pak Plus C 18 cartridge and eluted with 1 ml water and then 2 ml 10% acetonitrile in water. The product 18 was eluted with 20% acetonitrile in water (yield: ˜370 μCi; radiochemical yield: 46%). The radiolabeled product, co-spotted with nonradioactive compound 15 on reversed-phase TLC, showed a single spot on autoradiograph (solvent: acetonitrile-water, 1.5:2). Radiolabeled ( 151 I) Ammonium 2-(2′-Phosphoryloxyphenyl)-6-iodo-4-(3H)-quinazolinone 18 co-injected with 15 into the HPLC showed a single radioactive peak (R f =14 min) which matched the R f value of 15.
X-Gal (5-bromo-4-chloro-3-indolyl β-D-galactose) is routinely used for the identification of lac + bacterial colonies. The underlying principle is that the colorless X-gal which is freely water-soluble is converted to dark blue colored precipitate upon reaction with b-galactosidase enzyme.
Enzymatic Hydrolysis of X-Gal Type Prodrugs
In accordance with the present invention, a bromine atom within X-gal is replaced with a diagnostic/therapeutic nuclide (e.g. Iodine-131, boron-10). For example, an antibody-β-galactosidase immunoconjugate will be administered in the first step. Following its clearance, the water soluble nuclide-labeled X-gal (10) will be injected where at the sites of enzyme action, the X-gal substrate will loose the sugar moiety and the resulting aglycon (11) will precipitate within the targeted tissue. In another embodiment, prosthetic groups other than galactosyl (e.g. phosphate, sulfate, carbonate) as well as nuclides other than iodine-131 and boron-10 may be used.
When the prodrug ((1) or Compound A), a non-fluorescent, stable, water-soluble compound, is incubated (37° C.) with alkaline phosphatase (ALP), a bright yellow-green fluorescent, clearly visible precipitate is formed whose R f on thin layer chromatography (TLC) corresponds to drug ((2) or Compound B). In order to assess the kinetics of this enzyme-based hydrolysis (i.e. conversion of Compound A to Compound B) at 37° C., Compound A (60 μM) was mixed with 10 units ALP in 0.1 M Tris (pH 7.2) and the reaction kinetics followed over time using a Perkin-Elmer LS50B Luminescence Spectrometer with excitation at 340 nm and emission at 500 nm. There is a rapid increase in fluorescence intensity under these experimental conditions, as shown in FIG. 1 , demonstrating the hydrolysis of Compound A and the formation of Compound B. No fluorescence was observed when the enzyme was heat-inactivated prior to its incubation with Compound A.
In order to further characterize the 125 I-labeled prodrug, 125 I-labeled Compound A (˜10 μCi/100 μl 0.1 M Tris buffer, pH 7.2) was incubated with 5 units ALP or heat-inactivated (70° C., 2 hours) ALP; the samples were spotted on reversed-phase TLC plates that were then run in acetonitrile-water (1.5:2). Autoradiography demonstrates the complete conversion of 125 I-labeled Compound A to 125 I-labeled Compound B only in the presence of the active enzyme, as shown in FIG. 2 .
In order to determine blood clearance of AP 125 IQ, mice (n=5/group) were injected i.v. with the radioiodinated prodrug and bled over a 1 hour period, the radioactive content per gram of blood was measured, and the percentage injected dose per gram (% ID/g) calculated. The results as shown in FIG. 3 demonstrate a rapid biphasic blood clearance of radioactivity and a T 1/2β of 51.1±6.8 min.
In order to assess the chemical nature of the radioactivity in blood (i.e. determine stability of 125 I-labeled Compound A in blood), ethanol was added to the blood samples (collected during the first 40 min), the tubes were centrifuged, and the supernatant was spotted on TLC. The plates were run in acetonitrile-water (1.5:2) and autoradiographed. The results show (i) the presence of a single spot whose R f is the same as that observed with 127 I-labeled Compound A, and (ii) no evidence of free iodine. These data demonstrate the stability of 1-labeled Compound A in serum.
The biodistribution of 125 I-labeled Compound A in normal tissues was also considered. Mice (n=30) were injected i.v. with the radiopharmaceutical (˜5 μCi/100 μl), the animals were killed at 1 hour (n=15) and 24 hours (n=15), and the radioactivity associated with blood, tissues, and organs was determined. As shown in FIG. 4 , (i) the radioactivity in all organs and tissues declined over time; (ii) the radioactivity in the kidneys and urine was high, suggesting that the compound and/or its metabolic breakdown/hydrolysis products were rapidly excreted (since the weight of the thyroid is ˜5 mg, the activity within the thyroid indicates minimal dehalogenation of the compound); and (iii) <20% of the injected dose remained in the body by 24 hours. These results, therefore, demonstrate that 125 I-labeled Compound A and/or its metabolic breakdown/hydrolysis product(s) have a low affinity to normal tissues and that the presence of endogenous ALP leads to minimal hydrolysis of the compound.
The biodistribution of 125 I-labeled Compound B was also examined in various tissues in normal mice. In these experiments, 125 I-labeled Compound A was synthesized, purified, and incubated at 37° C. in the presence of ALP overnight. TLC demonstrated the complete conversion of 125 I-labeled Compound A to 125 I-labeled Compound B. Mice (n=10) were injected i.v. with 125 I-labeled Compound B (˜5 μCi/100 μl) and killed (n=5) at 1 hour and 24 hours. The 1 hour data, as shown in FIG. 5 , demonstrate the presence of this water-insoluble molecule in all the tissues examined (<15% ID/g). However, by 24 hours ( FIG. 5 ), all tissues and organs (with the exception of minimal activity in the thyroid) were virtually void of radioactivity (<4% of the injected dose remained in the body by 24 hours). These results show that 125 I-labeled Compound B has no avidity for any tissue in the mouse and that the tissue-associated activity seen at 1 hour reflects that within the blood. Since these data seem to argue for the inability of 125 I-labeled Compound B to traverse blood vessel walls and enter into tissues, this water-insoluble molecule if formed within a tissue (e.g. tumor mass) is likely to be retained, i.e. it will not leach back into circulation.
In order to demonstrate within an animal the conversion of the water-soluble 125 I-labeled Compound A to the water-insoluble 125 I-labeled Compound B, ALP was dissolved in saline (50, 100, 150, 200, 250, 300, 400 units/10 μl) and using a 10 μl syringe, 10 μl enzyme preparation was injected s.c. in the forelimb of Swiss Alpine mice. Five-minutes later, 20 μCi 125 I-labeled Compound A was injected i.v. (tail vein). The animals were killed 1 hour later and the radioactivity in the forelimbs was measured. The results, as shown in FIG. 6 , demonstrate that the radioactive content within the forelimbs of animals pre-injected with ALP increased with enzyme dose and plateaued at the highest concentrations. The fact that these increases were due to the enzymatic action of ALP was ascertained in studies that showed no increase in uptake in the forelimbs of mice pre-injected with heat-inactivated ALP ( FIG. 6 ). These results illustrate the specific dose-dependent accumulation of 125 I-labeled Compound A (more accurately, 125 I-labeled Compound B) within alkaline-phosphatase-containing sites in an animal.
In order to demonstrate that once formed, the water-insoluble Compound B is retained “indefinitely” within the tissue where it is formed, 125 I-labeled Compound B was dissolved in 100 μl DMSO (under these conditions, 125 I-labeled Compound B is completely soluble in DMSO; however, when 100 μl water are added, a visible precipitate forms immediately that contains 125 I-labeled Compound B radioactivity). Five μl of this solution was injected s.c. into the right forelimb of mice (n=15), followed by 5 μl saline. For comparison, 125 I-labeled Compound A (5 μCi/5 μl saline) was injected s.c. into the left forelimb of the same mice and followed with 5 μl DMSO. The animals were killed after 1 hour, 24 hours, and 48 hours, the radioactivity associated with the forelimbs was measured, and the percentage of radioactivity remaining was calculated (at the 24 hour time point, the biodistribution of radioactivity in various tissues and organs was also determined). The data ( FIG. 7 ) demonstrate that while greater than about 98% of the prodrug 125 I-labeled Compound A had seeped out of the s.c. pocket by 24 hours, 71±5% of the injected precipitable 125 I-labeled Compound B activity remained at the injection site at 24 hours. The biodistribution data ( FIG. 8 ) show that the radioactivity that escaped during the first 24 hours following the s.c. injection of 125 I-labeled Compound B does not localize in any normal tissues within the animal (activity within the thyroid indicates uptake of free iodine). Finally, the results show no change in the radioactivity in the forelimbs of the animals at 24 hours and 48 hours ( FIG. 7 ), thereby indicating that the precipitated 125 I-labeled Compound B is permanently and indefinitely trapped within tissues.
While this invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly to include other variants and embodiments of the invention which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.
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The present invention discloses a method for the enzyme-mediated, site-specific, in-vivo precipitation of a water soluble molecule in an animal. The enzyme is either unique to tumor cells, or is produced within a specific site (e.g., tumor) at concentrations that are higher than that in normal tissues. Alternatively, the enzyme is conjugated to a targeting moiety such as an antibody or a receptor-binding molecule.
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This is a continuation of U.S. patent application Ser. No. 09/029,494, filed Feb. 26, 1998, now abandoned and a con of PCT/IL96/00095 filed Sep. 2, 1996.
The present invention relates to novel polyolefin composites. More particularly, the invention relates to novel polyolefin composites material based on fiber and matrix of ultra-high molecular weight of polyolefin and to a process for the manufacture thereof.
BACKGROUND OF THE INVENTION
Polyolefins are considered non-polar polymers, used for many purposes such as, filaments, tapes, fibers, films, etc. One of the main field of polyolefins use is in the manufacturing of composite materials.
As known, a main problem encountered with production of composites, is the non-polarity of the polyolefins, which causes difficulties in obtaining a good adhesion between the non-polar polyolefins and the extraneous materials, such as plastic or resin, which generally are more polar than the polyolefins.
Ultra-high molecular weight polyethylene (hereinafter referred to UHMWPE) is a linear high density polyethylene (HDPE) with a molecular mass in the range of between 1×10 6 to 16×10 6 . Its very high molecular mass imparts an exceptional impact strength and abrasion resistance as well as special processing characteristics. These unusual properties preclude the use of conventional extrusion and moulding techniques.
Fibers made from this type of polyethylene are characterized by their high modulus and strength, light weight and high energy dissipation in comparison with other polymer fibers. However, the standard extrusion and molding techniques for obtaining fibers of UHMWPE are not applicable.
A main deficiency of UHMWPE fibers in its use as reinforcement in composites materials, is their relatively poor adhesion to the matrix in a composite and their chemical inertness as mentioned in a recent review (D. N. Hild et al, J. Adhesion Sci. Technol. 6, p. 879, 1992). As known, the stress-transfer ability of the fiber-matrix interface and accordingly the mechanical properties of such composites are greatly affected by the level of the fiber-matrix adhesion. The compatibility between the thermoplastic UHMWPE fiber and the thermoset resins is also limited due to the non-polar property of the polyethylene.
Composites of polyethylene and UHMWPE, obtained by hot compression molding at a temperature between the melting points of the fibers and the polyethylene matrix, were found to comprise a uniform transcrystalline layer of the polyethylene melt on the UHMWPE fiber surface (Teishev et al. J. Appl. Polym. Sci., 50, 1993, p.503).
The European Patent Application Number 313,915 is suggesting a process to improve the adhesion of polyolefin objects to polar polymer matrices. The process involves a treatment of the surface of polyolefin objects obtained from a solution or melt, having a molecular weight of at least 400,000 g/mol, by its immersion into a solvent at a temperature above that of the polyolefin dissolution. A most preferred solvent which is suggested is xylene. It is claimed that the treated objects according to this process retain their adhesive strength to the polar matrices for a long period of time.
In the U.S. Pat. No. 4,563,392, it is described a method for obtaining a coated polyolefin fiber having an increased adhesion to matrix materials. According to this method the multifilament fiber having a molecular weight of above 500,000, is coated with a polymer possessing the ethylene or propylene crystallinity, said coating being between 0.1% to about 200% by weight of the fiber.
According to a very recent paper by Roger S. Porter et al (Polymer, 35, 23, 1994, p.4979-84), high-modulus and high-strength UHMWPE bars or films are obtained, by a two-stage drawing technique: by direct compaction followed by calendering at a temperature below the melting point.
In another recent paper by B. L. Lee et. al. (Journal of Composite Materials, Vol. 28, No. 13.1994, p. 1202-26), there are described tests which were carried out on polyethylene fiber-reinforced composites and examined under ballistic impact loading.
The above brief review, illustrates that the subject of fiber and matrix of UHMWPE composite material is indeed considered an interesting problem which indicates that it requires more investigation.
It is an object of the present invention to provide novel composite materials based on fiber and matrix of UHMWPE. It is another object of the present invention to provide a process for obtaining composite materials based on UHMWPE having improved mechanical properties. It is yet another object of the present invention to provide a process for obtaining a material based on fibers of UHMWPE with improved adhesion property to a polymer matrix.
BRIEF DESCRIPTION OF THE INVENTION
The file of this patent contains at least one drawing executed in black and white photographs. Copies of this patent with the photograph(s) will be provided by the Patent and Trademark Office upon request and payment of necessary fee.
The invention relates to a polyolefin composite material based on fiber and matrix (hereafter referred to composite material) of a polyolefin selected from polyethylene and polypropylene possessing improved mechanical properties, comprising a net-work of fibers and matrix having a molecular weight of above 500,000, said net-work being held together by compressed and crystallized molecular brush layers obtained by swelling of the external surface of said fibers and reciprocal entanglement with it of the polymer matrix. According to a preferred embodiment, the tensile strength of said composite material is at least 75% of the volume average tenacity of the polyolefin fiber net work and matrix. A process for obtaining the polyolefin composite material as well as the significant advantages thereof are also described.
DESCRIPTION OF THE FIGURES
FIG. 1 . shows a SEM micrograph of a model sample of a composite prepared on a glass plate. The fiber under observation being near the glass surface. As can be noticed, the growth of UHMWPE fiber surface, i.e. crystallized brush layers, entangled with the fiber surface molecules before compression. It appears that the lamellae are perpendicular to the fiber surface.
FIG. 2 . illustrates in a graphic manner the transversal stress-percentage elongation of said composite material at a temperature of 25° C. This graph illustrates the much higher elongation property compared with typical composites (about 1%).
FIG. 3 . shows the X-ray diffraction pattern of the unidirectional composite material obtained in Example 4, after an ultimate transversal elongation at 25° C. (at fiber axis—vertical).
As can be noticed, from FIG. 3, the reflex (a) on the pattern, is caused by the oriented crystalline matrix. This feature is unique for all types of composites which are subjected to transversal elongation. It also proofs the extremely high adhesion which exists between the fibers and matrix inherent to the obtained composite material and to the unusual properties of UHMWPE matrix obtained from the solution.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, the composite material consists of unidirectional fibers, yarns, layers or cloths. Before and after the elongation process in a direction transverse to the fibers, there are two different materials, which can be used for different purposes. Before the elongation, the composite is a non-isotropic material which possesses a relatively low matrix modulus and strength which is most useful, e.g. for ballistic protection. After elongation of at least 300% and even more, the composite material will possess a high modulus, a high strength and a low creep of below 1.5% and even close to the melting point, in any desired directions; such composites are particularly useful as construction materials.
It was found that the entangled molecular brush layers, present in the polyolefin composite materials are obtained by the swelling of the fiber-based external surface, under conditions prevailing in the process as described in the present invention, and the reciprocal entanglement with it of the polymer in solution.
As known, swelling is a chemical property related to an interaction between a polymer and a solvent, which can be described as a penetration of the solvent molecules into the inter-molecular space of the polymer, weakening by them of the intermolecular interactions and alienation of the polymer molecules into said solvent. It is the reversible dimensional changes that occur when fibers undergo an absorption process. Since fibers are structurally anisotropic, they undergo greater transverse versus longitudinal swelling.
No particular information is mentioned in the literature relating to the kinetics of a simultaneous swelling and dissolution in polymers.
According to the present invention, the matrix of the ultra-high molecular weight polyethylene, is obtained as a result of the property of the respective solution to produce, under the prevailed conditions, “gel-like spherulites” due to the inclusion of a large amount of solvent of up to 90%. Most preferred solvents used for said polyethylene are selected from xylene, decalin, tetralin, and paraffin oil or any mixture thereof. Upon applying even a low pressure of about 50 atmospheres, a multilayer lamellar structure is formed, being oriented parallel to the plane of compression.
The polyethylene constituent to be used as matrix should possess an average molecular weight of at least 500,000 and preferably above 3,000,000 and most preferably in the range of 5,000,000 to 8,000,000, being substantially equal to the molecular weight of the fibers material.
Composite compaction has to be carried out under heating at a temperature, which is above the melting temperature of the polyolefin matrix but below the melting point of the loaded polyolefin material. The compression, may be carried out in a broad range of between 0.05 to 300 MPa for a period of between 5 minutes to 25 hours.
It was found that the composite material consisting of UHMWPE fibers according to the present invention has the following properties:
a low density of 0.98 g/cm 3 . i.e. lighter than water;
a high transversal strength of composite material i.e. at least 25 MPa for a 30% matrix composite;
a high shear strength of at least 25 MPa;
a high elongation in a direction transverse to fiber axis of at least 70% at 25° C.;
a high ultrasonic tensile modulus of at least 120 GPa for a 30% matrix composite;
a high tensile strength of at least 1.5 GPa for a 30% matrix composite;
high properties at the cryogenic temperature; thus at a temperature down to that of liquid helium UHMWPE based composites have the lowest dielectric and loss characteristics for radar operating frequencies within the millimetric frequency range; thus at frequencies up to 54 GHZ, the dielectric constant remains invariable at 2.25 and loss tangent at 0.0006;
an outstanding aptness for sonar technology, i.e. sonar domes; thus in UHMWPE composites reflection of the sound waves at all angles of incidence is minimal because the sound speed and the density of the composite and sea-water are closely matched;
In view of the above properties, the material can be easily work up by ordinary machining without any crack formation. Among the various uses as a construction material, the following may be mentioned; aircraft and spacecraft parts, helicopter structures, sonar domes, radoms, marine applications in deep underwater, surface effect ship and hydrofoil craft, antennas, sport goods, high pressure tanks, neutron and radiation shields, structural elements at cryogenic temperature, military applications, prosthesis, battery separators, microporous ultra-strength membranes for water and industrial sewage purifying, as additives in flame retardant material, etc. The invention also provides a method for the preparation of the composite material based on fiber and matrix of UHMWPE. The method comprises the following steps:
(a) Swelling of the UHMWPE fibers, whereby the solvent molecules penetrate into the inter-molecular space of the polymer. The swollen surface layer, serves as a disentanglement zone and thus become more free. The dissolution of the polyolefin objects in the solvent, or solution of the matrix forming polymer, at temperatures above that of the matrix bulk polyethylene, can be retarded by a preliminary loading of the respective polyolefin objects;
(b) growing of the “brush” layers from dissolved UHMWPE molecules entangled with the swelled UHMWPE fiber surface;
(c) growing supermolecular structures, i.e. crystallization of the brush layers, entangled with the fiber surface molecules and with the polymer molecules in the solution which accompanies them;
(d) compressing or molding the super molecular structures accumulated on the fiber surface, whereby a semi-product coating of the composite material is obtained; according to a preferred embodiment, this compression is carried out on fibers covered by gel-like spherulites, thus obtaining on the fiber surface a well packed zone having a high degree of regularity cover, and
(e) molding under heating and compression the semi-product coating, whereby the desired modifications and properties are imparted to the composite material.
The temperature which should prevail during the swelling, (step a), should be above the dissolution point of the polyolefin objects without loading, generally being below its melting point under the current conditions.
The tension applied in the first step (a) should be applied preferably by a force of between 0.1% to 30% of the force at break of the respective material.
The solvent used for obtaining the solution of the polyolefin matrix, may be selected from a broad class of solvents, provided that it possesses an interaction parameter (x) with the dissolved polymer in the range of between 0 to 0.3, at the treatment temperature in steps (a) and (b). Typical examples of such solvents are: xylene, tetralin, decalin, paraffin oil, or mixtures thereof.
The preferred concentration of the polyethylene solution is between 0.1% to 10% by weight and most preferred between 1% to 3% by weight.
The temperature which prevails during the crystallization in step (c) is generally between 20° to 120° C.
The composite materials obtained according to the present invention possess a number of improved characteristics in respect to good mechanical and ballistic properties, such as: improved tensile strength and elastic modulus at least 1.5 GPa and 120 GPa, respectively, a high energy absorption, a interlaminar shear strength of at least 25 mega-Pascal and a transversal strength of at least 25 mega-Pascal. As a result of the above properties, they will have a wide range of technical applications, such as: in boats manufacture, in aircraft parts, in printed circuit boards, ballistic protection armours, car parts, radomes, prosthesis etc.
The invention will be hereafter illustrated by the following Examples, being understood that these Examples are presented only for a better understanding of the invention, without imposing any limitation thereof. A person skilled in the art will be in a position, after reading the present specification, to insert slight modifications without being outside the invention as covered by the attached Claims.
EXAMPLE 1
A matrix was prepared from a solution of 1.5% by weight of polyethylene having an average molecular weight of about 3,000,000 in tetralin. The commercial yarn of UHMWPE (Trade Mark Spectra1000) having a tensile strength of 33 g/den and modulus of 1800 g/den, was chosen for the respective tests.
Value of load for monofilament was about 2 g, temperature of treatment of about 130° C. and time of treatment of about 5 minutes.
An amount of matrix from a solution (mats) was compressed with the monofilament in a cylinder of 2 mm diameter at a pressure of 20 MPa. The results of pull-out tests which were carried out were as follows (the data are given in MPa):
Table of Pull -out tests.
Composite matrix consists of
wet with
coagulated in
tetralin
Fibers
dried mats
alcohol mats
mats.
Untreated
0.6-1.7
1.5-3.5
Treated in pure tetralin
1.3-2.2
3.0-3.5
without drying
Treated in solution
7.0-9.0
crystallization and
coagulation in alcohol
without drying
Treated in solution
9.0-12
12-16
crystallization and
maintained wet with
tetralin
EXAMPLE 2
A yarn of ultra-high molecular weight of a commercial fiber polyethylene (Trade Mark Spectra 1000) having a tensile strength of 33 g/den and modulus of 1800 g/den, was tensile loaded by a force of 0.3 kg. The resulted loaded yarn was treated for six minutes with a solution of 1.5% by weight of polyethylene having an average molecular weight of 3,000,000 in tetralin at a temperature of 135° C.
The treated yarn was quenched in the same solution for 10 minutes at a temperature of 110° C. The resulted polyethylene yarn, was dried by vacuum, obtaining a yarn prepreg material consisting of a 10% by weight of the matrix material.
EXAMPLE 3
A solution of 1.5% by weight of polyethylene having a molecular weight of 3,000,000 was prepared and then cooled and filtered through a glass filter. The resulted sedimented polymer on the filter was compressed at 5 MPa, producing a polyethylene plate.
The yarn pre-preg obtained in Example 2, was winded on a steel plate thus producing unidirectional layers. The polyethylene plates were put between two unidirectional layers, producing a “sandwich” material, which was compressed at 10 MPa, obtaining unidirectional pre-peg having about 40% matrix material content.
EXAMPLE 4
The yarn as in Example 2 was tensile loaded by a force of 0.4 kg, The resulted loaded yarn was treated at a temperature of 130° C. with a solution of tetralin containing 1.75% of polyethylene having an average molecular weight of 3,000,000, for about 8 minutes. The treated yarn was cooled slowly to room temperature for about 20 minutes, while the temperature of the surrounding solution was maintained unchanged.
The yarn pre-preg obtained was winded on a steel plate, thus producing uni-directional layers and compressed at 15 MPa for about 30 minutes, the temperature being gradually increased up to 138° C.
The mechanical properties of the material obtained were as follows:
Density
0.98 g/cm 3
Tensile strength:
1.5 GPa
Shear Strength:
25 MPa;
Transversal strength:
25 MPa;
Ultimate transversal elongation at 25° C.:
70% and
Matrix Content:
30%
Tensile ultra-sonic elastic modulus
120 GPa
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A UHMWPE (ultra-high molecular weight polyethylene) composite and a method for its manufacture. Fibers of polyethylene or polypropylene are cause to swell in a solvent or in a solution of the polymer, thereby producing molecular brush layers within the external layers of the fibers and reciprocal entanglement of the surrounding polymer matrix with the external surfaces. Preferably, the fibers are placed under tension, and the swelling of the fibers and the growing of the brush layers is conducted at a temperature above the melting point of the unloaded fibers but below the melting point of the loaded fibers. The composite then is cooled under pressure to crystallize the brush layers, and then is molded under heating and further compression.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation in part of U.S. Ser. No. 08/748,228, filed Nov. 12, 1996, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
his invention relates generally to the contacting of hydrocarbon vapors with fluidized catalyst particles in a transport riser. More specifically this invention relates to a method of maintaining uniform dispersion of catalyst particles in a fluidized transport riser.
2. Description of the Prior Art
There are a number of continuous cyclical processes employing fluidized solid techniques in which carbonaceous materials are deposited on the solids in the reaction zone and the solids are conveyed during the course of the cycle to another zone where carbon deposits are at least partially removed by combustion in an oxygen-containing medium. The solids from the latter zone are subsequently withdrawn and reintroduced in whole or in part to the reaction zone.
One of the more important processes of this nature is the fluid catalytic cracking (FCC) process for the conversion of relatively high-boiling hydrocarbons to lighter hydrocarbons boiling in the heating oil or gasoline (or lighter) range. The hydrocarbon feed is contacted in one or more reaction zones with the particulate cracking catalyst maintained in a fluidized state under conditions suitable for the conversion of hydrocarbons.
It has been found that the method of contacting the feedstock with the catalyst can dramatically affect the performance of the reaction zone. Modem FCC units use a pipe reactor in the form of a large, usually vertical, riser in which a gaseous medium upwardly transports the catalyst in a fluidized state. Ideally the feed as it enters the riser is instantaneously dispersed throughout a stream of catalyst that is moving up the riser. A complete and instantaneous dispersal of feed across the entire cross section of the riser is not possible, but good results have been obtained by injecting a highly atomized feed into a pre-accelerated stream of catalyst particles. However, the dispersing of the feed throughout the catalyst particles takes some time, so that there is some non-uniform contact between the feed and catalyst as previously described. Non-uniform contacting of the feed and the catalyst exposes portions of the feed to the catalyst for longer periods of time which can in turn produce overcracking and reduce the quality of reaction products.
Much of the effort in improving the hydrocarbon conversion reactions in FCC units has focused on the objective of maximizing the initial dispersal of the hydrocarbon feed into the particulate catalyst suspension. Dividing the feed into small droplets improves dispersion of the feed by increasing the interaction between the liquid and solids. Preferably, the droplet sizes become small enough to permit vaporization of the liquid before it contacts the solids. Techniques such as agitation or shearing are used to atomize a liquid hydrocarbon feed into fine droplets which are then directed at the fluidized solid particles. A variety of methods is known for shearing such liquid streams into fine droplets.
U.S. Pat. No. 3,071,540 discloses a feed injection apparatus for a fluid catalytic cracking unit wherein a high velocity stream of gas, in this case steam, converges around the stream of oil upstream of an orifice through which the mixture of steam and oil is discharged. Initial impact of the steam with the oil stream and subsequent discharge through the orifice atomizes the liquid oil into a dispersion of fine droplets which contact a stream of coaxially flowing catalyst particles.
U.S. Pat. No. 4,434,049 shows a device for injecting a fine dispersion of oil droplets into a fluidized catalyst stream wherein the oil is first discharged through an orifice onto an impact surface located within a mixing tube. The mixing tube delivers a cross flow of steam which simultaneously contacts the liquid. The combined flow of oil and steam exits the conduit through an orifice which atomizes the feed into a dispersion of fine droplets and directs the dispersion into a stream of flowing catalyst particles.
U.S. Pat. No. 5,139,748 issued to Lomas et al. shows the use of radially directed feed injection nozzles to introduce feed into an FCC riser. The nozzles are arranged in a circumferential band about the riser and inject feed toward the center of the riser. The nozzle arrangement and geometry of the riser maintains a substantially open riser cross-section over the feed injection area and downstream riser sections.
Feed atomization, lift-gas and radial injection of feed have been used to more uniformly disperse feed over the cross-section of a riser reaction zone. While it may be possible to obtain a good initial dispersal of the catalyst particles as they contact the vaporized feed, it has been found that as the catalyst passes further up the transport riser it tends to form ribbons or bands of concentrated catalyst that hug the wall of the riser. As feed contacts the hot catalyst, cracking and volumetric expansion of the hydrocarbons causes an increase in the volumetric rate of fluids passing up the riser. A large portion of this volumetric increase occurs immediately downstream of the feed injection point. Downstream of the feed distributor this volumetric expansion occurs in a relatively uncontrolled fashion. The uncontrolled volumetric expansion occurring simultaneously with mixing of catalyst and hydrocarbon feed results in mal-distribution that adversely effects the quantity and quality of the products obtained from the cracking reaction. This maldistribution is believed to be caused by turbulent back mixing as well as quiescent zones in the riser section immediately downstream of the feed injection point.
These flowing ribbons of catalyst cause non-uniform regions of density and result in uneven contacting of the catalyst with the hydrocarbon feed. These ribbons of catalyst produce slippage between the fluid stream and the catalyst stream that further increase the nonuniformity of the contacting between catalyst and vapors. All of these phenomena contribute to an increase in the non-uniformity of the contacting between the catalyst and the gas.
It is known to use screens and obstacles in conduits that transport particulate material. U.S. Pat. No. 4,071,573 shows the use of screens to disperse bubbles that form in the dense phase transport and contacting of catalyst and a feedstream. U.S. Pat. No. 3,799,868 discloses a riser for the dilute phase contacting of gaseous hydrocarbons that blocks the center of the riser to eliminate the central area of the riser as a potentially more dilute flow area. It is also taught to intensify gas solids contacting by placing large obstacles in the path of circulating gas solids stream. "Hydrodynamics of a Pilot-Plant Scale Regularly Packed Circulating Fluidized Bed," was presented at an AIchE Symposium Series by A. G. J. van der Ham, W. Prins, and W. P. M. van Swaaij of Chemical Reaction Eng. Labs, Chemical Eng. Dept., Twente University, The Netherlands in 1993.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method and apparatus for reducing or eliminating non-uniformity in the density of the catalyst and gas mixture both downstream and upstream of the feed injection zone.
It is a further object of this invention to maintain well distributed catalyst over the entire cross section of a riser conduit both downstream and upstream of a location where the feed is injected.
Establishing and maintaining uniformly distributed catalyst has the added benefit of reducing backmixing. Backmixing results from the refluxing action brought about by regions of higher density catalyst. In particular the dense phase catalyst causes downflow of catalyst to occur at the walls of a riser.
These objects are achieved in a riser conduit that transports gas and particles by the use of redistributors over a specified length of the riser. The redistributors may provide a redistribution section that breaks up pickets and streamers of catalyst that tend to hug the wall of the riser with a ring of inwardly projecting spokes. This type of arrangement minimizes any disruption or interference with the flow of the catalyst through the riser. The redistributors may provide more complete dispersal of the catalyst by extending transversely over the cross section of the riser at periodic intervals to provide a uniform resistance over the cross section of the riser at the axial location of each redistributor. This type of redistributors can comprise open grates that provide a rectangular grid of openings for the passage of particles and fluid. Cross members defining the grids provide a distributed resistance. The addition of the distributed resistance across the riser and along its length provides better more uniform gas--particle contact. In catalytic processes such as the fluid catalytic cracking of hydrocarbons the use of the redistributors can result in shorter risers, reduced residence time, and improved selectivity and conversion.
The redistributors of this invention maintains a more uniform velocity of the particles and gases after their initial mixture and acceleration in both the lift and reaction zones. The redistributors of the present invention will introduce additional turbulence and pressure drop in the riser at redistributor location. Turbulence has generally been avoided in FCC risers since it is associated with maldistribution and backmixing. However since the general flow of gases and catalyst has been established the small amount of turbulence needed for effective redistribution will not disrupt flow to the degree of causing undesirable backmixing. Redistributors spaced at regular intervals can also accomplish the redistribution while imposing very little pressure drop on the overall length of the riser.
The redistribution sections are further characterized by a relatively open area that imposes little additional pressure drop on the system. The redistributor will leave at least 50% of the riser cross sectional area open for fluid and particle flow and will more preferably leave at least 60% of the area open for such flow. The use of radial spokes that ring the wall of the riser are particularly advantageous in keeping most of the riser cross section open for fluid and particle flow.
The number and spacing of the redistributors can be optimized for a given design configuration. When revamping older units, the redistributors will typically only extend to the location where complete reaction of the feed has been achieved. Beyond that point separation of the catalyst and gas is usually desirable.
Accordingly, in a specific embodiment, this invention is a method of contacting fluidized particles with a fluid feed stream comprising hydrocarbons. The method combines fluidized particles and a fluid feed stream in an upstream section of a riser conduit to accelerate the particles up the conduit and produce a dilute phase mixture of particles and gas that flows through the riser. The dilute phase mixture passes along the riser and through at least one redistribution section that extends transversely into the riser. The mixture is recovered from the end of the riser. The riser is preferably a vertically oriented riser conduit and so that the dilute phase mixture is formed in a lower section of the conduit.
In a more specific method embodiment, this invention is a method of contacting fluidized particles with a fluid feed stream comprising hydrocarbons that combines fluidized particles and a fluid feed stream in an upstream section of a riser conduit having a substantially open interior. The particles are accelerated up the conduit which produces a dilute phase mixture of particles and gas that flows through the riser. The dilute phase mixture passes through the riser at a superficial velocity of at least 10.0 ft/sec, with an average mixture density in the riser conduit of less than 20 lb/ft 3 , through at least one redistribution section that includes a plurality of spokes extending inwardly from the wall of the riser for a radial distance of at least 2 inches. Each distribution section provides at least four spokes in each quadrant of the riser. The method recovers the mixture from the end of the riser.
Additional objects, embodiments and details of this invention can be obtained from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional elevation of an FCC reactor and riser.
FIG. 2 is an enlarged section taken across the riser above one of the redistributor grids.
FIG. 3 shows a planar view of a redistributor grid.
FIG. 4 shows a planar view of an alternate redistributor arrangement.
DETAILED DESCRIPTION OF THE INVENTION
This invention will be described in the context of an FCC process for the catalytic cracking of hydrocarbons by contact with a fluidized catalyst.
In a typical FCC process flow arrangement, finely divided regenerated catalyst leaves a regeneration zone and contacts a feedstock in a lower portion of a reactor riser zone. FIG. 1 shows a reactor 10 with a vertical riser 20 having an upper section 12 and a lower riser portion 14 into which a regenerator standpipe 16 transfers catalyst from the regenerator (not shown). A fluidizing medium in the form of a steam or a light hydrocarbon stream enters the riser through a conduit 17 to begin acceleration of the catalyst up the riser. The amount of fluidizing medium entering the riser through conduit 17 may be limited to maintain dense phase conditions in the lower portion of the riser. Additional amounts of steam may be injected into the riser through conduit 15. Dense phase conditions for the fluidized catalyst are typically characterized by a mixture density of at least 20 lb/ft 3 . Additional fluidizing medium in the form of a hydrocarbon feed enters the riser through conduits 19. Conduits 19 will typically include nozzles at the end of the conduits for atomizing the feed as it exits the conduits. However, some commercial units inject the feed through a central conduit similar to conduit 17 and do not provide elevated feed injection as provided by conduits 19. While the resulting feed mixture, which has a temperature of from about 200° C. to about 700° C. and more typically to about 560° C., passes up through the riser, conversion of the feed to lighter products occurs and coke is deposited on the catalyst. The effluent from the riser is discharged from the top of the riser through a disengaging arm 22 into a disengaging space 24 where additional conversion can take place. The hydrocarbon vapors, containing entrained catalyst, are then passed through one or more cyclone separators 26 to separate any spent catalyst from the hydrocarbon vapor stream.
The separated hydrocarbon vapor stream is passed from an outlet nozzle 28 into a fractionation zone (not shown) known in the art as the main column wherein the hydrocarbon effluent is separated into such typical fractions as light gases and gasoline, light cycle oil, heavy cycle oil and slurry oil. Various fractions from the main column can be recycled along with the feedstock to the reactor riser. Typically, fractions such as light gases and gasoline are further separated and processed in a gas concentration process located downstream of the main column. Some of the fractions from the main column, as well as those recovered from the gas concentration process may be recovered as final product streams.
The separated spent catalyst from cyclones 26 passes into the lower portion of the disengaging space through dip legs 30 and eventually passes out of the reaction zone passing into a stripping zone 32. A stripping gas, usually steam, enters a lower portion of zone 32 through a distributor ring 34 and contacts the spent catalyst, purging adsorbed and interstitial hydrocarbons from the catalyst. A series of baffles 35 in the stripping zone improves contact between the catalyst and stripping gas.
The spent catalyst containing coke leaves the stripping zone through a reactor conduit 36 and passes into the regeneration zone where, in the presence of fresh regeneration gas and at a temperature of from about 620° C. to about 760° C., combustion of coke produces regenerated catalyst and flue gas containing carbon monoxide, carbon dioxide, water, nitrogen and perhaps a small quantity of oxygen. Usually, the fresh regeneration gas is air, but it could be air enriched or deficient in oxygen. Flue gas is separated from entrained regenerated catalyst by cyclone separation means located within the regeneration zone and separated flue gas is passed from the regeneration zone, typically, to a carbon monoxide boiler where the chemical heat of carbon monoxide is recovered by combustion as a fuel for the production of steam, or, if carbon monoxide combustion in the regeneration zone is complete, the flue gas passes directly to sensible heat recovery means and from there to a refinery stack. Regenerated catalyst which was separated from the flue gas is returned to the lower portion of the regeneration zone which typically is maintained at a higher catalyst density. A stream of regenerated catalyst leaves the regeneration zone, and in repetition of the previously mentioned cycle, contacts the feedstock in the reaction zone.
The particulate material used in these processes will typically comprise finely divided catalysts that include those known to the art as fluidized catalytic cracking catalysts. Specifically, the high activity crystalline aluminosilicate or zeolite-containing catalysts can be used and are preferred because of their higher resistance to the deactivating effects of high temperatures, exposure to steam, and exposure to metals contained in the feedstock. Zeolites are the most commonly used crystalline aluminosilicates in FCC.
Catalyst entering the lower section 14 of the riser conduit preferably forms a dense catalyst bed. Once the catalyst is mixed with the feed entering via nozzles 19 it will form a dilute phase catalyst regime. The dilute phase catalyst regime is characterized by a lower mixture density. Typical average mixture density in the dilute phase regime will be less than about 20 lb/ft 3 . In addition particles and gas in the dilute phase regime will have a higher superficial velocity. This velocity will usually be at least 10 ft/sec and more often at least 40 ft/sec. It is the higher velocities and the lower catalyst density that leads to the formation of the catalyst streamers or ribbons as previously described.
A series of redistribution sections containing redistributors 37 extend transversely across the cross section of riser 12 to break up any ribbons of particulate material that may form as the gas and particles pass upward through the riser. As few as one or two redistributors over the length of the riser will has a substantial impact on reducing the formation of the continuation of localized catalyst streams. For a single redistributor the most beneficial location may be one or two riser diameters above the feed injection conduits 19. Regular spacing of the redistribution grids up the length of the riser will maintain nearly uniform distribution of particles and gas over the entire cross section of the riser. To achieve a uniform distribution of the gas and catalyst mixture the redistributors are preferably spaced at regular intervals along a desired length of the riser. As stated previously the distributors are most beneficial in the section of the riser immediately upstream of the location where the feed is injected into the riser and downstream of the feed injection location where reaction is desired. Although any spacing can be used for the redistributors, the redistributors will preferably have a spacing along the length of the riser proportionately equal to about two riser diameters or less.
The number of redistributor grids may be limited to reduce pressure drop. The redistributors 37 are essentially planar and provide open areas for the particles and gases to pass through. Pressure drop limitations may restrict the number of redistributors. Preferably the grids have a high percentage of open area to minimize pressure drop through the riser. The grid may have any configuration that provides a high percentage of open area and preferably includes members that traverse the entire cross section of the riser.
The redistribution sections provide a high percentage of open area across the entire transverse cross section of the riser. Thus the central area of the riser has an open area equal to a 50% of its nominal area with nominal open areas of at least 60 to 70% across the central section of the riser being particularly preferred. The redistribution sections also provide a relatively open area across each portion of the riser where the redistributor is placed. Accordingly each unit area of the redistributor, i.e. that area of the grid that defines a single regular opening of the grid, will block less than 50% of corresponding area of the riser at any location across the riser. The term regular unit area excludes those areas where the grid intersects the wall of the riser and thereby defines irregular shaped openings. Again any regular unit area of the grid will preferably block less than 30 to 40% of corresponding area of the riser.
FIG. 2 shows a preferred redistributor configuration. The redistributor consists of a plurality of linear member 40 arranged orthogonally to another set of parallel members in a substantially planar arrangement of rectangular grid openings 43. The rectangular grids preferably have 2 to 4 inch square openings and are defined by relatively narrow bars. The redistribution section can comprise a plurality of radially oriented rods with open spaces between rods of 2" to 4" about the circumference of the riser. In order to provide the desired open area the members 40 defining the openings will have a smaller horizontal width than the minimum dimension across a regular shaped opening 43. The unit area for such a grid equals the area of any square opening measured about the centerline of the linear members 40 that define the opening. The ends of members 40 that contact the walls serve as spokes that have a radial extension into the riser and a location near the wall of the riser to break up any concentrated streams of particles near the wall of the riser.
The dilute phase flow of particulate material at high velocity creates a highly erosive environment. Therefore, the redistributors are designed to resist erosion. Erosion resistance may be provided by constructing the redistributors from ceramic materials. Alternately FIG. 3 shows a cross section of a grid arrangement where the grid has been constructed from horizontal bars 40 and 43 that retain an erosion resistant material 44 on the upstream and downstream portions of the bars. Erosion resistant materials are well known to those skilled art and generally comprise abrasion resistant refractories that readily cast in place on both sides of the bars using well known anchoring techniques. Where abrasion materials are cast on to the horizontal members of the grids, the grid bars will usually have a width of at least 1" to provide adequate surface for anchoring the refractory to the bars. For bars with a 1 inch width the grid openings will preferably have a minimum dimension of at least 2.5 inches.
The essential objective of breaking up concentrated streams of catalyst near the wall of the riser may be achieved with a simplified redistribution section as shown in FIG. 4. In FIG. 4 a plurality of spokes 45 extend radially inward from a riser wall 46 to provide a redistribution section in the form of a ring. The ends of spokes 45 typically extend at least 2 inches into the riser from the inside of an abrasion resistant lining 47 (See dimension B) that covers the interior wall riser 56. Rod or plate elements may provide the spokes. Preferably plate elements will have an orientation parallel to the flow direction through the riser. This orientation avoids imparting tangential velocity to the fluid and particles that can directionally serve to concentrate the relatively heavier catalyst particles back against the wall of the riser. The arrangement of FIG. 4 leaves the center of the riser completely open for fluid and particle flow while breaking up catalyst that travels near the wall of the riser and that has been discovered to be the most problematic.
The number of spokes in a riser section will vary with the size of the riser. Preferably the spokes will have a minimum circumferential spacing around the riser of at least 2 inches and a maximum open spacing between spokes of 4 inches. This maximum spacing eliminates any relatively large sectors where the streamers of catalyst may flow uninterrupted along the riser wall. The minimum spacing provides enough of a flow area so that the entire transverse area of the riser is still used effectively. For purposes of definition, the unit area for the spoke arrangement can consist of the truncated sector bordered on the sides by the centerline of the spokes and extending from the inside of the lining to the inner end of the spokes.
The spoke type of arrangement may be used with multiple redistribution section. The multiple redistribution section may use the same configuration of redistributor at all grid location or may change the configuration of the redistributor at different redistributor locations. When each redistributor configuration is substantially the same it is advantageous to angularly offset the adjacent redistribution sections. For example the linear members of grid type redistribitors are preferably rotated about 45° with respect to adjacent grid members to vary the pattern of openings presented to the stream as it flows up the riser. In a similar manner spokes of adjacent redistributors are preferably offset along the length of the riser to vary the pattern of spokes presented to the flowing particle stream.
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An dilute phase transport riser for the contacting of particles with a gas uses redistributors along the length of the riser to prevent the formation of localized regions of high particle concentration along the wall of the riser. A series of redistributors extend transversely across the riser to redistribute the particles and the gas. The redistributor can comprise radially extended spokes or simple rectangular grates spaced at regular intervals along the length of the riser. The arrangement is particularly suited for FCC application where the catalyst tends to form pickets or streamers of catalyst that may slip backward along the length of a vertical riser.
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FIELD
[0001] The present disclosure relates to engine camshaft assemblies.
BACKGROUND
[0002] This section provides background information related to the present disclosure which is not necessarily prior art.
[0003] Engines typically include a camshaft to actuate intake and exhaust valves. Some camshafts are concentric camshafts that provide for relative rotation between, for example, the intake and exhaust lobes. The intake lobes may be fixed to an outer shaft for rotation with the shaft and the exhaust lobes may be rotatably supported on the shaft. Alternatively, the exhaust lobes may be fixed to the outer shaft for rotation with the shaft and the intake lobes may be rotatably supported on the shaft. In any arrangement, the lobes that are rotatably supported on the outer shaft may be rotationally fixed to the inner shaft using a fastener.
SUMMARY
[0004] This section provides a general summary of the disclosure, and is not comprehensive of its full scope or all of its features.
[0005] A camshaft assembly method may include locating a first lobe member of a camshaft assembly on a first shaft of the assembly. A locking pin may be inserted into a first radial bore in the first lobe member and a second radial bore of the first shaft. The locking pin may have an annular wall defining a pin bore extending from a first end of the locking pin to a second end of the locking pin. A deforming member may be forced into the pin bore to displace the annular wall in an outward radial direction and into a frictional engagement with the first radial bore. The forcing may include a deforming member entering the pin bore at the first end of the locking pin and exiting the pin bore at the second end of the locking pin.
[0006] The locking pin may be hollow after the deforming member is forced through the pin bore.
[0007] A camshaft assembly may include a first shaft having a first radial bore, a first lobe member located on the first shaft and including a second radial bore aligned with the first radial bore, and a locking pin. The locking pin may be located within the first and second radial bores. The locking pin may include an annular body defining a generally hollow longitudinal bore extending from a first longitudinal end of the locking pin to a second longitudinal end of the locking pin. The first and second longitudinal ends may be frictionally engaged with the first lobe member.
[0008] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0009] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way.
[0010] FIG. 1 is a schematic illustration of an engine assembly according to the present disclosure;
[0011] FIG. 2 is a perspective view of the camshaft and cam phaser of FIG. 1 ;
[0012] FIG. 3 is a perspective exploded view of the camshaft of FIG. 1 ;
[0013] FIG. 4 is a first schematic illustration of a camshaft and a tool assembly according to the present disclosure; and
[0014] FIG. 5 is a second schematic illustration of the camshaft and tool according to the present disclosure.
[0015] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0016] Examples of the present disclosure will now be described more fully with reference to the accompanying drawings. The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0017] Referring now to FIG. 1 , an exemplary engine assembly 10 is schematically illustrated. The engine assembly 10 may include an engine 12 including a plurality of cylinders 14 having pistons 16 disposed therein. The engine 12 may further include an intake valve 18 , an exhaust valve 20 , and intake and exhaust valve lift mechanisms 22 , 24 for each cylinder 14 , as well as a camshaft 26 and a cam phaser 28 .
[0018] The intake valve lift mechanism 22 may include a pushrod 30 and a rocker arm 32 . The exhaust valve lift mechanism 24 may additionally include a pushrod 30 and a rocker arm 32 . Pushrods 30 may be engaged with the camshaft 26 to actuate the rocker arms 32 and selectively open the intake and exhaust valves 18 , 20 . While the engine assembly 10 is illustrated as a pushrod engine, it is understood that the present disclosure is not limited to pushrod engines and may be applicable to a variety of other engine configurations as well, such as overhead cam engines.
[0019] With reference to FIGS. 2-5 , the camshaft 26 may include first and second shafts 34 , 36 , a first set of lobe members 38 , 40 , 42 , 44 , 46 , a second set of lobe members 48 , 50 , 52 , 54 , and fasteners 56 . In the present example, the first set of lobe members 38 , 40 , 42 , 44 , 46 may form an intake lobe set and the second set of lobe members 48 , 50 , 52 , 54 may form an exhaust lobe set. However, it is understood that alternate arrangements may be provided where the first set of lobe members 38 , 40 , 42 , 44 , 46 may form an exhaust lobe set and the second set of lobe members 48 , 50 , 52 , 54 may form an intake lobe set. Further, each of the first and second sets of lobe members 38 , 40 , 42 , 44 , 46 , 48 , 50 , 52 , 54 are not limited to only intake or exhaust valves. For example, the first and second sets of lobe members 38 , 40 , 42 , 44 , 46 , 48 , 50 , 52 , 54 may each include an intake lobe and/or an exhaust lobe. The first shaft 34 may be fixed for rotation with a first phaser member 58 and the second shaft 36 may be fixed for rotation with a second phaser member 60 . The first and second phaser members 58 , 60 may be rotatable relative to one another and relative to a rotationally driven member 62 of the phaser 28 .
[0020] The first shaft 34 may include an annular wall 64 defining an inner bore 66 . The second shaft 36 may be rotatably disposed within the inner bore 66 of the first shaft 34 . The first shaft 34 may include slots 68 (seen in FIGS. 4 and 5 ) therethrough and the second shaft 36 may include apertures 70 that receive the fasteners 56 therein and couple the second set of lobe members 48 , 50 , 52 , 54 for rotation with the second shaft 36 . The slots 68 may form radial bores through the first shaft 34 and the apertures 70 may form radial bores through the second shaft 36 . The slots 68 in the first shaft 34 may generally allow for a rotational travel of the fasteners 56 therein.
[0021] The first set of lobe members 38 , 40 , 42 , 44 , 46 may be fixed for rotation with the first shaft 34 . The engagement between the first set of lobe members 38 , 40 , 42 , 44 , 46 and the first shaft 34 may include a friction fit engagement. The second set of lobe members 48 , 50 , 52 , 54 may be disposed between adjacent ones of the first set of lobe members 38 , 40 , 42 , 44 , 46 . The second set of lobe members 48 , 50 , 52 , 54 may be rotatably disposed on the first shaft 34 and fixed for rotation with the second shaft 36 by the fasteners 56 .
[0022] As seen in FIGS. 4 and 5 , the fasteners 56 may each include a locking pin 72 . The locking pin 72 may include an annular wall 74 defining a longitudinal bore 76 extending from a first end 78 of the locking pin 72 to a second end 80 of the locking pin 72 . By way of non-limiting example, the locking pin 72 may be in the form of a cylindrical member having a generally circular outer surface 82 . The longitudinal bore 76 may also have a generally circular cross-section. A deforming member 84 may be forced through the longitudinal bore 76 of the locking pin 72 to couple the locking pin 72 to the second set of lobe members 48 , 50 , 52 , 54 .
[0023] A tool 86 may be used to force the deforming member 84 through the longitudinal bore 76 of the locking pin 72 . In the non-limiting example shown in FIGS. 4 and 5 , the deforming member 84 may be generally spherical, having a diameter (D d ). The slots 68 in the first shaft 34 may have an axial width (D S1 ) and the apertures 70 may have a diameter (D S2 ). The axial width (D S1 ) may be greater than the diameter (D S2 ). The second set of lobe members 48 , 50 , 52 , 54 may each include a radial bore 88 defining a diameter (D C ). The diameter (D C ) may be less than the axial width (D S1 ) and approximately equal to the diameter (D S2 ).
[0024] Referring to FIG. 4 , the longitudinal bore 76 of the locking pin 72 may have an initial inner diameter (D Ii ) and an initial outer diameter (D Oi ). The initial inner diameter (D Ii ) may be less than the diameter (D d ) of the deforming member 84 and the initial outer diameter (D Oi ) may be less than the diameter (D C ) of the radial bore 88 in the lobe member 48 . The deforming member 84 may force the annular wall 74 of the locking pin 72 in an outward radial direction as the deforming member is forced through the longitudinal bore 76 in an axial direction (A).
[0025] More specifically, the relationship between the diameter (D d ) of the deforming member 84 and the initial inner diameter (D Ii ) of the locking pin 72 may provide the outward radial displacement of the annular wall 74 as the locking pin is advanced axially along the longitudinal bore 76 . After the deforming member 84 has been displaced through the longitudinal bore 76 , the locking pin 72 may have a final inner diameter (D If ) and a final outer diameter (D Of ), as seen in FIG. 5 .
[0026] The final inner diameter (D If ) may be approximately equal to the diameter (D d ) of the deforming member 84 and the final outer diameter (D Of ) may be approximately equal to the diameter (D C ) of the bore 88 of the lobe member 48 . The locking pin 72 may therefore be frictionally engaged with and retained within the bore 88 of the lobe member 48 . Additionally, the final outer diameter (D Of ) of the locking pin 72 may be approximately equal to the diameter (D S2 ) of the aperture 70 in the second shaft 36 , fixing the locking pin 72 to the second shaft 36 as well.
[0027] After the deforming member 84 is forced through the longitudinal bore 76 of the locking pin 72 , the locking pin 72 may be fixed relative to the lobe member 48 . The locking pin 72 may remain hollow after being fixed to the lobe member 48 . Additionally, the first and second ends 78 , 80 of the locking pin 72 may be swaged, or deformed in an outward radial direction, to further fix the locking pin 72 relative to the lobe member 48 . More specifically, the first and second ends 78 , 80 may be displaced radially outward from the bore 88 of the lobe member 48 and into counter bores 90 , 92 .
[0028] It is understood that the fastener 56 is shown in combination with the lobe member 48 in FIGS. 4 and 5 for simplicity and the description applies equally to the remainder of the second set of lobe members 50 , 52 , 54 .
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A camshaft assembly method may include locating a first lobe member of a camshaft assembly on a first shaft of the assembly. A locking pin may be inserted into a first radial bore in the first lobe member and a second radial bore of the first shaft. The locking pin may have an annular wall defining a pin bore extending from a first end of the locking pin to a second end of the locking pin. A deforming member may be forced into the pin bore to displace the annular wall in an outward radial direction and into a frictional engagement with the first radial bore. The forcing may include a deforming member entering the pin bore at the first end of the locking pin and exiting the pin bore at the second end of the locking pin.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Provisional Application Ser. No. 60/717,041 filed Sep. 14, 2005, the contents of which are hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention pertains to processes for the isomerization of non-equilibrium xylenes and dealkylation of ethylbenzene; to catalysts comprising molecular sieve, platinum and tin in certain relationships with each other and with the molecular sieve and aluminum phosphate binder; and to processes for preferentially depositing platinum on molecular sieve on supports comprising molecular sieve and amorphous aluminum-containing binder.
BACKGROUND OF THE INVENTION
[0003] Catalysts containing platinum and tin have been proposed for use in many chemical and petrochemical reactions including dehydrogenation, dehydrocyclization, aromatization, reforming and isomerization of aliphatics and aromatics. For many of the proposed catalysts, the presence of molecular sieve, acidic or non-acidic, is suggested.
[0004] One of the more demanding chemical processes is the isomerization of a non-equilibrium mixture of xylenes and the dealkylation of ethylbenzene. The isomerization processes are practiced on a large, commercial scale to produce para-xylene and, in some instances, ortho-xylene, which have significant uses as raw materials for other chemical processes. For instance, para-xylene is in high demand since it is a raw material to make terephthalic acid for the manufacture of polyester.
[0005] The sought xylene isomers, para-xylene and ortho-xylene are often found in a mixture containing meta-xylene which is the most thermodynamically favored of the xylene isomers and with ethylbenzene, another C 8 aromatic isomer. The sought isomers are removed and the remaining isomers are subjected to isomerization to convert a part of the undesired isomer to a sought isomer. For instance, where para-xylene is sought, the para-xylene can be removed by selective crystallization or selective sorption; and ortho-xylene can be recovered by distillation. The remaining xylenes are subjected to isomerization to convert a portion to desired isomers. The isomerization, however, is limited by the equilibria among the isomers. Hence, the isomerate will at best contain about 24 mass-% of para-xylene and about 23 mass-% of the ortho-isomer with the balance being the meta-isomer, based on total xylenes.
[0006] The isomerate is recycled for recovery of the sought xylene isomer. The objective in a commercial facility is to ultimately by isomerization and recycle for selective recovery, to convert as much of the xylene feed as possible to the desired isomer and recover that isomer. Complicating the process is the typical presence of another C 8 aromatic, ethylbenzene, in feeds to a xylene recovery operation. To maintain a steady state operation in the cyclic xylene isomer recovery—isomerization loop, ethylbenzene must be removed. Additionally, greater concentrations of ethylbenzene in the recovery—isomerization loop adversely affect the economics of the facility as more energy will be required for the various unit operation. For purposes of illustration of energy requirements reference can be made to a prior art aromatics complex flow scheme disclosed by Meyers in part 2 of the H ANDBOOK OF P ETROLEUM R EFINING P ROCESSES , 2d. Edition, in 1997 published by McGraw-Hill. In this process, feed is introduced into a xylene column which separates C 8 aromatics as overhead and heavies are withdrawn from the bottoms. The C 8 aromatics are subjected to a separation process to selectively remove the sought isomer or isomers and then isomerized. Lights are removed from the isomerate by distillation to provide a recycle stream containing C 8 aromatics which is directed to the xylene column.
[0007] Removal of ethylbenzene by distillation is problematic due to similarity of boiling points. Accordingly, the most efficient mechanism for its removal is by either ethylbenzene isomerization in which some of the ethylbenzene is converted to xylene in the presence of naphthenes or by dealkylation to yield benzene and ethylene that can be more readily removed from xylenes by distillation.
[0008] Accordingly, isomerization processes have been developed that not only isomerize xylenes but also dealkylate ethylbenzene. These processes must effect very distinct and different chemical reactions. First, the xylene isomerization must redistribute the methyl groups on the benzene ring of the xylene isomers. Second, the ethylbenzene must be dealkylated to yield benzene and ethylene, and then third, ethylene must be hydrogenated to ethane. Ideally, these reactions would proceed selectively; however, in practice, numerous side reactions occur. For instance, ethylene could react with a xylene molecule to make methylethylbenzene. Similarly, during the redistribution of methyls on a xylene isomer could lead to the formation of trimethylbenzene and toluene. These and other highers are removed from the recovery—isomerization loop and represent lost xylene. Toluene represents another loss of xylene. Also, the hydrogenation can result in loss of aromatics to naphthenes and acyclic paraffins.
[0009] Naphthenes and acyclic paraffins can contaminate products as well as side products that can find some commercial use. One of the more sought side products is benzene. However, stringent specifications need to be met for the benzene to be marketable for certain uses. One such specification is that the benzene purity be at least about 99.85 percent. Naphthenes and paraffins having 6 and 7 carbon atoms (benzene co-boilers) tend to have boiling points close to that of benzene making purification of the benzene by distillation difficult. Accordingly, isomerization processes that generate very low amounts of benzene co-boilers are especially desirable.
[0010] Accomplishing the isomerization and dealkylation with a single catalyst while minimizing the undesirable side reactions has proven to be difficult especially since a catalyst needs to perform in a plant environment with adequate catalytic activities and acceptable life. Due to the disparate functions that must be accomplished for isomerization and ethylbenzene dealkylation, proposals have been made to conduct each reaction in a separate zone using different catalysts. This approach, however, increases capital costs and complexities of operation.
[0011] U.S. Pat. No. 3,856,872 discloses xylene isomerization and ethylbenzene conversion with a catalyst containing ZSM-5, -12, or -21 zeolite. U.S. Pat. No. 4,362,653 discloses a hydrocarbon conversion catalyst which could be used in the isomerization of isomerizable alkylaromatics that comprises silicalite (having an MFI-type structure) and a silica polymorph. The catalyst may contain optional ingredients. One of the applications of the catalyst is for aromatics isomerization.
[0012] U.S. Pat. No. 4,485,185 discloses a catalyst comprising a crystalline aluminosilicate such as MFI and at least two metals which are (a) platinum and (b) at least one other metal from the group consisting of titanium, chromium, zinc, gallium, germanium, strontium, yttrium, zirconium, molybdenum, palladium, tin, barium, cerium, tungsten, osmium, lead, cadmium, mercury, indium, lanthanum and beryllium. The catalyst is said to be useful for the isomerization of aromatic hydrocarbons and reforming of naphtha. The patentees state at column 4, lines 20 to 23 that “Titanium, tin, barium, indium and lanthanum are preferred as metal (b) because they have the great ability to inhibit side reactions. Titanium and tin are most preferred.”
[0013] U.S. Pat. No. 4,899,012 discloses the use of a catalyst containing lead, a Group VIII metal, a pentasil zeolite and an inorganic-oxide binder to isomerize xylenes and dealkylate ethylbenzene.
[0014] One type of catalyst that has had commercial application for xylene isomerization and ethylbenzene dealkylation comprises platinum on MFI in an inorganic matrix. This type of catalyst generally exhibits a good balance between the desired activities, i.e., approach to xylene isomer equilibrium and ethylbenzene conversion, but, as indicated above, suffers from C 8 aromatic loss through transalkylation and ring saturation.
[0015] U.S. Pat. No. 6,143,941 discloses that the use of an amorphous aluminum phosphate binder in a platinum group metal and molecular sieve-containing catalyst in a xylene isomerization and ethylbenzene dealkylation process can substantially reduce xylene loss. The preferred catalyst compositions comprise platinum and MFI with the aluminum phosphate binder. The patentees state: “It is within the scope of the present invention that the catalyst may contain other metal components known to modify the effect of the platinum-group metal component. Such metal modifiers may include without so limiting the invention rhenium, tin, germanium, lead, cobalt, nickel, indium, gallium, zinc, and mixtures thereof. Catalytically effective amounts of such metal modifiers may be incorporated into the catalyst by any means known in the art to effect a homogeneous or stratified distribution.” The patentees in several of the examples deposit platinum or palladium on an aluminum phosphate and MFI molecular sieve support using the tetraamineplatinum chloride or tetraaminepalladium chloride, but no example discloses the use of a metal modifier.
[0016] Although the aluminum phosphate binder does reduce xylene loss, these platinum-containing catalysts still leave room for improvement. In copending application Ser. No. 11/226,036, filed Sep. 14, 2005, the applicants disclose that the substitution of molybdenum for platinum in combination with an aluminum phosphate binder and molecular sieve such as MFI unexpectedly reduces xylene loss to even lower levels and in preferred embodiments, the net naphthene make is less than 0.02 mass-% based on total xylenes and ethylbenzene in the feed to the isomerization.
[0017] Copending application Ser. No. 11/226,037, filed on Sep. 14, 2005, discloses that the addition of a minor amount of platinum group metal to an isomerization catalyst using molybdenum as the hydrogenation metal component can enhance the approach to isomerization while still retaining a reduced xylene ring loss, especially low naphthene make, as compared to a catalyst containing platinum as the hydrogenation component.
[0018] Although platinum has desirable catalytic properties for achieving a close approach to xylene equilibrium during isomerization, it is not evident how to achieve the low levels of xylene loss, especially the low levels of net naphthene make, achievable with other hydrogenation metal components. And it is further not evident how to achieve such low levels of xylene loss, especially low levels of net naphthene make, without adversely affecting other catalyst properties such as activity for ethylbenzene conversion and approach to xylene isomer equilibrium.
[0019] Many metals including tin have been proposed as a modifier for platinum-containing catalysts for xylene isomerization and for other chemical reactions. The efficacy of any of these modifiers to achieve, e.g., a low level of net naphthene make without adversely affecting other catalytic properties, is not specifically disclosed in the above prior art.
[0020] Tin can have a complex relationship with platinum. For instance, U.S. Pat. No. 6,600,082 discusses platinum and tin-containing dehydrogenation catalysts. By way of background, the patentees observe that “catalysts based on PtSn contain different forms of tin.” They refer to Mössbauer spectroscopy which appears to confirm the existence in a reduced catalyst of an Sn 0 species in a Pt x Sn y type phase (x and y from 1 to 4) in which the tin is in oxidation state 0. They also point to the belief that on alumina, the formation of metallic tin in the reduced state is responsible for the loss in performance of PtSn catalysts. They further add: “A number of documents describe the use of catalysts containing a PtSn phase dispersed on alumina or tin that is essentially in a higher oxidation state than that of metallic tin (U.S. Pat. No. 3,846,283 and U.S. Pat. No. 3,847,794). Under such conditions, the conventional preparation methods used cannot guarantee a close association between tin and platinum, an intimate association between those metals in the catalyst in the reduced state being generally desirable, however, to best exploit the bimetallic effect in processes for transforming organic compounds.” (col. 3, lines 21 to 30)
[0021] The background discussion in this patent pertains to alumina supported catalysts for dehydrogenation. One can envisage even further complexities with respect to a catalyst that needs to effect both xylene isomerization and ethylbenzene conversion which contains catalytically-active molecular sieve.
DEFINITIONS
[0022] The following description of the invention, particularly the catalysts of the invention, is made with reference to various test procedures and analyses. The interrelation of the elements of the catalysts of this invention means that a change in one of the components will likely require a change in one or more other components. Additionally, process conditions and the form of the raw materials to make the catalysts of the invention can result in physical differences in the catalyst that may require alterations in ratios of components used. Once understanding the principles of the invention as taught below, one of ordinary skill in the art can readily make and use the invention with reference to Up-Take Analyses.
[0023] As used herein, an Up-Take Analysis is performed by immersing known quantities of a sample of the aluminum phosphate used for the binder of the catalyst and a sample of the molecular sieve used in the catalyst in the impregnating solution to be used to make the catalyst. If platinum and tin are co-impregnated in making the catalyst, then the solution will contain both the platinum and tin. If platinum is impregnated after the tin in the process for making the catalyst, then the molecular sieve used for the Up-Take Analysis will contain the intended amount of tin. The immersion is at 25° C. for 1 hour. The immersed samples are withdrawn taking care to remove excess liquid and washed with deionized water. Each of the withdrawn samples is dried at room temperature and then subjected to ICP elemental analysis to determine the amount of platinum in each.
[0024] Evaluation Conditions comprise using feed stream containing 15 mass-% ethylbenzene, 25 mass-% ortho-xylene and 60 mass-% meta-xylene; a hydrogen to hydrocarbon ratio of 4:1; a pressure of 1000 kPa gauge; a weight hourly space velocity of 15 hr −1 based upon the mass of the molecular sieve, and a temperature sufficient to convert 75 mass-% of the ethylbenzene with the data taken at 50 hours of operation. These specified conditions are for the purpose of providing common conditions for catalyst evaluation and are not limiting as to the xylene isomerization conditions that may be used in the processes of this invention.
[0025] Isomerization Activity is equal to the mass-% of para-xylene to total xylenes in the product obtained under Evaluation Conditions. The relative concentrations of xylenes is determined by gas chromatography using a J&W DB Wax #200-0370 column (60 meters by 0.25 millimeters with 0.5 micron film thickness) available from Agilent Technologies, Inc., Palo Alto, Calif.
[0026] Net C 6 Naphthenes Make is the mass-% of C 6 naphthenes in the product obtained under Evaluation Conditions determined by gas chromatography using a J&W PONA column #190915-001 (50 meters by 0.2 millimeter with 0.5 micron film thickness) available from Agilent Technologies.
SUMMARY OF THE INVENTION
[0027] By this invention, novel platinum-containing catalysts are provided, processes for depositing platinum on amorphous aluminum-containing supports are provided, and processes are provided for using platinum and tin-containing catalysts for the isomerization of xylenes and the dealkylation of ethylbenzene that exhibit excellent isomerization activities as well as ethylbenzene dealkylation activities comparable with attenuated aromatic ring hydrogenation activities. Advantageously, the catalysts of this invention can achieve the isomerization and dealkylation activities characteristic of platinum-containing catalysts yet enjoy low net naphthene make.
[0028] The catalysts of this invention require certain combinations of platinum, tin, molecular sieve and binder. In one broad aspect the catalysts of this invention comprise: (a) catalytically-effective amount of acidic molecular sieve having a pore diameter of from about 4 to 8 angstroms and a silica to alumina ratio of at least about 20:1, preferably at least about 35:1 and sometimes at least about 40:1; (b) platinum (calculated as atomic platinum) in an amount of between about 150 and 600, preferably between about 150 and 450, parts per million by mass (mass-ppm) based upon the mass of the molecular sieve; (c) amorphous aluminum phosphate binder in an amount of between 1 and 100, preferably 5 to 70, mass parts per 100 mass parts of molecular sieve; and (d) tin wherein the amount of tin (calculated as atomic tin) is in an atomic ratio to platinum in the catalyst of between about 1.2:1 to 30:1, preferably 1.5:1 to 25:1, wherein an Up-Take Analysis provides at least about 90, preferably at least about 95, percent of the platinum on an atomic basis being on a sample of the molecular sieve based upon the total platinum on the sample of the molecular sieve and a sample of the aluminum phosphate.
[0029] In another broad aspect, the catalysts of this invention suitable for isomerization of xylenes and conversion of ethylbenzene comprise: (a) a catalytically-effective amount of acidic molecular sieve having a pore diameter of from about 4 to 8 angstroms and a silica to alumina ratio of at least about 20:1, preferably at least about 35:1; (b) a catalytically-effective amount of platinum hydrogenation component on the molecular sieve; and (c) amorphous aluminum phosphate binder and tin both present in an amount sufficient to provide a Net C 6 Naphthenes Make under Evaluation Conditions of less than 0.05, preferably less than about 0.02, mass-% of the total C 8 aromatics in the feed wherein the catalyst under Evaluation Conditions exhibits an Isomerization Activity of at least about 23.0, preferably at least about 23.4, and most preferably at least about 23.6, wherein an Up-Take Analysis provides at least about 90, preferably at least about 95, percent of the platinum on an atomic basis being on a sample of the molecular sieve based upon the total platinum on the molecular sieve and aluminum phosphate samples.
[0030] The broad aspects of the processes of this invention comprise contacting a feed stream containing a non-equilibrium admixture of at least one xylene isomer and ethylbenzene wherein preferably between about 1 and 60, and more frequently between about 5 and 35, mass-% of the feed stream is ethylbenzene, with a catalyst comprising (a) a catalytically-effective amount of acidic molecular sieve having a pore diameter of from about 4 to 8 angstroms and a silica to alumina ratio of at least about 20:1, preferably at least about 35:1; (b) a catalytically-effective amount, preferably in an amount of between about 150 and 600, preferably between about 150 and 450, parts per million by mass (mass-ppm) based upon the mass of the molecular sieve, of platinum hydrogenation component on the molecular sieve; (c) amorphous aluminum phosphate binder, preferably in an amount of between 1 and 100, preferably 5 to 70, mass parts per 100 mass parts of molecular sieve, and (d) tin, preferably the amount of tin (calculated as atomic tin) is in an atomic ratio to platinum in the catalyst of between about 1.2:1 to 30:1, preferably 1.5:1 to 25:1, wherein an Up-Take Analysis provides at least about 90, preferably at least about 95, percent of the platinum on an atomic basis being on a sample of the molecular sieve based upon the total platinum on the molecular sieve and aluminum phosphate samples. The isomerization conditions include the presence of hydrogen in a mole ratio to hydrocarbon of between about 0.5:1 to 6:1, preferably 1:1 to 2:1 to 5:1, wherein an Up-Take Analysis provides at least about 90, preferably at least about 95, percent of the platinum on an atomic basis being on a sample of the molecular sieve based upon the total platinum on the molecular sieve and aluminum phosphate samples. Preferably, the isomerization is conducted under at least partially vapor phase conditions. In the preferred aspects of the processes of this invention, the net C 6 naphthenes make under the conditions of the process is less than about 0.05, preferably less than about 0.02, mass-% based on the xylenes and ethylbenzene in the feed.
[0031] A further aspect of the invention pertains to processes for co-impregnating platinum and at least one metal modifier a support comprising a catalytically-effective amount of acidic molecular sieve having a pore diameter of from about 4 to 8 angstroms and a silica to alumina ratio of at least about 20:1 and amorphous aluminum-containing binder such as gamma-alumina and aluminum phosphate, in an amount of between 1 and 100 mass parts per 100 mass parts of molecular sieve with platinum comprising contacting an aqueous solution of a compound having a platinum cation, preferably tetraamineplatinum chloride, and a soluble compound of the at least one metal modifier at a temperature of at least about 70° C., preferably between about 80° C. and 150° C., and for a time sufficient to deposit platinum on the support and evaporate water. The impregnation process preferentially provides the platinum deposited on the molecular sieve as compared to the aluminum-containing binder, and the metal modifier is deposited in association with the platinum to provide the modifying effect. The metal modifier may be one or more of tin, rhenium, germanium, lead, cobalt, nickel, indium, gallium, zinc, uranium, dysprosium, thallium, and molybdenum, most preferably tin. While not wishing to be limited to theory, it is believed that an association of the platinum and at least one metal modifier occurs in the impregnating solution which facilitates the preparation of a modified platinum catalyst.
DETAILED DESCRIPTION OF THE INVENTION
[0000] The Catalyst
[0032] The catalysts used in the processes of this invention comprise an acidic molecular sieve having a pore diameter of from about 4 to 8 angstroms, platinum and tin in an amorphous aluminum phosphate binder. Examples of molecular sieves include those having Si:Al 2 ratios greater than about 20:1, and often greater than about 35:1 or 40:1, such as the MFI, MEL, EUO, FER, MFS, MTT, MTW, TON, MOR and FAU types of zeolites. Pentasil zeolites such as MFI, MEL, MTW and TON are preferred, and MFI-type zeolites, such as ZSM-5, silicalite, Borolite C, TS-1, TSZ, ZSM-12, SSZ-25, PSH-3, and ITQ-1 are especially preferred.
[0033] The zeolite is combined with binder for convenient formation of catalyst particles. The relative proportion of zeolite in the catalyst may range from about 1 to about 99 mass-%, with about 2 to about 90 mass-% being preferred.
[0034] The binder or matrix component comprises an amorphous phosphorous-containing alumina (herein referred to as aluminum phosphate) component. The atomic ratios of aluminum to phosphorus in the aluminum phosphate binder/matrix generally range from about 1:10 to 100:1, and more typically from about 1:5 to 20:1. Preferably the aluminum phosphate has a surface area of up to about 450 m 2 /gram, and preferably the surface area is up to about 250 m 2 /g.
[0035] The amount of the aluminum phosphate binder is preferably sufficient to reduce the transalkylation activity of the catalyst, e.g., co production of toluene and trimethylbenzene. Advantageously, the catalysts of this invention can be characterized as having under Evaluation Conditions, a net make of toluene and trimethylbenzene of less than about 3, preferably less than about 2, mass-% based on the mass of C 8 aromatics (xylenes and ethylbenzene) in the feed.
[0036] The aluminum phosphate may be prepared in any suitable manner. One suitable technique for preparing aluminum phosphate is the oil-drop method of preparing the aluminum phosphate which is described in U.S. Pat. No. 4,629,717. This technique involves the gellation of a hydrosol of alumina which contains a phosphorus compound using the well-known oil-drop method. Generally this technique involves preparing a hydrosol by digesting aluminum in aqueous hydrochloric acid at reflux temperatures of about 80° to 105° C. The mass ratio of aluminum to chloride in the sol often ranges from about 0.7:1 to 1.5:1. A phosphorus compound is added to the sol. Preferred phosphorus compounds are phosphoric acid, phosphorous acid and ammonium phosphate. The relative amount of phosphorus and aluminum expressed in atomic ratios ranges from about 10:1 to 1:100, and often 10:1 to 1:10.
[0037] If desired, the molecular sieve can be added to the hydrosol prior to gelling the mixture. One method of gelling involves combining a gelling agent with the mixture and then dispersing the resultant combined mixture into an oil bath or tower which has been heated to elevated temperatures such that gellation occurs with the formation of spheroidal particles. The gelling agents which may be used in this process are hexamethylene tetraamine, urea or mixtures thereof. The gelling agents release ammonia at the elevated temperatures which sets or converts the hydrosol spheres into hydrogel spheres. The spheres are then continuously withdrawn from the oil bath and typically subjected to specific aging and drying treatments in oil and in ammoniacal solution to further improve their physical characteristics. The resulting aged and gelled particles are then washed and dried at a relatively low temperature of about 100° to 150° C. and subjected to a calcination procedure at a temperature of about 450° to 700° C. for a period of about 1 to 20 hours.
[0038] The combined mixture preferably is dispersed into the oil bath in the form of droplets from a nozzle, orifice or rotating disk. Alternatively, the particles may be formed by spray-drying of the mixture at a temperature of from about 425° to 760° C. In any event, conditions and equipment should be selected to obtain small spherical particles; the particles preferably should have an average diameter of less than about 5.0 mm, more preferably from about 0.2 to 3 mm, and optimally from about 0.3 to 2 mm.
[0039] Alternatively, the catalyst may be an extrudate. The well-known extrusion method initially involves mixing of the molecular sieve with optionally the binder and a suitable peptizing agent to form a homogeneous dough or thick paste having the correct moisture content to allow for the formation of extrudates with acceptable integrity to withstand direct calcination. Extrudability is determined from an analysis of the moisture content of the dough, with moisture content in the range of from about 30 to about 50 mass-% being preferred. The dough is then extruded through a die pierced with multiple holes and the spaghetti-shaped extrudate is cut to form particles in accordance with techniques well known in the art. A multitude of different extrudate shapes is possible, including, but not limited to, cylinders, cloverleaf, dumbbell and symmetrical and asymmetrical polylobates. It is also within the scope of this invention that the extrudates may be further shaped to any desired form, such as spheres, by marumerization or any other means known in the art.
[0040] Another alternative is to use a composite structure having a core and an outer layer containing molecular sieve and aluminum phosphate. Often, the thickness of the molecular sieve layer is less than about 250 microns, e.g., 20 to 200, microns. The core may be composed of any suitable support material such as alumina or silica, and is preferably relatively inert towards dealkylation. Advantageously, at least about 90 mass-% of the platinum in the catalyst is contained in the outer layer. The catalyst may be in any suitable configuration including spheres and monolithic structures.
[0041] The catalyst may contain other components provided that they do not unduly adversely affect the performance of the finished catalyst. These components are preferably in a minor amount, e.g., less than about 40, and most preferably less than about 15, mass-% based upon the mass of the catalyst. These components include those that have found application in hydrocarbon conversion catalysts such as: (1) refractory inorganic oxides such as alumina, titania, zirconia, chromia, zinc oxide, magnesia, thoria, boria, silica-alumina, silica-magnesia, chromia-alumina, alumina-boria, silica-zirconia, phosphorus-alumina, etc.; (2) ceramics, porcelain, bauxite; (3) silica or silica gel, silicon carbide, clays and silicates including those synthetically prepared and naturally occurring, which may or may not be acid treated, for example, attapulgite clay, diatomaceous earth, fuller's earth, kaolin, kieselguhr, etc.; and (4) combinations of materials from one or more of these groups. Often, no additional binder component need be employed.
[0042] The catalyst of the present invention may contain a halogen component. The halogen component may be fluorine, chlorine, bromine or iodine or mixtures thereof, with chlorine being preferred. The halogen component is generally present in a combined state with the inorganic-oxide support. The optional halogen component is preferably well dispersed throughout the catalyst and may comprise from more than 0.2 to about 15 mass-%, calculated on an elemental basis, of the final catalyst. The halogen component may be incorporated in the catalyst composite in any suitable manner, either during the preparation of the inorganic-oxide support or before, while or after other catalytic components are incorporated. Preferably, however, the catalyst contains no added halogen other than that associated with other catalyst components.
[0043] If desired, the catalyst composite can be dried and then calcined. Drying is often at a temperature of from about 100° to about 320° C. for a period of from about 2 to about 24 or more hours and, usually, calcining is at a temperature of from 400° to about 650° C. in an air atmosphere for a period of from about 0.1 to about 10 hours until the metallic compounds present are converted substantially to the oxide form. If desired, the optional halogen component may be adjusted by including a halogen or halogen-containing compound in the air atmosphere.
[0044] The catalytic composite can optionally be subjected to steaming to tailor its acid activity. The steaming may be effected at any stage of the molecular sieve treatment, but usually is carried out on the composite of molecular sieve and binder prior to incorporation of the platinum. Steaming conditions comprise a water concentration of about 1 to 100 vol-%, pressure of from about 100 kPa to 2 MPa, and temperature of from about 600° to about 1200° C.; the steaming temperature preferably is at least about 650° C., more preferably at least about 750° C., and optionally may be about 775° C. or higher. In some cases, temperatures of about 800° to 850° C. for preferably least about one hour.
[0045] Alternatively or in addition to the steaming, the composite may be washed with one or more of a solution of ammonium nitrate, a mineral acid, and/or water. Considering the first alternative, the catalyst may be washed with a solution of about 5 to 30 mass-% ammonium nitrate. When acid washing is employed, a mineral acid such as HCl or HNO 3 is preferred; sufficient acid is added to maintain a pH of from more than 1 to about 6, preferably from about 1.5 to 4. The catalyst is maintained in a bed over which the solution and/or water is circulated for a period of from about 0.5 to 48 hours, and preferably from about 1 to 24 hours. The washing may be done at any stage of the preparation, and two or more stages of washing may be employed.
[0046] If the molecular sieve is in a metal salt form, the composite is ion-exchanged with a salt solution containing at least one hydrogen-forming cation such as NH 4 or quaternary ammonium to provide the desired acidity. The hydrogen-forming cation replaces principally alkali-metal cations to provide, after calcination, the hydrogen form of the molecular sieve component. Usually, the ion exchange is conducted prior to providing the platinum and tin components.
[0047] Platinum is an essential component of the present catalyst. The platinum component may exist within the final catalyst composite as a compound such as an oxide, sulfide, halide, oxysulfide, etc., or as an elemental metal or in combination with one or more other ingredients of the catalyst composite. It is believed that the best results are obtained when substantially all the platinum component exists in a reduced state. The platinum component is preferentially deposited in the molecular sieve. The concentration of platinum (calculated on an atomic basis) based upon the mass of molecular sieve present falls within a relatively narrow range. With too little platinum, not only will the isomerization activity of the catalyst suffer but also the ethylbenzene dealkylation activity suffers and transalkylation side reactions may become more prominent. If the amount of platinum is too great, net naphthene make increases as does transalkylation. Accordingly, by this invention, the concentration of platinum is typically within the range of 150 and 600, preferably between about 150 and 450, mass-ppm based upon the mass of the molecular sieve.
[0048] The catalysts of this invention, and the processes of this invention use catalysts, have the platinum component preferentially in the molecular sieve as compared to the amorphous aluminum phosphate. Determining where the platinum component resides in a finished catalyst is difficult and is subject to uncertainties. Accordingly, the Up-Take Analysis procedure is adopted as an indicator of where platinum would be preferentially deposited. It is not, nor is it intended to be, a measure of the amounts and portions of platinum actually deposited on the molecular sieve and on the aluminum phosphate binder. Hence, the catalysts of this invention may actually have a lesser portion of the platinum in the molecular sieve based upon total molecular sieve and aluminum phosphate than indicated by the Up-Take Analysis. Nevertheless, the Up-Take Analysis, by indicating where the platinum is preferentially deposited, is a viable and useful tool for characterizing the catalysts.
[0049] The platinum component may be incorporated into the catalyst composite in any suitable manner that achieves the preferential deposition in the molecular sieve. The platinum may be incorporated before, during or after incorporation of the tin component. One method of preparing the catalyst involves the utilization of a water-soluble, decomposable compound of platinum to impregnate the calcined sieve/binder composite. Alternatively, a platinum compound may be added at the time of compositing the molecular sieve component and binder. Complexes of platinum which may be employed according to the above or other known methods include chloroplatinic acid, ammonium chloroplatinate, bromoplatinic acid, platinum trichloride, platinum tetrachloride hydrate, platinum dichlorocarbonyl dichloride, tetraamineplatinum chloride, dinitrodiaminoplatinum, sodium tetranitroplatinate (II), and the like.
[0050] The tin component is provided in a critical amount. With insufficient tin, the low net naphthene make is not achieved, but as the amount of tin is increased, the ethylbenzene dealkylation activity decreases. Moreover, the optimal amount of tin will depend upon the amount of platinum in the catalyst. Often, the amount of tin (calculated as atomic tin) is in an atomic ratio to platinum in the catalyst of between about 1.2:1 to 30:1, preferably 1.5:1 to 25:1, and in some instances from about 1.5:1 to 5:1.
[0051] The tin component may be incorporated into the catalyst composite in any suitable manner and may be incorporated before, during or after incorporation of the platinum component. One method of preparing the catalyst involves the utilization of a water-soluble, decomposable compound of tin to impregnate the calcined sievelbinder composite. Alternatively, a tin compound may be added at the time of compositing the molecular sieve component and binder. It is essential that the manner in which the tin is provided to the catalyst does not result in undue loss of acidity of the molecular sieve.
[0052] The tin compound and composition of the impregnating solution can have an effect on the desired association of tin with platinum group metal. Tin compounds include halogens, hydroxides, oxides, nitrates, sulfates, sulfites, carbonates, phosphates, phosphites, halogen-containing oxyanion salts such as chlorates, perchlorates, bromates, and the like, as will as hydrocarbyl and carboxylate compounds and complexes, e.g., with amines and quaternary ammonium compounds. Exemplary compounds include, but are not limited to tin dichloride, tin tetrachloride, tin oxide, tin dioxide, chlorostannous acid, tetrabutyl tin, tetraethyl tin, ammonium hexachlorostannate, and tetraethylammonium trichlorostannate.
[0053] It is within the scope of the present invention that the catalyst composites may contain other metal components. Such metal modifiers may include rhenium, germanium, lead, cobalt, nickel, indium, gallium, zinc, uranium, dysprosium, thallium, molybdenum and mixtures thereof. Catalytically effective amounts of such metal modifiers may be incorporated into the catalysts by any means known in the art to effect a homogeneous or stratified distribution.
[0054] The preferred processes of this invention for making the catalyst comprise depositing platinum on a molecular sieve and binder support from a solution, preferably an aqueous solution, in which the platinum is in a cationic form such as tetraamineplatinum chloride. The solution containing the sought amount of platinum, and optionally tin component, and support are combined an mixed and the solvent is evaporated while mixing, preferably at a temperature of at least about 70° C., and more preferably between about 80° C. and 140° C., and the catalyst is dried, e.g., at a temperature of between about 100° C. and 250° C.
[0055] The catalysts of this invention are preferably calcined, e.g., at a temperature within the range of about 400° C. and 800° C., preferably in the presence of steam, e.g., about 0.5 to 20 volume percent of the vapor phase, for about 1 to 24, preferably about 1 to 6, hours.
[0056] The prepared catalyst, especially due to the calcining, will contain platinum and tin in oxidized states. To obtain the beneficial performance properties, the catalyst is subjected to reducing conditions. Adequate reducing conditions exist for the purposes of activating the catalyst in the isomerization process itself. If desired, the catalyst may be partially or completely pre-reduced. Any suitable reducing technique may be employed. Often the pre-reducing comprises using a gaseous atmosphere comprising at least one of hydrogen and hydrocarbon at elevated temperatures, e.g., from about 250° to 550° C. for 0.5 to 50 hours.
[0057] Catalysts may be regenerated. Where the loss of catalytic activity is due to coking of the catalyst, conventional regeneration processes such as high temperature oxidation of the carbonaceous material on the catalyst may be employed.
[0000] The Process
[0058] The feed stocks to the aromatics isomerization process of this invention comprise non-equilibrium xylene and ethylbenzene. These aromatic compounds are in a non-equilibrium mixture, i.e., at least one C 8 aromatic isomer is present in a concentration that differs substantially from the equilibrium concentration at isomerization conditions. Thus, a non-equilibrium xylene composition exists where one or two of the xylene isomers are in less than equilibrium proportion with respect to the other xylene isomer or isomers. The xylene in less than equilibrium proportion may be any of the para-, meta- and ortho-isomers. As the demand for para- and ortho-xylenes is greater than that for meta-xylene, usually, the feed stocks will contain meta-xylene. Generally the mixture will have an ethylbenzene content of about 1 to about 60 mass-%, an ortho-xylene content of 0 to about 35 mass-%, a meta-xylene content of about 20 to about 95 mass-% and a para-xylene content of 0 to about 30 mass-%. Usually the non-equilibrium mixture is prepared by removal of para-, ortho- and/or meta-xylene from a fresh C 8 aromatic mixture obtained from an aromatics-production process. The feed stocks may contain other components, including, but not limited to naphthenes and acyclic paraffins, as well as higher and lower molecular weight aromatics.
[0059] The alkylaromatic hydrocarbons may be used in the present invention as found in appropriate fractions from various refinery petroleum streams, e.g., as individual components or as certain boiling-range fractions obtained by the selective fractionation and distillation of catalytically cracked or reformed hydrocarbons. Concentration of the isomerizable aromatic hydrocarbons is optional; the process of the present invention allows the isomerization of alkylaromatic-containing streams such as catalytic reformate with or without subsequent aromatics extraction to produce specified xylene isomers and particularly to produce para-xylene.
[0060] According to the process of the present invention, the feedstock, in the presence of hydrogen, is contacted with the catalyst described above. Contacting may be effected using the catalyst system in a fixed-bed system, a moving-bed system, a fluidized-bed system, and an ebullated-bed system or in a batch-type operation. In view of the danger of attrition loss of valuable catalysts and of the simpler operation, it is preferred to use a fixed-bed system. In this system, the feed mixture is preheated by suitable heating means to the desired reaction temperature, such as by heat exchange with another stream if necessary, and then passed into an isomerization zone containing catalyst. The isomerization zone may be one or more separate reactors with suitable means therebetween to ensure that the desired isomerization temperature is maintained at the entrance to each zone. The reactants may be contacted with the catalyst bed in upward-, downward-, or radial-flow fashion.
[0061] The isomerization is conducted under isomerization conditions including isomerization temperatures generally within the range of about 100° to about 550° C. or more, and preferably in the range from about 150° to 500° C. The pressure generally is from about 10 kPa to about 5 MPa absolute, preferably from about 100 kPa to about 3 MPa absolute. The isomerization conditions comprise the presence of hydrogen in a hydrogen to hydrocarbon mole ratio of between about 0.5:1 to 6:1, preferably about 1:1 or 2:1 to 5:1. One of the advantages of the processes of this invention is that relatively low partial pressures of hydrogen are still able to provide the sought selectivity and activity of the isomerization and ethylbenzene conversion. A sufficient mass of catalyst (calculated based upon the content of molecular sieve in the catalyst composite) is contained in the isomerization zone to provide a weight hourly space velocity with respect to the liquid feed stream (those components that are normally liquid at STP) of from about 0.1 to 50 hr −1 , and preferably 0.5 to 25 hr −1 .
[0062] The isomerization conditions may be such that the isomerization is conducted in the liquid, vapor or at least partially vaporous phase. For convenience in hydrogen distribution, the isomerization is preferably conducted in at least partially in the vapor phase. When conducted at least partially in the vaporous phase, the partial pressure of Cs aromatics in the reaction zone is preferably such that at least about 50 mass-% of the Cs aromatics would be expected to be in the vapor phase. Often the isomerization is conducted with essentially all the Cs aromatics being in the vapor phase.
[0063] Usually the isomerization conditions are sufficient that at least about 10, preferably between about 20 and 80 or 90, percent of the ethylbenzene in the feed stream is converted. Generally the isomerization conditions do not result in a xylene equilibrium being reached. Often, the mole ratio of xylenes in the product stream is at least about 80, say, between about 85 and 99, percent of equilibrium under the conditions of the isomerization. Where the isomerization process is to generate para-xylene, e.g., from meta-xylene, the feed stream contains less than 5 mass-% para-xylene and the isomerization product comprises a para-xylene to xylenes mole ratio of between about 0.20:1 to 0.25:1 preferably at least about 0.23:1, and most preferably at least about 0.236:1.
[0064] The particular scheme employed to recover an isomerized product from the effluent of the reactors of the isomerization zone is not deemed to be critical to the instant invention, and any effective recovery scheme known in the art may be used. Typically, the isomerization product is fractionated to remove light by-products such as alkanes, naphthenes, benzene and toluene, and heavy byproducts to obtain a C 8 isomer product. Heavy byproducts include dimethylethylbenzene and trimethylbenzene. In some instances, certain product species such as ortho-xylene or dimethylethylbenzene may be recovered from the isomerized product by selective fractionation. The product from isomerization of C 8 aromatics usually is processed to selectively recover the para-xylene isomer, optionally by crystallization. Selective adsorption is preferred using crystalline aluminosilicates according to U.S. Pat. No. 3,201,491. Improvements and alternatives within the preferred adsorption recovery process are described in U.S. Pat. No. 3,626,020, U.S. Pat. No. 3,696,107, U.S. Pat. No. 4,039,599, U.S. Pat. No. 4,184,943, U.S. Pat. No. 4,381,419 and U.S. Pat. No. 4,402,832, incorporated herein by reference.
EXAMPLES
[0065] The following examples are presented only to illustrate certain specific embodiments of the invention, and should not be construed to limit the scope of the invention as set forth in the claims. There are many possible other variations, as those of ordinary skill in the art will recognize, within the spirit of the invention.
Example I
[0066] Catalyst samples are prepared.
[0067] Catalyst A: Steamed and calcined aluminum-phosphate-bound MFI zeolite spheres are prepared using the method of Example I in U.S. Pat. No. 6,143,941. The pellets are impregnated with an aqueous solution of 1:2:6 moles of tin(II)chloride:ethylenediamminetetraacetic acid:ammonium hydroxide and tetra-ammine platinum chloride to give 0.023 mass-% platinum and 0.20 mass-% tin on the catalyst after drying and calcination in air with 3% steam at 538° C.
[0068] Catalyst B: Steamed and calcined aluminum-phosphate-bound MFI zeolite spheres are prepared using the method of Example I in U.S. Pat. No. 6,143,941. The pellets are impregnated with an aqueous solution of 1:2:6 moles of tin(II)chloride:ethylenediamminetetraacetic acid:ammonium hydroxide and tetra-ammine platinum chloride to give 0.039 mass-% platinum and 0.29 mass-% tin on the catalyst after drying and calcination in air with 3% steam at 538° C.
[0069] Catalyst C: Steamed and calcined aluminum-phosphate-bound MFI zeolite spheres are prepared using the method of Example I in U.S. Pat. No. 6,143,941. The pellets are impregnated with an aqueous solution of 1:2:6 moles of tin(II)chloride:ethylenediamminetetraacetic acid:ammonium hydroxide and tetra-ammine platinum chloride to give 0.046 mass-% platinum and 0.11 mass-% tin on the catalyst after drying and calcination in air with 3% steam at 538° C.
Example II
[0070] Catalysts A, B and C are evaluated in a pilot plant for the isomerization of a feed stream containing 7 mass-% ethylbenzene, 1 mass-% para-xylene, 22 mass-% ortho-xylene and 70 mole-percent meta-xylene. The pilot plant runs are at a hydrogen to hydrocarbon ratio of 4:1, total pressure of 1200 kPa, and weight hourly space velocity of 10 based on the total amount of catalyst loaded. The pilot plant runs are summarized in the following table. The product data are taken at approximately 50 hours of operation.
Catalyst A B C Sn/Pt atomic ratio 14 12 4 EB Conversion, % 75 75 75 WABT*, ° C. 385 390 385 Para-xylene/xylene 23.8 23.8 23.8 Toluene + Trimethylbenzene, 1.8 1.6 2.0 mass-% yield C 6 Naphthenes, mass-% yield 0.02 0.04 0.08 *weighted average bed temperature
Example III
[0071] Catalysts are prepared using similar procedures and components as in Example I and are evaluated in a similar manner to that described in Example II. The following table sets forth the catalyst compositions and performance. The benzene purity (BZ purity) is the mass percent benzene based upon total benzene and naphthenes and paraffins of 6 and 7 carbon atoms. The table also sets forth the temperature of the impregnation of each catalyst. The evaluation is at 75 percent conversion of ethylbenzene.
Impreg Pt Sn Temp WABT BZ purity Para-xylene/ Catalyst ppm-m %-mass ° C. ° C. %-mass xylene % M 220 0.19 130 391 99.9 23.70 N 280 0.22 100 393 99.7 23.65 O 430 0.096 130 388 99.6 23.80 P 280 0.22 130 396 99.8 23.74 Q 450 0.052 130 388 99.6 23.83 R 380 0.07 130 384 99.7 23.45 S 230* 0.07 130 387 99.9 23.40 T 350 0.04 130 387 99.7 23.60 U 370 0.04 130 387 99.3 23.60 *Catalyst S, when analyzed appears to not be at target platinum concentration.
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Catalysts of certain combinations of platinum, tin, acidic molecular sieve and aluminum phosphate binder achieve the isomerization and dealkylation activities characteristic of platinum-containing catalysts yet enjoy the low net C 6 naphthenes make properties.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of application No. 60/727,206, “Interactive Mapping Method and System,” filed Oct. 14, 2005, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
The present invention relates to the field of computer-network-based mapping. In particular, the present invention relates to an interactive mapping method and system.
BACKGROUND OF THE INVENTION
With the increasing popularity of the Internet, millions of users use the Internet to get maps of address locations of interest to them or to get driving directions for getting to such address locations. With conventional map applications, a user would enter a start address and an end address in order to get a driving direction. The conventional map applications would return a map and a list of driving directions from the start address to the end address.
One drawback of the conventional map applications is that they are limited to a point-to-point solution, for getting from point A to point B, for example. However, if the user wants to visit a number of other address locations in the same trip, he would have to break down the whole trip into a series of point-to-point entries and get the map and driving directions for each point-to-point entry separately. This conventional approach involves printing multiple maps and their corresponding driving directions on multiple pages of paper, typically one page for each point-to-point entry. It is not only time-consuming but also a waste of resources because of the multiple maps and their corresponding driving directions that the user has to create and print.
Therefore, there is a need for a new interactive mapping method and system to address the drawbacks of the conventional map applications.
SUMMARY
The present invention generally relates to an interactive mapping method and system. In one embodiment, a method for presenting a set of address locations in a browser window of a user device via the Internet includes receiving a set of address locations in a given order, presenting the set of address locations as a list of directions, and presenting the set of address locations graphically on a map, where the map includes a route connecting the set of address locations according to the given order and a marker for each of the address locations. The method further includes creating a new order of the set of address locations from the given order by dragging an address location from the map to a different position in the list of directions, updating the list of directions according to the new order of the set of address locations, and updating the map according to the new order of the set of address locations.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned features and advantages of the invention as well as additional features and advantages thereof will be more clearly understandable after reading detailed descriptions of embodiments of the invention in conjunction with the following drawings.
FIGS. 1 a - 1 d illustrate a multipoint routing method according to embodiments of the present invention.
FIGS. 2 a - 2 c illustrate re-ordering of destinations in the multipoint routing method according to embodiments of the present invention.
FIGS. 3 a - 3 b illustrate removing a destination in the multipoint routing method according to embodiments of the present invention.
FIGS. 4 a - 4 b illustrate creating a roundtrip in the multipoint routing method according to embodiments of the present invention.
FIGS. 5 a - 5 e illustrate a map navigator according to embodiments of the present invention.
FIG. 6 illustrates result clusters associated with the map navigator according to embodiments of the present invention.
FIGS. 7 a - 7 b illustrate aspect ratio of the map navigator according to embodiments of the present invention.
FIGS. 8 a - 8 c illustrate an address-to-business lookup method according to embodiments of the present invention.
FIGS. 9 a - 9 c illustrate a method for updating an address in the uniform resource locator (URL) according to embodiments of the present invention.
FIGS. 10 a - 10 c illustrate a method for printing a map with directions and search results according to embodiments of the present invention.
FIG. 11 illustrates a method for auto-completing an address entry using information from an address book according to an embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
The following descriptions are presented to enable any person skilled in the art to make and use the invention. Descriptions of specific embodiments and applications are provided only as examples. Various modifications and combinations of the examples described herein will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the examples described and shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
Some portions of the detailed description that follows are presented in terms of procedures, steps, logic blocks, processing, and other symbolic representations of operations on data bits that can be performed on computer memory. A procedure, computer-executed step, logic block, process, etc., are here conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those utilizing physical manipulations of physical quantities. These quantities can take the form of electrical, magnetic, or radio signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system. These signals may be referred to at times as bits, values, elements, symbols, characters, terms, numbers, or the like. Each step may be performed by hardware, software, firmware, or combinations thereof.
In various embodiments, the interactive mapping method and system of the present invention implement Web 2.0 functionalities using a combination of HTML, CSS, JavaScript, Asynchronous JavaScript and XML (AJAX), Y!Q, Yahoo! Maps, Yahoo! Widget Engine, and Yahoo! Toolbar for Internet Explorer.
FIGS. 1 a - 1 d illustrate a multipoint routing method according to embodiments of the present invention. FIG. 1 a shows a user entering a first location at the location entry box A. FIG. 1 b shows the user entering a second location at the location entry box B. Similarly, FIGS. 1 c and 1 d show the third and fourth locations are entered at locations entry boxes C and D respectively. Note that upon entering the second location at the location entry box B, the method automatically provides the next location entry box C for the user to enter additional locations, if any. This process is repeated for the subsequent entries, for example the fourth and fifth locations at location entry boxes D and E respectively.
As shown in FIGS. 1 a - 1 d , the interactive mapping system affords a user the ability to create routes with multiple way-points. The user not only is able to create a route from one address/location (A) to another address/location (B), but also may have the option to continue his route to other addresses/locations, such as addresses/locations C, D, and beyond. The route steps between two way-points (e.g., A and B) are described in U.S. application Ser. No. 10/849,083, filed May 19, 2004, entitled “Mapping Method and System,” and its continuation-in-part U.S. application Ser. No. 11/137,603, filed May 25, 2005, entitled “Mapping Method and System,” both of which are incorporated herein by reference in their entirety.
FIGS. 2 a - 2 c illustrate re-ordering of destinations in the multipoint routing method according to embodiments of the present invention. FIG. 2 a shows the user (cursor shown as a hand) grabbing the D point to be moved to in front of the C point (Livermore) in the route. FIG. 2 b shows the D point (Oakland) being dragged and inserted prior to the C point (Livermore). FIG. 2 c shows the new C point (Oakland) both in the map and directions list and in the route drawn on the map. The previous C point (Livermore) becomes the new D point.
As shown in FIGS. 2 a - 2 c , the user may re-order way-points within his route by dragging and dropping within the list view of the route or by dragging a way-point from the map view into the desired point in the list view. For example, the user may decide to change way-point D to be the first stop, so he can drag that point and drop it before the current B way-point in the route list view, and it becomes the new B way-point. The previous B way-point is displaced and becomes the new C way-point and so on. The route steps description and representation on the map are refreshed to describe and show the new route.
FIGS. 3 a - 3 b illustrate removing of a destination in the multipoint routing method according to embodiments of the present invention.
FIGS. 3 a - 3 b show the user may delete one or more way-points from his route. For example, the user may remove way-point B from a route that has way-points A-B-C-D. After way-point B is removed, way-point C becomes the new B way-point, and D becomes the new C way-point. In FIG. 3 a , the delete icon at the right-side of way-point C is selected. After the way-point C (Oakland) is deleted, the original way-point D (Livermore) becomes the new way-point C as shown in FIG. 3 b.
FIGS. 4 a - 4 b illustrate creating a roundtrip in the multipoint routing method according to embodiments of the present invention. This is done by selecting the Roundtrip link as indicated by the cursor (hand) in FIG. 4 a . The user may create a multipoint route by drag and drop of local entities (e.g., businesses) represented on the map from the map to the desired position within the route list view. FIG. 4 b shows the complete roundtrip both on the map and on the directions list. As a result, the total distance of the trip is increased to 70.7 miles (the sum of the distance of each of the two routes), and the amount of time is increased to one hour and thirty four minutes (the sum of the time of each of the two routes).
FIGS. 5 a - 5 e illustrate a map navigator according to embodiments of the present invention. A map navigator includes a small map that gives the surrounding geographic context of the large map view. Within the map navigator, the extent of the current large map view is represented by a shaded rectangular driving (panning) control super-imposed on the surrounding geographic context map, as shown in FIG. 5 a . For example, while the large map may show the City of San Francisco, the map navigator map shows the Bay Area with a shaded rectangular area representing San Francisco.
The user can use this shaded area as a control to “drive” to other locations and so explore the geographic context of the current map. As shown in FIG. 5 b , this is done by dragging the driving control (shown as the cursor over the grey box) in the direction he wants to drive. In FIG. 5 c , the map navigator continuously pans in the direction the user is moving the panning control for as long as the user continues to hold and drag it. In FIG. 5 d , the user releases the panning control, and in FIG. 5 e , the driving control then settles on the center of the map navigator area, and the large map redraws to the new location the user just drove to.
FIG. 6 illustrates result clusters associated with the map navigator according to embodiments of the present invention. The map navigator may also show representations of data points of interest, for example, businesses such as cafes, hotels, or restaurants. While the large map may only show, say, three points of interest, the map navigator is able to display representations of further similar points of interest in geographic areas adjacent to the view shown by the large map. This allows the user to quickly see and navigate to areas outside the large map view that may contain data of interest. For example, the large map only shows three hotels, but the map navigator shows a cluster of six more to the southwest. Other data of interest such as routes, traffic, demographic statistics, and any other geo-data may be similarly represented.
FIGS. 7 a - 7 b illustrate aspect ratio of the map navigator according to embodiments of the present invention. FIG. 7 a shows a default view of the map navigator, which has substantially the same aspect ratio as the main map. FIG. 7 b shows an all-map view of the map navigator, which also has substantially the same aspect ratio as the main map. Note that the aspect ratio of the driving control corresponds to that of the large map, such that it changes due to the browser window re-sizing or the closing of the control panel.
FIGS. 8 a - 8 c illustrate an address-to-business lookup method according to embodiments of the present invention. The interactive mapping system matches an address entered into a location field with a known business. For example as shown in FIG. 8 a , a user may enter “701 First Ave, Sunnyvale Calif. 94089” into location field A, and upon submission of this entry, the system returns a match for the business known to be at this address, as shown in FIG. 8 b as Yahoo! Incorporated. Additional information about that business may then be displayed, such as the phone number, user ratings (stars) of the business, etc. The user may access further information about this business by linking to supplementary pages shown in FIG. 8 c , which may include user reviews, photos, hours of operation, and other relevant information.
FIGS. 9 a - 9 c illustrate a method for updating an address in the URL according to embodiments of the present invention. The interactive mapping system automatically updates the URL in the browser address bar in real time. This URL contains sufficient information to allow for the redrawing of the current map view, including any data superimposed on it, such as driving directions, points of interest, etc. For example, instead of using the # symbol to designate in-page anchor links, the system designates the # symbol with a query string that describes the contents of the page (e.g., search results and other map zoom levels etc.). This is represented by the text after the “#” near the middle of the first line in the example shown in FIG. 9 c . This function allows the user to copy and paste the URL of the current view, and email it to a friend who may then link to this exact view.
FIGS. 10 a - 10 c illustrate a method for printing a map with directions and search results according to embodiments of the present invention. The interactive mapping system provides the capability of automatically sending a layout of the current map view (shown in FIG. 10 a ) and data that is optimized for printing. This occurs when the user selects the print function within the application or when the user chooses the print function from the browser. The printed version of the map and map data, as shown in FIG. 10 b , is not what the user is seeing on the screen, such as a “print screen,” but is a different layout specifically designed for printing. The print view of the same data is automatically sent to the printer. The user may also send a text-only variant.
In FIG. 10 c , two stylesheets are used to control what is viewed onscreen as being different from what is sent to the printer. Stylesheet 1 designates the screen view and hides the print view; and stylesheet 2 designates the print view and is activated when the user initiates a print function either from within the application or from the browser print commands. This stylesheet also hides the screen view from the print function so that only the print view is sent to the printer.
FIG. 11 illustrates a method for auto-completing an address entry using information from an address book according to an embodiment of the present invention. The interactive mapping system provides the capability of displaying auto-complete selections drawn from the user's address book and the universal location manager (ULM). The ULM stores recently visited or previously saved locations. As the user types in letters or numbers of, for example, a person's name, nickname, or address, into a location box that match entries within his address book or ULM data, the system displays these matches for selection, as shown in FIG. 11 . The user can choose to ignore or select these options. If the user selects one of these auto-complete options, the map then centers on the chosen address.
It will be appreciated that the above description for clarity has described embodiments of the invention with reference to different functional units and processors. However, it will be apparent that any suitable distribution of functionality between different functional units or processors may be used without detracting from the invention. For example, functionality illustrated to be performed by separate processors or controllers may be performed by the same processor or controller. Hence, references to specific functional units are only to be seen as references to suitable means for providing the described functionality rather than as indicative of a strict logical or physical structure or organization.
The invention can be implemented in any suitable form, including hardware, software, firmware, or any combination of them. The invention may optionally be implemented partly as computer software running on one or more data processors and/or digital signal processors. The elements and components of an embodiment of the invention may be physically, functionally, and logically implemented in any suitable way. Indeed the functionality may be implemented in a single unit, in a plurality of units, or as part of other functional units. As such, the invention may be implemented in a single unit or may be physically and functionally distributed between different units and processors.
One skilled in the relevant art will recognize that many possible modifications and combinations of the disclosed embodiments may be used, while still employing the same basic underlying mechanisms and methodologies. The foregoing description, for purposes of explanation, has been written with references to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described to explain the principles of the invention and their practical applications, and to enable others skilled in the art to best utilize the invention and various embodiments with various modifications as suited to the particular use contemplated.
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Method and computer program product for presenting a set of address locations in a browser window of a user device via the Internet are disclosed. The method includes receiving a set of address locations in a given order, presenting the set of address locations as a list of directions, and presenting the set of address locations graphically on a map, where the map includes a route connecting the set of address locations according to the given order and a marker for each of the address locations. The method further includes creating a new order of the set of address locations from the given order by dragging an address location from the map to a different position in the list of directions, updating the list of directions according to the new order of the set of address locations, and updating the map according to the new order of the set of address locations.
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REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my copending application Ser. No. 912,727, filed Aug. 4, 1992, now U.S. Pat. No. 5,283,976, which is a continuation of my application Ser. No. 729,222, filed Jul. 12, 1991, now U.S. Pat. No. 5,131,186, issued on Jul. 21, 1992, which is a continuation-in-part of my copending application Ser. No. 07/372,839, filed on Jun. 29, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for preventing unauthorized entry into buildings via window openings. More particularly, the invention relates to a portable apparatus which may be installed in a window opening to permit air and light to enter a building, while preventing persons from entering the building through the window opening.
2. Discussion of Background Art
It is an unfortunate fact that the crime rate in our country is on the increase. Thus, many individuals who because of their geographic location, away from high crime rate areas, or for other reasons, felt themselves immune from the crime problem, must now confront one manifestation of that problem; namely the ever-increasing rate of business and residential burglaries.
Most rational individuals would not wish the material fruits of their labors to be stolen from them by burglars. More importantly, most people are genuinely concerned that those criminals who would break into their dwelling places or residences to steal their possessions often are the type of individuals who would just as soon kill or injure the owner or his loved ones, should they be present during the course of a burglary.
As a result of their concern for the protection of their property, and the lives of themselves and their loved ones, a substantial percentage of the population have begun to take measures to protect themselves from burglars. For example, many homeowners and business owners have installed more secure door locks, and burglar alarms in their homes and shops. Another form of protection which has found increasing favor are security bar devices which, when installed over window openings or doorways, provide a very effective barrier to unauthorized entry through the protected opening. Such security bar devices generally take the form of a grill comprising a parallel array, or lattice array of heavy metal bars which are spaced closely enough to prevent passage through the array by a person.
Security bar devices of the type described above generally provide an effective means of preventing undesired entry to buildings through the protected areas. However, most such security bar devices suffer from one or more disadvantages which limit their wider usage. For example, many older security bar devices are not equipped with a safety mechanism which permits escape of the building occupants in the case of fire or other accidents within the building, or the entrance of firemen or other emergency personnel. Unfortunately, the absence of such a safety release provision in some security bar devices has resulted in the tragic loss of life.
Although there are now available security bar devices that are provided with safety release mechanisms, these as well as the older type security bar devices have an inherent feature which limits their more widespread usage. Specifically, most available security bar devices are relatively heavy and costly, and are intended for relatively permanent, and correspondingly costly, installation. Accordingly, such security bar devices are generally unsuitable for people who rent or have limited incomes. Some devices have been disclosed which would seem to address the problem of providing a security bar device which might be usable in non-permanent installation applications. Typical of such disclosures are those contained in the following U.S. patents:
Iyersen, U.S. Pat. No. 4,757,465, Mar. 18, 1986, Security Grill Apparatus for Doors and Windows.
Zilkha, U.S. Pat. No. 4,624,072, Nov. 25, 1986, Adjustable Security Window Gates.
Merklingen, et al., U.S. Pat. No. 4,671,012, Jun. 9, 1987, Security Barrier.
Jokel, U.S. Pat. No. 4,680,890, Jul. 21, 1987, Window Intrusion Barrier.
The present invention was conceived of to provide a security grill apparatus which is highly portable and useable in window openings of various dimensions.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a portable security grill apparatus which may be readily installed in a window opening, while providing an effective bar to entrance by individuals through the window opening.
Another object of the invention is to provide a portable security grill apparatus for windows which is readily adjustable to fit within various height spaces between a window sill and the bottom of a raised window.
Another object of the invention is to provide a portable security grill apparatus for windows which may be quickly and securely clamped into a compressively locking contact between parallel structural members, such as the lower surface of a raised window and the upper surface of a window sill.
Another object of the invention is to provide a portable security grill apparatus for windows which may be optionally secured in locking position with a key lock, after being compressively locked into position.
Another object of the invention is to provide a portable security grill apparatus for window openings which may be quickly unlocked and removed from a window opening.
Various other objects and advantages of the present invention, and its most novel features, will become apparent to those skilled in the art by perusing the accompanying specification, drawings and claims.
It is to be understood that although the invention disclosed herein is fully capable of achieving the objects and providing the advantages described, the characteristics of the invention described herein are merely illustrative of the preferred embodiment. Accordingly, I do not intend that the scope of my exclusive rights and privileges in the invention be limited to details of the embodiments described. I do intend that equivalents, adaptations and modifications of the invention, reasonably inferable from the description contained herein be included within the scope of the invention as defined by the appended claims.
SUMMARY OF THE INVENTION
Briefly stated, the present invention comprehends a portable security grill apparatus for removable installation in openings in the walls of structures such as shops, industrial buildings, and dwelling places such as homes and apartments. The apparatus according to the present invention is particularly well adapted to removable installation in window frames with the window slid to an open upper or side position. The apparatus prevents unauthorized entrance through the window opening, while allowing the window to be open for ventilation purposes, and allowing light to enter the room protected.
The portable security grill apparatus according to the present invention includes a grill comprising a plurality of regularly spaced horizontally disposed rigid metal bars, welded to a plurality of vertically disposed, hollow rigid metal bars. The lower ends of the vertical bars are fastened to a horizontally disposed, flat lower beam adapted to seat firmly against the upper surface of a window sill. The upper ends of the hollow vertical bars slidably contain a short bars. Each of the upper ends of the short bars is in turn attached to a horizontally disposed, flat plate adapted to seat firmly against the lower surface of an open window, or window frame. The lower beam and each of the upper plates support resilient pads which have concave depressions to form suction cups which grip the window frame surfaces. Also, window clamps extend coextensively along the outside edge of the lower beam and upper plates and seat over the inside flanges of the window tracks, thereby firmly interlocking the grill apparatus in place.
Toggle clamp mechanisms are connected between each short bar and the hollow bar in which it is positioned. When the toggle clamp mechanism is compressed into its closed position, the short bar is forced upwards with respect to the hollow bar to which it is joined by the toggle clamp mechanism. Thus, closing the toggle clamp forces a short bar to move telescopically upwards, moving its upper plate upwards.
Means are included within the toggle clamp mechanism to adjust the amount of upward travel of the short bar and its upper plate. Also, the toggle clamp mechanism is so constructed as to have a substantial mechanical force advantage. Therefore, a substantial compressive force may be exerted between the upper and lower window frame members when the toggle clamps are closed. That force is sufficiently large to preclude pulling the security bar apparatus from the window frame, without releasing the toggle clamp operating lever, and the resistance of the apparatus to dislodgement is enhanced by the resilient pads and window clamps which are secured to each of the lower beam and upper plates. Since the toggle clamp lever is located inside the structure protected, it is not accessible to an intruder. In the preferred embodiment of the apparatus, a key lock is attached to the toggle clamp, permitting release of the toggle clamp lever only by first inserting a key and turning the key lock to an unlocked position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an inside elevation view of the security grill apparatus according to the present invention, showing the apparatus installed in a window opening;
FIG. 2 is a fragmentary side elevation view of the apparatus of FIG. 1, on a somewhat enlarged scale, showing the apparatus in a retracted position;
FIG. 3 is a view similar to FIG. 2, but showing the apparatus in an extended position;
FIG. 4 is a fragmentary side elevation view of the apparatus of FIG. 1, showing the toggle clamp mechanism in a closed and locked position;
FIG. 5 is a fragmentary front elevation view of the apparatus of FIG. 4, showing the lever of a toggle clamp forming part of the apparatus pivoted into an upward position;
FIG. 6 is a top view of the window frame clamp pad used with the security grill apparatus of this invention;
FIG. 7 is an elevational view of the window frame clamp pad shown in FIG. 6;
FIG. 8 is an elevational view of the clamp pad engaged against a window frame;
FIG. 9 is a enlarged view of the area within line 9--9' of FIG. 3, showing the window clamp and clamp pad used in the invention; and
FIG. 10 is a perspective view of a window clamp used with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 through 5, a portable security grill apparatus 10 is shown. As shown in FIG. 1, the apparatus 10 is vertically positioned for installation in a window frame with a horizontally slidable window. However, the apparatus may also be oriented for installation in a window frame having a vertically slidable window.
As shown in FIG. 1, the security grill apparatus includes a grill 11 having a plurality of elongated straight rigid metal bars 12. Bars 12 are arranged in vertically disposed parallel positions, at regular horizontal intervals, and all lie in a common plane.
As may be seen best by referring to FIGS. 1, 2 and 3, at least the upper end of each of the bars 12A contains a hollow coaxial bore 13 extending longitudinally inward some distance from the upper transverse face 14 of the bar 12A. Preferably, bars 12 and 12A are fabricated from square cross-section, hollow steel tubes. When so fabricated, bore 13 has a square cross-sectional shape, and extends through the entire length of a bar 12 or 12A.
The lower transverse ends 15 of bars 12 are welded or otherwise secured to a flat, elongated rectangular base plate 16 made of steel or other rigid material. The lower surface of base plate 16 supports an elongated rectangular pad 17 formed of an elastomer, preferably rubber, which is secured to plate 16 with a plurality of rivets (not shown) at spaced-apart locations. The rivets pull the pad 17 into a plurality of cup depressions (see FIG. 2) in the uncompressed state. The plate 17 also supports an elongated window clamp 22, described in greater detail with reference to FIGS. 2, 3, 9 and 10.
As may be seen best by referring to FIG. 1, grill 11 of security grill apparatus 10 includes a plurality of elongated, straight rigid metal cross bars such as upper bar 18A and lower bar 18B. Cross bars 18A and 18B are arranged in horizontally disposed parallel positions, at regular vertical intervals. The cross bars are welded to the front, or inner surface of vertical bars 12, thus forming therewith a rigid, planar grill structure. Cross bars 18A and 18B may be fabricated from the same type of steel tubing as vertical bars 12, if desired.
As may be seen best by referring to FIG. 1, grill 11 of security bar apparatus 10 includes at least a pair of upper clamps 19 which are spaced apart at locations which are preferably symmetrical across the apparatus 10. Each of the clamps 19 is vertically telescopable with respect to lower section 20 of the grill 11, in a manner which will now be described.
As shown in FIGS. 1, 2 and 3, each clamp 19 includes an upper elongated rectangular flat steel plate 21, which is substantially identical in thickness and width to base plate 16, and can be of a variable length. Each plate 21 supports a clamp pad 25 of the same rubber material as clamp pad 17 and which is secured to plate 21 by spaced-apart rivets, forming cup shaped depressions, as described for pad 17. Each base plate 21 supports a coextensive window clamp 22.
Each clamp 19 includes a straight, relative short metal bar 23, which is fastened to plate 21, and which extends perpendicularly downwards from the plate. The short metal bars 23 have smaller outer cross-sectional dimensions than the corresponding dimensions of the bores 13 in long vertical bars 12A and are telescopingly received therein, to permit the clamps 19 to move up and down vertically with respect to lower section 20 while maintaining the upper plates 21 in parallel alignment with the lower plate 16.
As shown in FIG. 1, a toggle clamp mechanism 24 is operatively interconnected between the upper portion of a hollow vertical tube 12A and a short vertical bar 23 which is telescopically slidably located within the bore 13 of the vertical bar 12A. Preferably, each security bar apparatus 10 includes two such toggle clamp mechanisms 24, spaced at equidistant intervals from the lateral sides of the grill 11.
The structure and operation of toggle clamp mechanism 24 may be best understood by referring to FIGS. 2, 3, 4 and 5. FIG. 2 illustrates the toggle clamp mechanism 24 in an open position, in which the short metal bars 23 are in a downward, retracted relationship relative to the lower vertical bars 12. In this position, the clamp pad 17 rests on the upper surface or sill A of a window frame and the upper clamp pads 25 are positioned below the lower surface C of the window frame.
The window is a conventional horizontal sliding window with an upper track 64 and a lower track 63 with one or two sliding glass panels 44 and 46.
As shown in FIGS. 2, 9 and 10, each of the plates 16 and 21 support coextensive window clamps 22, formed of sheet metal. Each clamp 22 has a flat web that projects to the inside edges of window tracks 64 and 63. The clamp 22 is bent into a channel 37 having a width sufficient to receive the inside flange of each track 64 and 63.
As shown in FIG. 10, the opposite ends of each channel 37 are chamfered, preferably at 45°, to prevent binding of the sliding window panels.
As shown in FIGS. 2, 3, 4 and 5, the toggle clamp mechanism 24 includes a channel frame section 26 which is fastened to an outer vertical surface of a lower rigid vertical bar 12A. The toggle clamp mechanism 24 also includes a multi-component lever mechanism 27 which is vertically slidably attached to the channel frame section 26, and pivotally attached to a short vertically disposed, metal upper bar 23, the latter being vertically slidable within the bore 13 of lower tubular bar 12A.
As shown in FIGS. 2, 3, 4 and 5, the lever mechanism 27 of toggle clamp mechanism 24 includes a base plate 28, an operating arm 39, and an engagement lug 30. The base plate 28 of lever mechanism 27 is vertically slidably supported within channel frame section 26, as will now be described.
Channel frame section 26 has a tubular lower end 31 of relatively short length, the major, upper portion of the channel frame section 26 having the shape of a vertically elongated, open U-shaped channel 32. The opposite upper edges of the side walls of channel 32 flare inwardly to form opposed laterally spaced-apart, longitudinally disposed parallel flanges 33 (see FIG. 5). Base plate 28 has a generally uniform thickness, and has in elevation view the approximate shape of a vertically elongated trapezoid. The inner vertical surface 34 of base plate 28 is flat and adapted to move slidably on the bottom surface 35 of channel 32 of channel frame section 26. Near the bottom end of base plate 28, are rounded bosses 36 (see FIG. 5) which project perpendicularly outward from the front and rear vertical surfaces 37 and 38, respectively, of base plate 28. The lateral distance between the outer surfaces of bosses 36 is greater than the distance between the inner facing wall surfaces of flanges 33 of channel frame section 26. Thus, base plate 28 is vertically slidable within channel 32 in channel frame section 26, but prevented from moving laterally out of the channel by contact of bosses 36 with flanges 33.
As shown in FIGS. 1 through 5, the lever mechanism 27 of toggle clamp mechanism 24 includes an outer lever arm 39. Lever arm 39 is an elongated member having an upper channel-shaped portion 40 having front and rear side walls 41 and 42 (see FIG. 5) formed therein. The lateral spacing between the inner surfaces of front and rear side walls 41 and 42 of upper channel section 40 of lever arm 39 is slightly larger than the thickness of base plate 28 of lever mechanism 27. This difference permits the upper end of base plate 28 to reside pivotally within channel section 40 of lever arm 39. The pivotal joint between base plate 28 and lever arm 39 consists of a pivot pin 43 which extends through registered holes and in the front and rear sidewalls 41 and 42, respectively, of upper channel section 40 of the lever arm. Pivot pin 43 is located about one-fifth of the longitudinal distance between the upper and lower ends of the lever arm 39.
The upper end of lever arm 39 is secured to a generally trapezoidal or triangular shaped lug 47 of generally uniform thickness, pivotally held between the front and rear walls 41 and 42 of the lever arm. The lug can be fixedly secured, by welding, to the short bar 23. The inner, smaller vertex or base of lug 47 is pivotally attached within the upper channel section 40 of lever arm 34 by means of a pivot pin 48 fastened in holes in the front and rear walls, and passing through a clearance hole through the lug.
The lower end of lever arm 39 has a generally flat plate-like handle section 54. Plate-like handle section 54 has a flat outer lateral surface 55. Plate-like handle section has a generally rectangular plan-view shape and is joined near its upper end to the lower ends of front and rear side walls 41 and 42 of upper channel section 40 of the lever arm 39, perpendicular thereto. A generally uniform-thickness locking tab 56 having a generally triangular-shaped plan-view is fastened to the inner wall surface of the lower end of front side wall 41 of upper channel section 40. Locking tab 56 lies in a vertical plane and extends perpendicularly inward from the inner wall surface 57 of plate-like lower handle section 54.
FIG. 3 illustrates the grill 10 in place and compressed within the window. The compression flattens the base clamp pad 17 and its cup-shaped depressions function as suction cups to enhance the resistance of the grill against dislodgement from the window. Similarly, the clamp pads 25 associated with each clamp 19 are flattened and secure against the under surface C of the window frame.
The channels 37 which extend coextensively with plates 16 and 21 are received over the inner flanges of window tracks 64 and 63 to interlock the grill to the window and prevent its dislodgement.
As may be seen best by referring to FIGS. 2 and 3, lever arm 39 may be pivoted in a vertical plane with respect to channel frame section 26 of toggle clamp mechanism 24, about intermediate pivot pin 43. As shown in FIG. 3, downward and inward pivotal motion of lever arm 39 relative to channel frame section 26 and attached lower tubular vertical bar 12 moves lug 47 upwards. This in turn moves upper vertical bar 23, which is engaged by lug 47 which is rigidly secured to the upper vertical bar 23, upwards with respect to the lower tubular 12. Thus, as shown in FIGS. 2 and 3, base plate 16 and roof plate 21 are spread apart vertically, allowing a compressive force to be exerted between window sill A and window top frame C. Owing to the fact that the ratio of the distance between the lower end of handle section 54 and intermediate pivot pin 43 on the one hand, and the distance between the intermediate pin 43 and upper pivot pin 48, on the other, is about 5 to 1, a substantial, locking compressive force may be exerted which requires only a modest closing force on handle section 54. This force can be sufficiently great to render the removal of the security bar apparatus 10 from a window frame a virtual impossibility unless the window and/or frame are destroyed.
As shown in FIGS. 2 through 5, a threaded stud 58 is contained in a threaded bore 59 in lower tubular end 31 of channel frame section 26. Stud 58 is an adjustable support for the lever mechanism, as the upper end 60 (see FIG. 5) of the threaded stud abuts the lower end 61 of base plate 28 of lever mechanism 27, thus permitting the lower limit of motion of the base plate to be adjusted to a desired value. Thus, turning threaded stud 58 permits adjusting the locked and unlocked vertical extension of security bar apparatus 10 to fit various size window openings.
As shown in FIG. 2, the lower end of base plate 28 and locking tab 56 are provided with through holes 62 and 63, respectively. Holes 62 and 63 are equal distances from intermediate pivot pin 43. Thus, with the toggle clamp mechanism 24 in a locked position, as shown in FIG. 3, holes 62 and 63 are in a registered position, permitting a locking member, such as the hasp of a conventional combination or key lock, to be inserted through the holes.
As may be seen best by referring to FIGS. 1 and 4, the upper portion of each toggle clamp mechanism 24 is preferably concealed by means of a U-channel-shaped cover 71 which is fastened to the outer wall of upper channel-shaped portion 40 of lever arm 39 by any convenient means.
Referring now to FIGS. 6 through 8, the construction and functioning of the resilient pads 25 and 17 will be described. As previously mentioned each pad is formed of an elastomer, preferably rubber, and is attached to its supporting plate 16 or 21 with a plurality of spaced-apart rivets 50. The rivets contort the surface of the rubber pads 25 and 17 and form a plurality of concave depressions, similar to suction cups in the uncompressed state, shown in FIGS. 6 and 7. When the pads are compressed, however, they flatten to the shape shown in FIGS. 8 and 9, creating a suction between the rubber pads and the opposing window frame surface. This suction greatly resists lateral displacement of the grill apparatus. Preferably, each concave depression in the pads 17 and 25 is provided with a through aperture 51 which releases the suction when the toggle clamp mechanism is opened, thereby permitting easy removal of the pads from the window surfaces. The apertures are sealed when the pads are flattened and compressed, as the plates 16 and 21 seat against and seal the apertures 51.
Preferably each plate 16 and 21 also is provided with a window track clamp which extends coextensively the length of the plates 16 and 21. As shown in FIG. 9, the window clamp has a flat web 22 that projects towards the window track 64 and has a channel 37 on its outer edge which is received about the inner flange of the track 64 when the grill apparatus is compressed in the window opening.
The invention has been described with reference to the illustrated and presently preferred embodiment. It is not intended that the invention be unduly limited by this disclosure of the preferred embodiment. Instead, it is intended that the invention be defined by the means, and their obvious equivalents, set forth in the following claims.
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A portable security grill apparatus which may be installed in window openings of buildings includes two rectangular grill sections longitudinally telescopically fastened to one another. Opposite longitudinal ends of the two grill sections have beams disposed perpendicularly to the axis of longitudinal telescoping movability of the two grill sections, the beams having flat outer surfaces adapted to abut a window edge at one end of the grill apparatus, and a window frame edge, at the other end of the apparatus. At least one toggle clamp connected between telescopically joined members of the two grill sections is capable of exerting a large outward extension force when in a closed, clamped position, thereby exerting compressive forces on the window and window frame sufficient to prevent the grill apparatus from being removed from the window opening.
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BACKGROUND OF THE INVENTION
The present invention relates to a transfer system for transferring in a clean room a wafer cassette between semiconductor processing apparatuses for producing semiconductor devices such as very large-scale integrated circuits and large-scale integrated circuits.
In most of such conventional transfer systems, semiconductor processing apparatuses are placed within highly clean areas in a clean room, the areas being kept in a degree from 10 to 100 cleanliness class by using laminar air flow method. A wafer cassette which is loaded with wafers is transferred to a stacker crane of each highly clean area by means of an automatic wafer transport line using, for example, a linear motor carriage and then transported by a wafer automatic transfer robot to each of semiconductor processing apparatuses. This type of transfer system is disadvantageous in equipment cost and maintenance cost for producing a highly clean environment.
For overcoming these drawbacks, there has been, as illustrated in FIGS. 1 and 2, proposed a clean room using SMIF (TM) system, which includes a sealing cover 32 which covers over the top of a semiconductor processing apparatus 34, a clean air supply device 36 which incorporates both a high efficiency filter and a blower into it, a pair of SMIF arms (TM) 38 and 38 (hereinafter referred to as ARMs) which transfer wafer cassettes into and out of the semiconductor processing apparatus, and a pair of SMIF pods (TM) 40 (hereinafter referred to as pod). Each pod 40 includes a rectangular box door or removable bottom 42, on which a wafer cassette 44 is secured, and a box 46 which engages with the box door 42 for enclosing the wafter cassette 44 on the box door 42 in an airtight manner. Wafers 48 are loaded in the cassette 44 as illustrated in FIG 2. One pod 40 with wafer cassette 44 loaded with wafers 48 is manually placed on the top of one ARM 38 on the loading side and the other pod (not shown), having empty wafer cassette 44 received in it, is also manually placed on the top of the other ARM 39. Then, both the box door 42 and the wafter cassette 44, secured it, of each pod 40 are introduced into the corresponding ARM, from which only wafer cassette 44 is transferred into the semiconductor processing apparatus 34. Wafers 48 thus placed within the semiconductor processing apparatus 34 are sequentially subjected to processing and then transferred into the wafer cassette 44 on the unloading side. After this, the wafter cassette 44 loaded with the wafers 48 is returned back to the ARM 38 on the unloading side, where it is placed on the box door 42, which is then engaged with the box 42 placed on the top of that ARM 38 without exposing the wafers 48 to the atmosphere. The pod 40, containing the wafers 48 thus processed, is manually transported to another semiconductor processing apparatus for further processing. The following papers disclose the SMIF (TM) system: The Journal of Environmental Sciences, U.S.A., May/June '84 issue: "The Challenge to Control Contamination: A Novel Technique for the IC Process", page 23; Solid State Technology, U.S.A., July 1984, "SMIF, A Technology for Wafer Cassette Transfer in VLSI Manufacturing", page 111; and "Standard Mechanical Interface for Wafer Cassette Transfer" (Proposed), Document #1332, issued by Semiconductor Equipment and Materials Institute, Inc., U.S.A., Dec. 6, 1985.
The SMIF (TM) system ensures a high yield of product even in a clean room of a relatively low cleanliness, e.g., cleanliness class 1000 to 100000 since wafers are not allowed to be exposed to outside contamination and are placed in highly clean air during both processing and transportation thereof. However, both manual transportation of the pod 40 between semiconductor processing apparatuses and manual setting of pods 40 to respective ARMs 38, 39 are laborious.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a transfer system for transferring a pod in a clean room, in which costs in construction, equipment and maintenance of the clean room are considerably reduced.
It is another object of the present invention to provide a transfer system for transferring a pod in a clean room, in which transportation of the pod between various semiconductor processing apparatuses and setting thereof to the ARM are automatized, so that production cost of the semiconductor is considerably reduced.
With these and other objects in view, the present invention provide a transfer system for transferring a pod in a clean room, in which the pod is adapted to receive a wafer cassette. The transfer system includes: at least one pair of ARMs, the ARMs disposed adjacent to a semiconductor processing apparatus for transferring wafers, carried in the wafer cassette, into and out of the semiconductor processing apparatus; a transfer tube disposed near the ARMs; a vehicle adapted to carry the pod and adapted to move within the transfer tube; evacuation mechanism for evacuating the transfer tube to produce a negative pressure within the transfer tube so that the vehicle is moved along an axis of the transfer tube due to the negative pressure; and at least one pair of conveying mechanisms for conveying the vehicle between the transfer tube and respective arms.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a semiconductor processing apparatus according to the prior art, using SMIF (TM) system;
FIG. 2 is an enlarged vertical section of the pod in FIG. 1;
FIG. 3 is a diagrammatic view of a pod transfer system according to the present invention, in which first loading and unloading station tubes are partly broken away;
FIG. 4 is an enlarged perspective view of part of the transfer tube in FIG. 4 in which an arm is located just below a corresponding station tube;
FIG. 5 is an enlarged vertical section of one end of the station tube in FIG. 4;
FIG. 6 is a view taken along the line VI--VI in FIG. 5;
FIG. 7 is an enlarged plan view of the stopper in FIG. 4;
FIG. 8 is a view taken along the line VIII--VIII in FIG. 7;
FIG. 9 is an enlarged vertical section of part of the lifting chamber in FIG. 4;
FIG. 10 is a view taken along the line X--X in FIG. 9;
FIG. 11 is an enlarged vertical section of part of the station tube in FIG. 4;
FIG. 12 is an enlarged perspective view, seen from the bottom, of the vehicle in FIG. 4;
FIG. 13(A) is an enlarged, sectional side view of the vehicle in FIG. 12 on which the pod rides, the vehicle being lifted;
FIG. 13(B) is an enlarged fragmentary view, partly in section, of the vehicle in FIG. 13(A), in which the vehicle is being placed on an ARM;
FIG. 13(C) is an enlarged fragmentary view, partly in section, of the vehicle in FIG. 13(A), in which the vehicle is placed on the ARM;
FIG. 13(D) is an enlarged fragmentary view, partly in section, of the vehicle in FIG. 13(A), in which the vehicle is about to disengage from the two-arms lever;
FIG. 14 is a perspective view, seen from the bottom, of a modified form of the pod in FIG. 13;
FIG. 15 is a perspective view of a modified form of the lifting mechanism in FIG. 4;
FIG. 16 is an enlarged view taken along the line XVI--XVI in FIG. 15;
FIG. 17 is a vertical section of a modified form of the closure plate in FIG. 11, having a turning mechanism;
FIG. 18 is a diagrammatic plan view of the second embodiment of the present invention;
FIG. 19 is an enlarged, exploded view of one station tube in FIG. 18;
FIG. 20 is a diagrammatic side view of the station tube in FIG. 19 when the communicating portion of the station tube is in communication with the transfer tube;
FIG. 21 is a diagrammatic side view of the station tube in FIG. 19 when the conveying portion thereof is in communication with the transfer tube;
FIG. 22 is a diagrammatical side view of the station tube in FIG. 19 when the communication portion is in communication with the transfer tube again with the vehicle received within the conveying portion;
FIG. 23 is a diagrammatic plan view, partly in section, of a third embodiment of the present invention with the first loading and unloading station tubes partly broken away;
FIG. 24 is an enlarged perspective view, partly in section, of part of the transfer tube in FIG. 23 in which the bottom and the lateral partition plates are placed in closed positions;
FIG. 25 is a diagrammatic vertical sectional view of each station tube in FIG. 24;
FIG. 26 is a diagrammatic vertical sectional view of the station tube in FIG. 24, in which the bottom and the lateral partition plates are placed in open positions with the vehicle sliding on the bottom thereof;
FIG. 27 is a diagrammatical vertical sectional view of the station tube in FIG. 24, in which the bottom and the lateral partition plates are returned to the closed positions with the vehicle placed on the closure plate; and
FIG. 28 is a diagrammatic vertical section of a modified form of the station tube in FIG. 24.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, like reference characters designate corresponding parts throughout views and descriptions of corresponding parts are omitted after once given. FIG. 3 illustrates a pod transfer system according to the present invention, in which four semiconductor processing apparatuses 50A, 50B, 50C and 50D for various production processes are aligned. The transfer system includes a duct 52 and a rectangular transfer tube 58 disposed parallel to the duct 52 and communicated at its opposite ends to the duct 52 through connecting tubes 60 and 60. The duct 52 is communicated at one end to a first blower 54 and at the other end to a second blower 56. The transfer system is horizontally disposed above the semiconductor processing apparatuses 50A-50D. The transfer tube 58 is designed so that a vehicle 62, which carries a pod 40 as illustrated in FIG. 13, is movable within it by vacuum pressure as described hereinafter. The transfer tube 58 has an inlet door 59 swingably mounted to its one end for introducing vehicles 62 into it and further has an outlet door 61 swingably attached to the other end for taking vehicles 62 out of it. The transfer tube 58 includes a pair of parallel rectangular station tubes 66A, 68A; 66B, 68B; 66C, 68C; and 66D, 68D branched near semiconductor processing apparatuses 50A-50D, respectively. As shown in FIG. 4, each of the loading station tubes 66A-66D and 68A-68D has an open proximal end 84 and a closed distal end 86 and has a square closure plate 70 mounted on a distal end portion of the bottom wall 72 (FIG. 11) thereof. ARMs 38A-38D and 39A-39D are installed just below the closure plates 70 of respective station tubes 66A-66D and 68A-68D as illustrated in FIG. 4. The station tubes 66A-66D and 68A-68D are each communicated at their distal ends to the duct 52 through a connecting duct 76 having a solenoid valve 78 incorporated in it. The station tubes 66A-66D constitutes loading station tubes and the station tubes 68A-68D constitutes unloading station tubes.
As shown in FIG. 5, the proximal end 84 of each of the loading and unloading station tubes 66A-66D and 68A-68D is communicated to the transfer tube 58 through a rectangular opening 80 formed through one side wall 82 of the transfer tube 58. The loading and unloading station tubes 66 and 68 are each provided near proximal ends 84 thereof with a square door plate 88 for sealingly closing the proximal ends. The door plate 88 includes a closure plate portion 90 and a shaft portion 92 integrally formed with the upper edge of the closure plate portion 90 to be parallel with that upper edge. The inner face of the upper wall 96 of each of station tubes 66A-66D and 68A-68D has a substantially semicircular groove 94 formed crosswise in it near its proximal end 84. The shaft portion 92 of the door plate 88 is fitted in the groove 94 and rotatably supported on opposite side walls 98 and 100 of each of the station tubes 66A-66D and 68A-68D. One journal 102 is concentrically threaded to each shaft portion 92 and passes through one side wall 100 as illustrated in FIG. 6. The journal 102 is hermetically sealed with a sealing ring 106 fitted around it and has an arm 104 projecting radially outwardly from its outer end. The arm 104 slidably passes through a through slot formed through a plunger 108 of a solenoid 110 for turning the shaft portion 92. Each of station tubes 66A-66D and 68A-68D has an annular groove 112 formed in its inner faces to be perpendicular to its axis 114, the annular groove 112 communicating to the semicircular groove 94. An annular seal 116 is bonded to the walls of each annular groove 112. The shaft portion 92 of each door plate 88 hermetically contacts an upper horizontal portion 118 of the annular seal 116 and the periphery of the closure plate portion 90 is normally brought into hermetical contact with the other portions of the annular seal 116 since the plunger 108 of the solenoid 110 is spring biased to a retracted position to place the arm 104 in a position shown by the solid line in FIG. 5. A conventional photodetector 120 is provided to the transfer tube 58 upstream of each of its openings 80 for detecting a vehicle 62 passing through the transfer tube 58. Mounted on the inner face of the bottom wall 122 near each opening 80 is a pair of stoppers 124 which face each other when they stand although only right stopper 124 is in a stand position in FIG. 4. Each stopper 124 is normally received in a recess 126, which is formed in the bottom wall 122 of the transfer tube 58 as shown in FIGS. 7 and 8, and includes a support portion 130, rotatably supported on the opposite walls of the recess 126, and a rectangular stopping plate 128 integrally formed at its proximal end with the supporting portion 130. One journal 132 of the supporting portion 130 is sealingly supported with a sealing ring 134 fitted around it and has an arm 136 radially outwardly projecting from its distal end. This arm 136 slidably passes to the outside of the transfer tube 58 through a slot 138 formed in the outer face of the bottom wall 122. The arm 136 slidably passes through a slot 140 formed through a plunger 142 of a solenoid 144. The plunger 142 is spring biased to a position shown by the solid line in FIG. 8 for placing the stopping plate 128 within the recess 126. When the solenoid 144 is actuated, the plunger 142 is retracted to place the stopping plate 128 in a stand position shown by the dot-and-dash line in FIG. 8. As illustrated in FIG. 11, each of station tubes 66A-66D and 68A-68D has a square bottom opening 146 formed through its bottom wall 72. Each closure plate 70 has a shape similar to the door plate 88 and is attached to walls of the opening 146 of the bottom wall 72 in a similar manner as in that door plate. The closure plate 70 hermetically closes the bottom opening 146 with an annular seal 148 which is bonded to an annular shoulder 150 of the bottom opening 146. One journal 154 of the closure plate 70 sealing passes through the bottom plate 72 to the outside and an arm 156 of the journal 154 is slidably fitted in a slot (not shown) which is formed in a plunger 158 of a solenoid 160. The solenoid 160 is mounted on the lower face of the bottom wall 72. The closure plate 70 is normally urged against the seal 148 by the spring biasing of the plunger 158 as shown by the solid line in FIG. 11 but it is turned downward to a position shown by the dot-and-dash line when the solenoid 160 is actuated. In the same manner as the stopper 124, a stopper 162 is mounted on the bottom plate 72 of each station tube 66A-66D, 68A-68D just in front of the bottom opening 146. The stoppers 162 have the same shape and structure as stoppers 124 and are normally received in recesses 164 and turned to a stand position, illustrated by the dot-and-dash line in FIG. 11, in the same manner as the stoppers 124 when a solenoid 166 is actuated. On the rear side of each bottom opening 146, a stopping wall 168 is erected on the bottom wall 72 to face the stopper 162 in the stand position. As shown in FIGS. 4, 9 and 10, each station tube 66A-66D, 68A-68D is provided on its upper wall 170 with a lifting chamber 172 which communicated to the interior of the station tube through a communication hole 174. In each lifting chamber 172 there is furnished with a lifting mechanism 176 which includes an electric motor 178, a speed reducer 180 connected to the motor 178, a winding drum 182 rotatably mounted on the chamber 172 for winding an electric code 184, as a lifting rope, around it and a pulley 186 rotatably mounted on the ceiling of the chamber 172 and engaging the code 184. One end of the electric code 184 is attached to the winding drum 182 and electrically connected to an electric source 188 (FIG. 10) through an conventional electric control unit 190 and the other end is connected to an electromagnet 192 for holding vehicles 62 by electromagnetic attraction.
FIGS. 12 and 13 illustrate details of each vehicle 62, which has a hollow rectilinear box shape and has an open upper end 200 and a bottom wall 202 having a rectangular bottom opening 204. Each wall defining the vehicle 62 has four conventional ball rollers 206, . . . , rotatably mounted on its outer face for making rolling contact with inner faces of walls of both the transfer tube 58 and station tubes 66A-66D, 68A-68D. Each pod 40 is carried on a vehicle 62 by holding a bottom flange 47 of its box 46 in the bottom opening 204 by means of four holding devices 214 (only two of which are shown). Each holding device 214 includes an inverted L-shaped supporting member 216, having its one leg erected on the inner periphery of the bottom wall 202, and a wedge member 218 connected through a coil spring 220 to the other leg of the supporting member 216. The walls 222 which define the bottom opening 204 are inclined with respect to the horizontal line to guide wedge members 218. The pod 40 is held to the vehicle 62 by frictionally engaging outer faces 213 of the bottom flange 47 with the wedge members 218 as shown in FIG. 13(A). This is manually performed.
As illustrated in FIG. 13(A), an attraction plate 194 made of a steel is mounted at its one end to the open end 200 of one side wall of the vehicle 62 by means of a hinge 195 so that it may turn about the hinge 195. The other end of the attraction plate 194 is detachably attached to the open end 200 of the opposite side wall of the vehicle 62 by means of a conventional latch and catch mechamism (not shown). The attraction plate 194 is arranged so that it comes into contact with the electromagnet 192 in lifting the vehicle 62.
Each ARM 38A-D, 39A-D has four recesses 402 formed in the periphery of its top face although only two recesses are shown in FIG. 13(A). A two-arms lever 406 is pivotally mounted through a bracket 404 to the bottom wall of each recess 402.
In operation, a vehicle 62A (FIG. 4) which is carrying a pod 40 is introduced into the transfer tube 58 through the inlet door 59 and then the inlet door 59 is closed. The first blower 54 is actuated to evacuate the transfer tube 58, thus providing a negative pressure in front of the vehicle 62A for moving the latter forwards. When the vehicle 62A passes through the detector 120 disposed near the first unloading station tube 66A for the first semiconductor processing apparatus 50A, the detector 120 provides an electric signal to the control unit for deactivating the first blower 54 to decelerate the vehicle 62A and for actuating the solenoid 144 of the stopper 124 disposed in front of the first unloading station tube 66A, thus placing the stopping plate 128 in the stand position shown by the dot-and-dash line in FIG. 8. The vehicle 62A is thus stopped by the stopping plate 128 to be positioned just in front of the door plate 88 of the first unloading station tube 66A. Then, the other stopper 125 is similarly raised for slidably holding the vehicle 62A against the stopper 124. Thereafter, the first blower 54 is actuated again and the solenoid valve 78 of the first unloading station tube 66A is opened for evacuating it. Then, the solenoid valve 110 of the door plate 88 of the first unloading station tube 66A is actuated for turning the closure plate portion 90 to the open position shown by the dot-and-dash line in FIG. 5 and the vehicle 62A is thereby forced to move into the first unloading station tube 66A due to the difference in pressure between its opposite lateral sides. The vehicle 62A is stopped by the stopping wall 168 near the closed end of the first station tube 66A and then the stopper 162 is raised to the position shown by the dot-and-dash line in FIG. 11 by actuating the solenoid 166 for positioning the vehicle 62A on the closure plate 70. After these operations, the first blower 54 is deactivated and the electric motor 178 of the lifting mechanism 176 is energized for rotating the winding drum 182 through the speed reducer 180, and a gear train 230 interconnecting the speed reducer 180 to a shaft of the drum 182. The code 184 is thus unwound to descend the electromagnet 192 for electromagnetically holding the steel plate 194 of the pod 40 of the first vehicle 62A as illustrated in FIG. 13. After this, the solenoid 160 of the closure plate 70 is actuated to turn the closure plate 70 to the position shown by the dot-and-dash line in FIG. 11 and the vehicle 62A is then gradually descended together with the pod 40 since they are connected together through the wedge members 218. When the vehicle 62A is coming into contact with the top face of the first loading ARM 38A, each ball roller 206 on the bottom wall 202 of the vehicle 62 impinges upon the free end of the outer arm of a corresponding lever 406 and forces the lever 406 to turn counterclockwise in FIG. 3(C), so that the free end of the inner arm impinges upon the corresponding wedge member 218 to move the latter upwards relative to the bottom wall 202 against the spring 220. Thus, the pod 40 is disengaged from the vehicle 62 and the bottom flange 47 of its box 46 is placed on the inner periphery 408 of the top face of the ARM 38A of the first semiconductor processing apparatus 50A. The lever 406, bracket 404, recess 402 and inner periphery 408 of the top face of the ARM 38A constitute a pod disengaging mechanism 400. The box door 42 is suppoted on an elevating plate 410 and then conventionally separated from the box 46 with a wafer cassette 44 placed on it and then introduced into the semiconductor processing apparatus 50A, where wafers 48 are removed from the wafer cassette 44 and then processed. During this processing, another vehicle 62B is introduced into the transfer tube 58 through the entrance door 59, the vehicle 62B carrying an empty wafer cassette 44. In the same manner, the vehicle 62B is then transferred into the first unloading station 68A, from which the vehicle 62B is lowered to the first unloading ARM 39A, which transfers the empty wafer cassette to the unloading side of the first semiconductor processing apparatus 50A. Thereafter, the wafers 48 processed are sequentially transferred into the wafer cassette 44 located on the unloading side and this wafer cassette 44 is then transferred to the unloading ARM 39A for placing it on the box door 42, which is then returned and engaged with the box 46, placed on the top of the unloading ARM 39A, by elevating the elevating plate 410 (FIG. 13(C)). Then, vehicle 62 is lifted by energizing both the electric motor 178 and the electromagnet 192 of the lifting mechanism 176 of the first unloading station tube 68A, so that the wedges 218 depresses the inner arm of the two-arm lever 406 with the force exerted by the spring 220. Thus, each wedge 218 is brought into engagement with both the outer face 213 of the bottom flange 46 and the corresponding inclined wall 222 of the vehicle 62B, with the result that the pod 40 is frictinally held to the vehicle 62B (FIG. 13(D)). Then, the vehicle 62B is lifted together with the pod 40 (FIG. 13(A)). When the vehicle 62B is lifted to the position shown by the dot-and-dash line in FIG. 11, the photosensor 242 detects the vehicle 62B and provides a signal to the control unit, which thus deactivates the solenoid 160, with the result that the plunger 158 is projected by the spring force for returning the closure plate 70 to the position shown by the solid line in FIG. 11 so as to sealingly close the bottom opening 146. Then, the electromagnet 192 is deenergized and the vehicle 62B is thus supported on the closure plate 70.
Thereafter, the first blower 54 is actuated for evacuating the transfer tube 58 again and vehicle 62B is thereby forced to move toward the opening of the unloading station tube 68A since the door plate 88 is left open and it is then moved to the second loading station tube 66B for the second semiconductor processing apparatus 50B in the same manner as the vehicle 62A is moved to the first loading station tube 66A. When the second vehicle 62B is placed on the closure plate 70 of the second loading station tube 66B, the door plate 88 is closed. Then, the wafer cassette 44 transferred by the vehicle 62B is introduced into the second semiconductor processing apparatus 50B in the same manner as in the first semiconductor processing apparatus 50A.
During the processing of the last wafer in the first semiconductor processing apparatus 50A, the empty wafer cassette 44 on the loading side is returned within the pod 40 on the first ARM 38A and in the same manner as in the second vehicle 62B, the pod 40 is then returned to the first loading station 66A together with the first vehicle 62A, which is then forced to move into the second unloading station tube 68B for introducing the empty wafter cassette 44 into the second semiconductor apparatus 50B.
By repeating sequentially the above procedures in connection with the second, third and fourth semiconductor processing apparatuses 50B, 50C and 50D, predetermined processing is made to the wafers 48. The finished semiconductor products are loaded to the empty wafer cassette 44 in the fourth semiconductor processing apparatus 50D and then transferred into the pod 40 on the fourth unloading ARM (not shown) and then, this pod 40 similarly rides on the first vehicle 62A, which is transferred to the fourth unloading station tube 66D. From this station tube 66D, the first vehicle 62A is transferred to a position in front of the outlet door 61 by actuating the first blower 54. Similarly, the empty wafer cassette 44 in the fourth semiconductor processing apparatus 50D is returned into the pod 40 on the fourth loading ARM (not shown) and then this pod 40 rides on the second vehicle 62B, which is then returned to the fourth loading station tube 66D, from which it is transferred in front of the first unloading station tube 68A by actuating the second blower 56. Then, the second vehicle 62B is returned to the first unloading ARM 39A, from which the empty wafer cassette 44 is reintroduced into the first semiconductor processing apparatus 50A.
For transferring each pod 40, ball rollers 206 may be directly mounted on it as illustrated in FIG. 14. In this case, the vehicles 62A and 62B are not used.
As shown in FIGS. 15 and 16, four parallel angle rails 244 may be erected on the top face of each ARM 38, 39 for smoothly guiding vehicles 62 to position on the ARM 38 or to the bottom opening 146 (FIG. 11) of the corresponding station tube 66A-66D, 68A-68D. Two of the angle rails 244 are, as illustrated by the dot-and-dash line in FIG. 11, attached at their upper ends to peripheries of corners of the bottom opening 146, the corners being remote from the journals 154. The other two angle rails 244 have a height such that their upper ends are located just below the free end of the closure plate 70 when the latter is opened, the upper ends being jointed to adjacent angle rails 244 with connecting rods 246. When guided, each vehicle 62 has balls of the its ball rollers 206 brought into rolling contact with inside faces of the guide rails 244 as illustrated in FIG. 16, the ball rollers 206 being mounted on its lateral sides.
As illustrated in FIG. 17, each closure plate 70 may be provided with a turning mechanism 246 for horizontally turning a vehicle 62 placed on it. The turning mechanism 246 includes a circular turning table 248 fitted in a circular opening 250 formed through the closure plate 70. The turning table 248 has a rotation shaft 250 coaxially mounted on it. The rotation shaft 252 is supported on a bracket 254, mounted on the closure plate 70, so that it is rotatably about its axis. The turning table 248 has an external gear 256 coaxially mounted on its lower face. A pinion 258, which is mounted on an output shaft of a step motor 260, is meshed with the external gear 256, the step motor 260 being mounted on the closure plate 70. With such a construction, the control unit may energize the step motor 260 for rotating the turning table 248 a predetermined angle through the pinion 258 and the external gear 256. Thus, each vehicle 62 placed on the closure plate 70 may appropriately set its horizontal direction for matching the pod 40 in direction to semiconductor processing apparatuses 50A-50D.
FIGS. 18 and 19 illustrate another embodiment of the present invention, in which each of loading and unloading station tubes 270, having closed opposite ends, is mounted to the transfer tube 272 to be slidable perpendicularly to the axis of the latter, i.e., in the direction X-Y. In this embodiment, the transfer tube 272 includes nine tube pieces 274A-274H aligned with a spacing substantially equal to the width W of station tubes 270. Each station tube 270 is slidably supported on a pair of guide flanges 276 and 276 mounted to lower edges of opposing ends of two adjacent tube pieces 274A and 274B and on another guide flange 276 mounted to the upper edge of one of the two adjacent tube pieces. The flanges 276 extend along the edges. A drive unit 275 including an electric motor is mounted on a top wall of the other tube piece 274A, . . . , near its upper edge and a pinion 277 is mounted on the output shaft of the drive unit 275. The pinion 277 meshes with a rack 279 mounted on the top wall of the station tube 270 in the X-Y direction for moving that station tube. Each station tube 270 has a communicating portion 278 formed at its one end and a conveying portion 280 formed at the other end. The communicating portion 278 is partitioned with a partition wall 282 from the other portion of the station tube 270 and its opposite lateral sides are opened to have rectangular openings 284 for allowing vehicles 62 to pass through it. Each conveying portion 280 is partitioned with a partition wall 286 from the other portion of the station tube 270 and has closure plate 70 for closing its bottom opening 146 as in the station tubes 66A-66D and 68A-68D. The opposite lateral sides of the conveying portion 280 are opened to form openings 288 for allowing vehicles 62 to enter into and exit from it. When the station tube 270 is located at a position diagrammatically shown in FIG. 20, the communicating portion 278 communicates to two adjacent transfer tube pieces 274A and 274B, . . . through its opposite openings 284 and 284. Thus, a vehicle 62 which moves within the transfer tube piece 272A, . . . may pass through the communicating portion 278 into the adjacent tube piece 272B, . . . In transferring a vehicle 62 to an ARM 38, 39 disposed below this station tube 270, the drive unit 275 is actuated to move the station tube 270 by the rack-and-pinion mechanism in the X direction to another position illustrated in FIG. 21, in which the conveying portion 280 is communicated through the openings 288 to the tube pieces 274A and 274B. After the vehicle 62 is stopped within the conveying portion 280 by the stoppers 124 and 125 in the same manner as in the first embodiment, the station tube 270 is returned back to the original position illustrated in FIG. 22 by moving it in the direction Y. At this position, the conveying portion 280 is positioned just above the ARM 38, 29 for transferring the vehicle 62, placed on the closure plate 70, to the ARM 38, 39 in the same manner as in the first embodiment. For returning the vehicle 62 to the transfer tube 272, the station tube 270 at the position in FIG. 22 is moved in the direction X to the position in FIG. 20, from which the vehicle 62 is forced to move into the tube piece 274B by actuating the first blower 54. In this embodiment, detection of the position of the station tubes 270 is made by means of photodetectors (not shown).
A third embodiment of the present invention is illustrated in FIGS. 23 and 24, in which each of station tubes 66, 68 is fixed at its proximal portion to the transfer tube 289 so that it is inclined downwards. One lateral wall 292 and the bottom wall 294 of the transfer tube 289 respectively have rectangular lateral opening 299 and bottom opening 301, both the openings formed at portions surrounded with the fixed ends of the station tubes 66, 68. The opposite lateral walls 290 and 290 of each station tube 66, 68 are welded at their proximal ends to both the one lateral wall 292 and the bottom wall 294 of the transfer tube 272. The upper wall 304 and the bottom wall 296 of the station tube 66, 68 are welded at their proximal ends to the upper edge of the one lateral wall 292 and the lower edge of the other side wall 298 respectively. Thus, a double bottom is formed at the proximal end of the bottom wall 296 in combination with the proximal portion of the bottom wall 294 of the transfer tube 289. A rectangular swingable bottom plate 300 is fitted in the opening 301 to form a double bottom wall together with the proximal portion of the bottom plate 296. One lateral edge of the bottom plate 300 is connected to the lower edge portion of the side wall 298 to be pivotable about a horizontal axis. The bottom plate 300 is pivoted by a solenoid (not shown) in the same manner as in the closure plate 70. It is normally placed in a horizontal position shown in FIGS. 24 and 25 by spring biasing the plunger of the solenoid and is swung to an inclined position shown in FIG. 26 by actuating the solenoid. When the bottom plate 300 is placed in the horizontal position, it is flush with the bottom wall 294 of the transfer tube 289. The one lateral wall 292 has a rectangular partition plate 302 designed to normally fit into the lateral opening 299. The partition plate 302 is supported at its upper edge on the proximal end of the upper plate 304 for swinging about a horizontal axis as in the door plate 88. The partition plate 302 is swung by actuating a solenoid (not shown) to an upper limit position shown in FIG. 26 and is normally placed at a vertical position in FIGS. 24 and 25. The pivoting mechanism of the partition plate 302 is similar to that of the door plate 88 and description thereof is omitted.
For introducing a vehicle 62 into each of the station tubes 66, 68, it is stopped by the stoppers 124 and 125 in front of the partition plate 302 as illustrated in FIG. 25. Then, the bottom plate 300 and the partition plate 302 are swung as stated above to the respective positions shown in FIG. 26, so that the vehicle 62 slides down on the bottom wall 296 of the station tube 66, 68 until it impinges upon a spring coil damper 306, which absorbs the impact energy. Thus, the vehicle 62 is placed on the closure plate 70 as in FIG. 27, without applying any considerable impact to wafers carried by the vehicle 62.
FIG. 28 illustrates a modified form of the station tube 66, 68 in FIG. 24. This modified station tube 308 includes a downwards inclined proximal portion 310, jointed to the transfer tube 272, and a horizontal distal portion 312 integrally and continuously formed with the free end of the proximal portion 310. With such a construction, wafers carried by the vehicle 62 is subjected to less impact than in the vehicle 62 in FIG. 27 when the vehicle 62 is positioned on the closure plate 70.
While the invention has been disclosed in specific detail for purposes of clarity and complete disclosure, the appended claims are intended to include within their meaning all modifications and changes that come within the true scope of the invention.
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A transfer system for transferring a SMIF pod™ in a clean room, in which the pod is adapted to contain a wafer cassette. The transfer system includes: at least one pair of SMIF arms™, the arms disposed adjacent to a semiconductor processing apparatus for transferring wafers, carried in the wafer cassette, into and out of the semiconductor processing apparatus; a transfer tube disposed near the arms; a vehicle adapted to carry the pod and adapted to move within the transfer tube; evacuation mechanism for evacuating the transfer tube to produce a negative pressure within the transfer tube so that the vehicle is moved along an axis of the transfer tube due to the negative pressure; and at least one pair of conveying mechanisms for conveying the vehicle between the transfer tube and respective arms.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of provisional U.S. application 61/450,220, confirmation no. 7624 filed on Mar. 8, 2011.
FIELD OF THE INVENTION
The invention has particular application to methods and apparatus for a practical odor treatment apparatus to help reduce odors, associated with sewer gases, from escaping from sewer manholes that are part of a non-pressure sewer system. The escape of the odors into the ambient air constitutes a nuisance and/or presents a health risk to pedestrians and maintenance personnel. It will be understood that the term “non-pressure sewer system” includes gravity sewer systems. So-called pressure sewer systems are not vented to the atmosphere and do not have this issue. However, because pressure storage systems are more expensive, they are much less prevalent.
One of the harmful gases that is prevalent in sewage systems is hydrogen sulfide. Hydrogen sulfide is a colorless, flammable, extremely hazardous gas with a “rotten egg” smell. Some common names for the gas include sewer gas, stink damp, swamp gas and manure gas. It occurs naturally in crude petroleum, natural gas, and hot springs. In addition, hydrogen sulfide is produced by bacterial breakdown of organic materials and human and animal wastes (e.g., sewage).
Municipal sewer systems inherently carry varying capacities and concentrations of sewage, air and odorous gases. Although the present application will refer repeatedly to sewer manholes, those skilled in the art will recognize that the present invention has application to other manholes or closed areas as well as storm drain grates and vaults. For example, decaying vegetation within an underground drainage vaults may also produce gases that are malodorous and/or harmful.
Many known devices utilize a manhole insert below the manhole cover and an odor absorbing media such as activated carbon or other type media(s). The manhole insert may be plastic high density polyethylene (HDPE) or stainless steel with provisions for the gasses above the liquid in the sewer line or manhole to pass through, around or over the absorbing media, which is often activated carbon. Such systems treat the odor before it passes through the manhole cover to the street level. Such prior art devices may include a one way drain valve to allow water leaking through the cover to pass through the device. The device may also have a relief valve to prevent gasses from passing through the device until the sewer gas pressure in the manhole is above ambient air pressure. Lift handles may also aid in removing of the absorbing media. The absorbing media may also be in a cartridge or canister. The housing may be dish shaped with a support lip that fits between the manhole cover and the frame. This housing then becomes a barrier or seal between the sewer gases below and the treated air above the housing. Prior art housings are rigid and form a fixed volume barrier between the sewer gases and the treated air. In some cases chlorine or other chemicals is sometimes added to sewer systems to neutralize the sewer odors.
The primary problem with prior art devices is that fluctuations in the pressure or other conditions of the ambient air, treated air and sewer gas results in frequent flow in and out through the odor absorbing media. Such increased flow quickly depletes the capacity of the absorbing media and neutralizes the effectiveness and odor absorbing function of the absorbing media. This phenomenon will be better understood by the following elaboration. Each time a small volume of sewer gas passes through the odor absorbing media and becomes treated air that passes through the manhole cover it depletes part of the absorbing media. Likewise, each time a small volume of ambient air flows through the manhole cover and then passes through the odor absorbing media into the sewer gas area the absorber media is depleted. In addition, the original ambient gas is now contaminated with sewer gases and must again flow over or through the media to be decontaminated. (Thus, a once small volume of ambient air, immediately mixes with a very large volume of highly concentrated sewer gas and becomes contaminated.) Thus, the absorbing media will be still further depleted by the subsequent flow the same gas back to the ambient above the manhole cover. With frequent fluctuating air and sewer gasses passing back and forth through the absorber media the life of the media is quickly shortened thus requiring frequent replacement.
Furthermore, during the inward flow of air through the manhole cover an equal volume of the treated air (air between the carbon filter and the manhole cover) passes through the absorber material into the sewer gas containing area of the manhole. This movement of air also further degrades the absorber media.
Another problem with prior art is the preformed lip on the housing insert that fits between the manhole cover and frame for non-standard size manholes frequently does not fit properly. Most manhole covers were not designed to allow space for the support lip and molding apparatus for each unique size is very costly.
Problems inherent in prior art treatment methods that require frequent replacement of odor absorbing media include:
1. The high cost of labor to replace the odor absorbing media. 2. The high disposal cost and waste associated with the frequent replacement of odor absorbing media. 3. The high cost of frequent replacement of odor absorbing media. 4. The frequent disruption of personnel and vehicle traffic when service to manhole odor absorbing media is provided. 5. The added exposure danger to service personnel and those that are in the vicinity, of noxious sewer gasses due to the frequent replacement of odor absorbing media. 6. The frequent abandonment of manhole odor protection devices because they do not work well for long and become a manpower and financial burden to municipalities that are in charge of service. 7. Adverse dangers to health by all that breathe in or are exposed to the poorly treated sewer gasses escaping from the manhole cover. 8. Frequent service and removal of heavy manhole covers increases the risk for back injuries and other health problems as well as increasing workers compensation claims. 9. The initial cost for housing inserts having customized dimensions is very high. 10. Pre-molded housing inserts frequently cannot fit under manhole covers due to close tolerances between the cover and frame. 11. The use of chlorine and other chemicals to treat odors in sewer systems can cause unintended pollution problems to bays and other areas where the treated water eventually ends up.
BACKGROUND OF THE INVENTION
Various apparatus and methods have been devised to reduce sewer odors that are released from manholes. These include sealed covers, inserts with activated carbon and odor control materials, chlorine and chemical treatment and mechanical ventilation systems. Most of these methods do not deal with the fluctuations of sewer gas and ambient air movement in and out through the manhole cover. Frequently it is not practical or economic to provide some of these prior art methods such as chemical treatment or forced ventilation. Many sewer systems have just a few isolated manholes that have odor problems where an odor absorbing type insert can quickly be used to reduce odor complaints from pedestrians and businesses.
Sewer manholes customarily are disposed within a structure that has a relatively large volume of sewer gas above the sewer slurry and liquid in fluid communication with the flow portion of the system piping and the associated manhole covers. A slight change in sewer flow rate, chemical activity, temperature, ambient air pressure or wind velocity can cause an emission of gases from manhole covers or an inflow of ambient air into the sewer system. The gas pressure and the volume of gases within the system is not constant. Numerous environmental, biological, chemical, sewer flow rates and other conditions cause the gases within the system to be formed or displaced, expanded or contracted along with outside influences such as wind velocity over the grate, outside temperature and influences such as the fluid communication with other manholes, pumps, and flow streams. The lower the fluid in the sewer pipe the greater the volume above the slurry in the pipe. This is where many odorous gases are formed. Some municipalities have complained that the low flow plumbing shower and toilet fixtures have added to the odor problems by reducing flow rates that result in less scouring of the pipe interiors.
No two manholes are exactly the same as to emissions of sewer gases. From normal well known odor complaints by the public and experience, what is well known is that in certain manhole areas, they have very objectionable odors that occur at random times and at varying intensity. The sewer gas emissions and air egression into a manhole vary in volume size from very small to large quantities. The frequency of these fluctuations, also vary widely but certain times and conditions are more predictable problem periods. For example during time periods where more people are using plumbing fixtures at the same time over low use night time periods.
SUMMARY OF THE INVENTION
An object of this invention is to prevent, reduce or minimize sewer manhole odors from exiting manhole covers. The odor that escapes from sewer manholes through the cover is a common nuisance and gasses can be dangerous to health plus they have explosion potential. Venting may occur through pick holes, vent holes, and or the rim frame.
Another object of some embodiments of the present invention is to provide a practical variation with a simple universal housing support band that can easily fit any size manhole and not require customization for each of the respective sizes and shapes known to man.
Additional objects of the invention include providing an easy to install, long life device that needs a minimum of odor absorbing media replacement resulting in low overall costs and safer operation. With less service required, less disruption of pedestrian and traffic occurs along with less exposure to the harmful gasses by service personnel and others.
It has now been found that these and other objects of the present invention may be attained in a sewer gas odor absorption apparatus for a manhole having a perforate manhole cover disposed in the manhole which includes an imperforate housing having a seal dimensioned and configured for sealing engagement with the manhole, the housing having a first extremity and a second extremity; the housing having a passageway in fluid communication with ambient air above the manhole cover at the first extremity and in fluid communication with sewer gases at the second extremity thereof.
The apparatus also includes a sub-assembly including a porous absorption media and a variable volume device disposed in mutual fluid communication in a subassembly having first and second axial extremities, the first extremity of the subassembly being disposed in fluid communication with one of the first and second extremities of the imperforate housing and the second extremity of the subassembly being disposed in fluid communication with the other of the first and second extremities of the imperforate housing. The variable volume device having interior and exterior surfaces and an internal volume that is a function of the internal and external pressures on the respective internal and external surfaces of the variable volume device; and the variable volume device has a first internal volume when the pressure inside of the variable volume device is equal to the pressure on the external surface of the variable volume device.
In some embodiments of the apparatus the first extremity of the sub-assembly is in fluid communication with the first extremity of the housing and the second extremity of the sub-assembly is in fluid communication with the second extremity of the housing. The apparatus may have the internal volume of the variable volume device exposed to sewer gas and the external surface is exposed to air within the housing that is not within the bladder.
The apparatus may further include a pressure relief valve having an inlet in fluid communication with the housing and an outlet in fluid communication with treated air whereby surges in the sewer gas pressure relieve sewer gas to the interior of the housing and displace an equal volume of treated air that exits the manhole. The housing may be supported by a pan shaped support have a lip engaging the support surface for the manhole cover. The housing may be supported by a band extending around the housing and secured to a side wall of the manhole.
In other embodiments the housing may be supported by a band having first and second axial extremities that are respectively fixed to opposed faces of the manhole with the midsection thereof being curvilinear and at a lower elevation than the attachment points for the axial extremities. The housing may include a perforated riser pipe extending between the first and second extremities of the sub-assembly.
In some embodiments the variable displacement device is concentric with the riser pipe. Similarly, the absorbent media may be disposed in a cartridge. The cartridge may be substantially concentric with the riser pipe. In some embodiments the riser pipe is disposed in a substantially vertical orientation in normal operation and the highest extremity is exposed to ambient air and the lowest extremity is exposed to sewer gas.
Some embodiments of the present invention include a sensing tube communicating with the housing to allow determination of particular gases that may be present. Various embodiments of the present invention may include an indicator that displays the condition okay of the adsorbent media. For some applications the variable volume device has an internal volume without the application of internal or external pressures or other forces that is about half of the maximum internal volume of the variable volume device.
Another aspect of the present invention is the method for removing malodorous and harmful substances from sewer gases passing through and around a perforate manhole cover disposed in a manhole above an existing sewer conduit which includes providing an imperforate housing having an inlet and an outlet, the inlet and the outlet being in fluid communication; providing a seal between the housing and the manhole; providing an absorbent media within the housing; providing fluid communication between the housing and sewer gases in the sewer conduit; providing fluid communication between the outlet of the housing and ambient air above the perforate manhole cover; providing within the housing a variable volume device having a first internal volume when the pressure inside of the variable volume device is equal to the pressure on the external surface of the variable volume device; providing fluid communication between sewer gases below the housing and the internal volume within the variable volume device; providing fluid communication between ambient air above the manhole cover and the outer surface of the variable volume device; providing fluid communication between the internal volume of the variable volume device and the absorber media within the housing whereby the flow through the media is minimized by utilizing the variable volume device as a cache that reduces the impact of oscillations in sewer gas pressure and ambient air pressure.
Still another form of the present invention includes the apparatus for removing odors from an associated building vent such as the vent used for bathroom plumbing which includes a perforated riser pipe dimensioned and configured to engage and axially extend from the associated building vent that substantially seals with respect to the associated building vent to force all gases flowing through the vent to pass through the perforated riser pipe; a housing engaging the top of the vent and surrounding the riser pipe; a variable volume device surrounding the riser pipe within the housing; and an absorbent media disposed within the housing that is in fluid communication with the riser pipe whereby fluctuations in the pressure of gases rising through the vent and riser pipe and the pressure of the ambient air have a reduced impact on the total flow through the absorbent media because the variable volume device acts as a cache.
Yet another embodiment of the present invention is a sewer gas odor absorption apparatus for a manhole having a perforate manhole cover disposed in the manhole which includes an imperforate flexible housing having a seal dimensioned and configured for sealing engagement with the manhole, the housing having a first extremity and a second extremity; the housing having a passageway in fluid communication with ambient air above the manhole cover at the first extremity and in fluid communication with sewer gases at the second extremity thereof and a porous absorption media. The imperforate flexible housing has internal and external surfaces and an internal volume that is a function of the internal and external pressures on the respective internal and external surfaces of the imperforate flexible housing.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by reference to the accompanying figures of the drawing in which:
FIG. 1 is a schematic elevation view of a first embodiment of a manhole odor eliminator that shows the cross-section of a manhole insert, housing, odor absorbing cartridge and bladder.
FIG. 2A is a diagrammatic view of a manhole odor eliminator with the bladder in a minimum volume position. In this case the ambient air pressure is higher than the sewer gas pressure.
FIG. 2B is a diagrammatic view of a manhole odor eliminator invention with bladder in neutral or bias position. In this case the ambient air pressure and the sewer gas pressure are the same. Thus, the bladder is in the position defined during manufacture that exists when no external or internal forces are applied to the bladder.
FIG. 2C is a diagrammatic view of a manhole odor eliminator with the bladder in maximum volume position. In this case the sewer gas pressure is higher than the ambient air pressure. If 1 cubic foot of sewer gas entered bladder, no flow occurs through cartridge and 1 cubic foot of treated air exits the manhole cover.
FIG. 2D is a diagrammatic view of a manhole odor eliminator with the bladder in maximum position. In this case the sewer gas pressure is higher than the ambient air pressure. If 2 cubic foot of sewer gas entered inlet pipe, one cubic foot of sewer gas will enter the bladder and 1 cubic foot of sewer gas will pass through the cartridge where it becomes treated air and 2 cubic feet of treated air exits the manhole cover.
FIG. 3 is a schematic elevation view of a second embodiment of the manhole odor eliminator that shows the cross-section of a manhole insert, housing, odor absorbing cartridge and bladder. This view shows a water drain trap and drain tube in lieu of pressure relief valves.
FIG. 4 is a schematic elevation view of a third embodiment of the manhole odor eliminator for applications where the drain water needs to be filtered. A water filter is shown that filters and absorbs hydrocarbons and chemicals from the water before draining while maintaining a water seal.
FIG. 5 is a schematic elevation view of fourth embodiment of the manhole odor eliminator that includes an alternate support apparatus having a support band that circumvents the manhole interior. The band is tightened by an expansion device. The manhole insert, brackets, flexible housing (bladder) and cartridge are all supported by the band.
FIG. 6A is an enlarged view of the support band utilized in the embodiment of FIG. 5 that includes a welded nut and hole for use in securing brackets and a housing.
FIG. 6B is a partial view of the support band with welded nuts and holes for use in securing the band to the interior of the concrete wall of the manhole.
FIG. 6C is a partial view of the manhole odor eliminator with a support band, ring gasket and flexible housing that act to accomplish the same function of the manhole insert, housing and bladder.
FIG. 7 is a schematic view of a manhole odor eliminator mounted on the top of a residential plumbing vent to reduce odors from such vents.
FIG. 8 shows a diagrammatic representation of hypothetical fluctuations of sewer gas and ambient air volume, flow and duration over a period of time. The representation of sewer gas displacement is shown above the base line. The representation of ambient air displacement is shown below the base line.
FIG. 9 shows a small portion of the FIG. 8 chart over a brief period of time and fluctuations. The dashed horizontal lines parallel to the baseline and respectively above and below the base line depict the volume retained by the bladder without flow occurring through the cartridge. The dark shading above the dashed line show the sewer gas and ambient treated air flow through the cartridge.
FIG. 10 is a schematic elevation view of a fifth embodiment of a manhole odor eliminator (MOE) in accordance with the present invention that shows the cross-section of a manhole insert, housing, odor absorbing cartridge and bladder. In this variation the bladder has one open connection to the sewer gas and a separate inlet leading to a pressure relief valve at the inlet to the carbon filter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In essence, the emissions and ingressions of air and gas in embodiments of the present invention are analogous to a lung during repetitive inhalation and exhalation cycles and wherein the cycles have a non-uniform amplitude and non-uniform frequency. This concept is the key to this invention. Some embodiments of the present invention use a variable volume device such as a biased pneumatic bladder. The term bladder as used herein refers to any pouch or other flexible enclosure that can hold liquids or gases. In some embodiments of the present invention the variable volume device is a bellows. Some vendors may refer to the variable volume devices as utilizing flexible containment technology. The volume of the variable volume device such as a bladder or bellows, may be constrained or biased by a spring, an elastic band, a raised weight, or a compressed gas. Although the variable volume device may be constrained or biased in this manner, many embodiments of the present invention rely on the physical and construction of the device to establish the normal position of the variable volume device. Thus, for example, a bladder having a 50% bias is constructed in a manner that results in the bladder, when sitting at rest on a planar surface without the application of any external forces, that will have a volume within the interior thereof that is 50% of the maximum volume which the device can be expanded to by the application of fluid pressure to the interior of the bladder.
Some embodiments of the present invention utilize a bladder biased to a volume that is 50% of the maximum volume of the bladder. Preferably the bladder is dimensioned and configured to contain the usual and customary quantity of the emissions of sewer gas and ingressions of ambient air within a volume that equals 50% of the maximum volume of the bladder. Only the peak overflow of the displacement volume that exceeds the portion captured in the bladder will be treated with the activated carbon. This extends the life of the odor absorbing media. In addition, by having a larger overall volume of treated air space above the sewer gas portion allows for a substantial volume of treated air that will be available to be expelled due to any burp or positive displacement or increase in volume of sewer gas that exceeds the bladder capacity. The large housing and insert volume can hold a large volume of treated air that is always ready to be expelled. Thus, when emissions occur, the treated air will be expelled first.
Manhole covers generally have a pick holes dimensioned and configured for engagement with a pick that are approximately 0.5 inch in diameter. The varying air pressure differential between the ambient air and the sewer gases usually fluctuate between plus or minus 0.01″ water column. During this condition the gas flow rate will be plus or minus 0.5 cubic feet per minute. There are times where no flow occurs and times where much higher pressures occur. If, for example, the treated air volume between the sewer gases and manhole lid were 15 cubic feet, and a sudden high rate surge of sewer gas expelled 10 cubic feet above the capacity of the bladder, mostly odor reduced treated air will exit the manhole. The treated air portion of the apparatus is always being deodorized by the carbon cartridge.
Referring particularly now to FIG. 1 the manhole odor eliminator in accordance some embodiments of the present invention includes a high-density polyethylene (HDPE) manhole insert 11 having a flange that fits under the manhole between the grate and frame rim. A sealing ring or gasket 42 may be provided. The insert includes a large opening dimensioned and configured to allow the body of a housing 12 to pass through the opening and to engage a circumferential lip on the housing 12 as shown in FIG. 1 . In one embodiment of the invention, the high-density polyethylene (HDPE) housing 12 is a cylindrical tank having an open top surrounded by the circumferential lip. The housing ordinarily holds an odor absorbing media that is contained in a cartridge 13 or filter in the upper portion of the housing 12 .
The cartridge 13 is filled with odor absorbing carbon and/or other absorbents in other embodiments of the invention. The cartridge 13 has a perforated outer shell or in some cases a screened cartridge housing to constrain the carbon media within the cartridge while concurrently allowing gas to flow through or pass over the media within the cartridge. The cartridge 13 further includes a center perforated tube or perforated riser pipe 20 through which sewer gases pass through cartridge 13 . A securing cap or cover 24 holds the cartridge in place on the perforated riser pipe 20 . In a typical embodiment the bottom of the perforated tube 20 contains a ½″ diameter orifice that slightly restricts sewer gas flow, and connects to a 1½″ riser pipe. The riser pipe 20 extends downward and fits through the bottom of the housing 12 with an opening or riser pipe inlet 17 for sewer gases. A bladder 14 fits over the riser pipe 20 . The riser pipe 20 has perforations to allow sewer gases to enter the bottom of the riser pipe, pass through the perforations and enter the bladder interior.
A variable volume device, which may be in the form of a bladder 14 is connected to the perforated riser pipe 20 so the interior volume of the bladder 14 is in fluid communication with the sewer gasses below. When any fluctuation in sewer gas volume occurs, the expansion or contraction of the gas volume affects the bladder. More specifically, the bladder expands or contracts in response to the expansion or contraction of the gas volume of the sewer gases. If, for example, any displaced sewer gas volume that occurred due to thermal temperature conditions or changes in the sewer flow rate or velocity or the changing level of the sewer liquids, or any chemical or biological or other reason, the displaced sewer gasses volume will enter or leave the bladder. The variation in volume may only be a fraction of a cubic foot or more. However, repetitive occurrences of these volumetric changes in the prior art apparatus dramatically increases the depletion of the absorbent media. The apparatus of the present invention utilizes a variable volume device, such as a bladder, that substantially reduces the impact on the media because the variable volume device dramatically reduces because of repetitive volumetric changes. In normal operation the volumetric changes will impact only the size of the variable volume device without causing flow of contaminated gases repetitively over the media. Thus, in a typical environment the quantity of contaminated gases passing over the media in the apparatus of the present invention may be 20% or less of the quantity of containment gases passing over the media in the prior art apparatus. This feature may extend the practical life of the absorber media to one to two years whereas prior art systems require a change in a 4 to 6 months or less.
The manhole odor eliminator in some embodiments includes a water drain trap (also called a P-trap) 15 creates a 2″ water seal that allows any rainwater that passes through the manhole lid to enter the housing and then pass through a 1″ drain tube 16 that extends near the bottom of the drain trap 15 , thereby creating a water seal, with excess water overflowing the rim of the drain trap 15 and entering the sewer system below. During periods of high sewer gas pressure surges, a portion of the sewer gas can pass through the drain trap into the housing 12 . This untreated gas will displace and mix with the treated air with part of it exiting the manhole.
The odor treatment apparatus provides a housing 12 that forms a treatment chamber between the manhole cover and the sewer gases. An odor absorbing filter media cartridge 13 “filters” the sewer gas flow into the housing 12 . A lightweight bladder 14 acts as a buffer for the sewer gases flowing through the cartridge by accommodating the frequent gas and air flow in and out through the cartridge 13 . Only flow rates that exceed the bladder capacity flow through the cartridge 13 . This greatly extends the life of the cartridge. The treated gas disposed in the space between the housing 12 and the manhole cover 31 becomes treated air. That treated air is expelled when a pulse of sewer gas rushes through the cartridge 13 that exceeds the bladder 14 maximum expansion volume.
A variable volume device in the form of a flexible housing or bladder 14 that is normally in a partially biased position (partially collapsed) remains in fluid communication with sewer gases. This bladder will accommodate the frequent fluctuations of displaced sewer gas and displaced treated air thereby reducing the flow of sewer gas that passes through the odor absorbing filter media. This greatly extends the active life of the odor absorbent. The present invention describes an apparatus which, when inserted into a standard manhole of any of size, reduces the odors which are typically vented to the atmosphere from the manhole. By greatly reducing the fluctuating flow of sewer gas and treated air through the cartridge the life of the odor absorbing media is greatly extended. This allows for significantly less service and replacement of the odor absorbing media.
The sewer manhole odor eliminator (MOE) apparatus in accordance with the present invention fits under manhole covers of various sizes. The apparatus contains a housing with a perforated riser tube, variable volume bladder, and an activated carbon cartridge for removal and odor control of Hydrogen Sulfide and other odors typically found in sewer gases. Fluctuating sewer gas volumes that exceed the bladder volume will be treated through the cartridge. This causes an equal volume of treated air to exit the manhole cover. This apparatus reduces or eliminates vented nuisance odors above the manhole cover. During long periods of no flow or air pressure changes, the air space between bladder and manhole cover will continue to be treated by exposure to the activated carbon cartridge to further reduce any remaining sewer gases in the treated air.
The manhole odor eliminator (MOE) is comprised of a manhole insert 11 , HDPE housing 12 , odor absorber cartridge 13 , pressure relief valve or orifice 19 , perforated riser pipe 18 , bladder 14 , water drain tube 16 and water drain trap 15 or P-trap or drain valve. A manhole insert 11 in one embodiment of the present invention is a fabricated stainless steel or plastic shaped insert dimensioned and configured to fit a specific size manhole frame 33 . Thus, a typical embodiment has a cylindrical pan shape. The insert 11 may vary in size from 18″ diameter to 48″ diameter. Various embodiments are square or rectangular to accommodate the manhole size and shape. The plastic insert 11 in some embodiments has a thickness of 3/16″ although other embodiments may be thicker or thinner. In some embodiments insert 11 may be 6″ to 10″ deep although other embodiments may have other dimensions. A hole is provided in the insert to accommodate a removable HDPE housing 12 . Such a removable housing 12 has certain cost advantages because it allows for utilization of a more uniform or standard size housing with a more uniform size cartridge and a bladder so that the entire or assembly will fit with virtually all outside diameter manhole insert 11 . Standardization of such components will result in economies of scale with regard to manufacture, distribution and stockpiling or warehousing spare units required for maintenance. Typical manholes 31 may be 24, 30, 36″ in diameter as well as many other sizes. Variation note: In some cases the manhole insert 11 may have a built in deep housing. For example a 14″ diameter by 24″ deep lower portion built in housing may be provided. In this variation the insert and housing might be molded as one piece. This variation has certain cost advantages with large quantities on one specific manhole cover size. An alternative to the lip shaped suspension described and shown in FIG. 1-3 .
Alternate embodiments of the present apparatus replace the support lip with fabricated or pre-manufactured specific size inserts 11 , and support the manhole housing insert may have a universal support band 41 as shown in FIGS. 6A , 6 B, and 6 C that can be expanded to fit any diameter manhole 34 . In some embodiments the support band 41 is a 3″ wide, 12 gauge circular stainless steel band with a series of holes and with welded nuts over holes for use in fastening brackets, securing the housing and anchoring the band 41 to the manhole 34 interior. An expansion device such as a long threaded bolt with nuts and brackets can be used to crank the band to expand tightly to the interior of the manhole. Once tightened, a drill can be used to pass through the welded nuts into the manhole basin. Angle support brackets may be used to help support band to lip of the manhole frame 33 .
A standard removable HDPE housing 12 is utilized in some embodiments of the present invention. This approach maximizes the economies of scale. Such a uniform housing 12 will normally fit in any size manhole insert 11 . The housing 12 may be a HDPE open top tank with a volume capacity of 15 gallons. The purpose of using larger volume housing is to maintain a large treated air 39 volume between the manhole cover 31 and the housing 12 . This space includes the volume of the manhole insert and available housing space. The housing contains a riser pipe 18 and a bladder 14 . This is in contrast to many prior art systems have a relatively small volume of space that can hold treated air. Some prior art devices simply have a manhole insert with a container of activated carbon. The treated air volume may only be 1 to 2 cubic feet. Embodiments of the apparatus in accordance with the present invention utilize a relatively large housing 12 to hold the cartridge 13 and bladder 14 for additional treated air 39 space. Certain sewer manholes have more active sewer gas odor problems due to greater volume displacements and larger housings 12 will hold more treated air.
The operation of the present apparatus will be better understood by considering a hypothetical operating condition characterized by a small fluctuation of sewer gas and ambient air pressure, volume and flow. When a “burp” or displacement of sewer gas occurs, from a positive gas pressure, the bladder will expand to accommodate all or a portion of the “burp” volume. This in turn will displace an equal volume of treated air that will exit the manhole cover into the ambient air. As long as the bladder capacity is not exceeded, either no sewer gas or a very slight amount of sewer gas will pass through the activated carbon cartridge 13 .
Subsequently, when the ambient air 40 pressure was greater than the pressure of the sewer gas 37 , ambient air 40 will enter through the manhole 31 cover. An equal volume of treated air 39 will first displace the bladder 14 volume. As long as the bladder 14 capacity is not exceeded, either (1) none of the treated air 39 or (2) a slight amount of treated air 39 will pass through the activated carbon cartridge 13 into the sewer gas 37 space.
The operation of the present apparatus will be better understood by considering a hypothetical operating condition characterized by a large fluctuation of sewer gas 37 and ambient air 40 pressure, volume and flow. Once the sewer gas 37 fluctuation resulted in a displacement that exceeds the bladder 14 capacity, only the excess sewer gas 37 will result in flow through activated carbon cartridge 13 . When this occurs, treated air 39 will first exit the manhole 31 and then a mixture of treated air and sewer gas will exit the manhole 31 cover.
The odor absorbing media 13 a in the cartridge 13 may be activated carbon with a hydrogen sulfide treatment additive or some other odor absorbing or neutralizing media. One preferred material is Coconut Shell Activated Carbon for H 2 S Adsorption by Carbon Activated Corporation. The properties include: H 2 S Capacity (ASTM D6646-03) of 0.30 g/ml, min. This material is 4.0 pelletized designed for vapor phase odor control. The cartridge 13 in some forms of the invention has a 12″ diameter, a 10″ height with a concentric 3″ diameter perforated tube in the center of the cartridge. This allows it to slip over a 2″ diameter perforated riser pipe 20 with a pressure relief valve 29 or ½″ diameter orifice 19 restrictor between the cartridge 13 and bladder 14 and in fluid communication with the sewer gases 37 .
The cartridge 13 acts to remove, reduce or eliminate the odor associated with the sewer gases 37 driven by a positive pressure through the cartridge media and while any sewer gases remain in the treated air 39 space. As the sewer gases pass through the cartridge it becomes treated air 39 . Since this invention includes a variable volume device or bladder 14 , the amount of sewer gases 37 that passes through the cartridge 13 is greatly reduced to an estimated 20% to 30% of prior art systems without a bladder. This allows for much less absorber media to be used and reduces the need for service and cartridge 13 replacement by several times.
The cartridge 13 in some embodiments of the present invention may be a single complete replaceable module that is replaced as required. In some embodiments of the present invention the odor absorbing carbon 13 a media may be disposed in a removable filter sack. Thus, a used removable filter sack may be removed with a simple cap removal and replacement of the carbon 13 a media in a fresh removable filter sack. The maintainer of the apparatus will not be burdened with the task of changing out 20 pounds of activated carbon 13 a media every 2 to 4 months for a total of 60 to 120 pounds total per year as required with some prior art devices. In a hypothetical example embodiments of the present invention will use on one cartridge every year with a total activated carbon 13 a media use of 10 to 20 pounds per year. Of course, the actual use may differ because the actual sewer gas volume fluctuation and concentration will vary widely at respective sites. Other odor absorbing media can be provided in addition to or in place of the activated carbon media to control the hydrogen sulfide and other sewer gases that can exit at manholes. An activated alumina media with chemicals to remove hydrogen sulfide and iron based chemicals that convert hydrogen sulfide to solids and pyrite like substance may also be used. Some of these change color after use.
The cartridge 13 a may also, in some embodiments, have an indicator sight glass 25 with color changing media on top of the cartridge. This allows for visual inspection of media condition without removal of cartridge and alerts service person when the media should be replaced.
All pressure relief valves may be of flap, ball float, check or other type valves. In most applications, it is preferable that each valve is adjustable so that the valve can be set at one of a range of different relief pressures. A low pressure relief valve 27 is located at bottom of housing 12 . This allows air or water flow at 0.25″ water column or other setting. Rainwater that collects in housing 12 can drain through the valve. Also, when the sewer gas pressure is less than the ambient air pressure, air 38 , 39 will pass through the valve into the sewer gas 37 area. A high pressure relief valve 28 is located in the housing 12 to allow for high pressure surges of sewer gases 37 . If a surge exceeds the maximum flow rate through the cartridge 13 , the high pressure relief valve 28 allows sewer gas to enter the housing 12 . Typically, the high pressure relief valve 28 is set at 3″ water column although various applications may require another setting. A medium pressure relief valve 29 is located in the riser pipe 18 between the bladder 14 and the cartridge 13 . This helps direct positive pressure sewer gas 37 flow into the bladder 14 first and may be set at 0.2″ to 1″ positive water column or other setting. The excess sewer gas 37 will thus flow through the carbon cartridge 13 . In lieu of the medium pressure relief valve 29 a small ½″ diameter orifice 19 may be fitted in the riser pipe 18 between the cartridge 13 and the bladder 14 . This orifice 19 restriction and the resistance of flow by the carbon 13 a helps direct any positive pressure sewer gasses 37 first into the bladder 14 to accommodate gas fluctuations. In some cases no orifice or pressure release valve is required and the pressure drop through the activated carbon 13 a in the cartridge 13 is all that is required. The pressure drop will depend on the resistance to flow by the odor absorbing media.
The housing 12 shall have a partially perforated tube or riser pipe 18 that may be a 2″ PVC pipe from the center bottom of housing 12 extending upward to an orifice 19 or pressure release valve 29 . The perforated riser pipe 20 extends through the center of the odor absorbing cartridge 13 . The riser pipe 18 is open at the bottom and is in fluid communication with the sewer gases 37 . The function of the riser pipe is to allow displaced sewer gases to first travel to a bladder instead of entering the cartridge. A low pressure relief valve (PRV) or orifice may be located in or at the riser pipe above the bladder and below the odor absorber cartridge. In the preferred embodiment the bladder 14 may encompass a portion of the riser pipe 18 as shown on the drawings.
The bladder 14 in some embodiments of the present invention is in fluid communication with the sewer gases 37 and thereby allows at least a portion of displaced sewer gases to first enter the bladder 14 instead of passing through the odor absorber cartridge 13 . The bladder 14 is ordinarily biased in a midway or partially closed or deflated condition so it is always ready to receive sewer gases or be further depressed when the treated air pressure exceeds the sewer gas pressure. For example, a 2 cubic foot volume bladder biased to 50% will allow plus or minus 1 cubic foot of displacement. In a preferred form of the invention the bladder 14 may have an outside diameter of 12″ diameter by 18″ high and with a volume of over 1 cubic foot. The bladder will be in this maximum position only when the pressure of the sewer gas was above the treated air pressure above the cartridge. When no-pressure differential exists the bladder 14 will be biased to a 50% volume position of 0.50 cubic feet and be 9″ diameter by 18″ high. If the treated air pressure was above the sewer gas 37 pressure, the bladder 14 will deform, adjacent to and around the perforated riser tube 18 , to the minimum near zero volume.
Increase or decrease in bladder 14 volume will occur when there is a very low pressure differential in the order of fractions of an inch of water column. The fluctuating volume range will be from zero to 1 cubic feet. Larger or smaller bladders are used to suit application. The bladder may be constructed of a thin pliable butyl rubber, polyethylene, urethane or neoprene coated nylon fabric or any other flexible material with a bias to a predetermined normal no-pressure condition of approximately 50% volume capacity. Thus, the bias of the bladder is inherent in the construction of the bladder. The material is preferably resistant to the hydrogen sulfide and other common sewer gases found in sewer systems. In some embodiments the bladder has a 2″ diameter opening connection in fluid communication with the sewer gases as well as in fluid communication with the odor absorbing cartridge.
The volume of sewer gases may be affected by any one or more of multiple possible occurrences. For example, any ambient air or treated air condition may cause a fluctuation in volume. Ordinarily, the variable volume device such as the bladder 14 minimizes repetitive flow of sewer gas through the cartridge 13 . In some cases a change in pressure above the manhole cover 31 may cause the bladder 14 to contract and have the least possible internal volume. Such an occurrence will cause treated air to pass through the cartridge and back into the sewer gases area of the manhole where it will immediately be contaminated. Without the bladder 14 , the fluctuations of sewer gases and treated air volumes passing through the odor absorber cartridge will significantly deplete the odor absorbing properties of the media in the cartridge. In another form of the invention the bladder may be biased to other volumetric positions such as 25% or 75% of the maximum volume of the bladder 14 . The volumetric changes in such embodiments have utility when ambient air is drawn through the manhole. For example if any condition caused 1 cubic foot of ambient air to be drawn through the manhole cover this same volume will depress the bladder from its 50% position to a lesser volume. Thus, the volumetric changes prevent treated air that has already been exposed to the activated carbon media from re-entering the sewer gas area. With the frequent fluctuations in volume that occur, this feature will extend the life of the odor absorbing media. Likewise, if 0.5 cubic foot of sewer gas were to be displaced or added to the area below the manhole odor eliminator 10 , the displaced 0.5 cubic foot volume will enter the bladder 14 to expand the internal volume of the bladder 14 by 0.5 cubic foot. This feature prevents the fluctuating sewer gas displacement from passing through the absorber cartridge.
In various embodiments of the present invention the variable volume device may also be a bellows, accumulator or a deforming sheet of flexible material or the housing 12 , 14 may be flexible. The housing may be flexible and in some variations it may extend to a large volume above the sewage 36 level. As noted elsewhere herein, the variable volume device may take many forms. One embodiment utilizes a lightweight bladder that will inflate at a very low pressure. A 1 mill polyethylene trash bag, for example, may be inflated by a human blowing in the opening. Other embodiments use a 3 to 6 mill polyethylene bag for the bladder.
Existing prior art systems may require replacement of 20 pounds of the absorber media every 3 months to help keep the odors under control. This may equal 80 pounds of activated carbon every year. However, many municipalities with limited resources are slow to service some of these installed applications and operate with spent absorber media due to the high cost of service and replacement. In other words the odor absorber media quickly becomes depleted and has no utility. This invention may only require 20 pounds of absorber media and it may need to be changed every 6 months or yearly. This will equal 40 pounds of activated carbon every year or one half that of prior art. In some applications with more frequent small volume fluctuations the media may last over a year wherein only 20 pounds a year will be required.
In lieu of a low pressure relief valve 27 , a 1″ diameter water drain tube 16 provided with an opening at the bottom of the housing and extend to near the bottom of the water drain trap 15 . When rainwater enters the manhole 21 pick hole or frame it drops to the bottom of the housing and enterers the drain tube 16 and drains to the drain trap while maintaining a water seal. In addition, when a high pressure surge of sewer gas occurs that exceeds the capacity of the bladder 14 , the excess portion of the sewer gas 37 will force its way through the drain tube 16 . First it will force some of the water in the drain trap 15 up the drain tube and enter the housing 12 . Then the excess sewer gas will enter the housing directly. When the high pressure subsides, the water in the housing will drain back to the drain trap.
FIGS. 2A-2D illustrate sequential operating steps of the system shown in FIG. 1 . FIG. 2A illustrates a manhole odor eliminator with the bladder in a minimum volume position. In this case the ambient air pressure is higher than the sewer gas pressure. FIG. 2B is a diagrammatic view of a manhole odor eliminator invention with bladder in neutral or bias position. In this case the ambient air pressure and the sewer gas pressure are the same. FIG. 2C is a diagrammatic view of a manhole odor eliminator with the bladder in maximum volume position. In this case the sewer gas pressure is higher than the ambient air pressure. If 1 cubic foot of sewer gas enters the bladder 14 , no flow occurs through cartridge 13 and 1 cubic foot of treated air exits the manhole cover. FIG. 2D is a diagrammatic view of a manhole odor eliminator with the bladder 14 in maximum volume position. In this case the sewer gas pressure is higher than the ambient air pressure. If 2 cubic foot of sewer gas entered inlet pipe, one cubic foot of sewer gas will enter the bladder and 1 cubic foot of sewer gas will pass through the cartridge where it becomes treated air and 2 cubic feet of treated air exits the manhole cover.
As best seen in FIG. 3 , in lieu of a high pressure relief valve 28 , a water drain trap also known as a P-trap 15 may be provided below the housing to allow drainage of any water that passes through manhole 31 cover, pick hole 32 or frame 33 while forming a water seal thereby preventing sewer gases from entering the treated area or housing. The rim of the water drain trap 15 is suspended at least 1″ below the bottom of the housing, to maintains an air gap, and is in fluid communication with the 1″ drain tube 16 .
Referring now to FIGS. 6A-6C various other embodiments may include other alternate constructions. For example, some manhole frames and lids are difficult to fit with a pre-manufactured plastic dome flange insert 11 . The following description includes a 12 gauge stainless steel metal band 41 that may be 2″ to 3″ wide and circumvent the interior of the manhole 34 opening below the frame 33 . An expansion securing device tightens the band to the interior of the manhole opening. The band in some case is located 4″ below the frame. Threaded nuts that are welded to the band allow for anchoring the band firmly to the concrete opening. A ⅜″ drill may pass through the nut and band to provide a hole in the concrete for a threaded bolt to pass through the nut, metal band and enter the hole in the side of the manhole. The forces on the bolt are in shear and can withstand high forces and protect against slippage downward even if the band becomes loose. Brackets can be secured to the band that can extend to support the housing and odor absorber cartridge 13 .
Referring now to FIG. 5 and FIG. 6C a fourth embodiment of the manhole odor eliminator is illustrated. This embodiment also uses a variable volume device. Unlike other embodiments that use a bladder, this embodiment utilizes a flexible housing 112 that is functionally equivalent to the bladder 14 in other embodiments. The flexible housing 112 is secured to the support band with a ring gasket 42 to form a tight seal to the manhole interior. The ring gasket 42 is a foam material or an inflatable flexible tube filled in various embodiments. The flexible housing 112 can contour to the absorber cartridge 13 much more closely than the rigid housing 12 . When sewer gas pressure is positive the flexible housing 112 deforms to minimum volume before gases start to flow through cartridge 13 . When sewer gas pressure is negative the flexible housing 112 deforms to maximum volume before treated air passes through cartridge 13 into the sewer gas area. This embodiment includes an alternate support apparatus having a support band 41 that circumvents the manhole interior. The band 41 is tightened by an expansion device. The manhole insert, brackets, flexible housing (bladder) and cartridge are all supported by the band 41 The flexible housing 112 is shown in alternate positions. The drawing illustrates diagrammatically the expanded or inflated position 114 B of the flexible housing 114 and the deflated position 114 W of the flexible housing 114 .
As best seen in FIG. 7 a small variation of the manhole odor eliminator 10 may be applied to office and residential plumbing vent pipes 42 that extend through the roof and emit nuisance odors. In this variation the main basic components are rearranged as shown in FIG. 7 . This illustration shows a perforated pipe riser pipe 45 surrounded by a bladder 46 . The assembly includes a removable service cap 43 , small carbon cartridge 44 , small perforated riser pipe 45 , small bladder 46 , cartridge housing 47 , pressure relief valve 48 , vacuum relief valve 49 , plumbing vent 50 and roof surface 51
Commonly, manhole 31 covers are 22″ to 48″ in diameter although other sizes are known. They are generally of round shape to prevent falling through the round opening. The average weight may be 250 to 300 pounds. They may contain several “pick” holes having a ⅝″ diameter that may be referred to a “vent” holes. Some covers may be without holes to form a tighter seal. Sewer gas leaks through the “pick” or “vent” holes and or the rim that may not be a gas tight fit due to dirt, debris, rust or deformed cover or frame. The sewer gases 37 that escape through a manhole cover may be caused by numerous conditions including environmental, thermal temperatures, wind velocity, air pressure changes, sewer flow rates, biological activity, chemical activity, sewer pipe fluid level, manhole position in system, forced pumping systems, and many other factors. If the total vent area through the pick 32 holes equaled ½ square inch orifice, and if the pressure differential was 0.01″ we for 1 minute, the flow will be approximately 0.5 cubic feet per minute (cfm) or 0.50 cubic foot of displacement. The actual sewer gas pressure and time interval may be more or less.
Accurate information is not readily available on the fluctuation frequency, time, volume or flow rate. A schematic copy of sewer gas pressure readings on sewer system is represented in FIGS. 8-9 of the drawings that have been obtained from a specific tested sewer line. On a completely inactive system, a plumbing fixture with 7.5 gallons of water was drained in 1 minute. This caused 1 cubic foot of added volume displacement to the sewer piping system. This displacement caused increased flow in the sewer pipe and affected sewage flow, level and air entrainment along with other conditions including displacement of sewer gas in a manhole. Many homes and businesses are connected to sewer systems and the frequency of plumbing use, flow rates, chemical activity in the sewer system and all the other factors cannot be calculated with any degree of accuracy. Thus, in a typical sewer system it is difficult to predict which manholes within the system will be subject to periodic odor complaints.
The most common odors residential homeowners complain about are the rotten eggs smell of hydrogen sulfide (H 2 S) and methane (CH 4 ). The odors emanating from wastewater sewer line manholes can be an extreme nuisance to the public and property owners. The persistent nuisance odor complaints translate into costly service and treatment for cities. One interesting result of the implementation of recent codes and regulations to reduce water use by mandating “Low Flow Toilets” and “Low Flow Showers” has been an increase in sewer generated odors. A recent study in San Francisco, Calif. attributed the reduction of water flow into sewer systems to less scrubbing and flushing action along with lower flow level in the sewer pipe and that results in more pipe surface area above the sewage level and that is where more odors are formed. This resulted in a dramatic increase in nuisance odor complaints. San Francisco is spending millions of dollars to add chlorine and chemicals to help reduce the odor complaints.
FIG. 10 is a schematic elevation view of another embodiment of the manhole odor eliminator in accordance with the present invention that shows the cross-section of a manhole insert, housing, odor absorbing cartridge and bladder. In this variation the bladder has one open connection to the sewer gas and a separate inlet leading to a pressure relief valve at the inlet to the carbon filter. This embodiment may be easier to fabricate than the embodiment shown in FIG. 1 .
The illustrated embodiments of the present invention position the media in the absorber cartridge 13 above the bladder 14 . Other embodiments may reverse this arrangement, however, positioning the media nearer to the manhole cover 31 enables easier access by maintenance personnel who must periodically change the absorption media.
The manhole odor eliminator insert in accordance with the present invention is a substantial improvement over prior art because it includes a variable volume bladder device that accommodates the frequent variations of plus and minus pressure buildup of the gasses above the liquid in the manhole and below the manhole cover. This variable volume device expands and contracts to accommodate the frequent fluctuating small volume changes that will otherwise pass through and deplete the absorber media. This greatly reduces the treated air from entering the sewer gas area and reduces the volume of sewer gas that passes through the cartridge. This greatly reduces all the above service and cartridge related change-out costs. Less absorber medial can be used. Fewer service visits to replace odor absorbing media is required resulting in greater safety for workers and the public along with less cost to the taxpayer. Another advantage of the present apparatus and method is to provide a simple universal housing support band that can easily be adjusted to fit any size manhole and not be dependent on the manhole cover.
ITEM DESCRIPTION
10 Invention. The manhole Odor Eliminator (MOE).
11 Insert. This fits under manhole cover 31 and sets on frame 33 lip. It supports HDPE housing 12 that fits in a hole in the center of the insert 11 .
12 Housing. This may be a 15 gallon HDPE open top tank with an extended rim that sets into the insert 11 .
13 Odor absorbing cartridge. This cartridge holds 10 to 20 pounds of odor absorbing carbon and other media. The cartridge exterior is perforated or screened 22 .
14 Bladder. This bladder accommodated the sewer gas flow from pressure fluctuations. The bladder may be biased in the one half full position.
14 A Bladder in the expanded position.
14 B Bladder in the deflated position.
15 Water drain trap. This drain trap or P-trap forms a water seal to prevent sewer gas from entering housing 12 .
16 Drain tube. This 1″ drain tube allows any rainwater that enters manhole cover to drain out of the housing 12 and into the drain trap 15 .
17 Riser pipe inlet. This inlet is where sewer gas enters the riser tube and then the bladder.
18 Riser pipe. This riser pipe may be 2″ diameter and is perforated and extends from the bottom of the housing and through the center of the cartridge.
19 Orifice. This small orifice may be ½″ diameter and is located near the inlet to the cartridge 13 and causes a restriction to flow that result in sewer gasses to first flow into the bladder 14 space.
Perforated riser pipe. This is located above orifice and in center of odor absorbing cartridge 13 .
21 Fine mesh screen. This is a screen over the perforated pipe to prevent the odor absorbing media from passing through and entering the perforated riser pipe 20 .
22 Screened cartridge housing. This is the outer surface of the cartridge that restrains the carbon media while allowing gas flow to pass through.
23 Cartridge top. This is a removable top to the cartridge to allow access to activated carbon with H2S media for replacement.
24 Secure cap. This is a securing cap that holds the cartridge in place over the perforated riser pipe.
25 Indicator. This is a clear plastic sight glass that shows the color change of indicating media to determine when it is time to replace spent media.
26 Sensing tube. This sensing tube allows test instrument access to the sewer gases to measure H2S concentration without removing the MOE.
27 Low Pressure relief valve. This is located at bottom of housing. This may be flap, ball float or check valve that allows air or water flow at 0.25″ water column or other setting.
28 High Pressure relief valve. This is located in housing to allow for high pressure surges of sewer gases that exceed capacity through cartridge to enter the housing. This may be flap, ball float or check valve that allows air or water flow at 3″ water column or other setting.
29 Medium Pressure relief valve. This is located in riser pipe between bladder and cartridge. This may be flap, ball float or check valve that allows sewer gas flow at 1″ positive water column or other setting.
30 Seal. This is a foam or gasket seal between the insert and the manhole frame lip to
form a gas tight seal.
31 Manhole cover. This is the sewer manhole cover.
32 Pick hole. This is the pick hole or vent hole in the manhole. It is used when removing the manhole cover and allows for sewer gas venting and air ingression.
33 Frame. This is the metal frame for the manhole cover.
34 Sewer manhole. This is the basin or manhole where the sewer pipe is located.
35 Sewer pipe. This is the pipe where sewage flows through the base of the manhole.
36 Sewage. This is the liquid sewage that flows through the sewer pipe.
37 Sewer gas. This is a mixture of various sewer gases including hydrogen sulfide H2S, methane gas, CH4 and many other gases.
38 Combination sewer gas and treated air. This mixture occurs within the bladder when sewer gas mixes with treated air due to pressure fluctuations.
39 Treated air. This is the combination air and gas that is located between the manhole cover and the exterior of the bladder within and above the housing and cartridge.
40 . Ambient air. This is the ambient air located above the manhole cover.
41 . Metal band. This is an expandable ring band that secures to the inside of the manhole below the frame.
42 Ring gasket. This may be used to help seal the metal band to the interior of the manhole.
Note: Items 43 - 51 apply to the small version of MOE for residential vent systems.
43 Removable service cap.
44 Small carbon cartridge.
45 Small perforated riser pipe.
46 Small bladder.
47 Cartridge housing.
48 Pressure relief valve.
49 Vacuum relief valve.
50 Plumbing vent.
51 Roof surface.
52 Relative volume of sewer gas expelled from manhole with prior art without bladder.
53 Relative volume of sewer gas expelled from manhole with bladder.
54 Restrained fluctuation gases by bladder.
55 Air drawn into manhole with prior art without bladder.
56 Filter. This may contain polypropylene and other filter/absorbent media.
57 P-Trap
112 Flexible housing that also takes the place of a bladder.
112 A Flexible housing in the expanded position.
112 B Flexible housing in the deflated position.
The terms used in the claims will be better understood by reference to the embodiment of FIG. 1 where the terms “ambient air” refers to air above the manhole cover 31 , the term “treated air” refers to air within the housing 12 that is not within the bladder 14 and thus will be treated by the absorber cartridge 13 , and “sewer gas” refers to the gas below the cartridge. A goal of the present invention is to have a large volume of treated air ready in the event that a surge of sewer gas exceeds the bladder capacity. “Treated air” is air that is within the housing 12 which at any given time may be a combination of incoming ambient air, air treated by the absorption cartridge 13 and sewer gas that surged through the pressure relief valve 28 . All gases within the housing will be exposed to the absorber cartridge 13 . Accordingly, any hydrogen sulfide or other sewer gas in the housing 14 will be treated.
The pressure differential between ambient air above the manhole cover and the treated air pressure within the housing 12 is very small. Ambient air above the manhole cover and “treated air” within the housing 12 are in fluid communication with one another because of the pick holes within the manhole cover 24 .
The apparatus and method for manhole odor elimination solves all of the above described problems with the prior art apparatus and methods by use of a variable volume device to accommodate the frequent fluctuations of air and gasses passing through the absorber cartridge.
All publications and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
Although the description above contains many specifics, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus, the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
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A sewer gas odor absorption apparatus for a manhole having a perforate manhole cover disposed in the manhole which includes an imperforate housing having a seal dimensioned and configured for sealing engagement with the manhole, the housing has a first extremity and a second extremity and a passageway in fluid communication with ambient air above the manhole cover at the first extremity and in fluid communication with sewer gases at the second extremity thereof. A sub-assembly including a porous absorption media and a variable volume device disposed in mutual fluid communication in a subassembly having first and second axial extremities, the first and second extremities of the subassembly being disposed in fluid communication respectively with the first and second extremities of the imperforate housing.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to wireless telecommunication. More specifically, the present invention relates to a system and method for providing information regarding the use of a wireless communication device and customization of a services plan for the wireless communication device.
[0003] 2. Description of the Related Art
[0004] The competition in the wireless telecommunications market has increased as the technology advances and the wireless communications service becomes more affordable. In order to attract new subscribers and increase the market share, wireless service providers offer a variety of service plans that fit different needs. For example, for a salesperson who is on the road most of time, a service plan for a larger fee that offers a large number of free prime time minutes and free long distance may be more desirable. Yet, for a non-working person, a service plan for a lower fee with a small number of free prime time minutes and a larger number of free weekend minutes may be more adequate.
[0005] When a user signs up for a wireless service provider, he may be offered a service plan with a specific allocation of air time minutes, such as prime time, evening or weekend minutes and, for a fixed price and when the user exceeds these limits, the user will be charged additionally. Though, the user has been informed of these limits, it is difficult for him to remember these limits and it is very difficult for him to know when his use is actively approaching these limits.
SUMMARY OF THE INVENTION
[0006] The invention is a system and method that address the above problems by tracking and informing a user about use of the wireless communications service. In one embodiment, the method is executed on a wireless device for tracking use of an application on the wireless device, wherein the wireless device is capable of communicating with a server through a wireless communication network. The wireless device receives subscription plan information for an application, and, in response to the subscription plan information received, establishes a subscription plan for a user, wherein the subscription plan includes available resource information. The wireless device receives a request for activating the application, and, in response to the request for activation, activates the application. After activating the application, the wireless device adjusts the available resource information to reflect the activation of the application, and displays the available resource information to the user.
[0007] The application can be a wireless communications application or an interactive game application. Further, the user of an application can have the airtime measured in connection minutes or in a money amount.
[0008] In an alternative embodiment, the method is executed on a server tracking use of an application on a wireless device, wherein the wireless device is capable of communicating with a server through a wireless communication network. The server receives a subscription request for an application from a user, and, in response to the subscription request, the server establishes a subscription plan for the user, with the subscription plan including available resource information. The server receives a request for use of the application from the wireless device, adjusts the available resource information according to the use of the application, and transmits the available resource information to the wireless device.
[0009] The system can be implemented as a computing device capable of tracking use of an application and providing notification to a user, wherein the computing device being capable of communicating with a server through a wireless communication network. The computing device has a wireless transmitter module for communicating with the server and receiving the application from the server, a controller for executing the application, an user interface unit for receiving inputs from the user for controlling the application, a display unit for displaying the application to the user, a timing module for tracking the execution of the application, and available resource information registers for storing available resource information, wherein the controller updates the available resource information in the available resource information registers according to the execution of the application.
[0010] Other objects, advantages, and features of the present invention will become apparent after review of the hereinafter set forth in Brief Description of the Drawings, Detailed Description of the Invention, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates a known architecture of a wireless network.
[0012] FIG. 2 is a flow chart for a subscription process executing at a server.
[0013] FIG. 3 is a flow chart for a usage tracking process executing at a wireless computer device.
[0014] FIG. 4 is a block diagram for a wireless device platform.
[0015] FIG. 5 is an archived file retrieval process.
[0016] FIG. 6 is an illustration of a resource tracking table resident on either a wireless computer device, a server, or both.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In this description, the terms “communication device,” “wireless device,” “wireless telephone,” “wireless communications device,” and “wireless handset” are used interchangeably, and the term “application” as used herein is intended to encompass executable and nonexecutable software files, raw data, aggregated data, patches, and other code segments. Further, like numerals refer to like elements throughout the several views. With advent of 3d generation (3G) wireless communication technology, more bandwidth has become available for wireless communications, and handsets and wireless telecommunication devices, such as cellular telephones, pagers, personal digital assistants (PDAs) have increasing wireless capabilities.
[0018] FIG. 1 depicts a prior art cellular telecommunication network 100 . The communication network 100 includes one or more communication towers 106 , each connected to a base station (BS) 110 and serving users with communication devices 102 . The communication devices 102 can be cellular telephones, pagers, personal digital assistants (PDAs), laptop computers, or other hand-held, stationary, or portable communication devices that use a wireless and cellular telecommunication network. The commands and data input by each user are transmitted as digital data to a communication tower 106 . The communication between a user using a communication device 102 and the communication tower 106 can be based on different technologies, such code division multiplexed access (CDMA), time division multiplexed access (TDMA), frequency division multiplexed access (FDMA), the global system for mobile communications (GSM), or other protocols that may be used in a wireless communications network or a data communications network. The data from each user is sent from the communication tower 106 to a base station (BS) 110 , and forwarded to a mobile switching center (MSC) 114 , which can be connected to a public switched telephone network (PSTN) 118 .
[0019] The MSC 114 may be connected to a server 116 that supports different applications available to subscribers using the wireless communications devices 102 . Optionally, the server 116 can be part of the MSC 114 or connected to the PSTN 118 . The server 116 can be operated by the wireless service supplier or a third party. The server 116 stores a directory of telephone service subscribers. The wireless subscribers can be identified by mobile identification number (MIN) or the wireless device's electronic identification number (EIN).
[0020] When a user subscribes a wireless communications service from a service provider, the user selects a service plan that allocates certain free resources to him and the service provider stores the information about the service plan and the free resource information into the server 116 . The user, when equipped with a wireless handset 102 according to the present invention, may download the service plan and the corresponding free resource information into the wireless handset 102 . The user can also set up few personal settings on the wireless handset 102 that allow him to track use of the wireless handset 102 .
[0021] FIG. 2 illustrates this subscription process 200 . The user subscribes to an application, step 202 , that may be a wireless communications service or a game application, and a subscription plan is established for the user according to the user's selection, step 204 . The user may also set up a few personal settings, such as when the user desires to be notified, step 206 . If the user sets up a flag for a notification when the remaining prime time minutes is 10 minutes, the service provider will provide a notification when the prime time minutes left in the subscription plan is 10 minutes. The user may also set up a flag for when a certain individual call exceeds a preset duration. For example, if the user sets a flag for a five minutes call duration, every time a call exceeds five minutes, the user will receive a notification. The user may also set up a flag so he will receive a summary of remaining minutes in his subscription plan at the end of every call.
[0022] The usage tracking feature can be implemented on the wireless handset 102 . The user enters a setting on the wireless handset 102 and the wireless handset 102 will track the usage. Every time the user receives a call or places a call, the wireless handset 102 records the duration of the call and deducts it from the available resource. If the call is made during the weekend, then the duration of the call is deducted from the weekend minutes. Alternatively, if the subscription plan is created by the service provider and stored in the server 116 , the user can request download a copy of the service plan into his wireless handset 102 , before tracking the use with the wireless handset 102 .
[0023] In an alternative embodiment, the subscription plan may be established in terms of a money amount. For example, a user may have purchased $100.00 of air time from a service provider who charges a flat rate of five cents per minute. The subscription plan will record that there are $100.00 available of resource for the user. When the user places a call, the wireless handset records the cost of connection by adding five cents for each connection minute, and at the end of the call the cost of connection is deducted from the available resource.
[0024] FIG. 3 is a flow chart for a usage tracking process 300 . The usage tracking process 300 can be implemented on the wireless device 102 or on the server 116 . When executed on the wireless handset device 102 , the request for an application, step 302 , is received after the user enters a destination telephone number at the wireless handset 102 , and the wireless handset 102 activates the application, step 304 , by sending the destination telephone number to the server 116 and requesting a connection to the destination telephone number. The wireless device 102 receives the available resource information either downloading from the server 116 or entered manually by the user. The flags are also entered by the user and stored in the wireless handset without being transmitted to the server.
[0025] The wireless device 102 tracks the activation time, step 306 , compares the activation time with a preset limit, step 308 , and notifies the user, step 310 , if the activation time is larger than the preset limit, by displaying a message on a display screen on the wireless device 102 . After checking for the activation time, the wireless handset 102 adjust the available resource information to reflect the duration of the call, i.e., the wireless handset 102 deducts the duration of the call from the available resource information, step 312 . The wireless handset also tracks the accumulate usage time by adding the activation time to the total of accumulated usage time. For example, if the call lasted 10 minutes during the prime time and the user had 190 prime time minutes of the available resource and 34 minutes of accumulated prime time usage, the wireless handset 102 will deduct the 10 minutes from the 190 minutes and add 10 minutes to the 34 minutes. The new available resource will then be 180 prime time minutes and the new accumulated usage prime time would be 44 minutes.
[0026] The wireless handset 102 will check the adjusted available resource against preset limits, step 314 . If the adjusted available resource consists of 80 prime-time minutes, 150 non-prime time minutes, and 230 weekend minutes, the wireless handset 102 checks these numbers against the corresponding flags (preset limits) set by the user. If an available resource is less or equal than a preset limit, then the wireless handset 102 notifies the user, step 316 . The notification can be a display message or an audio message.
[0027] The wireless handset 102 also checks whether it is time to reset the available resource to a default value. An example is that the wireless handset 102 will reset the available resource to a default value at the beginning of each billing period. The wireless handset 102 first determines whether the current date is the beginning of a billing period, step 318 , if so, the wireless handset 102 resets the available resource to the default value, step 320 .
[0028] When it is implemented on the server 116 has steps similar to the ones executed on the server 116 . The server 116 checks whether it has received a request for an application, step 302 , e. g., a request to connect to a destination telephone. If the request is received, the server 116 activates the application, step 304 , by connecting the wireless handset 102 to a destination telephone, which may be another wireless telephone 102 or a wireline telephone 120 . After the connection is established, the server 116 records the activation time, step 36 , i.e., the duration of the call between the user and the destination telephone.
[0029] After the call is completed, the server 116 compares the activation time with a limit set by the user, step 308 . If the activation time is greater than the preset limit, the server 116 sends a notice to the user, step 310 . The notice can be a message to the wireless device 102 or an audio message played after the end of the connection. The steps 312 - 320 can be substantially the same as described above for when the usage tracking process 300 is executed on the wireless handset 102 .
[0030] FIG. 4 is a block diagram 400 of the platform of a wireless handset 102 . The wireless handset 102 , besides being capable of supporting wireless communications applications, is capable of tracking use of specific applications and providing notifications to the user when certain user settable parameters have been achieved or surpassed. The wireless handset 102 includes a wireless transceiver 402 connected to an antenna 404 , a controller 406 , a display unit 408 , a timing module 410 , resource and setting registers 412 , and a user interface unit 414 . The wireless handset 102 communicates with a wireless network via radio transmissions through the wireless transceiver 402 . The wireless handset 102 receives user settings through the user interface unit 414 , which may include a keypad, a speaker, a microphone, or other suitable input devices. After the user settings are received, they are saved in the resource and setting registers 412 . The settings are transmitted to the server if the server tracks controls the usage tracking and notification operations. The resource and setting registers 412 may be part of a computer readable memory accessible by the controller 406 . The available resource information is also stored in the resource and setting registers 412 , and the controller 406 may update the resource and setting registers 412 according to the usage information. The timing module 410 is essentially a timer that the controller 406 can set up to track the usage information. The display unit 408 may be a liquid crystal display (LCD) screen or a plasma based display screen.
[0031] The wireless handset 102 is also capable of archiving, retrieving, and viewing summaries of previous activities at the device. At the beginning of each billing period, before resetting the available resources to their default value, the wireless handset 102 archives the usage information that has been recorded. The usage information, such as number of prime time, non-prime time, and weekend minutes used, is stored and available for later retrieval and review. The archiving can occur at pre-determined intervals, such as every 7 days. Alternatively, the archiving of files can occur after another event, such as the threshold of available minutes being met or like activity.
[0032] FIG. 5 is a retrieval process 500 of data at the wireless handset 102 . When the user wants to review the usage of an application in a particular month, the user can enter his selection at the wireless handset 102 . The wireless handset 102 receives a selection for an archived usage file, step 502 , and retrieves the archived file, step 504 . After retrieving the archived file, the wireless handset 102 displays it to the user, step 506 .
[0033] The archiving of usage information can also be done in the server 116 . The user will enter his selection of an archived file on the wireless handset 102 , and the wireless handset 102 sends the requests to the server 116 . The server 116 retrieves the archived file and transmits it to the wireless handset 102 . The wireless handset 102 then displays it to the user.
[0034] FIG. 6 illustrates a resource tracking table 600 that may be stored in the resource and setting registers 412 or in other accessible media. The resource tracking table 600 stores available resource information 602 for different resources, such as prime time minutes 604 , non-prime time minutes 606 , and weekend minutes 608 . It also stores user settable flags (preset limits) 610 for different resources, including for the call duration 612 .
[0035] The available resource information 602 for each resource may be updated after each call. For example, if a call lasted 15 minutes, where 9 minutes were made during the prime time hours and 6 minutes were made during non-prime time hours, then 9 minutes is deducted from the prime time minutes 604 and 6 minutes are deducted from the non-prime time minutes 606 . For the table shown in FIG. 6 , where a flag is set for 10 minutes for the call duration 612 , a notification is provided to the user.
[0036] It should be noted that the system is not limited to communications applications, and can be applied to any application that runs on a remote wireless device and requires a subscription. The following is a description of a use scenario, where the user requests an interactive game from a server. The user subscribes to the interactive games from the service provider and chooses a subscription plan that affords him 100 prime time minutes, 500 non-prime time minutes, and 700 weekend minutes. After subscribing to the service plan, the user proceeds to set up flags for each individual resource, so he can receive notification when, for example, he plays a game more than 10 minutes continuously or exceeds 10 minutes in each resource category. FIG. 6 is an example of the user's subscription plan and settings. The information of FIG. 6 can be stored on user's wireless handset 102 or on the service provider's server 116 . The user can change the settings by using his wireless handset 102 or through an Internet web access.
[0037] After subscribing to the service and setting up his preferences, the user may use the wireless handset 102 to request an interactive game that he can play against others online users. The user makes a request to the server 116 for a menu of games, and the request is transmitted wirelessly to a communication tower 106 , passes through a base station 110 and a messaging switching center 114 , and delivered to the server 116 . The server 116 sends the menu to the wireless device 102 .
[0038] After receiving the menu, the user activates the application by selecting an application. The activation request is received by the server 116 , and the server 116 enables the user to become a player in a multi-user interactive game. The server 116 also starts a timer to record the user's play time.
[0039] When the user is finished playing the game, the server 116 deducts the playing time from the user's subscription plan and sends the call duration and the available resource information to the user's wireless handset 102 . The wireless handset 102 stores the available resource information received from the server 116 in the resource and setting registers 412 and compares the call duration with the flags in the resource and setting registers 412 . If the call duration exceeds any of the flags, the wireless handset 102 displays a corresponding notification to the user.
[0040] In view of the method being executable on a wireless service provider's computer device or a wireless communications device, the system can be implemented with a program resident in a computer readable medium, where the program directs a wireless computer device having a computer platform to perform the steps of the method. The computer readable medium can be the memory of the device, or can be in a connective database. Further, the computer readable medium can be in a secondary storage media that is loadable onto a wireless communications device computer platform, such as a magnetic disk or tape, optical disk, hard disk, flash memory, or other storage media as is known in the art.
[0041] In the context of the invention, the method may be implemented, for example, by operating portion(s) of the wireless network to execute a sequence of machine-readable instructions, such as the wireless communications device or the server. The instructions can reside in various types of signal-bearing or data storage primary, secondary, or tertiary media. The media may comprise, for example, RAM (not shown) accessible by, or residing within, the components of the wireless network. Whether contained in RAM, a diskette, or other secondary storage media, the instructions may be stored on a variety of machine-readable data storage media, such as DASD storage (e.g., a conventional “hard drive” or a RAID array), magnetic tape, electronic read-only memory (e.g., ROM, EPROM, or EEPROM), flash memory cards, an optical storage device (e.g. CD-ROM, WORM, DVD, digital optical tape), paper “punch” cards, or other suitable data storage media including digital and analog transmission media.
[0042] While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail maybe made without departing from the spirit and scope of the present invention as set for the in the following claims. Furthermore, although elements of the invention may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated
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A system, method, and program for tracking usage and reporting available resource information of a wireless communication device, such as a mobile telephone. A server, wireless device, or both, keeps a record of available resources for the wireless device. In one embodiment, a server receives a request for an application from the wireless device, enables the application, and tracks the time for which the application is enabled. After the application is stopped, the server adjusts the record of available resources to reflect the time consumed by the application and provides the updated available resource information to the wireless handset. The wireless device can assist in such monitoring of available resources, with either data storage, processing, or both.
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This is a continuation, of application Ser. No. 23,261, filed Mar. 23, 1979, now abandoned.
CROSS-REFERENCE TO RELATED APPLICATION
This application contains subject matter disclosed in Design patent application Ser. No. 654, filed Jan. 2, 1979, for MODULAR BUILDING UNIT, Leonard L. Long, inventor.
BACKGROUND OF THE INVENTION
The invention is an improvement on the construction module or unit disclosed in U.S. Pat. No. Des. 198,527 of June 30, 1964, issued to Leonard D. Long. In addition to the unit shown on the Long design patent, a variety of interlocking construction blocks or modules is known in the prior art. Some examples of the patented prior art are contained in the following United States patents which are made of record herein under 37 C.F.R. 1.56:
U.S. Pat. Nos. 708,499, 2,994,162, 903,907, 3,116,570, 1,365,162, 3,305,982, 1,552,077, 3,873,225, 2,221,416, 4,035,975, Des. 213,686
None of the known prior art building modules has positive interlocking and self-aligning means on all side surfaces as well as on the opposite end faces thereof, and none possesses the unique arrangement of vertical corrugations on the side surfaces in accordance with the present invention, which corrugations interfit complementally and lockingly in a variety of arrays of the modules.
A notable feature of this invention also absent in the prior art is the provision on the top and bottom end faces of each module of concentrically arranged steeply and gently sloping surfaces which shed water and resist water penetration through the structure while simultaneously cooperating in the alignment and interlocking of modules in adjacent courses above and below. The upper and lower end faces of the module also possess interlocking keys which also serve as barriers to water, sight and sound.
Other features and advantages of the invention will appear to those skilled in the art during the course of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly exploded perspective view of assembled construction modules in accordance with the invention.
FIG. 2 is a fragmentary exploded perspective view depicting the top end of one module and the bottom end of an adjacent module.
FIG. 3 is a top plan view of a single module in accordance with the invention.
FIG. 4 is a fragmentary side elevation of a pair of stacked modules as used in a wall structure and showing the interfitting relationship of their opposing end faces.
FIG. 5 is a fragmentary vertical section taken on line 5--5 of FIG. 4.
FIG. 6 is a horizontal cross section taken through a course of modules according to the invention in a typical wall structure.
FIG. 7 is a fragmentary vertical section through a portion of the course taken on line 7--7 of FIG. 6.
FIGS. 8 through 10 are schematic views in perspective of various columns or pilasters which can be constructed using various arrays of modules in accordance with the invention in the courses thereof.
DETAILED DESCRIPTION
Referring to the drawings in detail, wherein like numerals designate like parts, the numeral 20 in FIG. 1 designates a construction module or block in accordance with the invention which is generally rectangular and provided centrally with a single modified rectangular end-to-end through opening 21, the axis of which is normally disposed vertically in the use of the module 20 to form structures. Also in FIG. 1, a second module 22 according to the invention is depicted, namely a double module in comparison to the single module 20 and including a pair of spaced parallel vertical axis through openings 23, each of the openings 21 and 23 being of the same size and cross sectional shape. The single and double modules 20 and 22 are of equal height and equal thickness or width in one direction, but the double module 22 is twice the width of a single module in the other direction or across the axes of the two openings 23.
Each single module 20 is corrugated or ribbed on all of its side walls. Referring to FIG. 3, one projecting rib 24 is formed on each side wall and extends from top to bottom of such side wall and is outwardly tapering in transverse cross section from the adjacent flat marginal face 25 of the particular side wall of the module. Each projecting rib 24 is unequally spaced from the adjacent corners of the module which are beveled as at 26. Progressing clockwise in FIG. 3, each rib 24 is spaced an equal distance from the corner 26 rearwardly thereof. The four ribs 24, therefore, are spaced apart equidistantly circumferentially of the module 20 as viewed from the end thereof, FIG. 3.
Immediately following each projecting rib 24, the adjacent side wall has a recess or valley 27 which tapers inwardly in cross section oppositely from the taper of the adjacent rib 24. The outer surfaces of the ribs 24 are flat and the inner surfaces of the recesses 27 are flat. The recesses 27 are equidistantly spaced circumferentially from each other, and are unequally spaced like the ribs 24 from the two corners 26 forming the terminals of a given side wall of the module. The several ribs 24 and recesses 27, together with the corner portions of the module, form a regular corrugated or relief surface externally on all side walls of the module. When any two side surfaces of adjacent modules 20 or 22 are placed in abutment as in a wall course or other structure array, the vertical ribs 24 are adapted to interfit closely and lockingly in opposing vertical recesses 27 of the next adjacent module, as best shown in FIG. 6. Thus, the corrugated side walls form accurate alignment means for the building modules in various structures, and also form interlocking or rigid keying means for the modules.
The described arrangement of ribs 24 and recesses 27 on the single module 20 is basically identical on each double width module 22 which is simply the equivalent of one side-by-side pair of single modules 20 integrally joined at abutting side surfaces. On its opposite longer side surfaces, each double module 22 has a continuous top-to-bottom vertical V-groove 28 formed therein to simulate an adjacent pair of the beveled corners 26 of two side-by-side single modules 20.
Each single or basic module 20 has a male end face as depicted in FIGS. 2 and 3 and an opposite female end face shown partially in FIG. 2 and elsewhere in the drawings. The male end face comprises a central uniform height inner shoulder 29 or shallow wall immediately surrounding the rectangular core opening 21 and including rounded corners 30. The flat end face of this shoulder 29 forms the surface of maximum elevation on each module 20 when the same is arranged upright in a structural array as depicted in FIG. 1.
The outer marginal surface of the rectangular shoulder 29 indicated at 31 in the drawings is steeply inclined for a reason to be set forth. Immediately outwardly of this inclined surface 31 at a slightly lower elevation beginning at the base of shoulder 29 is a considerably less abruptly inclined surface or shoulder 32 extending entirely around the end face of the module 20. The outer margin of the inclined shoulder 32 forms a corner junction with the four corrugated side faces of the module, such junction being indicated by the numeral 33 in FIG. 2.
The male end face of each module further comprises on each of the four sides thereof a dual elevation or stepped alignment and locking key 34, 34'. Both portions of each dual locking key 34, 34' are inclined relative to each other and to the adjacent shoulder surface 32 with different degrees of inclination. Each dual key 34, 34' is centered on the adjacent side face of the module 20. Each key portion 34' has its outer margin forming a junction with the outer flat vertical face of one rib 24, and the corresponding key portion 34 has its outer margin forming a junction with the base surface of a vertical recess 27, the arrangement being clearly shown in FIGS. 2 and 3.
The opposite female end face of each module 20 can be termed a mechanical relief negative of the male end face described above. That is to say, with particular reference to FIG. 2, the female end face of the module 20 disposed lowermost in the drawings has a concave relatively wide inclined lowermost surface 35 whose inclination matches that of the shoulder surface 32 so that these two surfaces 35 and 32 may nest interlockingly when two modules are stacked in a structural array, as in FIGS. 1, 4 and 5.
Immediately inwardly of the concave female end face 35 is a generally rectangular recess 36, having a steeply inclined uniform height marginal wall 37 which matches the inclination of the inclined surface 31 and receives the same snugly in interfitting and interlocking relationship on all sides of the stacked modules. The floor of the recess 36 is flat for substantial abutment with the flat end face of rectangular shoulder 29 when the modules are stacked as in FIGS. 4 and 5. On each of the four sides of the female end face of each module 20, dual stepped inclined keying surfaces 38, 38' are provided, FIG. 2, which surfaces are the relief negative of the dual key 34, 34' which they engage lockingly in assembled relationship, as in the construction of a wall or the like. In essence, each male end face of a module 20 is adapted to enter a female end face of an adjacent module for the automatic alignment and structural interlocking of the two modules in end-to-end relationship, so that they cannot rotate around the axis of the through opening 21 or be displaced laterally of such axis in any direction. As shown best in FIG. 1, each double construction module or block 22 has a pair of male end face portions which are individually identical to the male end face of each single module 20. Each male end face portion on the double module 22 is adapted to nest or socket within one female end face of the single module 20. In other cases, the two male end face portions of a double module 22 may be socketed in two corresponding female end face portions of another double module or block. In this latter connection, each double module 22 at its lower end, FIG. 1, has two female end face portions which are individually identical to the female end face of the single module 20.
The versatile utility of the construction module in single or double units is exemplified in FIGS. 1, 6 and 8 through 10. In FIG. 6, a wall is illustrated including offset parallel sections 39 and 40 intervened by a short right angular connecting portion 41 which may be laid up from a series of stacked double modules 22. The wall section 40, as illustrated, is formed by laying up in side-by-side engaged relationship double and single modules 22 and 20.
Also shown in FIG. 6 and in FIG. 7 is the capability of filling selected vertical passages in the wall structure formed by the openings 21 or 23 with steel reinforced concrete masses 42 to soundly integrate the particular wall or structure composed of the modules.
Another capability of the invention shown in FIG. 6 is the utilization of the corrugated or ribbed module side faces for superior bonding with a facing of stucco 43 or the like. The increased surface area available for bonding because of the relief surface enables the use of a thinner layer of stucco with success, which is an economic advantage in the invention.
FIG. 7 shows the locking action of the reinforced concrete masses 42 in a wall structure, and this figure also illustrates that successive courses of modules are laid up in overlapping relationship to thereby interlock each module with an adjacent upper, lower and side module in a given course. It has already been explained that modules can be laid with or without mortar.
The arrangement of the steeply and less steeply inclined surfaces 31 and 32 and 35 and 37 in a wall or the like formed by the invention affords multiple advantages in addition to self-alignment and interlocking of modules. The interengaging sloping surfaces of the male and female end faces form a barrier against driving rain and cause a natural drainage of water outwardly and downwardly from the interface of stacked modules. The rectangular shoulder 29 is a part of this barrier. The described stepped dual keys 34, 34' at each side of each module act further as a water seal and as a barrier to sight and sound. All of the described features coact mutually to provide a superior and more efficient construction module in the overall and one having maximum versatility in construction.
The use versatility of the invention to some extent is shown in schematic drawing FIGS. 8 through 10. For example, FIG. 8 shows the formation of a column or pilaster wherein two of the double modules 22, above-described, are utilized in each course with the modules of successive courses rotated 90 degrees relative to those above and below a given course. This produces a staggered overlapping relationship with full interlocking engagement of all opposing side faces and top and bottom end faces, as described in detail. The interlocking male and female end faces are completely symmetrical in terms of 90 degree rotations of modules in successive courses when building a column or any other structure.
FIG. 9 schematically shows the construction of a column or pilaster utilizing three of the modules 22 in each course. One pair of modules in each course are side-by-side and parallel with the third module across corresponding shorter side faces so that the corrugations of the three modules are interlocked. Also in FIG. 9 the three module array of successive courses is rotated 180 degrees between adjacent courses so that in each course the single crossing module will rest on the two side-by-side modules below, and the two side-by-side modules 22 above will rest partially on the single module below.
FIG. 10 shows a column construction in which four modules 22 per course are employed with full interlocking of all abutting vertical corrugated side faces and engaging male and female end faces. Also in FIG. 10 the module array in each course is rotated in relation to courses immediately above and below to form desirable course overlaps without any loss of interlocking engagement.
In view of the foregoing detailed description, the many significant improvements of the invention over the prior art and the increased versatility of usage should now be recognized by those skilled in the art without further description.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.
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A masonry construction module is provided which possesses versatility in the formation of various types of structures. The module has corrugations on all of its side walls which interfit complementally with the corrugations of adjacent modules in a horizontal course, thus rendering the courses of modules self-aligning and interlocked. The opposite ends of the module are respectively recessed and step projected to promote self-alignment and interlocking with modules in courses above and below. Sloping end shoulder surfaces shed water and form a barrier to water, sight and sound. The modules are designed to be laid up without mortar but can be laid up with mortar if desired and core openings can accept concrete reinforced with metal or the like to integrate structures. The corrugated side surfaces also provide ideal adhesion with stucco and the like.
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BACKGROUND OF THE INVENTION
The present invention is directed to a hollow cylindrical sleeve which can be removably mounted onto mandrels, bridge sleeves, or cylinders for use in printing, coating, or the like, and in particular to a thin-walled hollow, reinforced cylindrical sleeve having an integral compressible layer.
In flexographic printing operations, flat, flexible plates were hand mounted onto print cylinders by wrapping and adhering the plates to the underlying cylinder. Generally, the flat plate comprised a base layer having either a rubber layer with relief indicia or a photocurable polymer layer thereon. In some instances, a compressible layer was positioned between the base layer and rubber or photocurable layer to improve print quality. Such flat plates had the advantage that they could be relatively thin and flexible because they were to be directly mounted to the print cylinder. However, such mounting processes were labor intensive and slow.
More recently, hollow cylindrical sleeves have served as supports for various types of printing. In one existing flexographic printing process and product (commercially available in the United States from OEC Graphics, Inc. under the trademark SEAMEX), a photopolymerizable material in the form of a flat sheet is wrapped around a metal (such as nickel) or plastic sleeve whose surface has been primed with a heat activated adhesive. The sleeve and photopolymer material are then heated, bonding the photopolymer to the sleeve. The surface of the sleeve is then ground to a predetermined plate thickness. The plate may then be processed by registering a negative onto the sleeve, exposing the sleeve to radiation to cure exposed areas of the photopolymer, and then washing out unexposed portions of the photopolymer to leave a relief image for printing.
In other printing applications, including offset lithography, a rubber layer is applied to a base sleeve and vulcanized. The rubber may then be ground to thickness. Accordingly, for these applications, it is necessary that the sleeve be able to tolerate the high temperatures experienced during activation of adhesive and vulcanization of rubber. In both of these applications, the hollow cylindrical sleeve must be relatively smooth and stiff in order to be suitable for its intended support purpose and to provide a desired printing quality upon a substrate such as, for example, paper.
Hollow cylindrical sleeves of various configurations are known from U.S. Pat. Nos. 4,391,898; 4,503,769; 4,554,040; 4,601,928; 4,656,942; 4,812,219; 4,949,445; 4,963,404; 5,468,568; 5,819,657; 5,840,386; 6,038,971; and 6,038,975. Generally, these prior art sleeves consist of a plurality of associated concentric layers, typically an outer printing or surface layer and one or more underlying support layers.
For example, Anderson, U.S. Pat. No. 4,503,769, discloses a metal-coated, thin-wall plastic printing cylinder for rotogravure printing. An expanding mandrel containing journal bearings internally and laterally supports a metal coated, hollow, plastic cylindrical sleeve (glass fiber reinforced polyester or phenolic resin).
Van der Meulen, U.S. Pat. No. 4,949,445, teaches a cylindrical sleeve with a metal or plastic core which is covered with a compressible material onto which a perforated (stencil) printing sleeve may be mounted. Van der Velden, U.S. Pat. Nos. 4,601,928, 4,554,040, and 4,391,898, teach cylindrical printing sleeves formed on about a woven fabric mesh using sheets of photopolymer which are wrapped about the mesh core.
Vertegaal et al, U.S. Pat. No. 4,656,942, discloses a printing apparatus using flexible metal sleeves to transfer ink and a method of mounting the sleeves. The sleeves are made by electro depositing metal in a form that is very thin, readily collapsible, and imperforate. The outer surface of the sleeve is coated with a flexible, microcrystalline, wholly inorganic photoconductive material. One example of this type of material is sputtered ultra-pure cadmium sulfide.
Sattrup et al., U.S. Pat. No. 4,812,219, discloses a method of producing a surface sleeve for mounting on a plate cylinder in a printing process. A cylindrical sleeve made from an electrically conductive material such as nickel is mounted onto a supporting mandrel with a cylindrical outer surface. An inner metal layer is electrolytically deposited on the outer peripheral surface of the sleeve and an outer copper layer is electrolytically deposited on the inner metal layer. The printing pattern is etched directly on the copper layer or on a chrome layer covering the copper layer. Subsequently, after the engraving of the printing pattern, the opposite outer portions of the sleeve are removed due to the increased thickness of the metal layers.
Jenkins, U.S. Pat. No. 4,963,404, discloses a process for the production of a thin walled coated cylinder and an ink transfer roller. A thin-walled, seamless nickel cylinder is coated by plasma spraying a ceramic fluorocarbon polymer thereon. An adhesive layer of metal is applied between the surface of the cylinder and the coating. The adhesive layer consists of at least two metals reacting exothermally with each other under plasma spraying conditions.
Kühn et al, U.S. Pat. No. 5,468,568, is directed to a printing roller designed for a gravure printing process with a sleeve of fiber-reinforced thermoplastic which is then plasma sprayed to form a coating of copper or a copper alloy. A variety of fibers and plastics are disclosed for use in the sleeve, which is stated to have a wall thickness of less than about 3 mm.
Rossini, U.S. Pat. No. 5,819,657, teaches a carrier spacer sleeve for a printing cylinder. The patent contains a discussion of the use of thin sleeves in flexographic printing operations. Such thin sleeves are designed to be air mounted onto the carrier spacer sleeves to enable a printer to modify the effective diameter of printing cylinders for jobs of different print repeat lengths.
Hatch et al, U.S. Pat. No. 5,840,386, describes a sleeve that is adapted to be mounted onto a mandrel. The sleeve is used to transfer ink in anilox or gravure printing processes. The sleeve includes an inner layer, an intermediate compressible layer, and a metal outer layer. The inner layer may be fabricated from fiber-reinforced plastic and may be in the form of a DuPont Cyrel™ sleeve.
Fisher, U.S. Pat. No. 6,038,971 discloses a method and apparatus for producing a screen-printing stencil. A covering layer is applied to certain areas of a fine-mesh screen corresponding to a predetermined printing design. The screen is closed on the backside by a cylindrical support to prevent the covering liquid from passing through the screen. The support may be a thin walled metal cylindrical sleeve.
Hoffmann et al, U.S. Pat. No. 6,038,975, discloses a gapless sleeve for offset printing. The sleeve includes a roller core and a thin intermediate layer, which can be either a self-adhesive plastic sheet or a coating of plastic, metallic, or ceramic material.
The known hollow cylindrical sleeves however exhibit a number of constraints with respect to their manufacture and use. For example, one problem has been that one currently-used manufacturing process for such hollow cylindrical sleeves produces a seam in the sleeve which may affect the print quality of high quality flexographic printing. Other substrates such as nickel, zinc, copper, or other metal sleeves are much higher in cost and cannot effectively serve as consumable items. Another problem is that current polyester sleeve materials are not able to withstand the high temperatures required to vulcanize rubber print layers.
None of the thin-walled hollow cylindrical sleeve constructions of the prior art solely utilizes a reinforcing fibrous material to provide a low-cost product which is capable of withstanding the heat of vulcanization of rubber and which has the capability of being mounted onto a carrier in an airtight manner. Conventional hollow cylindrical sleeves having a base layer of fabric have seen only limited use due to their lack of holding strength on a cylinder as well as their lack of air-tightness required for proper mounting of the sleeve. A thin-walled fiber-reinforced hollow cylindrical sleeve would be advantageous because of low manufacturing costs and could be used as a consumable item when paired with either a photopolymer plate or a rubber layer.
Therefore, there remains a need in the art for an inexpensive, thin-walled fiber-reinforced hollow cylindrical sleeve which does not suffer from the problems of prior art sleeves.
SUMMARY OF THE INVENTION
The present invention is directed to fiber reinforced, thin-walled hollow cylindrical sleeves used in flexographic printing as supports for imageable surface layers such as photo-polymerizable printing plates or rubber layers. By “imageable surface layer” we mean material which can be acted upon (such, for example, as by actinic radiation to cure, or by mechanical grinding, or by laser ablation) to form an imaged relief surface. The hollow cylindrical sleeve has the advantages of having a low manufacturing cost, rigidity, and provides the necessary heat resistance to withstand rubber vulcanization temperatures. The hollow cylindrical sleeve is also airtight, and remains properly positioned during printing operations. The hollow cylindrical sleeve can also be used in applications that include plate-on-sleeve systems.
In accordance to one aspect of the present invention, a thin-walled print sleeve is provided and includes a hollow cylindrical base comprising a fiber-reinforced polymer resin having a wall thickness of from between about 0.1 mm to about 0.8 mm, preferably from about 0.2 mm to about 0.7 mm, a compressible layer on the cylindrical base, and a layer of material having an imageable surface on the compressible layer. The cylindrical base is expandable under the application of fluid pressure and provides a fluid-tight seal when said sleeve is mounted onto a cylinder, mandrel, or the like. In a preferred embodiment, the material having an imageable surface is selected from the group consisting of photocurable (e.g., photopolymerizable) materials and natural or synthetic rubbers. Preferably, the imageable material has a thickness of from between about 0.5 mm to about 1.4 mm.
It is preferred that the fiber is selected from the group consisting of glass fibers, aramid fibers, carbon fibers, metal fibers, and ceramic fibers. Preferred polymer resins for use in the fabrication of the sleeve include phenolic resins and aromatic amine-cured epoxy resins. The compressible layer improves print quality and preferably has a thickness of from between about 0.5 mm to about 1.4 mm. The print sleeve typically has an overall thickness of from between about 3.0 mm to about 3.5 mm. Generally, the sleeve is expandable under a fluid pressure of from between about 70 to about 112 psi (4.9 to about 7.9 kg/cm). The sleeve may be designed to be mounted onto a print cylinder, a mandrel, or a bridge mandrel, depending upon the desired use.
In accordance with another aspect of the present invention, a method of fabricating a thin-walled print sleeve is provided and includes providing a cylindrical support, applying a fibrous material and a polymer resin to the support to form a thin-walled fiber-reinforced resin base sleeve, curing the base sleeve, and working an outer surface of the base sleeve to provide a wall thickness of from between about 0.1 mm to about 0.8 mm. A layer of compressible material is applied to the outer surface of the base sleeve, and a layer of material having an imageable surface is applied over the compressible material to form the print sleeve. The print sleeve is cured, and an outer surface of the print sleeve is worked (such as by mechanical grinding) to provide a predetermined overall wall thickness.
Preferably, the fibrous material comprises a fiber strand which is wound onto said support. Alternatively, the fibrous material may comprise a woven fabric. The fibrous material and polymer resin may be applied to the support in a variety of ways. For example, polymer resin may be coated onto the support and the fibrous material wound or wrapped about the polymer resin. Alternatively, the fibrous strand or woven fabric may be impregnated with polymer resin and applied to the support. The application of fibrous material and resin may be repeated to build up a sufficient wall thickness for the base sleeve. Once the base sleeve reaches a predetermined thickness, the outer surface of the base sleeve is worked, such as by mechanically grinding it, to achieve desired tolerances. Alternatively, the base sleeve may be fabricated by a pultrusion process in which the support comprises a forming die.
The compressible layer may also take a number of forms. For example, in one embodiment of the invention, the compressible layer comprises a sheet material that is applied to the base sleeve by spirally wrapping the compressible layer around the base sleeve. Alternatively, the compressible layer is applied to the base sleeve by wrapping and seaming opposite ends of the compressible layer. The compressible layer may include a layer of adhesive on at least the surface in contact with the base sleeve to secure the two together.
In another embodiment of the invention, the compressible layer comprises an uncured elastomer, preferably containing uniformly distributed microspheres, and the elastomer is spread onto the surface of the base sleeve and then cured and ground to a predetermined thickness and diameter. The elastomer, in the form of a liquid, may be applied to the base sleeve while the base sleeve is rotating. Preferably, the elastomer is a foamable composition which is foamed and cured in place on the base sleeve without the need for additional adhesives to secure the compressible layer to the base sleeve. While the application and curing may take place without the need for a mold, it is within the scope of the invention to use a mold to shape the compressible layer.
The outer layer of the sleeve comprises a material having an imageable surface. In one embodiment of the invention, the material comprises a photocurable material in the form of a sheet. The sheet of photocurable material is applied to the compressible layer by spirally wrapping the sheet around the layer of compressible material, or, alternatively, by wrapping and seaming opposite ends of the sheet. In yet other alternative embodiments, the photocurable material may be applied to the compressible layer by spreading, dipping, casting, or molding the photocurable material on the layer of compressible material. As with the compressible layer, the outer layer may be applied as a liquid while the underlying sleeve and compressible layer are rotating. Again, when such a rotary casting method is used, there is no need for any additional adhesives to secure the compressible and outer layers to one another.
In another embodiment of the invention, the material having an imageable surface comprises uncured natural or synthetic rubber in the form of a sheet. The rubber layer is applied to the compressible layer by spirally wrapping the sheet around the layer of compressible material or by wrapping and seaming opposite ends of the sheet. Alternatively, the material having an imageable surface may comprise uncured natural or synthetic rubber in the form of an extruded tube which is mounted over the compressible layer by expanding the extruded tube under fluid pressure and pulling the tube onto the base sleeve and compressible layer. In yet another embodiment, the material having an imageable surface comprises uncured natural or synthetic rubber which is spread or cast over said compressible layer. The entire sleeve is then cured.
Accordingly, it is a feature of the present invention to provide a reinforced, thin-walled sleeve for use in printing operations having a low manufacturing cost, rigidity, and the necessary heat resistance to withstand rubber vulcanization temperatures. The hollow cylindrical sleeve is also airtight, and remains properly positioned during printing operations. These, and other features and advantages of the present invention, will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description of the embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like elements are indicated with like reference numerals and in which:
FIG. 1 illustrates a view in cross section of one embodiment of the hollow cylindrical sleeve of the present invention;
FIG. 2 illustrates a view in cross section of another embodiment of the hollow cylindrical sleeve of the present invention;
FIG. 3 shows a flow chart depicting process steps for fabricating a hollow cylindrical sleeve in accordance with one embodiment of the present invention;
FIG. 4 illustrates a partial longitudinal sectional view of a mandrel supporting one embodiment of the hollow cylindrical sleeve of the present invention;
FIG. 5 is a cross-sectional view taken along line 5 — 5 in FIG. 4; and
FIG. 6 is a cross-sectional view of another embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
One embodiment of a fiber reinforced, thin-walled hollow cylindrical sleeve 10 of the present invention is illustrated in FIG. 1 . The base sleeve 12 is fabricated from a polymer resin reinforced with a fibrous material, thereby enabling the sleeve 10 to have a seamless surface that is adapted to be covered with a layer of compressible material 13 and an imageable material 14 such as rubber, polymer, photopolymer, or any other material that can be imaged and used in a printing process. The fibrous material may contain glass fibers, aramid fibers, carbon fibers, metal fibers, ceramic fibers, or any other synthetic endless or long fibers that increases the stability, stiffness, and rigidity of sleeve 10 such that it may accommodate conditions found in conventional graphic arts environments.
In a preferred embodiment, the fibrous material is fiberglass. In alternative embodiments, aramid fiber or any desired combination of fibrous materials within the base sleeve 12 are also within the scope of the invention. Additionally, the fibrous material may be woven or non-woven. The fibrous material content in the base sleeve is preferably from about 30 to about 65% by weight, most preferably about 50% by weight. Commercially available fibers having desired diameters and lengths may be used.
Preferred polymer resins are those which are capable of withstanding rubber vulcanization temperatures of up to about 160° C. without softening or degrading. Suitable polymer resins include unsaturated polyester resins such as, for example, Synolite (trademark) and Atlac (trademark) resins commercially available from DSM Composite Resins, Zwolle, Netherlands, phenolic resins, and aromatic amine-cured epoxy resins. Preferably, the base sleeve 12 has a wall thickness of from between about 0.1 mm to about 0.8 mm, more preferably between about 0.4 mm to about 0.7 mm, and most preferably about 0.68 mm.
Compressible layer 13 is applied over base sleeve 12 as shown in FIG. 1 . Preferably, compressible layer 13 has a thickness of from between about 0.5 mm to about 1.4 mm. The compressible layer may take a number of forms. For example, in one embodiment, compressible later 13 is provided as a sheet material that is applied over base 12 by spirally wrapping it around the sleeve. Alternatively, compressible layer 13 may be wrapped around the base sleeve and opposite ends of the sheet seamed. Adhesive may be applied to the surface of base sleeve 12 or to one or both surfaces of the compressible layer to secure the compressible layer to base sleeve 12 and to secure imageable layer 14 to compressible layer 13 .
Alternatively, compressible layer 13 may be formed by uniformly mixing hollow microspheres with an uncured rubber and solvent and applying the mixture over base sleeve 12 . Further details of the composition of the compressible layer may be found in Gaworoski et al, U.S. Pat. No. 4,770,928, the disclosure of which is incorporated herein by reference. The rubber/microsphere mixture may be spread onto base sleeve 12 using a knife or blade to provide a uniform thickness. Alternatively, the mixture may comprise polyurethane precursors (such as polyols and isocyanates) and be applied as a liquid while the underlying base 12 is rotating. In this embodiment, there is no need for a mold, although a molding or shaping step may optionally be utilized. The shape and dimensions of the compressible layer may be controlled by controlling the selection of the reactants, temperatures, and degree of crosslinking and by applying appropriate volumetric amounts of the materials to the underlying base sleeve. The compressible layer may then be cured or partially cured in place. Where a rotary casting method is utilized, there is no need for the use of additional adhesives to secure the compressible layer 13 to base 12 .
As shown in FIG. 1, imageable layer 14 may be applied and cured in place on compressible layer 13 to form an integral print sleeve. In this embodiment, an uncured polymer in liquid form is applied to compressible layer 13 while the sleeve is rotating. Again, desired dimensional thicknesses may be achieved by appropriate selection of reactants, temperatures, and degree of crosslinking and by applying appropriate volumetric amounts of the materials. No additional adhesives are needed to secure imageable layer 14 to compressible layer 13 .
FIG. 2 illustrates another embodiment of the invention in which imageable layer 14 is secured to compressible layer 13 via adhesive 16 . Adhesive 16 may be in the form of a thin film or tape having a thickness of between about 0.05 mm to about 1.5 mm, and may be either pressure sensitive or be activated by heat. Again, adhesive 16 is not required where imageable layer 14 has been formed by a casting method and cured in place.
Other methods may be used to fabricate base sleeve 12 . The fibrous material and polymer resin may be applied to the support in a variety of ways. For example, polymer resin may be coated onto the support and the fibrous material wound or wrapped about the polymer resin. Alternatively, the fibrous strand or woven fabric may be impregnated with polymer resin and applied to the support. The application of fibrous material and resin may be repeated to build up a sufficient wall thickness for the base sleeve. The fibrous material may be in the form of a woven mat which is spirally wrapped about the support or wrapped and then seamed.
Alternatively, base sleeve 12 may be manufactured by a pultrusion process. Conventional pultrusion processes involve drawing a bundle of reinforcing material (e.g., glass filaments or fibers) from a source. As the fibers are drawn from the source, the fibers are wetted and the fiber bundle impregnated (preferably with a thermosettable polymer resin) by passing the reinforcing material through a resin bath in an open tank. The resin-wetted and impregnated bundle is then pulled through a shaping die to align the fiber bundle and to manipulate it into the proper cross-sectional configuration. Next, the resin is cured in a mold while maintaining tension on the filaments. Because the fibers progress completely through the pultrusion process without being cut or chopped, the resulting products generally have exceptionally high tensile strength in the longitudinal (i. e., in the direction the filaments are pulled) direction. Exemplary pultrusion techniques are described in U.S. Pat. No. 3,793,108 to Goldsworthy; U.S. Pat. No. 4,394,338 to Fuway; U.S. Pat. No. 4,445,957 to Harvey; and U.S. Pat. No. 5,174,844 to Tong.
Imageable layer 14 is formed from a material which can be imaged, either mechanically, optically, or chemically. For example, in one embodiment of the invention, imageable layer 14 comprises a photocurable material. A number of photopolymeric materials are commercially available such as, for example, Cyrel (trademark) commercially available from DuPont and FAH II (trademark), commercially available from BASF. The photocurable material may be in the form of a sheet which may be applied to the base sleeve by spirally wrapping the sheet about the base sleeve. Alternatively, the sheet may be wrapped and seamed. In other alternative embodiments, the photocurable material may be applied to the base sleeve as a liquid by spreading, dipping, casting (including rotary casting), or molding the liquid photocurable material on the base sleeve.
Imageable layer 14 , in another embodiment of the invention, may be formed from a natural or synthetic rubber including elastomers such as polyurethanes and silicones. In one embodiment, uncured rubber, in the form of a sheet, may be applied to the base sleeve by spirally wrapping the sheet about the base sleeve. Alternatively, the sheet may be wrapped around the base sleeve, and opposite ends of the sheet seamed together. In an alternative embodiment, the imageable layer may be in the form of an extruded tube which is then mounted over the base sleeve. In still another alternative embodiment, the imageable layer may be applied by spreading uncured rubber onto the base sleeve.
The flow chart of FIG. 3 depicts a general representation of process steps used to produce print sleeve 10 in accordance with one embodiment of the present invention. In step 20 , a cylindrical support, which can be comprised of metal, is provided. The support may be rotated to facilitate application of the fibrous material. In step 22 , one or more layers of the fibrous material are applied and wound on the rotating support. The fibrous layer is then coated in step 24 with the polymer resin. The fibrous material may comprise a single fiber or a group of fibers formed into a strand or thread. The winding angle of the fibrous material is variably adjustable in a range from 0° to 90° in the hoop and axial directions. The deposit speeds of the fibrous material and the tension applied to the fibers are both adjustable within broad ranges as is known in this art. Steps 22 and 24 are repeated until a resulting hollow core base sleeve 12 is produced having the desired wall thickness.
In step 26 , base sleeve 12 is cured using heat and/or actinic radiation. Alternatively, base sleeve 12 simply may be formed, and the curing step postponed until the entire sleeve has been assembled. In step 28 , the outer surface of base sleeve 12 is worked, typically mechanically worked by grinding, skiving, or machining to produce a sleeve having high precision with respect to its wall thickness and outer diameter.
Compressible material is applied to the base sleeve in step 40 . Again, the compressible layer may be in the form of a sheet material which is wrapped around sleeve 12 , or the compressible material may be applied in uncured form to a desired thickness and then cured or partially cured in place. In step 42 imageable material is applied over the compressible material. Again, the imageable material may be in the form of a sheet, or may be applied as a viscous liquid. The entire sleeve assembly is then cured. If the imageable material is natural or synthetic rubber, the sleeve may be subjected to cure temperatures of up to about 160° C. In step 46 , the cured sleeve is worked, typically ground, to provide a final desired wall thickness for the imageable material and an overall diameter for the sleeve.
For example, it is possible to produce a base sleeve 12 having a length of up to 1 meter or more and with an outer diameter of up to 100 mm or more, and a wall thickness of between about 0.1 mm to about 0.8 mm, preferably from about 0.2 mm to about 0.7 mm, with an outside diameter tolerance of no greater than 0.0254 mm (0.001 inch). Additionally, it is possible to produce base sleeve 12 having a Total Indicated Runout (TIR) no greater than 0.0254 mm (0.001 inch), thereby ensuring good printing quality for the sleeve.
It should be apparent to those skilled in the art that a further advantage of the print sleeve 10 in accordance with the present invention is a lower material cost than nickel or other metal-based sleeves. The print sleeve, because of its low cost, may be used as a consumable item. Another advantage includes providing print sleeve 10 with the necessary heat resistance to withstand vulcanization temperatures up to about 160° C. that are used in conventional rubber curing applications. Moreover, due to the seamless surface of the sleeve, print sleeve 10 has no negative effects on the resulting print quality, as do some prior art print sleeves.
As the cylindrical wall of print sleeve 10 is airtight, and is capable of some slight expansion upon the application of fluid pressure, in a preferred embodiment, the sleeve may be mounted to a plate cylinder 30 as illustrated in FIG. 4 . Plate cylinder 30 may be of any conventional construction. In the embodiment illustrated, cylinder 30 is provided with an air inlet 31 which supplies air under pressure into the interior of the plate cylinder from a source (not shown). A plurality of air passageways 32 provide a path to the exterior surface of plate cylinder 30 . Pressurized air flows through passageways 36 and acts to expand sleeve 10 slightly, enough to permit sleeve 10 to slide easily along the length of cylinder 30 until it is completely mounted. Once the air pressure is removed, sleeve 10 contracts to form a tight friction fit with plate cylinder 30 .
Applying the supply of pressured fluid again, permits sleeve 10 to be completely removed from cylinder 30 . The preferred pressure of the pressurized fluid (typically air) is from about 70 to about 112 psi (about 4.9226 to about 7.8762 kg/cm). The sleeve 10 may be mounted onto a flexographic or rotogravure plate cylinder and is provided with a desired length such that a proper fit is provided on the plate cylinder. Alternatively, sleeve 10 may be mounted onto a mandrel or bridge mandrel which is in turn mounted onto a plate cylinder. A suitable bridge mandrel is taught in commonly-assigned Busshoff, U.S. Pat. No. 6,276,271, the disclosure of which is incorporated by reference herein.
FIGS. 5 and 6 illustrate embodiments of the invention in which sleeve 10 may be used in a printing operation. In particular, FIG. 5 depicts a first embodiment in which sleeve 10 comprises three components only, base sleeve 12 , compressible layer 13 , and imageable layer 14 . FIG. 6 depicts another embodiment in which plate cylinder 30 includes a compressible layer 34 thereon. Compressible layer 34 may comprise a polymeric foam material and, in certain instances, acts to cushion sleeve 10 to provide improved print quality.
In one application, sleeve 10 may be covered with natural or synthetic rubber as the imageable layer 14 and then vulcanized by conventional means to produce a rubber-coated liquid transfer device. The outer surface of imageable layer may then be laser engraved or otherwise machined as is known in the graphic arts to provide a raised relief surface or depressions for flexographic or gravure printing. For example, a typical plate-on-sleeve configuration will be a hollow, cylindrical fiberglass composite having a wall thickness of about 0.68 mm, a compressible layer having a thickness of about 1.3 mm, and a rubber plate having a thickness of from about 1.1 to about 1.7 mm mounted thereon using a thin (about 0.1 mm) adhesive tape or film.
In another application, sleeve 10 may be covered with a photopolymer and then exposed through a negative using actinic radiation. The exposed areas are cured, and the unexposed areas are then removed to produce a photopolymer printing plate. For example, a continuous photopolymer sleeve will have a typical configuration of a hollow, cylindrical fiberglass composite having a wall thickness of about 0.68 mm, a compressible layer having a thickness of from about 1.2 to about 1.3 mm, and a photopolymer plate thereon having a thickness of about 1.25 mm.
The invention having being described with reference to preferred embodiments, it will be apparent that the same may be varied in many ways. For example, although the sleeve has been described and shown therein used as liquid transfer rolls, the sleeve may be provided with a dielectric coating, such as alumina, and used in corona discharge systems. The sleeve also can be provided with ceramic or metallic coatings and used as a transporter roll for paper, film, textiles etc. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art were intended to be included within the scope of the following claims.
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A sleeve for a print cylinder comprising a fiber reinforced, thin-walled material and having a seamless surface ready to be covered with a surface material. The sleeve may be used in flexographic printing, either as a support for photo-polymerized printing plates or rubber layers. The sleeve has the advantages of having low manufacturing cost and providing the necessary heat resistance to withstand rubber vulcanization temperatures. The sleeve is also airtight, and remains properly positioned during printing operations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2009-206273, filed on Sep. 7, 2009, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The embodiments discussed herein are related to a technology for a connector and an interposer using the connector.
BACKGROUND
[0003] Conventionally, when a semiconductor integrated circuit (IC) package is mounted on a circuit board, lead wires projecting from the side surface of the IC package are inserted into through-holes with lands of a circuit pattern on the circuit board. And the lead wires are electrically connected to the lands with solder. On the other hand, in recent years, the number of input-output terminals of the IC package is increasing with improvement of the integration density of the IC. Furthermore since operating frequency of the IC rises, there is a demand for improving the high-frequency characteristic of the circuit board. Therefore demands for high density mounting on the circuit board and short distance connection in the circuit board and narrow pitch mounting on the circuit board are increasing.
[0004] For example, techniques for providing the input-output terminals in a reticular pattern formed on the back side of the IC package such as BGA (Ball Grid Array) and LGA (Land Grid Array) and for mounting the IC package on the surface of the circuit board so as to dispose the input-output terminals efficiently under these demands are proposed. The surface mount technology that uses an interposer as an interconnecting board between the IC package and the circuit board is proposed. The interposer includes an insulation material sheet and a conductor (for example, connector). The insulation material sheet has through-holes corresponding to input-output terminals formed in a grid-array pattern on the IC package. And the conductors are inserted into these through-holes to conduct electrically in vertical direction of the insulation material sheet. Terminal patterns arranged in a grid-array pattern that is similar to that of the IC package are formed on the circuit board. It is illustrated using FIG. 1 to mount the IC package on the circuit board using the interposer.
[0005] FIGS. 1A to 1C illustrate a conventional interposer. FIG. 1A illustrates that an interposer 2 is disposed between a circuit board 3 and an IC package 1 . Moreover, FIG. 1B illustrates a side view of FIG. 1A , and especially a cross-sectional view of the interposer 2 . Input-output terminals 4 (electrodes) are provided in a grid-array pattern formed on the back side of the IC package 1 . And for mounting the IC package 1 on the circuit board 3 , each of terminal patterns 6 (electrodes) is formed at position corresponding to each of the input-output terminals 4 .
[0006] The interposer 2 is disposed between the IC package 1 and the circuit board 3 , and connects the input-output terminals 4 on the back side of the IC package 1 to the terminal patterns 6 on the circuit board 3 . The interposer 2 has a plurality of through-holes 9 , which are formed into the insulation material sheet (hereinafter called an interposer substrate) 8 . Each of the through-holes 9 corresponds to each of the input-output terminals 4 in the grid-array pattern formed on the IC package 1 . A connector 5 is inserted into the through-hole 9 . Each of the connectors 5 is the same length, and the connector 5 is made of the conductive material that electrically conducts between the front side and the back side of the interposer substrate 8 .
[0007] The interposer 2 is generally disposed inside a socket 7 illustrated in FIG. 1C , and the socket 7 is mounted on the circuit board 3 by soldering. When the socket 7 is used, the IC package 1 is easy to mount and demount on the circuit board 3 .
[0008] In the interposer 2 as mentioned above, the structure of the connector 5 that is made of the conductor which conducts electricity between the front side and the back side of the interposer substrate 8 is important. The connector 5 is placed and compressed between the input-output terminal 4 on the back side of the IC package 1 and the terminal patterns 6 on the circuit board 3 . Therefore the connector 5 has elasticity to conduct electricity between the IC package 1 and the circuit board 3 while being compressed under pressure from both the IC package 1 and the circuit board 3 .
[0009] As a structure to provide elasticity to the connector 5 , Japanese Laid-open Patent Publication No. 2001-176580 (hereinafter called “patent document 1”) discloses the connector that includes a flexible conductive element wound around the compressible insulating core and a compressible elastic outer shell the surrounding the conducting element. The patent document 1 also discloses that the outer shell is an elastic body such as rubber, and that the outer shell surrounding the core is surrounded by an insulating layer made of a conductive wire mesh or a continuous metallic layer.
[0010] However, as a structure to provide elasticity to the connector 5 , the patent document 1 discloses the structure that builds a zigzag wire, a pleat wire or a coiled wire into the main body of the elastic body, and discloses the structure that builds a metallic spring into the main body of the elastic body. However, there is a problem that the structure disclosed in the patent document 1 physically has the limit of downsizing. Moreover, there are problems that the structure disclosed in the patent document 1 is complex and causes high cost.
[0011] FIGS. 2A to 2D illustrate a conventional connector. As the solution of the problems described above, the connector 50 that has an elastic connection body 52 illustrated in FIG. 2A is proposed. The connector 50 has the elastic connection body 52 that includes a U-shape conductive spring 53 , and the connector 50 is fitted in a through-hole 9 of the interposer substrate 8 as illustrated in FIG. 2B .
[0012] Both ends of the spring 53 of the elastic connection body 52 are contact parts 54 and 55 . As shown in FIG. 2C , when an interposer 80 is disposed at a predetermined position on the circuit board 3 and the IC package 1 is mounted on the interposer, the contact part 54 contacts the input-output terminal 4 of the IC package 1 and the contact part 55 contacts the terminal pattern 6 of the circuit board 3 . Consequently, the pressure received from the IC package 1 and the circuit board 3 is absorbed as the spring 53 is bent.
[0013] FIG. 2D illustrates an interposer 70 including a connector 60 with a similar structure to the connector 50 described in FIGS. 2A to 2C , and it is described in U.S. Pat. No. 4,969,826 (hereinafter called “patent document 2”). The interposer 70 includes an interposer substrate 68 having through-holes 69 and the connector 60 provided in the through-holes 69 . A contact 65 is provided in a housing 64 of the connector 60 . The contact 65 includes two contact parts 61 and 62 and a spring 63 that connects between the contact part 61 and the contact part 62 . The contact parts 61 and 62 protrude from the top surface and the bottom surface of the interposer substrate 68 respectively. The contact part 61 contacts with the input-output terminal 4 of the IC package 1 and the contact part 62 contacts with the terminal pattern 6 of the circuit board 3 as well as the structure of the connector 50 described in FIGS. 2A to 2C .
[0014] However, as illustrated FIGS. 2A to 2C , the interposer 2 in which the U-shape conductive spring 53 is built has some problems. There are problems that a downsizing of the interposer 2 is limited to secure a prescribed deformation amount of a metallic spring, a design of the interposer 2 is difficult, and an electric resistance of the interposer 2 is large because a current pathway is long. FIG. 7A illustrates relation between deformation amount of the connector and contact pressure of the connector. In FIG. 7A , P in y-axis indicates contact pressure of the connector, A in y-axis indicates a range of the contact pressure, D in x-axis indicates deformation amount of the connector and B indicates a range of the deformation amount. As disclosed in the patent document 2, there is a problem that the range of the contact pressure corresponding to the range of the deformation amount in the contact part is large, that is, the variation of the contact pressure is large, as illustrated in FIG. 7A .
SUMMARY
[0015] According to an aspect of the invention, a connector includes a movable conductive element and an elastic body. The connector electrically conducts between opposed external electrodes disposed vertically. The movable conductive element has a pair of rigid contact. And the elastic body deforms elastically to receive the load caused by the movement of the movable conductive element.
[0016] The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIGS. 1A to 1C illustrate a conventional interposer.
[0018] FIGS. 2A to 2D illustrate a conventional connector.
[0019] FIGS. 3A to 3E illustrate a connector according to a first embodiment.
[0020] FIGS. 4A to 4B illustrate a connector according to a second embodiment.
[0021] FIGS. 5A to 5F illustrate a connector according to a variation example of the second embodiment.
[0022] FIGS. 6A to 6C illustrate a connector according to a third embodiment.
[0023] FIGS. 7A to 7B illustrate relation between deformation amount of the connector and contact pressure of the connector.
[0024] FIGS. 8A to 8D illustrates a connector according to a fourth embodiment.
DESCRIPTION OF EMBODIMENTS
[0025] Hereafter, a connector and an interposer including the plurality of the connectors according to embodiments are described in detail with reference to the accompanying drawings.
[0026] FIGS. 3A to 3E illustrate a connector according to a first embodiment. As a housing unit, the connector 10 includes a base unit 11 , two frames 16 that extend from both ends of the base unit 11 and a positioning unit 17 that is provided with both ends of the two frames 16 as illustrated in FIG. 3A . In this embodiment, the two frames 16 are perpendicular to the base unit 11 , and the positioning unit 17 is perpendicular to the two frames 16 . Therefore, the positioning unit 17 is parallel to the base unit 11 in this embodiment.
[0027] A plate-like spring body 12 is extended from the base unit 11 inside the space enclosed by the base unit 11 , the two frames 16 and the positioning unit 17 . And, a holding unit 13 is disposed at the end of the spring body 12 . An enough space remains between the holding unit 13 and the positioning unit 17 . The holding unit 13 is made of conductor. The base unit 11 , the spring body 12 , and the holding unit 13 serve as an elastic body that receives the load caused by the movement of contacts 14 and 15 described below. The contacts 14 and 15 are an example of a movable conductive element described in claims.
[0028] In addition, nearly L-shaped two contacts 14 and 15 are fitted between the base unit 11 and the holding unit 13 . The contacts 14 and 15 are made of the conductor. There are a long axis 14 D and a short axis 14 E in the contact 14 . The end of the long axis 14 D is an action part 14 A. There is a sliding part 14 B in the intersection part between the long axis 14 D and the short axis 14 E. The end of the short axis 14 E is a contact part 14 C. Similarly, there are a long axis 15 D and a short axis 15 E in a contact 15 . The end of the long axis 15 D is an action part 15 A. There is a sliding part 15 B in the intersection part between the long axis 15 D and the short axis 15 E. The end of the short axis 15 E is a contact part 15 C. The action parts 14 A and 15 A are held by the holding unit 13 . The sliding parts 14 B and 15 B come into contact with the inner surface of the base unit 11 . The contact 14 and 15 are fitted between the base unit 11 and the holding unit 13 so that the contact parts 14 C and 15 C protrude outside the frame 16 .
[0029] As illustrated in FIG. 3D , a recess 18 may be provided to receive the action part 14 A of the contact 14 and the action part 15 A of the contact 15 on the inner surface of the holding unit 13 , so that the contacts 14 and 15 fitted between the base unit 11 and the holding unit 13 are prevented from being released. FIG. 3E illustrates that the contacts 14 and 15 are fitted between the base unit 11 and the holding unit 13 with a recess 18 .
[0030] The connector 10 that the contacts 14 and 15 are fitted between the base unit 11 and the holding unit 13 is inserted in a rectangular through-hole 9 formed in the interposer substrate 8 . The interposer substrate 8 is made of a dielectric material. Distance between the outer surface of the base unit 11 and the outer surface of the positioning unit 17 is equal to the length of the long side of the rectangular through-hole 9 . Each of width of the base unit 11 and width of the positioning unit 17 is equal to the short side of the rectangular through-hole 9 . The ratio between the length of the long side of the rectangular through-hole 9 and the length of the short side of the rectangular through-hole 9 is about 1.4:1. FIG. 3B illustrates that the connector 10 is inserted in the rectangular through-hole 9 that is formed in the interposer substrate 8 . That is, the interposer 10 P of the first embodiment is that the connector 10 of the first embodiment is inserted in the interposer substrate 8 instead of the connector 5 illustrated in FIG. 1A .
[0031] FIG. 3C illustrates that the IC package 1 is mounted on the front side of the interposer 10 P illustrated in FIG. 3B and the circuit board 3 is mounted on the back side of the interposer 10 P. When the contact part 14 C of the contact 14 of the interposer 10 P is pressed by an input-output terminal 4 of the IC package 1 and the contact part 15 C of the contact 15 of the interposer 10 P is pressed by a terminal pattern 6 of the circuit board 3 , the contact parts 14 C and 15 C are points of force, the sliding part 14 B and 15 B are fulcrums, and the action parts 14 A and 15 A are points of action. That is, when suppress strength is added to the contact parts 14 C and 15 C (the points of force), the sliding parts 14 B and 15 B (the fulcrums) slide on the inner surface of the base unit 11 and the action parts 14 A and 15 A (the points of the action) pushes the holding unit 13 . As a result, the spring body 12 is deformed, and the holding unit 13 moves by deforming
[0032] The contacts 14 and 15 conduct by contact with each other or conduct through the holding unit 13 which is made of conductor. Therefore, the length of path for an electric signal between the contact parts 14 C and 15 C is equal to the length that the length of the contact 14 is added to the length of the contact 15 . The length of the path for the electric signal is shorter than the length of the path for the electric signal in the elastic connection body 52 described in FIG. 2 . As the contacts 14 and 15 are made of rigid body, each length of the contacts 14 and 15 is not changed by movement of the contacts 14 and 15 . That is, the length of the path for the electric signal between the contact parts 14 C and 15 C before the IC package 1 is mounted as illustrated in FIG. 3B is the same as the length of the path for the electric signal between the contact parts 14 C and 15 C after the IC package is mounted as illustrated in FIG. 3C .
[0033] Next, FIGS. 4A to 4B illustrate a connector according to a second embodiment. The points that the connector 20 of the second embodiment is different from the connector 10 of the first embodiment are that the connector 20 has without the frame 16 and without the positioning unit 17 as illustrated in FIG. 4A . As the other components are the same as those of the connector 10 , and description thereof is omitted. When the connector 20 in the second embodiment is inserted into the rectangular through-hole 9 that is formed in the interposer substrate 8 , the outer surface of the base unit 11 is bonded on the inner surface of the rectangular through-hole 9 . Moreover, as illustrated in FIG. 4B , when grooves 9 A in which the base unit 11 is fitted are formed in the rectangular through-hole 9 of the interposer substrate 8 , the connector 20 may be fitted in the interposer substrate 8 without bonding.
[0034] FIGS. 5A to 5F illustrate a connector according to a variation example of the second embodiment. FIG. 5A illustrates that the connector 20 of the second embodiment illustrated in FIG. 4C is inserted into the through-hole 9 formed in the interposer substrate 8 . Moreover, FIG. 5B illustrates that the contact part 14 C of the contact 14 of the connector 20 and the contact part 15 C of the contact 15 of the connector 20 are pushed by two electrodes. When the action parts 14 A and 15 A push the holding unit 13 by movement of the contacts 14 and 15 , the spring body 12 is bent and thereby the holding unit 13 moves. As the contacts 14 and 15 are rigid bodies, the contacts 14 and 15 are not deformed.
[0035] FIG. 5C illustrates an interposer using a connector 20 A of the first variation of the connector 20 illustrated in FIG. 5A . In this first variation, the holding unit 13 is angularly disposed to the spring body 12 . The other components are the same as those of the connector 20 . FIG. 5D illustrates that the connector 20 A are compressed by the two electrodes. And when the IC package 1 is mounted on the circuit board 3 , as the holding unit 13 becomes parallel to the base unit 11 , the contacts 14 and 15 are stably held to the holding unit 13 .
[0036] FIG. 5E illustrates a connector 20 B of the second variation of the connector 20 illustrated in FIG. 5A . In this second variation, the spring body 12 is made of an accordion spring 12 B. The other components are the same as those of the connector 20 . In the second variation, FIG. 5F illustrates that the connector 20 B is compressed by the two electrodes, when the IC package 1 mounted on the circuit board 3 . As a result, the holding unit 13 becomes parallel to the base unit 11 as the accordion spring 12 B expands. Therefore, in the second variation, the contacts 14 and 15 are more firmly held by the holding unit 13 . The shape of the spring body 12 is not limited to the accordion type.
[0037] Next, FIGS. 6A to 6C illustrate a connector according to a third embodiment. The points that a connector 30 of the third embodiment are different from the connector 20 of the second embodiment are a structure of the holding unit 13 and the shape of the action part 32 of the contact 14 and the shape of the action part 33 of the contact 15 engaging with the holding unit 13 as illustrated in FIG. 6A . The other components are the same as those of the connector 20 of the second embodiment, and description thereof is omitted. In the connector 30 of the third embodiment, a hemisphere recess 31 is formed into the inner surface of the holding unit 13 . And the action part 32 of the contact 34 and the action part 33 of the contact 35 are spherically formed. Reference marks 34 B and 35 B represent sliding parts. Reference marks 34 C and 35 C represent contact parts. The contacts 34 and 35 are fitted between the hemisphere recess 31 of the base unit 11 and the holding unit 13 as well as the connector 10 of the first embodiment and the connector 20 of the second embodiment.
[0038] FIG. 6B illustrates a plan view that the connector 30 illustrated in FIG. 6A is assembled and is fitted into the through-hole 9 of the interposer substrate 8 . The action part 32 of the contact 34 and the action part 33 of the contact 35 are fitted in the hemisphere recess 31 that is formed in the inner surface of the holding unit 13 . When the terminal pattern 6 (electrode) of the circuit board 3 is connected with the top of the connector 30 (the contact part 34 C) and the input-output terminal 4 (electrode) of the IC package 1 is connected with the bottom (the contact part 35 C) of the connector 30 , the contact part 34 C of the contact 34 of the connector 30 and the contact part 35 C of the contact 35 of the connector 30 are pushed by the two electrodes and move as illustrated in FIG. 6C .
[0039] FIG. 6C illustrates that the spring body 12 curves and the holding unit 13 moves since the action parts 32 and 33 push the holding unit 13 by the movement of the contacts 34 and 35 . However, in the third embodiment, as the holding unit 13 has the hemisphere recess 31 , the action part 32 of the contact 34 and the action part 33 of the contact 35 are more firmly held and held in the hemisphere recess 31 . As a result, the action part 32 of the contact 34 and the action part 33 of the contact 35 are not easily released from the hemisphere recess 31 .
[0040] A recess may be provided to receive the sliding part 14 B of the contact 14 , the sliding part 15 B of the contact 15 , the sliding part 34 B of the contact 34 and the sliding part 35 B of the contact 35 on the inner surface of the base unit 11 , so that the sliding part 14 B of the contact 14 , the sliding part 15 B of the contact 15 , the sliding part 34 B of the contact 34 and the sliding part 35 B of the contact 35 do not release from the base unit 11 when they slide on the base unit 11 .
[0041] Next, FIGS. 7A and 7B illustrate relation between deformation amount of the connector and contact pressure of the connector. In FIGS. 7A and 7B , P in y-axis indicates the contact pressure of the connector, A in y-axis indicates a range of the contact pressure, D in x-axis indicates deformation amount of the connector and B indicates a range of the deformation amount. FIG. 7B illustrates linear change of spring load that a moving member receives from an elastic member. The range of the contact pressure illustrated in FIG. 7B in the connector of the embodiments is smaller than the range of the contact pressure illustrated in FIG. 7A in a conventional connector corresponding to the same range of the deformation amount. That is, the variation of the contact pressure in the connector of the embodiments is small. Therefore, in the interposer including the connector according to the embodiments, the interposer has the advantage of stability and high reliability even if the interposer connects a plurality of pins. Therefore the interposer using the connector of the embodiments improves high reliability and signal quality of a component that large and a high-speed IC package is stacked and mounted on the circuit board via the interposer. As a result, a higher-speed apparatus with higher density mounting may be developed.
[0042] FIGS. 8A to 8D illustrates a connector according to a fourth embodiment. The points that a connector 40 of the firth embodiment is different from the connector 30 of the third embodiment are shape of the base unit 11 , shape of the spring body 12 , shape of the holding unit 13 , shape of the first contact 44 , and shape of the second contact 45 as illustrated in FIG. 8A . In the connector 40 of the fourth embodiment, first of all, seen from the sides of the base unit 11 , the shape of the base unit 11 is W-character shape that height is small and width is horizontally long. And, two recesses 41 B and 42 B are formed on each inner surface of two concave parts in the base unit 11 so as to prevent the first contact 44 and the second contact 45 described later from releasing from the base unit 11 . The recesses 41 B and 42 B may be formed as one recess portion when boundary between the recesses 41 B and 42 B are took down. Moreover, concave parts 43 forming W-shape in the holding unit 13 are formed on the opposite surface to the base unit 11 . A recess further may be formed in the concave parts 43 .
[0043] As illustrated in FIG. 8C , the side face of the base unit 11 and the side face of the holding unit 13 are connected with the spring body 12 . On the other hand, seen from the sides of the first contact 44 and the second contact 45 , the shape of the first contact 44 and the shape of the second contact 45 in the fourth embodiment each is formed in r-character shape. Each of the contact 44 and the contact 45 has three ends. The ends 44 A and 45 A correspond to the action parts of the contacts 14 and 15 , respectively. The ends 44 B and 45 B correspond to the sliding parts of the contacts 14 and 15 , respectively. The ends 44 C and 45 C correspond to the contact parts of the contacts 14 and 15 , respectively.
[0044] The contacts 44 and 45 in the fourth embodiment are fitted between the base unit 11 and the holding unit 13 . The ends 44 A and 45 A (action parts) are fitted in the concave parts 43 in the holding unit 13 . The ends 44 B and 45 B (sliding parts) are fitted in recesses 41 B and 42 B. As illustrated in FIG. 8B , the ends 44 C and 45 C (contact parts) protrudes outside from the base unit 11 . The holding unit 13 and contacts 44 and 45 are made of conductive material as well as above-mentioned embodiments.
[0045] In the connector 40 of the fourth embodiment as illustrated in FIG. 8D , when the ends 44 C and 45 C (contact parts) are pushed by the force “F” in vertical direction, the ends 44 B (sliding part) of the contact 44 and the ends 45 B (sliding part) of the contact 45 respectively move in the center of the base unit 11 . When the ends 44 A and 45 A (action parts) push the holding unit 13 by the movement of the ends 44 B and 45 B (sliding parts), the spring body 12 curves and thereby the holding unit 13 moves. In the fourth embodiment, the ends 44 B and 45 B (sliding parts) are fitted in the recesses 41 B and 42 B of the base unit 11 , and the ends 44 A and 45 A (action parts) are fitted in the concave parts 43 of the holding unit 13 . Therefore the contacts 44 and 45 do not easily release from the base unit 11 and the holding unit 13 .
[0046] According to the embodiments, the interposer includes a metal component which is used as an electrical path and a metal which is elastically deformed. And as the metal which is used as the electrical path is formed in small size, the interposer has a short electrical path. Thereby the IC package and the circuit board are connected at a short distance, and the structure is simple. As a result the interposer is manufactured at low cost. In addition, this interposer improves high reliability and signal quality of a component that large and a high-speed IC package is stacked and mounted on the circuit board via the interposer.
[0047] All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a illustrating of the superiority and inferiority of the invention. Although the embodiment(s) of the present inventions have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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A connector includes a movable conductive element and an elastic body. The connector electrically conducts between opposed external electrodes disposed vertically. The movable conductive element has a pair of rigid contact. And the elastic body deforms elastically to receive the load caused by the movement of the movable conductive element.
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FIELD OF THE INVENTION
[0001] The present invention relates to apparatus useful in the casting of molten metal and more particularly to such devices as are utilized in the casting of so-called “logs”, “billet” or “round ingots” from, for example, molten aluminum.
BACKGROUND OF THE INVENTION
[0002] In the casting of molten metals such as aluminum apparatus and processes have been developed for the simultaneous casting of a plurality of logs, billets or round ingots, hereinafter logs, so as to increase the efficiency and productivity of the casting processes. In such processes and apparatus, a casting table having a plurality of apertures or molds is mounted over a pit from which emerge an equally numbered plurality of hydraulically operated bottom blocks. Each of the bottom blocks is registered, i.e. aligned with, one of the molds. The casting table includes troughs or distribution channels for the dissemination of molten metal introduced thereto to each of the individual molds or apertures located in the casting table. As metal from the distribution channels or troughs in the casting table enters the individual molds, the plurality of bottom blocks is lowered in unison to allow for removal of metal that has solidified in the mold therefrom and to provide space for the introduction of additional incoming molten metal. Such a prior art casting table is shown in FIG. 1 and described in greater detail hereinafter.
[0003] While the metal distribution of the casting tables of the prior art as depicted in FIG. 1 have proven highly useful and reliable over many years of service in a multitude of installations, they suffer a number of shortcomings.
[0004] As those skilled in the molten metal casting arts are well aware, it is critically important that molten metal reaching each of the molds or apertures at substantially the same time with minimal temperature loss to obtain a successful cast of the plurality logs being simultaneously cast. If metal reaching one or more apertures is too hot or hold time is too short and does not solidify as the base plate descends, a “bleedout” can result. In such a condition, molten metal can be brought into contact with water applied as a spray in the process to cool the solidifying metal. Such a conditions requires rapid plugging of the aperture or mold that is experiencing the “bleedout” with the result that that portion of the production is lost for the cast. Alternatively, if metal has resided in the mold for too long a period, it may be cooler than the balance of the molten metal and therefore solidify more quickly in the mold than metal entering other molds in the casting table resulting in a “freeze-in”, i.e. the solidified metal becomes caught in the mold. Freeze in can drop out during casting and also result in bleedout. Such a condition can result the aborting of the cast entirely and necessitating a freeing up of the metal caught in the mold and a restart of the cast. Such errors can cause significant productivity losses and place operators in significant danger from a safety standpoint. If metal enters the mold with too much velocity or too hot, penetrates between the mold and the head, solidified ingot head “flashing” may occur. Flashing is another condition that may result in molten metal coming into contact with cooling water applied to the ingot below the solidification point. Flashing also causes damage to molds or distortion or delays in the bottom block movement that can also result in casting defects, bleedouts or complete table freeze in.
[0005] In addition to the foregoing, as will be explained in greater detail below, the design of the prior art “dams”, i.e. barriers that control the flow of molten metal into the distribution troughs within the casting table, often required the presence of at least two operators on the casting table at the initiation of a casting drop to “lift” or remove the dams at the start of the cast. The presence of operators in the immediate vicinity of the molten metal casting operation is always a safety concern, and the ability to eliminate the exposure of operators to such a risk is critically important to casting facilities.
[0006] Finally, the mold portions of the prior art casting tables comprise multi-part elements that require assembly in the casting table costing valuable assembly or set-up time and which because of their design leave exposed joints between the individual elements of the assembly that are sometimes prone to leaking, particularly if not properly assembled.
OBJECTS OF THE INVENTION
[0007] It is therefore an object of the present invention to provide a multi-strand metal distribution system that provides more uniform molten metal distribution at the start of a cast, minimizes heat loss and controls the velocity and fill time differences of molten metal entering the molds.
[0008] It is another object of the present invention to provide a thimble assembly for the above-described multi-strand metal distribution systems that because of their design and construction provide simplified and more secure installation of the mold assemblies.
[0009] It is yet another object of the present invention to provide a metal distribution system that incorporates an improved dam release mechanism that obviates the need for the presence of operators on the casting table to release dams during start up of a cast.
SUMMARY OF THE INVENTION
[0010] According to the present invention, there is provided a metal distribution system for the simultaneous production of a plurality of logs or round billets from molten metal comprising: 1) a single main trough for the introduction of molten metal; 2) a plurality of side streams extending from the trough and each of the side streams including a plurality of opposing pairs of apertures each of the apertures including a mold for the shaping of molten metal passing through the trough and the side streams and into the molds. A controlled velocity and uniform flow of molten metal into the side streams and the individual apertures is provided by the controlled negative angular orientation of the entry angle of the most upstream of the opposing aperture pairs thereby providing relative uniformity of the temperature of molten metal reaching each of the plurality of apertures. A unique unitized thimble configuration and trough damming arrangement are also described.
DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a top view of a metal distribution system of the prior art.
[0012] [0012]FIG. 2 is a top view of one embodiment of the metal distribution system of the present invention.
[0013] [0013]FIG. 3 is a cross-sectional view of a mold of the prior art.
[0014] [0014]FIG. 4 is a cross-sectional view of one embodiment of a mold of the present invention.
[0015] [0015]FIG. 5 is a top plan view of a single secondary trough in accordance with the present invention.
DETAILED DESCRIPTION
[0016] Referring now to FIG. 1, in the prior art a metal distribution system 10 for the simultaneous production of multiple logs or round billets comprised an inlet 12 feeding a primary trough 14 that in turn fed secondary troughs 16 a , 16 b and 16 c . Located at approximately right angles to the major (long) axes 18 a , 18 b and 18 c of secondary troughs 16 a , 16 b and 16 c and on opposing sides thereof are pairs of opposed round apertures 20 (only some being specifically identified in FIG. 1 for clarity) each of apertures 20 containing a mold as will be described below in connection with FIG. 3. Insertion of manual dams 22 requires manual removal to begin the flow of metal into troughs 16 a , 16 b and 16 c . In the casting operation, molten metal was provide to primary trough 14 , passed therethrough to secondary troughs 16 a , 16 b and 16 c and thence into apertures 20 . While, as previously mentioned such a structure has provided a highly useful arrangement, it did demonstrate several shortcomings. Among these were that all of apertures 20 did not fill at the same time, thus resulting in temperature and solidification differences inside the sump between the first and last to fill in molten metal entering, for example the aperture designated 20 a and that designated 20 b in FIG. 1. Such a condition can and often did lead to the problems previously referred to as “bleedout” or “freeze-in”. Additionally, the casting practice commonly used with a metal distribution system of this type called for starting the flow of molten metal through inlet 12 and then sequentially and manually removing dams 22 . The need to manually operate the damming arrangement required the presence of operators, most generally 2 on the surface of casting table 10 to perform removal of the dams. This posed a significant safety hazard as the presence of personnel in the immediate area of the casting table is always a cause for safety concern. Thus, the design and availability of a casting table that eliminated such issues have been a long sought after objectives.
[0017] Referring now to FIG. 2 that presents a top plan view of the metal distribution system 30 of the present invention, there is provided an inlet 32 feeding a single preferably centrally located primary trough 34 having a plurality of relatively short secondary troughs 36 each feeding a plurality of opposing apertures 38 (not all numbered in FIG. 2 for clarity) that contain molds (not shown in FIG. 2). Dams 40 are provided at the entry of each of secondary troughs 36 . Dams 40 are controlled by a pneumatically or hydraulically operated dam control arm 42 that is remotely operated from an operators station (not shown). In operation, molten metal is flowed through inlet 32 into primary trough 34 where its flow is limited by the presence of dams 40 . Once primary trough 34 is filled to the appropriate level, dam control arm 43 is activated raising dams 40 allowing metal to flow simultaneously into all or selected secondary troughs 36 and thence into apertures/molds 38 . Thus, primary trough 34 and secondary troughs 36 are flowably connected. Because of the angular structure of entry angles 42 as described in greater detail below, molten metal of all relatively the same fill time and temperature rapidly fills apertures/molds 38 simultaneously thereby eliminating the problems of unequal temperature metal in the casting table at different locations, i.e. providing minimum fill time and accompanying minimum temperature loss with maximum velocity to avoid flashing. The incorporation of the remotely operated dams 40 , the need for the presence of operators on the casting table during the start up procedure is also eliminated.
[0018] Referring now to FIGS. 4 and 5, according to a specifically preferred embodiment of the present invention, aperture entry angles 42 located at the entry of apertures 38 those proximate primary trough 34 , i.e. those at the upstream end 37 of secondary troughs 36 , are negative and preferably range from about 15 to about 30 degrees and most preferably between about 20 and 25 degrees. The negative orientation of these angles and their particular pitch as specified herein provide for the rapid and uniform fill of apertures 38 downstream thereof toward extremities 44 with a minimum of metal fill time and velocity into apertures 38 thus preventing metal flash and inclusion causing turbulence and providing relative temperature uniformity in the molten metal. Stated differently, filling of secondary troughs 36 , because of the angular orientation of entry angles 42 results in secondary troughs 36 filling from the downstream ends 44 toward the upstream ends 37 . In operation, as molten metal enters secondary troughs 36 upon the raising of dams 40 molten metal immediately flows to the outermost extremities or downstream ends 44 of secondary troughs 36 whereupon it quickly fills apertures 38 further downstream of primary trough 34 and then commences to fill secondary troughs 36 “backwards” in the direction of primary trough 34 or the upstream ends of secondary troughs 36 . This action provides for the quick and controlled fill of all apertures 38 with a minimum of turbulence and with molten metal of relatively the same temperature to assure a uniform start to the cast with a minimum of the occurrence of “bleedthrough” or “freeze-in” and significant reductions in head and butt defects that reduce the need for head and butt crop and increase the productivity of the casting operation. Thus, relatively simultaneous fill time of all apertures 38 is achieved by the provision of negative entry angles 42 that are directed away from opposing apertures 38 closest to primary trough 34 thus insuring that the positions 38 furthest away from primary trough 34 , i.e, closest to extremities 44 or downstream, receive metal at approximately the same time as those closest to primary trough 34 or upstream.
[0019] Each of apertures 20 and 38 contains a “mold”. As shown in FIG. 3, (a cross-sectional view along the line 3 - 3 of FIG. 1) in the prior art, mold 50 comprised a crossfeeder 52 , a thimble 54 , a blanket of back-up insulation 56 , a “paper” (mica or the like) or similar gasket 58 , a transition plate 60 , a mold body 64 and a graphite ring 62 . A water reservoir 66 that produced a water spray 68 through the emission of water through spray channel 70 provided cooling of the solidifying metal 72 . The letters L and L′ in FIG. 3 indicates those areas where molten metal remains liquid as it moves through mold 50 before solidifying at 72 . The volume L′ is commonly referred to as the “sump”.
[0020] In the prior art, thimble 54 , crossfeeder 52 , back-up insulation 56 and transition plate 60 all represented individual components that were assembled “in situ” so to speak at the casting station or in a fabrication shop before the start-up of a cast. This clearly involved a significant amount of labor. Additionally, it was not uncommon for the vertical joint 74 between thimble 54 and crossfeeder 52 to leak resulting in a bleedthrough of molten metal into joint 76 at gasket 58 between crossfeeder 52 and blanket insulation 56 and casting table structure 78 . Such leakage was not only affected productivity, but could cause a safety issue under certain particularly severe leakage conditions. Additionally, the variability in assembly technique from operator to operator introduced a further element of uncertainty or variability into a casting operation that was already fraught with variables. Thus, a solution has been sought that would significantly reduce the labor intensity of the mold insertion/fabrication operation, reduce any variability in the assembly operation and reduce the potential for leakage at the previously described assembly joint(s).
[0021] Such a solution is shown in FIG. 4 that is a cross-sectional representation along the line 4 - 4 of FIG. 2. The improved metal handling system 80 of the present invention shown in FIG. 4 also comprises a crossfeeder 82 , back-up insulation 84 , and a thimble 86 , but all fabricated as a monolith that simply drops into aperture 38 through horizontal engagement with mold table 88 at horizontal joint 90 and transition plate 78 that is part of mold 60 that further engages mold table bottom plate 62 supported on mold member 73 . The entire structure is retained in close and tight engagement through the action of a bolt down arrangement through steel upright 100 that includes a nut 102 or other suitable fastening arrangement to bring the entire structure together. A graphite lubricating ring 62 as used in the prior art is incorporated in much the same fashion and for the same purposes as in the prior art. Cooling water sprays and a water reservoir are also preferably incorporated into the mold assembly, as shown in FIG. 4. The foregoing structure, has been found to: 1) reduce heat loss through the back-up insulation to a greater degree than the blanket back-up insulation used in the prior art; 2) results in fewer cracked logs at start up; 3) results in fewer cold start related defects such as bleedouts and freeze ins; and 4) quite obviously increases the ease of assembly, and greatly reduces the labor involved in the mold assembly operation.
[0022] What clearly differentiates refractory module 80 of the present invention is that it comprises a module that combines in a single integral unit, a hot face refractory for crossfeeder 82 and thimble 86 , with a peripheral, low density, cold face refractory, back-up insulation 84 thereby eliminating the need to separately insulate behind crossfeeder 82 and thimble 86 or to assemble the individual elements at the casting station or at some remote location. It also eliminates the need for a separate vertical joint ( 74 in FIG. 3) since thimble 86 is cast into the refractory module 80 providing the formation of a horizontal seal 90 (rather than a vertical seal) directly with the transition plate 78 .
[0023] The aim of the crossfeeder is mainly to distribute molten aluminum to the mold while minimizing turbulence and heat losses. The refractory material should be inert vis-à-vis molten aluminum, easy to clean and show a low heat storage. Prior art cross-feeders are made of light density refractories that have to be well preheated to avoid cold start-up. Depending on the material and design, maintenance can be quite extensive. The main mode of failure in such devices is crack propagation with time that renders the crossfeeder unusable. Typical life is difficult to determine because it depends on many variables such as: casting technology, design, casting parameters, maintenance, etc.
[0024] According to the present invention, two different refractory materials are used to extend the useful life of the crossfeeder and to enhance the aluminum casting process itself.
[0025] The material directly in contact with the aluminum 87 is a dense and hard refractory material showing excellent non-wetting characteristics to molten aluminum. It is provided in the form a thin skin, preferably between 6 and 10 mm thick. This material is a fiberglass fabric reinforced wollastonite that exhibits outstanding mechanical and non-wetting properties and is suitable for the fabrication of complex shapes. According to a highly preferred embodiment of the present invention the non-wetting properties of this material are further improved by coating its surface with a thin layer of boron nitride (not shown). Thin skin 87 is then backed up with a layer 84 of a highly insulating refractory material, preferably, Wollite, a mineral foam based wollastonite material. The skin 87 is used as the mold external surface and the Wollite insulation 84 is cast around this externally. The two materials constituting thin skin 87 and insulating refractory 84 , have very similar thermal expansion coefficients, which avoids delamination and cracking during the heat up and casting cycles. This material combination exhibits a number of desirable characteristics/advantages. Among these are: mechanical strength; crack propagation minimization because of structure; repairability; reduced heat transfer and therefore more consistent molten metal temperature; significantly reduced cross-feeder weight and casting table weight significantly reduced heat storage and table preheating schedule; and reduced steel shell temperature due to increased insulation factors thereby minimizing steel expansion, joint maintenance and crack propagation.
[0026] Thus, in the casting insert 80 of the present invention, cylindrical crossfeeder 82 and cylindrical thimble 86 present a continuous, joint free and uninterrupted cylindrical interior surface 87 surrounded by an integral peripheral layer of back-up insulation 84 .
[0027] While the elements of the monolithic assembly of the present invention can be fabricated from a wide variety of compatible materials, according to a highly preferred embodiment of the invention, crossfeeder 82 is formed from an SH or RFM Insural material available from Pyrotek, Inc. East 9503 Montgomery Ave, Spokane, Wash. RFM Insural is a moldable light density refractory composite material comprised of fiberglass fabric reinforced wollastonite. Back-up insulation 84 comprises Wollite an insulating castable also available from Pyrotek, Inc. Wollite is a solid lightweight mineral foam that is stable during its preparation and during curing and drying. It is a phosphate bonded foam insulation that can be made in densities ranging from 320 to 880 kg/m 3 and is mainly composed of wollastonite, a calcium silicate. Crossfeeder 82 , thimble 86 and backup insulation 84 can also be cast as a single unit. This is made possible by the compatibility of the various materials of fabrication.
[0028] There have thus been described: a novel metal distribution system incorporating; an automated and remotely operable dam removal system; and a monolithic mold insert assembly that each individually demonstrate significant operating advantages and which when combined into a single operating system provide a significantly improved log or round ingot casting system that is economically desirable and simultaneously provides noteworthy safety improvements.
[0029] As the invention has been described, it will be apparent to those skilled in the art that the same may be varied in any ways without departing from the spirit and scope thereof. Any and all such modifications are intended to be included within the scope of the appended claims.
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A metal distribution system for the simultaneous production of a plurality of logs or round billets from molten metal comprising: 1) a trough for the introduction of molten metal; 2) a plurality of side streams extending from the trough and each of the side streams including a plurality of opposing apertures each of the apertures including a thimble for the shaping of molten metal passing through the trough and the side streams and into the thimbles. A uniform flow of molten metal into the side streams and the individual apertures is provided by the controlled negative angular orientation of the most upstream opposing pair of apertures thereby providing relative uniformity of the temperature of molten metal reaching each of the plurality of apertures. A unique unitized thimble configuration and trough damming arrangement are also described.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Divisional Application of U.S. patent application Ser. No. 12/012,137 which was filed on Jan. 30, 2008 for which application this inventor claims domestic priority.
BACKGROUND OF THE INVENTION
This invention generally relates to wind turbines, and anchoring devices, such as bolts, which are used in the foundations because of the high overturning moments wind turbines are subjected. The invention more specifically relates to a plastic bolt sleeve used in combination with a threaded anchor, where the plastic sleeve is plastically deformed or “crimped” onto a portion of the threads of the bolt. The invention further discloses methods and devices for crimping the sleeve onto a portion of the bolt threads. Among other benefits, the crimped bolt sleeve protects the anchor bolts from moisture and resulting corrosive attack.
The bolts used for anchoring wind turbines may either be set in concrete or drilled into the rock. The integrity of the foundation of a wind turbine is subject to failure if the anchor bolts are not adequately protected. In particular, anchors are subject to corrosive attack caused by the accumulation of water or other electrolytes in the anchoring hole which results in the creation of a corrosion cell. As described below, the practices employed in preparing the foundation for a wind turbine often create an environment in which the anchor bolt is exposed to water or other liquid.
By way of background for wind turbine foundations, U.S. Pat. Nos. 5,586,417 and 5,826,387, both by Henderson, disclose a pier foundation “which can be poured-on-site monolithically and is of cylindrical construction with many post-tensioned anchor bolts which maintain the poured portion of the foundation under heavy compression, even during periods when the foundation may be subject to high overturning moment.” Henderson's foundation is preferably in the shape of a cylinder, having an outer boundary shell and an inner boundary shell each formed of corrugated metal pipe which are set within an excavation.
In the fabrication of foundations for wind turbines, elongated high strength steel bolts, generally fashioned from 1¼″ (#10) rebar material or 1⅜″ (#11) rebar material are set within the foundation excavation and concrete poured into the excavation such that the bolts extend vertically up through the concrete from a peripheral anchor plate or ring near the bottom of the cylinder to a peripheral connecting plate or flange at the base of the wind turbine tower. The bolts are typically threaded at the top and bottom ends for a length of approximately 24 inches. The bolts are largely contained within through hollow sleeves made of PVC which prevent adhesion of the concrete to the bolts. The sleeves are typically installed prior to delivery of the bolts to the job site, and nuts must be placed on each end of the anchor bolt to retain the PVC sleeve on the anchor bolt material.
Henderson further discloses the post-stressing of the concrete in great compression by tightening the high strength bolts to provide heavy tension from the heavy top flange (i.e., the flange at the base of the wind turbine) through which the bolts pass to the anchor flange or plate at the bottom of the foundation, thereby placing the entire foundation, between the heavy top plate or flange and lower anchor plate or flange, under high unit compression loading. The nuts on the bolts are tightened so as to apply tension to the bolts exceeding the maximum expected overturning force of the wind turbine tower structure on the foundation. Therefore, the entire foundation withstands various loads with the concrete always in compression and the bolts always in static tension. Because the bolts are each largely contained within a PVC sleeve, each bolt is free to move within its sleeve as the bolts are tensioned by tightening the nuts abutting the top flange. Steps are typically taken before the concrete is poured to seal the tops of the PVC sleeves to prevent the flow of concrete into the sleeves, such as wrapping duct tape around the tops of the sleeves. This can be a time-consuming process.
Based upon the discussion above, it is clear that the integrity of this type of foundation is dependent upon the integrity of the anchor bolts—the failure of a bolt creates a stress riser on the remaining bolts, leading to the potential failure of the entire foundation. The integrity of the steel anchor bolts can be compromised by corrosive attack. As described above, according to the current practice each anchor bolt is enclosed for most of its length within a PVC sleeve. However, because the outside diameter of the PVC sleeve is too large for the sleeve to enter the bolt hole of the flange of the tower structure, the sleeve typically terminates at approximately the top of the concrete foundation, with the bare metal of the anchor bolt extending above the sleeve, where the bolts extend through the flange and have a nut and bolt cap installed on the top side of the flange.
The tower flange is usually set on a grout base which overlies the concrete foundation. The grout base is placed within a circular “grout trough” which is formed by the pouring of the concrete foundation around a circular template. This circular template is utilized to collectively lift and place the anchor bolts within the excavation prepared for the foundation. As with the holes of the flange of the tower base, the bolt holes in the circular template are sized to accommodate the bolt diameter, but not the diameter of the PVC sleeve, so the tops of the bolt sleeves will generally be flush with the bottom of the grout trough formed by the circular template.
In order to prevent dehydration of the grout—thus adversely impacting the grout strength—it is a common practice to place water within the grout trough prior to the pouring of the grout to keep the grout properly hydrated during the curing process. However, water placed in the trough will gravitate into the ends of the PVC sleeves which are flush with the bottom of the grout trough. In the current installation practice, a foam sleeve is typically placed around a portion of each bare bolt extending above the bottom of the grout trough, with each foam sleeve and held in place with duct tape. The length (or height) of the foam sleeve is sized to extend above the anticipated thickness of the grout layer within the grout trough. In the known practice, the tower flange is set on the grout before the grout sets so that the tower base may be leveled. It is hoped that the foam sleeve will prevent grout from adhering to the body of the bolt, such that when the grout fully cures the bolt may be tensioned and slide through the foam sleeve without damage to the grout. However, in reality the foam sleeve is likely so deformed by the flange of the tower base that the bolts will not slide freely through the sleeves once the grout cures.
If low viscosity grout is used, the flow properties of the grout will cause it to flow into the annulus created by the PVC sleeve and the anchor bolt. Because of this problem, the use of low viscosity grouts, including epoxy grouts, has not been practical. However, the low viscosity grouts would otherwise be preferred because of the self-leveling characteristics of the grout. In particular, the use of self-leveling grout would eliminate the need for leveling shims and allow the grout to be poured and adequately cure before setting the flange onto the grout, as opposed to the current practice of setting and leveling the tower flange before the grout cures. The current practice requires the service of a high capacity crane for the initial setting of the tower flange and subsequently for the assembly of the complete turbine. However, if the tower flange can be placed at the same time as the other turbine tower components, the crane can be used more efficiently with less rigging up and rigging down time at each turbine tower installation.
Once the tower has been installed and a nut and bolt cap installed on the bolt ends extending above the tower flange, the annulus between the bolt and PVC is sealed. However, during the known installation method, the annulus between the bolt and the PVC sleeve is open thereby providing a pathway for water and other fluids to enter the annulus and be trapped between the PVC sleeve and the metallic bolt, forming a corrosion cell. Because of this opening, steps are usually taken to protect the bolt from corrosive attack and/or to seal the sleeve-bolt annulus during installation. Unfortunately, the currently practiced installation procedure aggravates the situation, because, as described above, the procedure typically includes pouring water in the grout trough to allow the grout to cure. This practice allows to water to accumulate at the top of the PVC sleeve, and potentially migrate into the sleeve-bolt annulus.
The initial attempt at solving the anchor bolt corrosion problem was to paint the anchor bolts along the entire length. However, this solution is labor intensive and does not prevent liquid accumulation around the anchors. In addition, this protection method requires that the anchors be repainted periodically, as well as after re-tensioning the anchor if required in the particular application. The currently practiced method of protecting the anchor bolts is to seal the annulus between the top of the PVC sleeve and the bolt with a sealant, such as a silicon gel.
As discussed above, the current practice also includes placing foam or other material around the portion of the bolt extending above the PVC sleeve, so as to prevent adhesion of the grout to the bolt and to block the migration of water into the sleeve-bolt annulus. Typically, foam cylinders with longitudinal slits are placed around the bolts, with duct tape wrapped around each cylinder, and the cylinder pushed downwardly into contact with the top of the PVC sleeve. However, with the large number of bolts utilized in these types of foundations, it is time consuming and difficult to seal the top of each PVC sleeve with sealant and to install the foam cylinders or similar devices. If hurried, the annulus may not be adequately sealed to prevent the intrusion of water into the PVC-bolt annulus. Moreover, once the tower base flange is set upon the foam cylinders, the cylinders are greatly deformed. It is non-unlikely that when the anchor bolts are tensioned, the bolt does not slide through the foam cylinder, but that the deformed foam cylinder moves within the grout, potentially damaging the integrity of the grout.
The PVC sleeves, because of the outside diameter, displace, in totality, a significant volume of concrete in the foundation, thereby reducing the overall compressive strength of the foundation.
SUMMARY OF THE INVENTION
The present application is directed toward a method and apparatus which addresses the problems identified above. In an embodiment of the disclosed invention, rather than utilizing PVC sleeves which terminate at the bottom of the grout trough, the present invention comprises anchor bolts comprising a sheath or sleeve which extends above the grout trough and, if desired, may partially extend inside the base flange of the wind turbine base. The sleeve may be manufactured from polypropylene, polyethylene or other materials having satisfactory mechanical properties, primarily that the material be capable of withstanding sufficient plastic deformation to cause the material to conform to the shape of the threads of the anchor bolts without failing. The term “polypropylene”, when used below, not only includes polypropylene materials, but other plastic materials having mechanical properties which allow those materials to be substituted for polypropylene. In the present application, each anchor bolt comprises a polypropylene sleeve in which a portion of the sleeve is “swaged” onto a portion of the threads of the bolt thereby creating a mechanical seal between the interior of the sleeve and the threads of the bolt. For purposes of distinguishing the presently disclosed sleeve from the prior art sleeves, the presently disclosed sleeve is hereinafter referred to as the “crimped sleeve”, although it is to be appreciated that only a portion of the sleeve actually comprises crimping or swaging.
The use of the polypropylene sleeve and the swaging of the sleeve onto a portion of the bolt threads accomplishes several improvements over the known apparatus and methods. The disclosed invention provides a bolt package (i.e. a bolt/sleeve combination) which has an overall diameter less than the overall diameter of the currently utilized bolt-PVC sleeve combination. This reduced diameter allows the bolt and crimped sleeve to extend through the bolt holes of the circular template, and into the bolt holes of the tower flange, which under the known apparatus and method, only a sleeveless bolt would extend. Because the crimped sleeve extends above the top of the grout trough, the encased bolts will not be exposed to water placed within the grout trough. Moreover, because a seal is formed between the top of the crimped sleeve and a portion of the threads of the bolt, access to the annulus between the bolt and the crimped sleeve is either eliminated or substantially reduced, thereby preventing or greatly limiting the axial migration of water or other electrolytes along the length of the bolt. In addition, because the top of the crimped sleeve extends above the level of the grout, the crimped sleeve prevents adhesion of the grout to the bolt, thereby allowing the bolt to move relative to the grout.
As another advantage over the known system, because the crimped sleeve places the top of the sleeve above the level to which grout will be placed, the grout has no access to the sleeve-bolt annulus and low viscosity grout may be utilized. As stated above, low viscosity grout is self-leveling, which allows the grout to cure before the tower base is set upon the grout.
As another advantage, the reduced diameter of the crimped sleeve displaces less cement than the larger diameter PVC sleeve, resulting in a stronger foundation. With respect to the grout around the tower base flange, the crimped sleeve of the present invention displaces less grout than the deformed foam cylinder presently used.
As another advantage, the expense of the materials utilized for the crimped sleeve, such as polypropylene, is less than the expense of the larger diameter PVC sleeves.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the base of a wind turbine which might utilize embodiments of the disclosed apparatus and method.
FIG. 2 shows a bolt assembly utilized for the foundation of a wind turbine being lowered into an excavation for the foundation.
FIG. 3 shows detailed view of a portion of the grout trough prior to the placement of the tower base flange, showing the use of foam sleeves for preventing adhesion of grout onto each bolt body, and the use of a spacer block for leveling the tower base.
FIG. 4 shows front view of a portion of a tower foundation, with the tower base flange begin lowered onto the anchor bolts.
FIG. 5 shows a cross section of a portion of the base flange, grout, and PVC sleeve of a prior art anchor bolt installation.
FIG. 6 shows a cross section of a portion of the base flange, grout, and sleeve of an embodiment of the present invention.
FIG. 7 shows a portion of an embodiment of the disclosed crimped sleeve, showing how the sleeve is swaged around some of the threads of the anchor bolt.
FIG. 8 shows an embodiment of a device which may be utilized for swaging the sleeve around the threads of the anchor bolt.
FIG. 9 shows the device of FIG. 7 , showing how it is placed around an anchor bolt.
FIG. 10 shows perspective side view of an embodiment of another swaging device which may utilized for swaging the sleeve around the threads of the anchor bolt.
FIG. 11 shows a perspective front view of the swaging device of FIG. 10 .
FIG. 12 shows a front view of the swaging device of FIG. 10 .
FIG. 13 shows a side vide of the swaging device of FIG. 10 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Prior Art Bolt Protection Devices
FIG. 1 generally depicts the base 10 of a wind turbine set upon a foundation 12 . Base 10 comprises a flange 14 , by which the base is attached to foundation 12 with anchor bolts 16 . As shown in FIG. 1 , the anchor bolts 16 may be placed in side-by-side pairs, the pairs extending radially from the center of the foundation 12 forming an inner ring of bolts and an outer ring of bolts. The bolt pattern is, of course, determined by the bolt pattern on the mounting flange 14 . Each anchor bolt 16 has a corresponding nut 18 which is used to secure the base 10 , and to apply tension to the bolt. The exposed portion of each bolt 16 is usually protected with a bolt cap 19 .
A large number of anchor bolts 16 is typically used for this type of foundation. For example, Henderson discloses an embodiment having forty-eight tensioning bolts in the inner ring and forty-eight tensioning bolts in the outer ring for a total of ninety-six. In Henderson's foundation, the lower ends of the bolts are anchored at the bottom of the foundation to a lower anchor ring which may be constructed of several circumferentially butted and joined sections. Although it is to be appreciated that other means may be employed for anchoring the bolts, including drilling a portion of the anchor bolt into the ground.
FIG. 2 depicts a bolt assembly 20 comprising a plurality of anchor bolts 16 being lifted in preparation for being placed within a relatively deep excavation prepared for construction of the foundation 12 . The anchor bolts 16 typically used for wind turbines are approximately thirty feet in length, and usually have outside diameters of 1¼ inch or 1⅜ inch. Each anchor bolt 16 is partially enclosed within a “hollow tube” or sleeve 22 . The sleeve is typically an elongated plastic tube fabricated from polyvinyl chloride (“PVC”) which encases the bolt 16 substantially through the entire vertical extent of the concrete and allows the bolt to be tensioned after the concrete has hardened and cured, thereby post-tensioning the entire concrete foundation. The bolts 16 comprising bolt assembly 20 are secured at the end by circular template 23 , which is attached to a lifting assembly 24 and lifted by crane 26 .
FIG. 3 shows a close view of a portion of the grout trough 28 before grout has been poured or base flange 14 has been placed. Grout trough 28 is formed as follows: when the concrete is poured, circular template 23 , which remains attached to lifting assembly 24 and held in place by crane 26 , holds the bolt assembly 20 in place. Concrete is poured up around circular template 23 , thereby forming an inner ring groove in the top of the foundation 12 known as the grout trough 28 . Before grout 30 is placed in grout trough 28 , a sealing member 32 comprising foam, plastic or other material, is placed around each bolt 16 . Sealing member 32 is typically cylindrical in shape, having a circular opening and longitudinal slit cut through from the outside edge to the circular opening so the sealing member may be placed around each bolt 16 . The sealing member 32 often has duct tape wrapped around it to secure it to the bolt 16 . Also shown in FIG. 3 is a leveling block 5 which is used, in combination with a number of other leveling blocks contained within the grout trough, to properly level the base flange 14 . It is to be appreciated that the placement of leveling block 5 immediately adjacent to sealing members 32 , which is not an uncommon occurrence in the prior art installations, inhibits the uniform deformation of the sealing members as the base flange 14 is lowered into the grout trough 28 , resulting in the non-uniform deformation discussed below.
FIG. 4 depicts a portion of a prior art foundation 12 after the grout has been poured and cured, but before flange 14 has been set upon the foundation and nuts 18 made up onto bolts 16 . As shown in FIG. 5 , flange 14 will be set on top of the grout 30 contained within grout trough 28 .
FIG. 5 shows a cross section of a portion of the base flange 14 , grout layer 30 , and sleeve 22 of a prior art anchor bolt installation for a wind turbine, where sleeve 22 contains bolt 16 . As shown in FIG. 5 , the top of sleeve 22 is generally flush with the bottom 34 of grout trough 28 . It is to be appreciated that before grout 30 is placed within grout trough 28 , the top of sleeve 22 is exposed to whatever liquids may enter the grout trough, such as water which may be placed in the grout trough to provide for hydration of the grout. An annulus 36 is formed between bolt 16 and sleeve 22 , which provides a potential path for water or other liquids, such as low viscosity grout, to travel along the length of bolt 16 .
As can be seen in FIG. 5 , sealing member 32 is substantially deformed once engaged by base flange 14 . It is to be appreciated that FIG. 4 shows an idealized view of the deformed sealing member 32 , in which the deformation has been uniform. In actuality, it is expected that the deformation will not be uniform because, for example, of obstructions which may inhibit uniform deformation such as the leveling block 5 shown in FIG. 3 . It is also to be appreciated that the deformed sealing member 32 displaces more volume than the non-deformed sealing member. Because each bolt requires the sealing member, a typical installation may have ninety-six of the deformed sealing members 32 in the grout trough 28 , thereby reducing the overall volume of grout which may be placed, resulting in a final grout pack with less strength than one having less grout displacement. It is also to be appreciated that once the grout 30 sufficiently cures, tension will be applied to each anchor bolt 16 by the tightening of a nut at the top of base flange 14 , causing the bolt to move relative to the grout. Ideally, sealing member 32 would remain stationary, allowing bolt 16 to slide through the sealing member 32 . However, deformation of sealing member 32 reduces the ease with which anchor bolt 16 will slide through the sealing member, potentially causing sealing member 32 to also move, potentially damaging the surrounding grout 30 .
Embodiments of the Present Invention
FIG. 6 shows a cross section of a portion of the base flange 14 , grout 30 ′, and sleeve 38 of an embodiment of the present invention. In contrast to the prior art shown in FIG. 5 , it can be seen in FIG. 6 that the crimped sleeve 38 does not terminate at the bottom 34 of the grout trough 28 , but rather extends upwardly through the space in which grout 30 ′ will be placed and partially penetrates the bolt hole 13 of base flange 14 . This feature prevents the top of crimped sleeve 38 from being exposed to the liquids which may be placed within grout trough 28 . The use of crimped sleeve 38 as the protective sleeve for bolt 16 ′ is a substantial departure from the present use of PVC sleeve 22 .
The critical distinction between the presently disclosed crimped sleeves from the prior art sleeves is that the wall thickness of the crimped sleeve is substantially reduced, and the tolerance between the internal diameter of the crimped sleeve and the outer diameter of the bolt threads is substantially reduced, resulting in an external diameter of the crimped sleeve which is smaller than possible with the thicker-walled PVC sleeves, allowing the crimped sleeves to extend into the bolt holes 13 of the base flange 14 . For example, a crimped sleeve comprising polypropylene sleeves has a closer tolerance than the available PVC, such that the crimped sleeves may have a clearance of 20 thousands of an inch between the internal diameter of the crimped sleeve and the outer diameter of the anchor bolt threads. As shown in FIG. 6 , this smaller outside diameter of the crimped sleeve 38 allows a portion of the sleeve to be disposed within the holes 13 in the base flange 14 rather than terminating at the bottom 34 of the grout trough 28 as shown in FIG. 5 for the prior art sleeves. The PVC tubes presently in use as sleeves do not extend into the base flange 14 of the wind turbine. The diameters of bolt holes 13 for the base flanges 14 for wind turbines are approximately 1½ inch, and the external diameters of commonly available PVC tubes which may be utilized as hollow tubes for 1¼ inch to 1⅜ inch bolts are too large to be inserted within the holes of the flange.
As shown in FIG. 6 , and in greater detail in FIG. 7 , the top of the crimped sleeve 38 is “swaged” such that a portion of the sleeve conforms to the threads of the anchor bolt 16 ′. The swaging serves several purposes. First, the swaging retains the crimped sleeve 38 on the anchor bolt 16 ′ such that nuts are not required to retain the sleeve on the anchor bolt during transportation. This characteristic allows the anchor bolts 16 ′ to be shipped without nuts, which reduces manpower required for placing the nuts on the bolts for transportation and removing of the bolts upon arrival.
The swaging further inhibits the flow of liquids into the annulus between the crimped sleeve 38 and the anchor bolt 16 ′, although it is to be appreciated that the exposure of the sleeve end to liquid is reduced or eliminated, because of the capability of placing the top of the crimped sleeve 38 within the base flange 14 rather than disposed at the bottom 34 of the grout trough 28 . It has been found that swaging approximately two inches of the top of the crimped sleeve 38 forms a sufficient length of “crimps” 17 (i.e., portions of the sleeve 38 which conform to the shape of individual threads 21 ) to form an interference fit which adequately inhibits liquid penetration into the sleeve-bolt annulus. It has been found that sleeves comprising polypropylene, or similar materials, have the desired mechanical properties for swaging the sleeve material such that it conforms to the shape of the threads. The mechanical properties of the polypropylene are such that the material has a “memory” and retains the crimps 17 once the swaging operation has been completed. It is also to be appreciated that when the anchor bolts 16 ′ are tensioned by the tightening of the nuts 18 , the mechanical properties of the sleeve material are such that upon tensioning of the anchor bolt 16 ′, the material will plastically deform and the crimps will relax and allow relative movement of the anchor bolt with little resistance.
Also disclosed are swaging devices utilized in forming the crimped sleeves 38 . FIGS. 8 and 9 show a die assembly 40 which may be utilized either with bolts 48 or with a hydraulic press to create the crimping of the crimped sleeve 38 . Die assembly 40 comprises two sides, wherein each side comprises a thread profile 46 which matches the thread profile of the anchor bolt 16 ′. Compressing each side of the die assembly against a sleeve encased anchor bolt causes the crimped sleeve 38 to conform to the thread profile of the anchor bolt 16 ′.
FIGS. 10 through 13 show another embodiment of a swaging tool 50 . This tool 50 comprises a swaging end 56 and a threaded end 54 , which define a longitudinal axis L, wherein the longitudinal axis is at the center of the tool. The swaging tool 50 comprises an opening coinciding with the longitudinal axis L, and the threaded end comprises internal threads 52 which match the threads of the anchor bolt 16 ′. The swaging end 56 comprises a plurality of rollers 58 a , 58 b , 58 c , 58 d , 58 e and 58 f , each roller having the same diameter. Rollers 58 a , 58 b , 58 c , 58 d , 58 e and 58 f are arranged at different points along the length of the longitudinal axis L and have different radial distances from the longitudinal axis. Rollers 58 a through 58 f are attached to the swaging end with fasteners 60 , such as bolts or screws.
The rollers 58 a through 58 f are disposed within the tool 50 to follow the threads 21 of an anchor bolt 16 ′, compressing the sleeve into the threads to create the crimps 17 . The rollers are disposed such that the center each roller is a different radial distance from the longitudinal axis L. It is to be appreciated that a different swaging tool 50 may be fashioned for each bolt diameter and thread type, including right-handed and left-handed threads.
By way of example only, for a tool having an overall radius of 2.0 inches, an inside diameter of 0.680 inches, and individual roller diameters of 1.250 inches, the centers of the rollers may have the following radial distances from the longitudinal axis L:
roller 58 a: 1.391 inches roller 58 b: 1.415 inches roller 58 c: 1.295 inches roller 58 d: 1.319 inches roller 58 e: 1.343 inches roller 58 f: 1.367 inches
Swaging tool 50 , which may comprise suitable material such as 1080 steel, is made up on at the end of a sleeve-encased anchor bolt, with the swaging end 56 made up first. As swaging tool 50 is screwed onto the threads, the bolt will ultimately engage internal threads 52 , which assist in guiding the tool. Once the swaging tool reaches the polypropylene sleeve, roller 58 f will be the first roller to engage the sleeve, followed by 58 e , etc., the rollers compressing the sleeve into the threads 21 . The swaging tool 50 may be attached to both power tools and hand tools.
While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. Thus the scope of the invention should not be limited according to these factors, but according to the following appended claims.
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A wind turbine installation comprises anchor bolts having a sheath or sleeve which extends above the cement foundation and the overlying grout layer. If desired, the sleeve may partially extend inside the base flange of the wind turbine tower. The sleeve may be manufactured from polypropylene, polyethylene or other materials having satisfactory mechanical properties, primarily that the material be capable of withstanding sufficient plastic deformation to cause the material to conform to the shape of the threads of the anchor bolts without the material failing. This swaging operation results in a crimped end which forms an interference fit with the threads of the anchor bolt thereby preventing or limiting the intrusion of water or other liquids into the bolt-sleeve annulus during the installation of the turbine foundation.
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BACKGROUND OF THE INVENTION
This invention relates monitoring systems for thermal energy storage (TES) plants, more specifically, an automatic monitoring system for TES plants wherein the system, when connected to a central control, acts as a pilot ice tank for the new and/or existing TES plants of all sizes and types to automatically and precisely monitor ice inventory to further improve efficiency and energy savings.
Immediate application of the invention relates to the capacity of the pilot ice tank to produce and relay to the central control of the TES information regarding available ice inventory in the TES on a realtime basis. This realtime ice inventory level tells the owner and/or operator of the TES how much cooling capacity is available in the main ice tanks at any given time.
Based on the information provided by the pilot ice tank, an owner or operator of the TES plant can create records to track ice inventory levels in the central control of the TES. These records will help the owner or operator to determine, despite variable ambient conditions and/or variations on water level on the main ice tanks, the best low and high ice inventory values to start and/or stop the operation of the chillers during an ice-making mode to achieve maximum efficiency of the TES operation. Maximum efficiency results in maximum energy conservation and minimum operational costs.
These records are also useful tools to corroborate and adjust along the useful life of the TES the best low and high ice inventory values to start and/or stop the chillers.
Realtime information regarding the ice inventory level in the main ice tanks is therefore essential to maximize the efficiency of the TES. Once the information is received at the central control, the ice inventory information is analyzed. Then, a decision is made as to whether to issue a command to either start the chillers during the ice making mode every time maximum efficiency ice inventory depletion level has been reached in the main TES ice tanks or to stop the chillers during the ice making mode when the maximum efficiency high ice inventory level has been reached on the main ice tanks of the TES.
Thermal energy storage (TES) plants are widely used as an energy conservation system in air conditioning and industrial processes. They have been used for cooling since the earliest days of mechanical refrigeration, initially and more specifically as an energy saving device in breweries. Recently, however, the concept has gained widespread exposure due the deregulation of energy rates and consequent changes in energy pricing policies. Utility companies are now using time-and-use rate schedules, attempting to encourage people to shift their electric demand to off-peak, low electrical demand periods of the day by raising daytime rates for energy consumption. Thus, in order to reduce energy costs, approximately five to ten thousand facilities in the United States and approximately five to eight thousand facilities in the rest of the world have switched to TES systems to air condition their buildings and to cool tools and manufactured parts in industrial processes.
The most basic TES cooling system is a chiller-based, closed loop system. Water is cooled by chillers during off-peak (less expensive) hours and stored in an insulated tank. During peak hours, the stored cool water is pumped to the air conditioning units in order to cool a facility. Thus, several benefits, both monetary and environmental, are achieved by using a TES system. More common TES systems accumulate ice instead of chilled water inside the tanks. Using ice in lieu of water allows the TES system to store the same amount of energy in a relatively smaller space.
Examples of facilities reaping the benefits of using TES systems include Florida Gulf Coast University in Fort Myers, Fla., which saves an estimated $11,000.00 per month on energy bills and the Centex building, a 180,000 square foot facility located in Dallas, Tex., which received a 99/100 rating by the Environmental Protection Agency's Energy Star Program in 2000.
A typical TES cooling system works by using an insulated tank (called a thermal energy storage tank) that contains a heat exchanger within the tank surrounded by water. During the off-peak hours (usually in the evening) the system is in the ice making mode, often referred to as the “off-peak” charge cycle. In this mode, a certain mixture of water and ethylene glycol is cooled by a chiller to a temperature below the freezing point of water and is circulated through the heat exchanger. Since the water/ethylene glycol solution is below freezing, the water surrounding the heat exchanger in the tank freezes. This process continues until a large percentage of the water in the tank is frozen solid. The percentage of water that should be frozen is specified by the tank manufacturer and determines the cooling capacity of each tank in terms of hours per cooling capacity (tons/hour).
During peak hours when energy costs are higher, usually during the day but always determined by hourly energy market costs, the process is reversed. The ice in the tanks thaws, thereby cooling the water-glycol solution now circulating through the air conditioning or industrial process system. The water-glycol solution then absorbs the energy from the building and its occupants or from an industrial process. This is known as the ice melting mode, also referred to as the “on-peak” discharge cycle.
Most current methods for monitoring, tracking and controlling ice inventory in the tanks of the TES are based on a calibrated electronic sensor permanently and hydraulically connected to the interior of the tank and installed inside a plastic tube externally attached to the tank. As the ice is made or thawed inside the tank, changes in the ice volume makes the water level in the tank go up and down, raising the water level as ice is made and lowering the water level as ice is thawed. As the water level changes inside the tank, the water level also changes inside the plastic tube at exactly the same pace and level as within the tank because the external plastic tube is permanently and hydraulically connected to the interior of the tank. Every change in water level inside the tank is therefore registered by the calibrated sensor inside the external plastic tube and converted by an electronic transducer into a digital or analog electronic signal sent to the TES central control as realtime data. The central control then displays the information as actual ice inventory percentage on the TES. the ice inventory information is used by the central control as previously described to start and/or stop the chillers in the ice making mode or as an indication of the cooling capacity available.
Another commonly used method to control the ice making process on a TES is by constantly monitoring the temperature of the water-glycol mixture returning from the tanks to the chillers. In this method, calibrated electronic sensors immersed in wells in the water-glycol mixture mainstream constantly read the temperature of the mixture and electronically send this information to the central control. The central control instantaneously and automatically translates the digital or analog signals from the sensors into Fahrenheit degrees. When the temperature of the mixture returning from the tanks equal a predetermined temperature setting on the central control, the chillers will stop. The central control settings to stop the chillers range from 26 to 28 degrees Fahrenheit. At that mixture temperature, the ice inventory in the tanks will be close to or at 100%.
Some external factors make these two monitoring systems inaccurate. The first system is inaccurate due to rainwater and high humidity affecting the internal water level, especially during the summer months. Despite best efforts to tightly seal the tanks, rainwater and humidity enter the tanks, causing the internal water level to rise. Subsequently, the level sensors in the plastic tubes will essentially be reading water levels not corresponding to actual ice inventory in the tanks. Thus, the sensors are relaying inaccurate information to the central control. During the dry season, water evaporation from the tanks will also lead to inaccurate ice inventory readings. Additionally, oftentimes the level sensors in the plastic tubes located outside the tanks go bad due to constant exposure to the elements.
The main causes for the inaccurate ice inventory level readings when using the second system are outdoor ambient temperature changes and temperature sensors failures. Inaccuracy in ice inventory level readings has a direct consequence: inefficiency.
Inaccuracy in ice inventory level readings risks not having air conditioning in a facility or no cooling available for an industrial process during the on peak hours of the day. In the occurrence of such an event, the owner has the option of running the chiller(s) during the on peak hours at great expense.
A third system measures the displacement of the heat exchanger and its supporting structure as the buoyancy of the ice lifts them up. Displacement is measured manually or electronically.
A fourth system positions a coil on springs and employs load cells to sense the uplifting force of the ice forming on the coils which are restrained from vertical movement.
Although accurate and reliable, the third and fourth systems include expensive, complicated to manufacture and difficult to install parts. Thus, cost, downtime and technical difficulties to adapt to existing TES have kept these systems out of the market.
Thus, there exists the need for a more accurate, economical and universal system and method to measure the amount of ice made and/or thawed on TES.
The relevant prior art includes the following patents:
Patent No.
(U.S. unless stated otherwise)
Inventor
Issue Date
5,090,207
Gilbertson et al.
Feb. 25, 1992
5,467,812
Dean et al.
Nov. 21, 1995
5,678,626
Gilles
Oct. 21, 1997
5,390,501
Davis
Feb. 21, 1995
JP359077254A
Okada et al.
May 2, 1984
JP362141435A
Takebayashi et al.
June 24, 1987
5,139,549
Knodel et al.
Aug. 18, 1992
4,088,183
Anzai et al.
May 9, 1978
6,185,483 B1
Drees
Feb. 6, 2001
5,046,551
Davis et al.
Sep. 10, 1991
6,298,676
Osborne et al.
Oct. 9, 2002
6,415,615
Osborne et al.
Jul. 9, 2002
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide an automatic monitoring system for thermal energy storage plants that is accurate.
A further object of the present invention is to provide an automatic monitoring system for thermal energy storage plants that is affordable.
An even further object of the present invention is to provide an automatic monitoring system for thermal energy storage plants that is adaptable.
An even further object of the present invention is to provide an automatic monitoring system for thermal energy storage plants that can be applied to new and existing thermal energy storage plants, regardless of the manufacturer, type or model of each tank within the plant.
A further object of the present invention is to provide an automatic monitoring system for thermal energy storage plants that keeps an accurate ice inventory, also known as cooling capacity, available in the main ice tanks of the TES.
The present invention fulfills the above and other objects by providing a pilot ice tank that claims the use of Archimedes' principle to determine the ice inventory level. According to Archimedes' principle, a body immersed in a fluid is buoyed up by a force equal to the weight of the displaced fluid. Thus, the present invention determines the ice inventory level by measuring the resultant force of the algebraic addition of the weight of the ice and the reaction of the water pushing the ice up with a force equal to the weight on the water displaced by the volume of the ice. Other forces, such as the weight of the heat exchanger, pivoting arm and accessories, piping, etc. are compensated by the use of a counterweight.
More precisely, the pilot ice tank has a pivoting arm, a heat exchanger and a counterweight. The pivoting arm, preferably made of metal, is secured to the pilot tank and has the heat exchanger affixed thereon. The proximal end of the pivoting arm has counterweight arm affixed thereon with the counterweight arm having a means for securing the counterweight. When there is no ice within the tank, the pivoting arm is parallel to the ground. Because the pivoting arm is hinged to a pivoting arm crossbar, when ice is formed, an upward force is exerted on the pivoting arm.
The resultant force applied on the pivoting arm is then transferred to a liquid filled bellow or cylinder and is then transformed into hydraulic pressure. The instantaneous hydraulic pressure is then applied to a pressure transducer which converts the hydraulic pressure into an electric current. The electric current is then sent as an electronic analog input to the central control of the TES for analysis or display.
An alternate embodiment of the invention includes weighting refrigeration evaporators and low temperature devices where the humidity contained in the surrounding humid air ices up and requires periodical thawing in order to ensure proper operation of the evaporator or any other low temperature device. In this particular application, the water source to make the ice is the humidity from the surrounding humid air. As humidity condenses and freezes on the evaporator, the weight of the ice formed on the evaporator will eventually reach a certain predetermined value. Having reached this value, the weighting device signals the initiation of the sequence to thaw the ice formed on the evaporator or other low temperature device. The thawing process will end when the ice weight disappears from the weighting device register, such as a scale.
In both embodiments, the measurement device is electrically connected to a either a building automation system (BAS) of the facility, the central control of the TES or to the control circuitry of the industrial process management system.
Finally, note that the non-ice weights, that is the weight not associated with the ice inventory, is accounted for in both embodiments. With regards to the pilot ice tank of the first embodiment, the weight of the structural support of the heat exchanger, hoses and all other accessories is balanced and nullified by the action of a counterweight. With regards to the second embodiment, the weight of the evaporator or low temperature devices and its accessories will be input into the force-measuring device as a tare on the scale.
The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following detailed description, reference will be made to the attached drawings in which:
FIG. 1 is a schematic diagram of a closed loop thermal energy storage system;
FIG. 2 is an exploded perspective view of a first embodiment of the present invention;
FIG. 3 is a perspective view of the data collecting devices of the present invention;
FIG. 4 is a diagram showing the relationship of the data collecting devices of the present invention; and
FIG. 5 is a cut-away perspective view of the first embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of describing the preferred embodiment, the terminology used in reference to the numbered components in the drawings is as follows:
1 . piping loop 2 . chiller 3 . thermal energy storage tanks 4 . cooling load 5 a . chiller check valve 5 b . loop check valve 6 . cooling load bypass piping 7 . chiller pump 8 . thermal energy storage tanks pump 9 . cooling load three-way bypass valve 10 . thermal energy storage tanks three-way bypass valve 11 . pilot ice tank 12 . proximal end of pivoting arm 13 . distal end of pivoting arm 14 . pivoting arm connecting u-bolts 15 . pivoting arm crossbar 16 . pivoting arm crossbar bearings 17 . pivoting arm counterweight 18 . hydraulic bellow support 19 . hydraulic bellow 20 . adjustable calibration rod 21 . pressure transducer 22 . heat exchanger heads 23 . heat exchanger coil 24 . heat exchanger inlet 25 . heat exchanger outlet 26 . hydraulic tubing 27 . electric power source for pressure transducer 28 . resultant force action 29 . 10 VDC digital signal line 30 . central control panel 31 . analog/digital communication line 32 . thermal energy storage plant 33 . chiller entry piping 34 . warmer pass loop section 35 . cooling load entry piping 36 . thermal energy storage tanks bypass piping 37 . pivoting arm 38 . counterweight arm
With reference to FIG. 1 , a schematic diagram of a closed loop thermal energy storage plant 32 is shown. During the ice making mode, which occurs during the nighttime or weekends off-peak hours, the chiller pump 7 circulates the chilled glycol/water solution through the piping loop 1 that passes the check valve 5 a to enter the chiller 2 which lowers the solution temperature below water freezing point. Then, the solution passes through the cooling load three-way bypass valve 9 opened to the cooling load bypass piping 6 , which reroutes the solution from entering the cooling load 4 . The solution then continues through the piping loop 1 , enters the thermal energy storage tanks three-way bypass valve 10 , which is open to thermal energy storage tanks 3 wherein the heat exchangers cause the water within the tanks to freeze and form ice. Then, the solution passes through the warmer pass loop section 34 , enters the chiller entry piping 33 , where the cycle is started again. When enough ice is formed within the tanks 3 , the system is turned off.
During the ice melting mode, which occurs during the on peak demand hours, the ice tank pump 8 circulates the solution through the loop check valve 5 b to the cooling load three-way bypass valve 9 which is opened to the cooling load 4 . The solution enters the cooling load entry piping 35 and enters the cooling load 4 . The solution continues through the piping loop 1 , through the thermal energy storage tanks three-way bypass valve 10 which is open to the thermal energy storage tanks 3 and ends at the thermal energy storage tanks pump 8 . Because no energy is needed to run the chiller during the on peak hours when energy is most expensive, users will find that using thermal energy storage systems saves much money in utility costs.
Finally, during off peak hours of the day, the system runs on chiller mode. During chiller mode, the chiller pump 7 circulates the solution through piping loop 1 that passes through the chiller check valve 5 a to the chiller 2 , which lowers the solution to about 40 degrees Fahrenheit, continues through the cooling load three-way bypass valve 9 to the cooling load 4 . The solution continues through the piping loop 1 to the thermal energy storage tanks three-way bypass valve 10 , which is now opened to the ice tanks bypass piping 36 , and continues to the chiller pump 7 .
In FIG. 2 , an exploded perspective view of a first embodiment of the present invention is shown. The pilot ice tank 11 has a pivoting arm 37 having a proximal end 12 and a distal end 13 . Heat exchanger heads 22 having heat exchanger coils 23 are firmly attached to the proximal and distal ends of the pivoting arm 12 and 13 by a fastening means, preferably by using u-bolts 14 , such that the heat exchanger inlet and outlet 24 and 25 are still exposed. Affixed to the proximal end of the pivoting arm 12 is a counterweight arm 38 wherein a counterweight 17 can be added. The pivoting arm crossbar 15 is mechanically affixed, preferably by welding, to the proximal end of the pivoting arm 12 . Located on each end of the pivoting arm crossbar 15 are pivoting arm crossbar bearings 16 , which permit the pivoting arm crossbar 15 , heat exchanger heads 22 and attached heat exchanger coils 23 to be secured within the pilot ice tank 11 .
The data collecting device, consisting namely of a hydraulic bellow support 18 , a hydraulic bellow 19 , an adjustable calibration rod 20 and a pressure transducer 21 , are also shown. The hydraulic bellow support 18 is affixed to the outside of the pilot ice tank 11 to support the hydraulic bellow 19 , an adjustable calibration rod 20 and a pressure transducer 21 . Together, these data collection devices work quantify the amount of ice in the pilot ice tank 11 .
Referring to FIG. 3 , a perspective view of the data collecting devices of the present invention is shown. The devices include a hydraulic bellow support 18 to install the hydraulic bellow 19 , or a hydraulic cylinder, an adjustable calibration rod 20 an a pressure transducer 21 . The adjustable calibration rod 20 is used to calibrate the system to zero after the heat exchanger inlet and outlet 24 and 25 , heat exchanger heads 22 and tubing are filled with the glycol/water solution. The pilot ice tank 11 is then filled with water and the counterweight 17 is secured onto the counterweight arm 38 to keep the pivoting arm 37 in a position parallel to the ground. Once the calibration is complete, the pilot ice tank 11 is ready to operate.
Despite the fact that the pivoting arm 37 and pivoting arm crossbar 15 are part of the invention, there are no moving parts located within the pilot ice tank 11 . During operation of the pilot ice tank 11 , the resulting force transmitted by the pivoting arm 37 to the adjustable calibration rod 20 is fully applied to the hydraulic bellow 19 . The bellow's 19 reaction force keeps the adjustable calibration rod 20 and the pivotal arm 37 motionless. The reaction is produced by the incompressibility of the fluid inside the bellow 19 . The effect will be the same as adding weights on top of a table, wherein the table reacting force supports the weights but nothing physically moves.
With reference to FIG. 4 , a diagram showing the relationship of the data collecting parts of the invention is shown. The hydraulic pressure generated at the hydraulic bellow 19 by the resultant force action 28 applied by the adjustable calibration rod 20 is transmitted through the hydraulic tubing 26 to the pressure transducer 21 , which has a electric power source 27 . The pressure transducer 21 then converts the pressure signal into a digital electronic signal carried by wires, preferably 10VDC digital signal lines 29 , to a central control panel 30 of the TES. Based on the analysis of the information gathered by the pilot ice tank 11 , the central control panel 30 sends the electrical/electronic signals through lines, preferably analog/digital communication lines 31 , to the chiller and ice tank pumps 7 and 8 and the chiller 2 , as well as the three-way bypass valves 9 and 10 , to the correct position during the different operating modes of the TES.
Finally, FIG. 5 shows a cut-away perspective view of the first embodiment of the present invention. The pivoting arm crossbar 15 is attached to the inside of the pilot ice tank 11 by affixing the pivoting arm crossbar bearings 16 to the inner sides of the pilot ice tank 11 . Thus, when ice forms within the tank, the pivoting arm 37 pushes up to produce a resultant force action 28 on the pressure transducer 21 , which converts the pressure signal into a digital electronic signal carried by wires, preferably 10VDC digital signal lines 29 , to a central control panel 30 of the TES.
Because the solution running through the heat exchanger has a lower freezing point than water during the ice making mode of the TES, any heat contained in the water and air within the pilot ice tank 11 will be absorbed, thereby lowering the temperature of the water within the tank 11 surrounding the heat exchanger coils 23 , thus causing ice to form around the heat exchanger coils 23 . Since the solution's freezing point is below 32 degrees Fahrenheit, the solution remains unfrozen, thus allowing the solution to continue to travel through the ice tanks 3 .
Because ice is less dense than water, the newly formed ice firmly attached to the heat exchanger coils 23 floats, an upward force is exerted on the pivoting arm 37 while the heat exchanger coils 23 are being pushed up. For mathematical purposes, it is conventionally accepted that the resultant upward force will be applied at the center of the pivoting arm 37 . The magnitude of the reacting force at the hydraulic bellow 19 will be equal to the product of the magnitude of the force exerted by the ice on the counterweight arm 38 , which is attached to pivoting arm 37 . The torque produced by such force will be compensated by a reaction force on the hydraulic bellow 19 applied to the counterweight arm 38 . The magnitude of the reacting force at the hydraulic bellow 19 will be equal to the product of the magnitude of the force exerted by the ice on the pivoting arm 37 times a ratio of the distances taken from the centers of the forces to the center line of the crossbar of the pivoting arm 15 . The ratio of the distances shall be the result of dividing the distance from the center line of the force at the distal end of the pivoting arm 13 by the distance from the center line of the force at the proximal end of the pivoting arm 12 to the center line of the crossbar of the pivoting arm 15 .
To use the first embodiment of the present invention, a user must first calibrate the flow of the ice pilot tank 11 to match the ice making/ice melting rate of all existing or new tanks being used for a facility. When calibration is complete, the user is now able to control the entire system by using the ice pilot tank 11 .
Contrary to existing thermal energy storage tanks, the use of the present invention will allow for the accurate reading of ice formed within a thermal energy storage tank by measuring and comparing the weight of the ice and of the water displaced by the ice.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not be considered limited to what is shown and described in the specification and drawings.
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An automatic monitoring system for thermal energy storage (TES) plants wherein a pilot ice tank ( 11 ) uses Archimedes' principle to determine the ice inventory level by measuring the resultant force ( 28 ) of the algebraic addition of the weight of the ice and the reaction of the water pushing the ice up with a force equal to the weight on the water displaced by the volume of the ice. The resultant force ( 28 ) applied on a pivoting arm ( 37 ) is transferred to a liquid filled bellow ( 19 ) and is transformed into hydraulic pressure. The instantaneous hydraulic pressure is transferred to a pressure transducer ( 21 ) which converts the hydraulic pressure into an electric current. The electric current is then sent as an electronic analog input to the central control panel ( 30 ) of the TES for analysis or display.
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OBJECT OF THE INVENTION
[0001] The present invention, as stated in the title of this specification refers to a flat cardboard sheet conveyor device for boxes forming machines, and more particularly to a device for pulling flat cardboard sheets from a dispensing stack arranged in the initial area of the conveyor device towards a station for forming the cardboard boxes provided at the end of the same conveyor device.
[0002] The new device of the invention provides simplicity in adjusting the conveyor in order to be suited to the different sizes of boxes, lengthening or shortening thereof, from the forming station.
BACKGROUND OF THE INVENTION
[0003] Currently, there are cardboard-box forming machines, among which should be noted, for example, U.S. Pat. No. 556,259.
[0004] The boxes are formed by folding the sides of a preformed cardboard sheet for forming a cardboard box, said cardboard sheet comprising a bottom panel that forms the bottom of the box, on which two separate panels are articulated by their respective edges, making up its side walls articulated to said bottom and those parts overlapping and adhering to two of such sides.
[0005] On this basis, the machine of the referred Invention patent is characterized in that it comprises, among other features, the following:
A station for storing preformed cardboard sheets from which said sheets are supplied, one by one, to form with them containers or boxes. Means for extracting the sheets contained in the storage station in order to deposit thereof between parallel guides arranged at the exit of the warehouse. Means for establishing a mechanism for transmitting force and motion, which acts on the removable sheets, making them slide on and between such guides until introducing thereof in the molding or forming station.
[0009] The cardboard boxes forming machines, among which is included the mentioned U.S. Pat. No. 556,259, in order to adjust the format of the box, require a length sufficient to modify the size of the conveyor of the preformed sheets or plates and the use of complex devices that ensure the correct tension of some chains and components making it up.
[0010] On the other hand, if it is accidentally stopped by some blockage of the above, it is necessary to synchronize again the thruster parts with the actual location of the cardboard sheets.
DESCRIPTION OF THE INVENTION
[0011] To achieve the objectives and avoid the drawbacks mentioned in the preceding paragraphs, the invention proposes a flat cardboard sheet conveyor device for boxes forming machines, which conveyor device pulls the flat cardboard sheets from a dispensing stack arranged in an initial area of the conveyor device, towards a forming station provided at the end of the conveyor device.
[0012] On this basis, the invention is characterized in that it includes means for varying the length of a horizontal entraining loader in combination with a tractive mechanism vertically movable along a fixed support, so that by varying the length of that tractive mechanism such tractive mechanism is raised or lowered, thus obtaining the desired length of said horizontal entraining loader according to the needs required depending on the sizes of the cardboard sheets and the relative location of the box forming station, supporting such flat cardboard sheets on that horizontal entraining loader.
[0013] This horizontal entraining loader essentially consists of a lateral chain coupled to a pair of end pinions, coupled to cross axles, to which a guiding structure that allows regulating the length of the horizontal entraining loader and thus varying the distance between said cross axles mentioned above is jointly connected.
[0014] The closed-loop lateral chain is in turn coupled to a large cogwheel and also to a tractive cogwheel that is part of the tractive mechanism, with a clutch mechanism being sandwiched in the transmission of motion in order to disengage that the transmission if needed when a blockage occurs.
[0015] In this way we avoid and/or moderate aggressive mechanical shocks or motor stops that can break any component of the conveyor.
[0016] The lateral chain includes transverse pushers to ensure the pulling of the flat cardboard sheets in forward movement along the horizontal entraining loader.
[0017] On the other hand, electronic means have been provided, such as an encoder, to always know the position of the drive chain and therefore of the transverse pushers for the flat cardboard sheets, which is essential to avoid manual adjustments to synchronize these components with the suction system that carries said flat cardboard sheets over the assembly of the conveyor device of the invention.
[0018] In a preferred embodiment of the invention, one of the end pinions is a double pinion that is connected to the cross axle connected to the tractive mechanism. This axle is also connected to a cross axle that is on the part of the entraining loader wherein the forming station is located, and which has a cross axle that is in the initial area of the entraining loader.
[0019] Thus, the entraining loader is divided into two sections, which are a first section comprising the initial area of the entraining loader and a second section that comprises the area in which the forming station is located. With the addition of the double pinion movement is provided for both the first section and second section of the entraining loader.
[0020] This embodiment is especially useful when you need to perform a first stage for transporting the cardboard sheets, in great length machines or machines that require previous operations.
[0021] So as in order to provide motion to the first section of the entraining loader, the same engine and the same clutch system are used as to provide motion to the second section of the entraining loader, there is achieved a very safe machine and no problems of synchronizing or mismatches.
[0022] In another preferred embodiment of the invention, the horizontal entraining loader is moved through various cross axles wherein simple pinions are connected. These cross axles are in fixed positions. In this preferred embodiment, the tractive mechanism is also in a fixed position.
[0023] This embodiment uses the same engine and the same clutch system described above, but in this case the elements of the device are fixed so that the conveyor device is simpler, very safe and has no problems of synchronization or mismatches.
[0024] Next, to provide a better understanding of this specification and being an integral part thereof, some figures wherein in an illustrative and not limitative manner the object of the invention has been represented, are attached.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 .—Shows an elevation view of the flat cardboard sheet conveyor device for boxes forming machines, object of the invention.
[0026] FIG. 2 .—Shows another elevation view of the conveyor device of the invention in a different location to that shown in FIG. 1 .
[0027] FIG. 3 .—Shows a perspective view wherein a vertically movable tractive mechanism for adjusting the length of a horizontal entraining loader that is part of the conveyor device of the invention can be seen.
[0028] FIG. 4 .—Shows an elevation view of the flat cardboard sheet conveyor device for boxes forming machines, in which the entraining loader is divided into a first section and a second section provided with motion.
[0029] FIG. 5 .—Shows an elevation view of an embodiment of the flat cardboard sheet conveyor device for boxes forming machines in which the cross axles of the entraining loader and the tractive mechanism are in a fixed position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Considering the numbering adopted in the figures, the conveyor device for flat cardboard sheets in cardboard-box forming machines is determined from a horizontal entraining loader 1 comprising a lateral chain 2 in principle coupled to two end pinions 3 , these being in turn coupled to cross axles 4 - 4 ′, to which a guiding structure 5 that allows adjusting the length of the horizontal entraining loader 1 and therefore the distance between the cross axles 4 - 4 ′ is jointly connected. In addition, on said guiding structure 5 the lateral chain 2 is moved.
[0031] For such purpose, the lateral chain 2 is coupled to a upper cogwheel 6 arranged below the horizontal entraining loader 1 , said lateral chain 2 also being coupled to a tractive cogwheel 7 that is part of a vertically movable tractive mechanism 8 by being supported on a movable carriage 9 driven in vertical guides 10 of a fixed support 11 , so that the vertical positioning of the tractive mechanism 8 is achieved by varying the length of the horizontal entraining loader 1 moving the cross axle 4 ′ backward or forward. This loader supports the flat cardboard sheets 12 that are pulled forward by transverse pushers 13 integral with the lateral chain 2 until reaching a forming station 14 for forming the boxes 23 , which final forming station is located at the end of the assembly of the conveyor device. In contrast, in an initial area and below thereof, the tractive mechanism 8 is located.
[0032] As shown more clearly in FIG. 3 , the tractive mechanism 8 comprises a gear motor 15 output shaft 22 of which transmits its motion to a drive assembly 30 by means of a adjustable clutch mechanism 20 axially driven by a spring 21 for disengaging the transmission power if necessary, said drive assembly 30 including the tractive cogwheel 7 mentioned above and a central pinion 19 which transmits its motion to a large cogwheel 17 by an intermediate chain 18 . Thanks to the clutch mechanism 20 aggressive mechanical shocks or geared motor stops that could break any component of the conveyor are avoided. In practice, a dry bite-type clutch has been chosen.
[0033] Through the connection of the central pinion 19 and the large cogwheel 17 , the encoder 16 knows the position of the respective transverse thruster 13 at any time.
[0034] If by any chance a blockage of the transverse thruster 13 occurs, the clutch mechanism would act as follows.
[0035] The tractive cogwheel 7 would be blocked, disengaging by means of the clutch mechanism 20 from the rotation of the gear motor 15 . The central pinion 19 forwarding to the encoder 16 would also be moved as being integral with the tractive cogwheel 7 , so that the machine would continue to monitor the position of the respective transverse thruster 13 .
[0036] In addition, if the clutch mechanism 20 does not exist, the gear motor 15 would try to keep moving the assembly of the encoder 16 , so that the machine would lose the position of the transverse thruster 13 and once the blockage of that transverse thruster 13 is solved, the reference point between the encoder 16 and the respective transverse thruster 13 should be found again.
[0037] Thus, the lateral chain 2 that moves on the guiding structure 5 is driven by the tractive cogwheel 7 , horizontally guided by the end pinions 3 and vertically by guided the upper sprocket wheel 6 . On the lateral chain 2 transverse pushers 13 are mounted, which sequentially and alternatively push the cardboard sheets 12 stacked from an initial area of the horizontal entraining loader 1 to the area wherein the forming station 14 for forming the boxes 23 is located. To facilitate the change of measure the cross axle 4 corresponding with the end pinion 3 located at the beginning of the horizontal entraining loader 1 is fixed and then the axle 4 ′ corresponding to the end pinion 3 located in correspondence with the forming station 14 is longitudinally moved forward and backward, as appropriate, bringing the movement of said cross axle 4 ′ to the whole tractive mechanism 8 . In this way, the horizontal run of the entire horizontal entraining loader 1 can be varied in the thrust area of the cardboard sheet 12 . Also worth noting that to keep the length and tension of the chain all the tractive mechanism 8 is vertically moved, pulled by the longitudinal displacement of the cross axle 4 ′ of the loader 1 as mentioned above.
[0038] The inclusion of the clutch mechanism 20 and the encoder 16 , allows you never miss the connection between the respective transverse thruster 13 and said encoder 16 , with the machine knowing at all times the position of the transverse thruster 13 , although traffic jams occur by cardboard blockages.
[0039] Another important detail is that the device of the invention facilitates the change of measure, when changing the route of the horizontal entraining loader 1 in the working area in order to fit it to the measure of the corresponding cardboard sheet 12 .
[0040] The guiding structure 5 that allows varying the length of the horizontal entraining loader 1 essentially comprises a flat centered body 27 guided between two sheets: top 28 and bottom 29 , so that when the flat centered body 27 is longitudinally moved in conjunction with the posterior movable section of the horizontal entraining loader 1 , the cross axle 4 ′ and the end pinion 3 adjacent to the forming station 14 for forming the boxes 23 , said longitudinal displacement will vertically pulled the whole tractive mechanism 8 .
[0041] The posterior movable section of the horizontal entraining loader 1 includes a lower extension 24 which supports a portion of the lower branch of the lateral chain 2 .
[0042] The posterior movable section of the horizontal entraining loader 1 is complemented with a longer anterior static section, defining an intermediate space 25 there between in order to adjust the length of the horizontal loader pulling 1 , said intermediate space 25 being complemented with another initial space 26 established in the anterior static section and delimited between the two sheets 28 and 29 , in order to perform the corresponding adjustment.
[0043] In a preferred embodiment of the invention, one of the end pinions 3 is a double pinion connected to the cross axle 4 which is connected to the tractive mechanism 8 . In this embodiment, the cross axle 4 connected to the tractive mechanism 8 is in turn connected to the cross axle 4 ′ which is part of the entraining loader 1 wherein the forming station 14 is located, and having a cross axle 4 ′ that is located in the initial area of the entraining loader 1 . Thus, in a first section 1 ′ of the entraining loader 1 , which runs from the cross axle 4 ″ to the cross axle 4 , and in a second section 1 ″ of the entraining loader 1 , which runs from the cross axle 4 to the cross axle 4 ′, the chain 2 has movement.
[0044] The first section 1 ′ of the entraining loader 1 has a fixed length. The second section 1 ″ of the entraining loader 1 is adjustable in the longitudinal direction being able to vary its distance as described above.
[0045] In another preferred embodiment of the invention, the horizontal entraining loader 1 moves through various cross axles that are in fixed positions and in which simple pinions area connected. In this embodiment of the invention, the tractive mechanism 8 is also in a fixed position.
[0046] Among others, the advantages gained with the new conveyor device are the following:
It allows reducing the length of the machine making it shorter and compact. It avoids the use of chain devices and/or tensioners ensuring the optimal tension, even when the length of the conveyor has been changed. It avoids complex adjustments when the conveyor is blocked or stopped by collision with a foreign object. It allows, when a blockage as those mentioned occurs, disconnecting the system from the motor torque preventing damages in the components or object caught. It eliminates problems of synchronization or mismatches.
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This comprises a horizontal entraining loader ( 1 ) on which are placed in an initial zone several piled cardboard sheets ( 12 ) to be driven by several transversal pushers ( 13 ) to a forming station ( 14 ) for cardboard boxes ( 23 ), said transversal pushers ( 13 ) being connected to a lateral chain ( 2 ) coupled to several end pinions ( 3 ) connected to several cross axles ( 4 - 4 ′). It is characterized in that the horizontal entrainment loader ( 1 ) can be adjusted longitudinally, thereby varying the distance between the transverse axles ( 4 - 4 ′), including for this purpose a vertically moveable tractive mechanism ( 8 ), that has a clutch mechanism ( 20 ) by means of which the movement is transmitted to a large cogwheel unit ( 17 ) and to an encoder ( 16 ) arranged coaxially with said large cogwheel unit ( 17 ), without ever losing the link between aforementioned encoder ( 16 ) and the respective transversal pusher ( 13 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 10/373,583, filed Feb. 25, 2003, allowed and pending, which claims the benefit of U.S. provisional patent application Ser. No. 60/359,544, filed on Feb. 25, 2002, and U.S. provisional patent application Ser. No. 60/438,159 filed on Jan. 6, 2003, the contents all of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to power distribution systems including circuit breakers, and more particularly to a method and apparatus for a circuit protection system providing adjustable circuit breaker trip curves in-situ.
[0003] In power distribution systems, power is distributed to various loads and is typically divided into branch circuits, which supply power to specified loads. The branch circuits also can be connected to various other power distribution equipment, such as, transformers that step down the supply voltage for use by a specific piece of electrical equipment.
[0004] Due to the concern of an abnormal power condition in the system, i.e., a fault, it is known to provide circuit protective devices, e.g., circuit breakers to protect the various loads, as well as the power distribution equipment. The circuit breakers seek to prevent or minimize damage and typically function automatically. The circuit breakers also seek to minimize the extent and duration of electrical service interruption in the event of a fault.
[0005] It is further known to utilize upstream circuit breakers having pre-programmed time delays so that the downstream circuit breakers are provided with an opportunity to clear the fault before the upstream circuit breaker opens or trips. In a known zone selective interlock system, a downstream circuit breaker can be in direct communication with an upstream circuit breaker through wiring such that the downstream circuit breaker sends a signal to the upstream circuit breaker placing the upstream circuit breaker in a restrained mode. In the restrained mode, the circuit breaker temporarily restrains from opening or tripping until after a pre-determined time delay has timed out. The circuit breakers each have pre-programmed time delay settings incorporated therein. This type of system provides for time delays based upon pre-set, invariable time periods associated with the upstream circuit breaker. Thus, the upstream circuit breaker will delay tripping by a pre-set period of time regardless of the location of the fault in the power distribution system.
[0006] The circuit breakers, can be arranged in a hierarchy or tree configuration having a plurality of layers or levels with the upstream circuit breakers closer to the power source and the downstream circuit breakers closer to the loads. In order to minimize service interruption, the circuit breaker nearest the fault will first attempt to interrupt the fault current. If this first circuit breaker does not timely clear the fault, then the next upstream circuit breaker will attempt to do so. However, this can result in the problem of a circuit breaker multiple levels upstream from a fault being tripped when the fault is detected, which causes power loss to the multiple levels of loads downstream that should otherwise be unaffected.
[0007] Such a system does not delay the upstream circuit breakers based upon an optimal time period to provide the downstream circuit breaker with the opportunity to clear the fault. Where a circuit has downstream circuit branches and circuit breakers having differing temporal properties, such as, for example, clearing time or pre-set delay time of the circuit breakers, such a system fails to account for these differences. This increases the risk of damage to the system where an upstream circuit breaker has a pre-set time delay that is too long based on the location of the fault. This also decreases the efficiency of the system where an upstream circuit breaker has a pre-set time delay that is too short based on the location of the fault and opens before the downstream circuit breaker has a full opportunity to clear the fault. This system also suffers from the drawback of the need to hardwire the upstream circuit breakers with each of the downstream circuit breakers. In a multi-tiered and multi-source system, this can require a complex and costly wiring scheme.
[0008] Accordingly, there is a need for circuit protection systems incorporated into power distribution systems that decrease the risk of damage and increase efficiency of the power distribution system. There is a further need for protection systems that can vary the zones of protection and the time delays of protection as the power distribution system changes and provide optimized protection without sacrificing selectivity.
SUMMARY OF THE INVENTION
[0009] In one aspect, a method of protecting a circuit having a first circuit breaker and a second circuit breaker downstream of the first circuit breaker is provided. The method comprises detecting a fault in the circuit with the fault being downstream of the second circuit breaker, determining a dynamic delay time for opening the first circuit breaker, and opening the first circuit breaker after the dynamic delay time has elapsed.
[0010] In another aspect, a method of protecting a circuit having a first circuit breaker arranged upstream of a plurality of second circuit breakers is provided. The method comprises detecting a fault in the circuit, determining a location of the fault, determining a dynamic delay time for opening the first circuit breaker based at least in part upon the location of the fault, and delaying opening the first circuit breaker until after the dynamic delay time has elapsed.
[0011] In yet another aspect, a protection system coupled to a circuit having a first circuit breaker arranged upstream of a plurality of second circuit breakers is provided. The system comprises a network and at least one control processing unit operatively controlling the first circuit breaker and the plurality of second circuit breakers. The network is communicatively coupled to the circuit, the first circuit breaker, the plurality of second circuit breakers and the control processing unit. The control processing unit determines a dynamic delay time for opening the first circuit breaker if a fault is detected in the circuit. The control processing unit delays opening the first circuit breaker until after the dynamic delay time has elapsed.
[0012] In a further aspect, a power distribution system is provided which comprises a circuit having a plurality of circuit breakers, at least one power source and at least one load. The plurality of circuit breakers are arranged with at least one first circuit breaker upstream of a plurality of second circuit breakers. The system further comprises a network and at least one control processing unit operatively controlling the plurality of circuit breakers. The network is communicatively coupled to the control processing unit and the circuit. The control processing unit determines a dynamic delay time for opening the first circuit breaker if a fault is detected in the circuit. The control processing unit delays opening the first circuit breaker until after the dynamic delay time has elapsed.
[0013] In yet a further aspect of the invention, a method of providing protection against arc flash during maintenance on a low voltage power circuit including a circuit breaker having a specified trip function for responding to a fault is provided. The specified trip function is overridden with a maintenance trip function that results in reduced arc energy in the fault during a trip over arc energy during a trip with the specified trip function, and the specified trip function is restored following maintenance.
[0014] In another aspect of the invention, a low voltage circuit breaker protecting from arc flash resulting from faults in a protected low voltage power circuit is provided. The circuit breaker includes separable contacts, current sensors sensing current in the protected low voltage power circuit, a trip unit responsive to the current sensors tripping open the separable contacts in response to a specified trip function, and maintenance means overriding the specified trip function with a maintenance trip function that results in reduced arc energy in the fault during a trip over arc energy during a trip with the specified trip function.
[0015] The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic illustration of a power distribution system;
[0017] FIG. 2 is a schematic illustration of a module of the power distribution system of FIG. 1 ;
[0018] FIG. 3 is a response time for the protection system of FIG. 1 ;
[0019] FIG. 4 is a schematic illustration of a multiple source power distribution system;
[0020] FIG. 5 is a schematic illustration of a portion of the system of FIG. 4 with a fault occurring downstream of Feeder Circuit Breaker 1 ;
[0021] FIG. 6 is a schematic illustration of the portion of the system of FIG. 4 with a fault occurring downstream of Feeder Circuit Breaker 2 ;
[0022] FIG. 7 is a schematic illustration of the portion of the system of FIG. 4 with a fault occurring downstream of Main Circuit Breaker 1 ;
[0023] FIG. 8 is a schematic illustration of a portion of the system of FIG. 4 with a Tie Circuit Breaker in an open or tripped state; and
[0024] FIG. 9 is a schematic illustration of the portion of the system of FIG. 8 with a Main Circuit Breaker 2 in an open or tripped state.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring now to the drawings and in particular to FIG. 1 , an exemplary embodiment of a power distribution system generally referred to by reference numeral 10 is illustrated. System 10 distributes power from at least one power bus 12 through a number or plurality of circuit breakers 14 to branch circuits 16 .
[0026] Power bus 12 is illustrated by way of example as a three-phase power system having a first phase 18 , a second phase 20 , and a third phase 22 . Power bus 12 can also include a neutral phase (not shown). System 10 is illustrated for purposes of clarity distributing power from power bus 12 to four circuits 16 by four breakers 14 . Of course, it is contemplated by the present disclosure for power bus 12 to have any desired number of phases and/or for system 10 to have any desired number of circuit breakers 14 .
[0027] Each circuit breaker 14 has a set of separable contacts 24 (illustrated schematically). Contacts 24 selectively place power bus 12 in communication with at least one load (also illustrated schematically) on circuit 16 . The load can include devices, such as, but not limited to, motors, welding machinery, computers, heaters, lighting, and/or other electrical equipment.
[0028] Power distribution system 10 is illustrated in FIG. 1 with an exemplary embodiment of a centrally controlled and fully integrated protection, monitoring, and control system 26 (hereinafter “system”). System 26 is configured to control and monitor power distribution system 10 from a central control processing unit 28 (hereinafter “CCPU”). CCPU 28 communicates with a number or plurality of data sample and transmission modules 30 (hereinafter “module”) over a data network 32 . Network 32 communicates all of the information from all of the modules 30 substantially simultaneously to CCPU 28 .
[0029] Thus, system 26 can include protection and control schemes that consider the value of electrical signals, such as current magnitude and phase, at one or all circuit breakers 14 . Further, system 26 integrates the protection, control, and monitoring functions of the individual breakers 14 of power distribution system 10 in a single, centralized control processor (e.g., CCPU 28 ). System 26 provides CCPU 28 with all of a synchronized set of information available through digital communication with modules 30 and circuit breakers 14 on network 32 and provides the CCPU with the ability to operate these devices based on this complete set of data.
[0030] Specifically, CCPU 28 performs all primary power distribution functions for power distribution system 10 . Namely, CCPU 28 performs all instantaneous overcurrent protection (IOC), short time overcurrent, longtime overcurrent, relay protection, and logic control as well as digital signal processing logged in single, central location, i.e., CCPU 28 . CCPU 28 is described herein by way of example as a central processing unit. Of course, it is contemplated by the present disclosure for CCPU 28 to include any programmable circuit, such as, but not limited to, computers, processors, microcontrollers, microcomputers, programmable logic controllers, application specific integrated circuits, and other programmable circuits.
[0031] As shown in FIG. 1 , each module 30 is in communication with one of the circuit breakers 14 . Each module 30 is also in communication with at least one sensor 34 sensing a condition or electrical parameter of the power in each phase (e.g., first phase 18 , second phase 20 , third phase 22 , and neutral) of bus 12 and/or circuit 16 . Sensors 34 can include current transformers (CTs), potential transformers (PTs), and any combination thereof. Sensors 34 monitor a condition or electrical parameter of the incoming power in circuits 16 and provide a first or parameter signal 36 representative of the condition of the power to module 30 . For example, sensors 34 can be current transformers that generate a secondary current proportional to the current in circuit 16 so that first signals 36 are the secondary current.
[0032] Module 30 sends and receives one or more second signals 38 to and/or from circuit breaker 14 . Second signals 38 can be representative of one or more conditions of breaker 14 , such as, but not limited to, a position or state of separable contacts 24 , a spring charge switch status, a lockout state or condition, and others. In addition, module 30 is configured to operate or actuate circuit breaker 14 by sending one or more third signals 40 to the breaker to open/close separable contacts 24 as desired, such as open/close commands or signals. In a first embodiment, circuit breakers 14 cannot open separable contacts 24 unless instructed to do so by system 26 .
[0033] System 26 utilizes data network 32 for data acquisition from modules 30 and data communication to the modules. Accordingly, network 32 is configured to provide a desired level of communication capacity and traffic management between CCPU 28 and modules 30 . In an exemplary embodiment, network 32 can be configured to not enable communication between modules 30 (i.e., no module-to-module communication).
[0034] In addition, system 26 can be configured to provide a consistent fault response time. As used herein, the fault response time of system 26 is defined as the time between when a fault condition occurs and the time module 30 issues an trip command to its associated breaker 14 . In an exemplary embodiment, system 26 has a fault response time that is less than a single cycle of the 60 Hz (hertz) waveform. For example, system 26 can have a maximum fault response time of about three milliseconds.
[0035] The configuration and operational protocols of network 32 are configured to provide the aforementioned communication capacity and response time. For example, network 32 can be an Ethernet network having a star topology as illustrated in FIG. 1 . In this embodiment, network 32 is a full duplex network having the collision-detection multiple-access (CSMA/CD) protocols typically employed by Ethernet networks removed and/or disabled. Rather, network 32 is a switched Ethernet for managing collision domains.
[0036] In this configuration, network 32 provides a data transfer rate of at least about 100 Mbps (megabits per second). For example, the data transfer rate can be about 1 Gbps (gigabits per second). Additionally, communication between CCPU 28 and modules 30 across network 32 can be managed to optimize the use of network 32 . For example, network 32 can be optimized by adjusting one or more of a message size, a message frequency, a message content, and/or a network speed.
[0037] Accordingly, network 32 provides for a response time that includes scheduled communications, a fixed message length, full-duplex operating mode, and a switch to prevent collisions so that all messages are moved to memory in CCPU 28 before the next set of messages is scheduled to arrive. Thus, system 26 can perform the desired control, monitoring, and protection functions in a central location and manner.
[0038] It should be recognized that data network 32 is described above by way of example only as an Ethernet network having a particular configuration, topography, and data transmission protocols. Of course, the present disclosure contemplates the use of any data transmission network that ensures the desired data capacity and consistent fault response time necessary to perform the desired range of functionality. The exemplary embodiment achieves sub-cycle transmission times between CCPU 28 and modules 30 and full sample data to perform all power distribution functions for multiple modules with the accuracy and speed associated with traditional devices.
[0039] CCPU 28 can perform branch circuit protection, zone protection, and relay protection interdependently because all of the system information is in one central location, namely at the CCPU. In addition, CCPU 28 can perform one or more monitoring functions on the centrally located system information. Accordingly, system 26 provides a coherent and integrated protection, control, and monitoring methodology not considered by prior systems. For example, system 26 integrates and coordinates load management, feed management, system monitoring, and other system protection functions in a low cost and easy to install system.
[0040] An exemplary embodiment of module 30 is illustrated in FIG. 2 . Module 30 has a microprocessor 42 , a data bus 44 , a network interface 46 , a power supply 48 , and one or more memory devices 50 .
[0041] Power supply 48 is configured to receive power from a first source 52 and/or a second source 54 . First source 52 can be one or more of an uninterruptible power supply (not shown), a plurality of batteries (not shown), a power bus (not shown) and other sources. In the illustrated embodiment, second source 54 is the secondary current available from sensors 34 .
[0042] Power supply 48 is configured to provide power 56 to module 30 from first and second sources 52 , 54 . For example, power supply 48 can provide power 56 to microprocessor 42 , data bus 42 , network interface 44 , and memory devices 50 . Power supply 48 is also configured to provide a fourth signal 58 to microprocessor 42 . Fourth signal 58 is indicative of what sources are supplying power to power supply 48 . For example, fourth signal 58 can indicate whether power supply 48 is receiving power from first source 52 , second source 54 , or both of the first and second sources.
[0043] Network interface 46 and memory devices 50 communicate with microprocessor 42 over data bus 44 . Network interface 46 can be connected to network 32 so that microprocessor 42 is in communication with CCPU 28 .
[0044] Microprocessor 42 receives digital representations of first signals 36 and second signals 38 . First signals 36 are continuous analog data collected by sensors 34 , while second signals 38 are discrete analog data from breaker 14 . Thus, the data sent from modules 30 to CCPU 28 is a digital representation of the actual voltages, currents, and device status. For example, first signals 36 can be analog signals indicative of the current and/or voltage in circuit 16 .
[0045] Accordingly, system 26 provides the actual raw parametric or discrete electrical data (i.e., first signals 36 ) and device physical status (i.e., second signal 38 ) to CCPU 28 via network 32 , rather than processed summary information sampled, created, and stored by devices such as trip units, meters, or relays. As a result, CCPU 28 has complete, raw system-wide data with which to make decisions and can therefore operate any or all breakers 14 on network 32 based on information derived from as many modules 30 as the control and protection algorithms resident in CCPU 28 require.
[0046] Module 30 has a signal conditioner 60 and an analog-digital converter 62 . First signals 36 are conditioned by signal conditioner 60 and converted to digital signals 64 by A/D converter 62 . Thus, module 30 collects first signals 36 and presents digital signals 64 , representative of the raw data in the first signals, to microprocessor 42 . For example, signal conditioner 60 can includes a filtering circuit (not shown) to improve a signal-to-noise ratio first signal 36 , a gain circuit (not shown) to amplify the first signal, a level adjustment circuit (not shown) to shift the first signal to a pre-determined range, an impedance match circuit (not shown) to facilitate transfer of the first signal to A/D converter 62 , and any combination thereof. Further, A/D converter 62 can be a sample-and-hold converter with external conversion start signal 66 from microprocessor 42 or a clock circuit 68 controlled by microprocessor 42 to facilitate synchronization of digital signals 64 .
[0047] It is desired for digital signals 64 from all of the modules 30 in system 26 to be collected at substantially the same time. Specifically, it is desired for digital signals 64 from all of the modules 30 in system 26 to be representative of substantially the same time instance of the power in power distribution system 10 .
[0048] Modules 30 sample digital signals 64 based, at least in part, upon a synchronization signal or instruction 70 as illustrated in FIG. 1 . Synchronization instruction 70 can be generated from a synchronizing clock 72 that is internal or external to CCPU 28 . Synchronization instruction 70 is simultaneously communicated from CCPU 28 to modules 30 over network 32 . Synchronizing clock 72 sends synchronization instructions 70 at regular intervals to CCPU 28 , which forwards the instructions to all modules 30 on network 32 .
[0049] Modules 30 use synchronization instruction 70 to modify a resident sampling protocol. For example, each module 30 can have a synchronization algorithm resident on microprocessor 42 . The synchronization algorithm resident on microprocessor 42 can be a software phase-lock-loop algorithm. The software phase-lock-loop algorithm adjusts the sample period of module 30 based, in part, on synchronization instructions 70 from CCPU 28 . Thus, CCPU 28 and modules 30 work together in system 26 to ensure that the sampling (i.e., digital signals 64 ) from all of the modules in the system are synchronized.
[0050] Accordingly, system 26 is configured to collect digital signals 64 from modules 30 based in part on synchronization instruction 70 so that the digital signals are representative of the same time instance, such as being within a predetermined time-window from one another. Thus, CCPU 28 can have a set of accurate data representative of the state of each monitored location (e.g., modules 30 ) within the power distribution system 10 . The predetermined time-window can be less than about ten microseconds. For example, the predetermined time-window can be about five microseconds.
[0051] The predetermined time-window of system 26 can be affected by the port-to port variability of network 32 . In an exemplary embodiment, network 32 has a port-to-port variability of in a range of about 24 nanoseconds to about 720 nanoseconds. In an alternate exemplary embodiment, network 32 has a maximum port-to-port variability of about 2 microseconds.
[0052] It has been determined that control of all of modules 30 to this predetermined time-window by system 26 enables a desired level of accuracy in the metering and vector functions across the modules, system waveform capture with coordinated data, accurate event logs, and other features. In an exemplary embodiment, the desired level of accuracy is equal to the accuracy and speed of traditional devices. For example, the predetermined time-window of about ten microseconds provides an accuracy of about 99% in metering and vector functions.
[0053] Second signals 38 from each circuit breaker 14 to each module 30 are indicative of one or more conditions of the circuit breaker. Second signals 38 are provided to a discrete I/O circuit 74 of module 30 . Circuit 74 is in communication with circuit breaker 14 and microprocessor 42 . Circuit 74 is configured to ensure that second signals 38 from circuit breaker 14 are provided to microprocessor 42 at a desired voltage and without jitter. For example, circuit 74 can include de-bounce circuitry and a plurality of comparators.
[0054] Microprocessor 42 samples first and second signals 36 , 38 as synchronized by CCPU 28 . Then, converter 62 converts the first and second signals 36 , 38 to digital signals 64 , which is packaged into a first message 76 having a desired configuration by microprocessor 42 . First message 76 can include an indicator that indicates which synchronization signal 70 the first message was in response to. Thus, the indicator of which synchronization signal 70 first message 76 is responding to is returned to CCPU 28 for sample time identification.
[0055] CCPU 28 receives first message 76 from each of the modules 30 over network 32 and executes one or more protection and/or monitoring algorithms on the data sent in all of the first messages. Based on first message 76 from one or more modules 30 , CCPU 28 can control the operation of one or more circuit breakers 14 . For example, when CCPU 28 detects a fault from one or more of first messages 76 , the CCPU sends a second message 78 to one or more modules 30 via network 32 , such as open or close commands or signals, or circuit breaker actuation or deactuation commands or signals.
[0056] In response to second message 78 , microprocessor 42 causes third signal 40 to operate or actuate (e.g., open contacts 24 ) circuit breaker 14 . Circuit breaker 14 can include more than one operation or actuation mechanism. For example, circuit breaker 14 can have a shunt trip 80 and a magnetically held solenoid 82 . Microprocessor 42 is configured to send a first output 84 to operate shunt trip 80 and/or a second output 86 to operate solenoid 82 . First output 84 instructs a power control module 88 to provide third signal 40 (i.e., power) to shunt trip 80 , which can separate contacts 24 . Second output 86 instructs a gating circuit 90 to provide third signal 40 to solenoid 82 (i.e., flux shifter) to separate contacts 24 . It should be noted that shunt trip 80 requires first source 52 to be present, while solenoid 82 can be operated when only second source 54 is present. In this manner, microprocessor 42 can operate circuit breaker 14 in response to second message 78 regardless of the state of first and second sources 52 , 54 . Additionally, a lockout device can be provided that is operably connected to circuit breaker 14 .
[0057] In addition to operating circuit breaker 14 , module 30 can communicate to one or more local input and/or output devices 94 . For example, local output device 94 can be a module status indicator, such as a visual or audible indicator. In one embodiment, device 94 is a light emitting diode (LED) configured to communicate a status of module 30 . In another embodiment, local input device 94 can be a status-modifying button for manually operating one or more portions of module 30 . In yet another embodiment, local input device 94 is a module interface for locally communicating with module 30 .
[0058] Accordingly, modules 30 are adapted to sample first signals 36 from sensors 34 as synchronized by the CCPU. Modules 30 then package the digital representations (i.e., digital signals 64 ) of first and second signals 36 , 38 , as well as other information, as required into first message 76 . First message 76 from all modules 30 are sent to CCPU 28 via network 32 . CCPU 28 processes first message 76 and generates and stores instructions to control the operation of each circuit breaker 14 in second message 78 . CCPU 28 sends second message 78 to all of the modules 30 . In an exemplary embodiment, CCPU 28 sends second message 78 to all of the modules 30 in response to synchronization instruction 70 .
[0059] Accordingly, system 26 can control each circuit breaker 14 based on the information from that breaker alone, or in combination with the information from one or more of the other breakers in the system 26 . Under normal operating conditions, system 26 performs all monitoring, protection, and control decisions at CCPU 28 .
[0060] Since the protection and monitoring algorithms of system 26 are resident in CCPU 28 , these algorithms can be enabled without requiring hardware or software changes in circuit breaker 14 or module 30 . For example, system 26 can include a data entry device 92 , such as a human-machine-interface (HMI), in communication with CCPU 28 . In this embodiment, one or more attributes and functions of the protection and monitoring algorithms resident on CCPU 28 can easily be modified from data entry device 92 . Thus, circuit breaker 14 and module 30 can be more standardized than was possible with the circuit breakers/trip units of prior systems. For example, over one hundred separate circuit breakers/trip units have been needed to provide a full range of sizes normally required for protection of a power distribution system. However, the generic nature of circuit breaker 14 and module 30 enabled by system 26 can reduce this number by over sixty percent. Thus, system 26 can resolve the inventory issues, retrofittability issues, design delay issues, installation delay issues, and cost issues of prior power distribution systems.
[0061] It should be recognized that system 26 is described above as having one CCPU 28 communication with modules 30 by way of a single network 32 . However, it is contemplated by the present disclosure for system 26 to have redundant CCPUs 28 and networks 32 as illustrated in phantom in FIG. 1 . For example, module 30 is illustrated in FIG. 2 having two network interfaces 46 . Each interface 46 is configured to operatively connect module 30 to a separate CCPU 28 via a separate data network 32 . In this manner, system 26 would remain operative even in case of a failure in one of the redundant systems.
[0062] Modules 30 can further include one or more backup systems for controlling breakers 14 independent of CCPU 28 . For example, system 26 may be unable to protect circuit 16 in case of a power outage in first source 52 , during the initial startup of CCPU 28 , in case of a failure of network 32 , and other reasons. Under these failure conditions, each module 30 includes one or more backup systems to ensure that at least some protection is provided to circuit breaker 14 . The backup system can include one or more of an analog circuit driven by second source 54 , a separate microprocessor driven by second source 54 , and others.
[0063] Referring now to FIG. 3 , an exemplary embodiment of a response time 95 for system 26 is illustrated with the system operating stably (e.g., not functioning in a start-up mode). Response time 95 is shown starting at T 0 and ending at T 1 . Response time 95 is the sum of a sample time 96 , a receive/validate time 97 , a process time 98 , a transmit time 99 , and a decode/execute time 100 .
[0064] In this example, system 26 includes twenty-four modules 30 each connected to a different circuit breaker 14 . Each module 30 is scheduled by the phase-lock-loop algorithm and synchronization instruction 70 to sample its first signals 36 at a prescribed rate of 128 samples per cycle. Sample time 96 includes four sample intervals 101 of about 0.13 milliseconds (ms) each. Thus, sample time 96 is about 0.27 ms for data sampling and packaging into first message 76 .
[0065] Receive/validate time 97 is initiated at the receipt of synchronization instruction 70 . In an exemplary embodiment, receive/validate time 97 is a fixed time that is, for example, the time required to receive all first messages 76 as determined from the latency of data network 32 . For example, receive/validate time 97 can be about 0.25 ms where each first message 76 has a size of about 1000 bits, system 26 includes twenty-four modules 30 (i.e., 24,000 bits), and network 32 is operating at about 100 Mbps. Accordingly, CCPU 28 manages the communications and moving of first messages 76 to the CCPU during receive/validate time 97 .
[0066] The protection processes (i.e., process time 98 ) starts at the end of the fixed receive/validate time 97 regardless of the receipt of first messages 76 . If any modules 30 are not sending first messages 76 , CCPU 28 flags this error and performs all functions that have valid data. Since system 26 is responsible for protection and control of multiple modules 30 , CCPU 28 is configured to not stop the entire system due to the loss of data (i.e., first message 76 ) from a single module 30 . In an exemplary embodiment, process time 98 is about 0.52 ms.
[0067] CCPU 28 generates second message 78 during process time 98 . Second message 78 can be twenty-four second messages (i.e., one per module 30 ) each having a size of about 64 bits per module. Alternately, it is contemplated by the present disclosure for second message 78 to be a single, multi-cast or broadcast message. In this embodiment, second message 78 includes instructions for each module 30 and has a size of about 1600 bits.
[0068] Transmit time 99 is the time necessary to transmit second message 78 across network 32 . In the example where network 32 is operating at about 100 Mbps and second message 78 is about 1600 bits, transmit time 99 is about 0.016 ms.
[0069] It is also contemplated for second message 78 to include a portion of synchronization instruction 70 . For example, CCPU 28 can be configured to send second message 78 upon receipt of the next synchronization instruction 70 from clock 72 . In this example, the interval between consecutive second messages 76 can be measured by module 30 and the synchronization information in the second message, if any, can be used by the synchronization algorithm resident on microprocessor 42 .
[0070] Once modules 30 receive second message 78 , each module decodes the message and executes its instructions (i.e., send third signals 40 ), if any, in decode/execute time 100 . For example, decode/execute time 100 can be about 0.05 ms.
[0071] In this example, response time 95 is about 1.11 ms. Of course, it should be recognized that system response time 95 can be accelerated or decelerated based upon the needs of system 26 . For example, system response time 95 can be adjusted by changing one or more of the sample period, the number of samples per transmission, the number of modules 30 , the message size, the message frequency, the message content, and/or the network speed.
[0072] It is contemplated by the present disclosure for system 26 to have response time 95 of up to about 3 milliseconds. Thus, system 26 is configured to open any of its circuit breakers within about 3 milliseconds from the time sensors 34 sense conditions outside of the set parameters.
[0073] Referring to FIG. 4 , an exemplary embodiment of a multi-source, multi-tier power distribution system generally referred to by reference numeral 105 is illustrated with features similar to the features of FIG. 1 being referred to by the same reference numerals. System 105 functions as described above with respect to the embodiment of FIGS. 1 through 3 , and can include the same features but in a multi-source, multi-layer configuration. System 105 distributes power from at least one power feed 112 , in this embodiment a first and second power feed, through a power distribution bus 150 to a number or plurality of circuit breakers 14 and to a number or plurality of loads 130 . CCPU 28 can include a data transmission device 140 , such as, for example, a CD-ROM drive or floppy disk drive, for reading data or instructions from a medium 145 , such as, for example, a CD-ROM or floppy disk.
[0074] Circuit breakers 14 are arranged in a layered, multi-leveled or multi-tiered configuration with a first level 110 of circuit breakers and a second level 120 of circuit breakers. Of course, any number of levels or configuration of circuit breakers 14 can be used with system 105 . The layered configuration of circuit breakers 14 provides for circuit breakers in first level 110 which are upstream of circuit breakers in second level 120 . In the event of an abnormal condition of power in system 105 , i.e., a fault, protection system 26 seeks to coordinate the system by attempting to clear the fault with the nearest circuit breaker 14 upstream of the fault. Circuit breakers 14 upstream of the nearest circuit breaker to the fault remain closed unless the downstream circuit breaker is unable to clear the fault. Protection system 26 can be implemented for any abnormal condition or parameter of power in system 105 , such as, for example, long time, short time or instantaneous overcurrents, or excessive ground currents.
[0075] In order to provide the circuit breaker 14 nearest the fault with sufficient time to attempt to clear the fault before the upstream circuit breaker is opened, the upstream circuit breaker is provided with an open command at an adjusted or dynamic delay time. The upstream circuit breaker 14 is provided with an open command at a modified dynamic delay time that elapses before the circuit breaker is opened. In an exemplary embodiment, the modified dynamic delay time for the opening of the upstream circuit breaker 14 is based upon the location of the fault in system 105 . Preferably, the modified dynamic delay time for the opening of the upstream circuit breaker 14 is based upon the location of the fault with respect to the circuit breakers and/or other devices and topology of system 105 . CCPU 28 of protection system 26 can provide open commands at modified dynamic delay times for upstream circuit breakers 14 throughout power distribution system 105 depending upon where the fault has been detected in the power flow hierarchy and the modified dynamic delay times for the opening of each of these circuit breakers can preferably be over an infinite range. Protection system 26 reduces the clearing time of faults because CCPU 28 provides open commands at modified dynamic delay times for the upstream circuit breakers 14 which are optimum time periods based upon the location of the fault. It has been found that the clearing time of faults has been reduced by approximately 50% with the use of protection system 26 , as compared to the use of contemporary systems.
[0076] Referring to FIG. 5 , an exemplary embodiment of a portion of power distribution system 105 having a two-tier circuit with a main- 1 circuit breaker (CB) 415 upstream of feeder 1 CB 420 and feeder 2 CB 425 , which are in parallel. Power flow is from transformer 412 through main- 1 CB 415 , feeder 1 CB 420 and feeder 2 CB 425 , to loads 431 , 432 . In the event of a fault X occurring between feeder 1 CB 420 and load 431 , the existence of the fault and the location of the fault is determined by CCPU 28 in the manner as described above and as schematically represented by reference numeral 450 . The nearest circuit breaker upstream of the fault X, i.e., feeder 1 CB 420 , is placed into “pickup mode” by CCPU 28 and waits a pre-defined delay time before being opened. The modified dynamic delay time for the opening of main- 1 CB 415 (the next nearest circuit breaker that is upstream of fault X) is then determined by zone selective interlock (ZSI) routine 426 . In an exemplary embodiment, ZSI routine 426 is an algorithm, or the like, performed by CCPU 28 . CCPU 28 determines the dynamic delay times for the opening of any number of upstream circuit breakers 14 and provides open or actuation commands to open the circuit breakers at the dynamic delay times.
[0077] In an exemplary embodiment, the modified dynamic delay time for main- 1 CB 415 is determined from the sum of the pre-defined delay time and the clearing time of feeder 1 CB 420 . The pre-defined delay time is set to best service load 431 . The clearing time of a circuit breaker, such as feeder 1 CB 420 , is dependent on the type of circuit breaker. The delay time for opening of main- 1 CB 415 is then modified based upon the value determined by CCPU 28 , as schematically represented by reference numeral 475 . This allows feeder 1 CB 420 the optimal time for feeder 1 CB 420 to clear the fault X before main- 1 CB 415 opens. The modified dynamic delay time determined by ZSI routine 426 reduces potential damage to system 105 . The modified dynamic delay time also increases the efficiency of system 105 by delaying the opening of main- 1 CB 415 for the optimal time period to provide the downstream circuit breaker, feeder 1 CB 420 , with the full opportunity to clear the fault X so that other loads, i.e., load 432 , can still receive power.
[0078] Referring to FIG. 6 , the portion of power distribution system 105 having a two-tier circuit is shown with a fault X occurring between feeder 2 CB 425 and load 432 . In the manner described above, the existence and location of fault X is determined, as represented by reference numeral 450 . ZSI routine 426 determines the dynamic delay time for opening of main- 1 CB 415 , as represented by reference numeral 475 . Where feeder 2 CB 425 has a different pre-defined delay time set to best service load 432 and/or a different clearing time than feeder 1 CB 420 , ZSI routine 426 will determine a different dynamic delay time for the opening of main- 1 CB 415 . The difference in the two modified dynamic delay times for the opening of main- 1 CB 415 ( FIGS. 5 and 6 ) is based upon the location of fault X in system 105 with respect to feeder 1 CB 420 and feeder 2 CB 425 .
[0079] Referring to FIG. 7 , the portion of power distribution system 105 having a two-tier circuit is shown with a fault X occurring between main- 1 CB 415 and either feeder 1 CB 420 or feeder 2 CB 425 . In the manner described above, the existence and location of fault X is determined, as represented schematically by reference numeral 480 . Since only main- 1 CB 415 is available to clear fault X, ZSI routine 426 does not modify the dynamic delay time of the opening of main- 1 CB and the main- 1 CB will open in its pre-defined delay, which is typically much less than the dynamic time delay in the previous two examples.
[0080] Referring to FIGS. 4 through 7 , CCPU 28 coordinates protection system 26 by causing the circuit breaker 14 nearest to the fault to clear the fault. Protection system 26 variably adjusts the dynamic delay time for opening of the upstream circuit breakers 14 to provide backup protection for the downstream circuit breaker nearest the fault. In the event that the downstream circuit breaker 14 nearest the fault is unable to clear the fault, the next upstream circuit breaker will attempt to clear the fault with minimal additional delay based upon its modified dynamic delay time. As shown in FIG. 7 , when a fault occurs between a main circuit breaker and a feeder circuit breaker, e.g., main- 1 CB 415 and feeder 1 CB 420 , the minimal delay of the main- 1 CB opening reduces the let-thru energy. This reduces system stress, damage and potential arc energy exposure of operating and service personnel while maintaining selectivity. In an exemplary embodiment, protection system 26 and CCPU 28 allow the implementation of ZSI routine 426 to modify the dynamic delay times for opening of any circuit breakers 14 throughout system 105 without the need for additional wiring coupling each of the circuit breakers to one another. CCPU 28 provides an open command to the upstream circuit breakers 14 for opening at dynamic delay times as determined by ZSI routine 426 .
[0081] In an exemplary embodiment, ZSI routine 426 is performed at CCPU 28 and interacts with the individual protection functions for each module 30 , which are also determined at the CCPU. ZSI routine 426 could also use pre-set clearing times for circuit breakers 14 or the clearing times for the circuit breakers could be determined by CCPU 28 based on the physical hardware, which is known by the CCPU. The CCPU 28 effectively knows the topology of power distribution system 105 , which allows the CCPU to open the circuit breakers 14 at an infinite range of times.
[0082] Referring to FIG. 8 , the portion of power distribution system 105 having a first two-tier circuit branch 490 and a second two-tier circuit branch 790 coupled by a tie CB 700 is shown. In this circuit, the opening of tie CB 700 has created two separate zones of protection in circuit branch 490 and circuit branch 790 , which has a transformer 712 . In the event of a fault, protection system 26 implements ZSI routine 426 , as described above with respect to the two-tier circuit branch of FIGS. 5 through 7 , independently for each of the circuit branches 490 , 790 .
[0083] Referring to FIG. 9 , the portion of power distribution system 105 is shown when main- 2 CB 715 is open and tie CB 700 is closed. The opening of main- 2 CB 715 and the closing of tie CB 700 has created a new single three-tiered zone of protection with feeder 3 CB 720 and feeder 4 CB 725 in the third tier or level of circuit breakers. The status of all of the circuit breakers, including main- 2 CB 715 and tie CB 700 , is known by CCPU 28 , as represented schematically by reference numerals 450 . In the event of a fault (not shown) in first circuit branch 490 downstream of the feeder 1 CB 420 or the feeder 2 CB 425 , the ZSI routine 426 would modify the dynamic delay time for the opening of main- 1 CB 415 , as described above with respect to FIG. 5 or FIG. 6 .
[0084] In the event of a fault (not shown) in second circuit branch 790 downstream of the feeder 3 CB 720 (or the feeder 4 CB 725 ), the ZSI routine 426 would modify the dynamic delay time for opening of both the tie CB 700 and the main- 1 CB 415 . In an exemplary embodiment, the modified dynamic delay time for the opening of tie CB 700 is determined from the sum of the pre-defined delay time and the clearing time of feeder 3 CB 720 (or feeder 4 CB 725 ). The dynamic delay time for opening of tie CB 700 is then modified based upon the value determined by CCPU 28 , as schematically represented by reference numeral 500 . This provides feeder 3 CB 720 (or feeder 4 CB 725 ) with an optimal time to clear the fault before tie CB 700 is opened. Furthermore, the modified dynamic delay time for the opening of main- 1 CB 415 is then determined from the sum of the modified dynamic delay time and the clearing time of tie CB 700 . The dynamic delay time for opening of main- 1 CB 415 is then modified based upon the value determined by CCPU 28 , as schematically represented by reference numeral 475 . This provides tie CB 700 with an optimal time to clear the fault before main- 1 CB 415 is opened by the open command from CCPU 28 .
[0085] In the event of a fault between tie CB 700 and feeder 3 CB 720 (or feeder 4 CB 725 ), the dynamic delay time for opening of main- 1 CB 415 is modified from the sum of the pre-defined delay and the clearing time of tie CB 700 . The delay for opening of tie CB 700 would not be modified since it is the nearest circuit breaker upstream of the fault for clearing the fault.
[0086] In an exemplary embodiment, the protection functions performed at CCPU 28 , including ZSI routine 426 , are based on state information or status of circuit breakers 14 , as well as current. Through the use of protection system 26 , the state information is known by CCPU 28 . The state information is synchronized with the current and the voltage in power distribution system 105 . CCPU 28 effectively knows the topology of the power distribution system 105 and uses the state information to track topology changes in the system. CCPU 28 and ZSI routine 426 utilizes the topology information of power distribution system 105 to optimize service and protection.
[0087] Of course, it is contemplated by the present disclosure for power distribution system 105 to have any number of tiers or levels and any configuration of branch circuits. The dynamic delay time for opening of any number of circuit breakers 14 upstream of the fault could be modified as described above based upon the location of the fault in the power flow hierarchy. Additionally, the zones of protection and the dynamic delay times can change as the power distribution system 105 changes. In an alternate embodiment, ZSI routine 426 can modify the dynamic delay time for opening of the upstream circuit breakers 14 based upon other factors using different algorithms. Protection system 26 allows for the dynamic changing of the delay times for opening of circuit breakers 14 throughout the power distribution system 105 based upon any number of factors, including the location of the fault. Protection system 26 also allows for the upstream circuit breaker 14 to enter the pickup mode as a function of the downstream circuit breaker 14 fault current and pickup settings as opposed to its own current and pickup settings.
[0088] The embodiments of FIGS. 1 through 9 describe the implementation of ZSI routine 426 at CCPU 28 . However, it is contemplated by the present disclosure that the use of dynamic delay times for opening of circuit breakers 14 and/or the use of ZSI routine 426 can be implemented in other ways such as, for example, in a distributed control system with supervision by CCPU 28 or a distributed control system with peer to peer communications. In such distributed control systems, the delay time for opening of the upstream circuit breaker 14 will be modified to a dynamic delay time and/or based at least in part on the location of the fault in the power flow hierarchy. The dynamic delay times for the upstream circuit breakers 14 can also be determined and communicated to the upstream circuit breakers and/or circuit breaker actuators operably connected to the breakers.
[0089] In an exemplary embodiment, protection system 26 using CCPU 28 and ZSI routine 426 replaces the traditional time-current and fixed-delay protection while achieving both selectivity and tight backup protection. The feeder breakers (load-side) are set best to serve their loads reliably, but the main breakers and tie breakers (line-side) dynamically set their delay and current settings to best fit each feeder when that feeder circuit experiences a fault. The determination of a fault can be based on the feeder's settings and the sensors. In a traditional system, the sensing of a fault at the tie or main breaker is based on the settings at those trips and the current flowing through the respective circuit breakers. If the current magnitude is not sufficient to be recognized as a fault the trip units will not initiate a trip and hence provide no back-up function. There are no additional margins of safety or unnecessary time delays needed to allow the protection system 26 to operate selectively and provide protection to the mechanical limits of the devices used. Protect system 26 also applies within the short-circuit ranges of the devices in power distribution system 105 . When the CCPU 28 senses a fault within the short-circuit range of any load-side device, the next line-side device is ready to operate immediately if the CCPU senses that the load-side device is not clearing the fault, even if the fault may not be in the instantaneous range assigned to the line-side device. This form of backup protection could save many cycles of fault current when a feeder breaker fails to open or if the fault occurs in the switchgear, without sacrificing selectivity.
[0090] In an embodiment, system 26 can be configured with circuit protection devices, circuit breakers 14 for example, located at service entrances and branch circuits. Load circuit over-current protection can be provided by module 30 , acting as a trip unit in conjunction with CCPU 28 , and current sensors 34 being integrated with the circuit breaker 14 . These devices will continue to measure the circuit currents but the information will be digitized and broadcast over network 32 . The network 32 communicates digital representation of the system parameters, current, and voltage, for example, from multiple points throughout the system and makes this information available to all control devices in the system. The network 32 can also communicate protective device status and has the ability to direct the protective device 14 to take action over the same digital network 32 . For example, optimum switching between protective devices 14 may be accomplished by controlling centrally via CCPU 28 each circuit breaker 14 which has an adjustable time delay that is remotely controllable. Having the system parameters and the ability to control the devices enables this control and communication system to perform all of the functions currently performed by the multitude of control devices and point to point wiring used in known systems. As disclosed, this control functionality can be added virtually via software rather than physically through hardware.
[0091] A form of over-current protection is provided by the inverse time-over-current characteristics and fixed, or dynamic as discussed above, time delays that can be assigned to each circuit breaker 14 in the system 26 . In a typical main and multiple-feeder system, the main breaker is set at the appropriate current setting to handle the maximum current that the bus may carry, or the sum of the currents of each of the feeders. However, the main breaker may also be set with a current setting equal to that of each of the feeder breakers and a time characteristic that allows it to provide backup protection to each individual feeder at that feeder's setting. The processor 28 would simultaneously monitor the current at the main bus and each of the branch circuits, reacting to an undesirable current at any point. This provides each branch circuit with secondary backup protection optimally set to supplement the primary protection with no compromise needed to achieve selectivity or to allow the bus current to flow unimpeded.
[0092] Through utilization of CCPU 28 , control algorithms at a circuit breaker 14 can be duplicated at its respective feeder in the event it or one of its sub-components fails. This approach for the centrally controlled power system 26 works by the central controller's ability to adjust the circuit breaker trip curves in-situ, based on the current status of the system. Therefore, if a feeder breaker happens to malfunction, for example, the central controller will be notified and will perform adjustments to its supplying breaker. These adjustments include altering the supply breakers trip curves, and/or performing an interpolation calculation. This interpolation calculation involves collecting information from the supply breaker and its remaining feeder breakers. With this information, the conditions at the failed feeder breaker are determined.
[0093] In an exemplary embodiment of system 26 , circuit breakers 14 , busbars 12 and current sensors 34 are labeled with tags that identify that component's current rating (and potentially other identifying characteristics). These tags interface with the node electronics associated with the equipment cabinet in which the component is located. Using tags allows for identification of circuit breakers, current sensors and bus-bars based on tags. As such, an embodiment provides a mechanism for identifying the current rating of circuit breakers, current sensors and bus-bars, and a means for communicating these current ratings to appropriate components of the circuit breaker control and protection system (for example, breaker node, central controller).
[0094] While the instant disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope thereof. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A method and apparatus is disclosed for providing protection against arc flash during maintenance on a low voltage power circuit including a circuit breaker having a specified trip function for responding to a fault is provided. The specified trip function is overridden with a maintenance trip function that results in reduced arc energy in the fault during a trip over arc energy during a trip with the specified trip function. The specified trip function is restored following maintenance.
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BACKGROUND OF THE INVENTION
This invention relates generally to a two-stage process for the reductive stripping of uranium from wet-process phosphoric acid, and more particularly, to providing the ferrous ions necessary for the reductive strip in the first stage without contaminating the uranium-enhanced reductive strip solution supplied to the second stage with undesirable impurity elements such as excess iron.
Phosphates for use in the fertilizer industry are obtained by mining phosphate-bearing rock and then converting the rock to an agriculturally useful fertilizer product by one of several alternative processes. In one of these processes, the "wet process", the mined rock is digested in sulfuric acid to produce dilute phosphoric acid and then concentrated to product grade phosphoric acid by evaporation. The phosphate bearing rock may contain several kinds of metallic elements in relatively low concentration which are also dissolved into the phosphoric acid, and these metallic elements may be removed from the acid either as valuable by-products or as undesirable contaminants.
Depending upon the specific type of phosphate rock, uranium may be present in the dilute wet-process phosphoric acid in an amount sufficient to warrant recovery of the uranium for use in the nuclear industry. Several processes for recovering uranium from wet process phosphoric acid are known, and in one such process disclosed in U.S. Pat. No. 3,711,591 the chemical properties of various oxidation states of the uranium ion are utilized to allow extraction of the uranium values by contacting the phosphoric acid with particular extractants dissolved in an organic solvent. This process functions more efficiently if the uranium content in the input feed is initially concentrated in a first stage, wherein the extractant in the organic solvent extracts uranium values from the wet-process phosphoric acid having a very low uranium concentration, and then transfers the uranium values to a uranium-enhanced reductive strip solution used as input to the second stage, by a reductive strip wherein ferrous ions reduce the oxidation state of the uranyl ions. The reduced uranous ions then transfer from the organic-based phase to the aqueous uranium-enhanced reductive strip solution. In existing processes of this type, ferrous ions for use in the first stage reductive strip are provided by treating a portion of the raffinate phosphoric acid from the extraction by the addition of iron metal, which reduces the ferric ions in the raffinate to the ferrous state.
Reduction of the ferric ions in the raffinate by the addition of metallic iron has the significant disadvantage of increasing the concentration of iron in the uranium-enhanced reductive strip solution which serves as the input to the second stage of the recovery process. The iron is extracted together with the uranium in the second stage, and the extracted iron contaminates the concentrated uranium oxide product, acting to complicate the subsequent purification of the uranium oxide product into a form usable in the nuclear industry. To overcome this problem of increased iron concentrations in the uranium-enhanced reductive strip solution, processes have been developed wherein the iron is removed prior to the second stage extraction by precipitation, or the second-stage extraction process itself may be modified to avoid extraction of the iron. In either approach to removing the iron, there are economic disadvantages in that costly chemicals or expensive capital equipment are required.
Accordingly, there has been a need for an alternative approach to providing ferrous ions to be used in the first stage reductive strip which eliminates the disadvantages produced by the addition of iron metal or other chemical reducing agent to the raffinate phosphoric acid. Preferably, the improved process would utilize the same basic process approach as the existing two-stage reductive stripping process for recovering uranium from wet process phosphoric acid, which has been proved to be reasonably efficient. The present invention fulfills this need, and further provides related advantages.
SUMMARY OF THE INVENTION
The present invention resides in a process for recovering uranium values from wet process phosphoric acid, by reductive stripping of uranium values from the acid using extractants in an organic solvent. In the first stage the uranium content of the acid is enhanced by a reductive strip wherein ferrous ions produced by autoclaving raffinate phosphoric acid in the presence of a pressurized reducing gas strip uranyl ions from the extractant into a uranium-enhanced reductive strip solution. The production of ferrous ions by exposing raffinate phosphoric acid to the pressurized reducing gas in an autoclave does not introduce excess iron metal as in conventional operations, thereby avoiding the contamination of the uranium-enhanced reductive strip solution fed to the second stage and in turn avoiding the contamination of the final extracted uranium product by excess iron, thereby reducing refinement requirements in the ultimate uranium purification process.
In accordance with the invention, raffinate phosphoric acid, produced by the first-stage extraction and containing a low concentration of ferric ions, is heated in contact with a reducing gas to reduce the ferric ions therein to the ferrous state, so that the resulting reducing solution may serve as a source of ferrous ions in the reductive strip of the first stage, wherein uranyl ions are reduced to uranous ions and transferred from the extractant and organic solvent to the aqueous uranium-enhanced reductive strip solution. In the presently preferred embodiment, the raffinate phosphoric acid is heated in contact with pressurized hydrogen gas in an autoclave to accomplish the reduction of the ferric ions, preferably at a pressure of up to about 15 atmospheres hydrogen and at a temperature of from about 150° F. to about 450° F., and most preferably at a pressure of from about 3 to about 7 atmospheres hydrogen gas and a temperature of from about 250° F. to about 300° F., for a period of time of about 5 to about 15 minutes. Other reducing gasses such as sulfur dioxide, carbon monoxide, methane, and hydrogen sulfide may also advantageously be used. The valence states of other ions present in the acid also are reduced by the reducing gas and may be used in subsequent processing steps.
No excess iron metal or other solid reducing agent is introduced into the raffinate phosphoric acid to accomplish the reduction of ferric ions, so that the uranium-enhanced reductive strip solution produced by the reductive strip has a relatively low concentration of iron and other impurities, thereby reducing the subsequent refinement requirements in processing the uranium found in the uranium-enhanced reductive strip solution to a final commercially usable uranium product. In its most commercially practical form, the second-stage process undesirably strips iron impurities into the final uranium product of this process, thereby contaminating the final product with a proportion of any iron metal found in the uranium-enhanced reductive strip solution. Therefore, accomplishing the reduction of ferric ions with a reducing gas rather than a solid reducing agent significantly enhances the final product.
It will be appreciated from the foregoing that the present invention represents an advance in the field of reductive stripping processes for recovering uranium from wet process phosphoric acid. With this improvement, the necessary ferrous ions required in the first-stage reductive strip are created without introducing an iron impurity, which is otherwise stripped in the second stage to contaminate the final uranium product.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawing, which illustrates, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a schematic flow diagram of a two-stage reductive stripping process for recovering uranium from wet process phosphoric acid, illustrating the reduction of ferric to ferrous ions by pressurized hydrogen gas in the first stage, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the FIGURE for purposes of illustrating the presently preferred embodiment, the present invention is concerned with a two-stage reductive stripping process for recovering uranium from wet process phosphoric acid and, more particularly, to a particular step in the first stage of this process wherein ferrous ions must be created for introduction into a reductive strip. In the first stage of this process, a uranium-enhanced reductive strip solution having an enhanced uranium concentration is produced from oxidized wet-process phosphoric acid having a low concentration of uranium by an extraction 10 of a portion of the uranium content into a first extraction medium, and a subsequent reductive strip 12 of this extraction medium by reaction with ferrous ions. The uranium-enhanced reductive strip solution is then treated by an oxidation 14 and introduced into a second-stage extraction 16 and subsequent strip 18, wherein the stripped uranium output is of sufficient concentration that it may be filtered by a filter 20 and calcined in a calcine unit 22 to produce a uranium oxide product.
A single-stage stripping process for producing uranium product from wet process phosphoric acid operates somewhat inefficiently because of the very low uranium concentration typically found in wet process phosphoric acid. As described in detail in U.S. Pat. No. 3,711,591, a two stage reductive stripping process was devised, wherein the extraction 10 and the reductive strip 12 of the first stage concentrated the uranium in the input flow to the second stage to an extent that the extraction 16 and the strip 18 may operate more efficiently, thereby raising the overall extraction efficiency of the process.
Briefly, oxidized wet-process phosphoric acid having the uranium in the oxidized uranyl ion form is introduced into the extraction 10, wherein a portion of the uranyl ions are extracted into the first extraction medium, which carries the uranyl ions to the reductive strip 12. The uranium-depleted raffinate phosphoric acid passes to evaporators 13 for use in agricultural fertilizer production. A small fraction of the raffinate phosphoric acid is diverted, processed to reduce the ferric ions therein to the ferrous state, and introduced as a reducing solution into the reductive strip 12 to serve as a source of ferrous ions to reduce the uranyl ions in the extraction medium to the uranous state, in which oxidation state the uranous ions are rejected from the first extraction medium into the aqueous reducing solution to produce a uranium-enhanced reductive strip solution. (As used herein, the term "ferrous" denotes iron ions in the +2 oxidation state, the term "ferric" denotes iron ions in the +3 oxidation state, the term "uranyl" denotes uranium ions in the +6 oxidation state, and the term "uranous" denotes uranium ions in the +4 oxidation state.)
In the second stage, the uranium-enhanced reductive strip solution output of the first stage is oxidized by oxygen gas in the oxidation 14, to convert the uranous ions therein to the uranyl state, and then introduced into the extraction 16 wherein the uranyl ions are transferred to a second extraction medium and the depleted oxidized reductive strip solution is recycled into the first extraction 10. The second extraction medium transfers the uranium values to the second-stage strip 18, wherein the uranyl ions are stripped from the second extraction medium by a reaction with ammonium carbonate solution to recover the uranium values as ammonium uranyl tricarbonate (AUT). The AUT slurry is then washed, filtered and calcined to yield a uranium oxide final product suitable for further treatment to produce purified uranium for use in the nuclear industry. Gasses from the extraction 16 and the calcine 22 are vented as stack gas, and aqueous waste from the filter 20 is cleaned in an extractor.
The extraction medium used in both the first-stage extraction and the second-stage extraction should be one that extracts uranyl ion from and gives up uranous ion to an aqueous phase. As disclosed in U.S. Pat. No. 3,711,591, an example of a satisfactory extraction medium is di (2-ethylhexyl) phosphoric acid and trioctylphosphine oxide dissolved in an organic diluent.
In accordance with the invention and as illustrated for the presently preferred autoclave reduction with hydrogen gas, in the first stage the ferric ions in the diverted raffinate phosphoric acid are reduced to the ferrous state required for the reductive strip 12 by an autoclave reduction 24. The diverted raffinate phosphoric acid is introduced into an autoclave pressure vessel and heated under hydrogen gas pressure, with continuous agitation. The reduction of ferric ions therein by hydrogen should proceed until a concentration of ferrous ions sufficient for the reductive strip 12 is obtained. In typical commercial-scale operation of the two-stage reductive stripping process described in U.S. Pat. No. 3,711,591 the oxidized wet-process phosphoric acid flows at 1000 l/min and gives up 0.07 g U/l to the first extraction medium, the first extraction medium flows at 500 l/min, and 6 l/min of raffinate phosphoric acid is withdrawn for introduction into the reductive strip. To effect the reductive strip under these conditions, a concentration of ferrous ions of about 5 to about 20 grams per liter in the reducing solution is required. Although the reduction of the ferric ions by hydrogen will proceed more rapidly with increasing pressures of hydrogen, as a practical matter a maximum hydrogen pressure of about 7 atmospheres is utilized to avoid the capital expense of providing a high-pressure autoclave. Preferably, the raffinate phosphoric acid is heated to a temperature of from about 150° F. to about with a hydrogen pressure of from about 1 to about 15 atmospheres. Most preferably, the raffinate phosphoric acid is heated to a temperature of from about 250° F. to about 300° F., with a hydrogen pressure of from about 3 to about 7 atmospheres for a time of from about 5 to about 15 minutes. Under these conditions, as an Example will demonstrate, the autoclave reduction 24 will provide the necessary 5-20 grams per liter of ferrous ion, with the reduction of ferric ion by hydrogen approaching completion.
The following Example will serve to illustrate the inventive method:
EXAMPLE
Eleven liters of 30% P 2 O 5 phosphoric acid was introduced into a mechanically agitated pressure vessel serving as an autoclave and heated to 295° F. under 6 atmospheres hydrogen gas pressure to effect reduction of the ferric ions in the phosphoric acid to the ferrous state. Samples of the acid were taken at predetermined time intervals up to 2 hours and titrated using 0.02 M ceric ammonium acid sulfate solution to determine the presence of ferrous ion. The titration analysis of the acid samples are summarized in the following table:
______________________________________Time Meg/L Grams/L(Minutes) Oxidation Requirement Ferrous Ion______________________________________0 77.0 4.35 110.2 6.215 189.7 10.620 213.4 11.930 223.6 12.545 244.2 13.660 249.0 13.975 267.8 15.0120 284.6 15.9______________________________________
In about 5-15 minutes, the hydrogen reduction produces an acid of sufficient ferrous ion content for use in a reducing solution to strip the uranyl ions from the extraction medium in the first stage. As seen from the table, after about 20-30 minutes the reduction reaction has proceded essentially to completion under the combination of pressure and temperature used in the Example, and further reduction is not economically justified in commercial processing.
It will now be appreciated that, through the use of this invention, the necessary concentration of ferrous ions may be produced in raffinate phosphoric acid to effect the reductive strip of the first stage in a two-stage process for reductive stripping to recover uranium from wet process phosphoric acid. The reduction of the ferric ion to the ferrous state is accomplished by a reducing gas rather than the introduction of iron metal, which, if used, would eventually be extracted into the final uranium oxide product and act as a contaminant to reduce the efficiency of further refinement steps. Hydrogen gas is the presently preferred reducing gas for use in this invention, but other reducing gasses, such as sulfur dioxide, carbon monoxide, methane, and hydrogen sulfide, may also be used. And, while in the described embodiment of the invention it is the ferric-to-ferrous reduction that is desired, other ions in the phosphoric acid may be reduced by the reducing gas and advantageously used in subsequent processing reactions. Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
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A two stage reductive stripping process for recovering uranium from wet process phosphoric acid, wherein the ferrous ions required for the first-stage reductive strip are supplied by heating a portion of acid raffinate phosphoric acid from the first-stage extraction in the presence of pressurized hydrogen gas. The pressurized hydrogen gas reduces the ferric ions in the raffinate to the ferrous state without any addition of metallic iron or other impurity, so that the uranium-enhanced reductive strip solution supplied to the second stage from the first stage reductive strip has a low concentration of iron impurity, and no further purification to remove iron impurity is required.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an eye refractometer for measuring the degree of spherical refraction, the degree of astigmatic refraction, the astigmatic angle, etc. of an eye.
2. Related Background Art
The eye refractometer of this type, as is shown in the pending U.S. patent application Ser. No. 755,362, filed July 16, 1985, is such that the light from a light source is directed to an eye to be examined. The light is projected as a light source image onto the fundus of the eye. The light beams reflected from the fundus of the eye in at least three meridian directions on the pupil of the eye to be examined are taken out to thereby accomplish the measurement of the refraction of the eye in each meridian direction. However since it deals with the light beams in at least three meridian directions, it is considerably complicated in structure and relatively high in cost.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an eye refractometer which is structurally simple, compact and inexpensive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows the optical arrangement of a first embodiment of the present invention.
FIG. 1B is a view of the first embodiment as seen from the direction of the optic axis.
FIG. 2 is a front view of a deflecting prism.
FIGS. 3 and 4 are front views of two-aperture stops.
FIG. 5 illustrates an image rotating prism.
FIG. 6A illustrates the light beam on a light-receiving surface.
FIGS. 6B and 6C illustrate a case where astigmatism is absent and a case where antigmatism is present, respectively.
FIG. 7 illustrates the conversions from a light position into degree of spherical equivalence, degree of astigmatism and astigmatic angle.
FIGS. 8A and 8B to 11A and 11B show various modifications of a stop.
FIG. 12 shows the optical arrangement of a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will hereinafter be described in detail with respect to the shown embodiments thereof. The meridian directions include not only a direction passing through the optic axis as viewed from the direction of the optic axis, but also directions parallel thereto.
Referring to FIGS. 1A and 1B, on the optic axis 01 passing through a light source 1 and an eye E to be examined, there are disposed, in succession from the light source 1 side, a lens 2, a deflecting prism 3 for deflecting the image of the light source in the direction of the y-axis, a first two-aperture stop 4, a mirror 5 and an objective lens 6. The apertures 4a and 4b of the two-aperture stop 4 are disposed on the left side as shown in FIG. 1B, and the mirror 5 is provided only on the right side as shown in FIG. 1B. On the optic axis 02 on the reflection side by the mirror 5 of the light beam travelling from the eye E to be examined toward the light source, there are successively arranged a second two-aperture stop 7 provided with apertures 7a and 7b on the right side as shown in FIG. 1B, a lens 8, an image rotating prism 9 and a light-receiving element 10 which is a two-dimensional position detecting element. The light source 1 and the light-receiving surface of the light-receiving element 10 are substantially conjugate with the eye fundus Er of an emmetropia, and the first and second two-aperture stops 4 and 7 are substantially conjugate with the pupil Ep of the eye E to be examined.
The deflecting prism 3, as shown in FIG. 2, comprises two wedgeprisms 3a and 3b which correspond to the apertures 4a and 4b, respectively, of the first two-aperture stop 4 shown in FIG. 3. Use may be made of two light sources 1, instead of the deflecting prism 3 and the single light source 1. The apertures 4a and 4b of the first two-aperture stop 4 are substantially symmetrical with the apertures 7a and 7b of the second two-aperture stop 7 shown in FIG. 4 with respect to the center of the stop, i.e., the center of the pupil Ep. The mirror 5, as previously mentioned, is disposed on one side with respect to the optic axis 01 and separates the light beams passing through the first two-aperture stop 4 and the second two-aperture stop 7. The image rotating prism 9 comprises two prisms 9a and 9b and, as is partly shown in FIG. 5, correspondingly to the apertures 7a and 7b of the second two-aperture stop 7, the two prisms are rotatively displaced by a predetermined angle and disposed so that the direction la, ma is the direction A and the direction lb, mb is the direction B.
Thus, the light beam emitted from the light source 1 passes through the lens 2, the deflecting prism 3, the first two-aperture stop 4 and the objective lens 6 to the eye E to be examined, and the reflected light reflected by the eye fundus Er passes through the objective 6 and is reflected toward the optic axis 02 by the mirror 5 and passes through the second two-aperture stop 7, the lens 8 and the image rotating prism 9 to the light-receiving surface of the light-receiving element 10.
In FIG. 1B, where the eye E to be examined is an emmetropia, the image of the light source 1 on the eye fundus is caused by the deflecting prisms 3a and 3b to assume positions A1 and B1 displaced in the direction of the y-axis from the optic axis 01. Where the eye E to be examined is an eye of abnormal refraction free of astigmatism, the image of the light source 1 passes through the positions A1 and B1 and is displaced on the directions ma and mb parallel to the measurement meridian directions la and lb, respectively. Where the eye E to be examined has astigmatism, the image of the light source 1 is displaced in a direction perpendicular to the measurement meridian directions.
FIG. 6A shows the state of the light beam on the light-receiving element 10. Where the eye E to be examined has no astigmatism, the two light beams rotated by the image rotating prism 9 travel on parallel straight lines A and B while blurring as indicated by A1, A2, A3 and B1, B2, B3 in conformity with the refractive power of the eye E to be examined as illustrated in FIG. 6B, and the refractive power of the eye E can be found from the amount of travel. Where the eye E to be examined has astigmatism, the light beams travel in the direction of travel in the case where astigmatism is absent and in a direction perpendicular thereto. By taking the amount of travel in this perpendicular direction also into consideration, that is, from the information of the amounts of travel in the two meridian direction and the information of the amounts of travel in the directions perpendicular to the two meridian directions, the degree of astigmatism and the astigmatic angle of the eye E to be examined can be found even if measurement is not effected with respect to three meridians. As shown in FIG. 1, operation is carried out by processing means 11 and the result of the operation is displayed by display means 12.
Reference is now had to FIG. 7 to describe the method of calculation. Straight lines A and B are caused to overlap each other to form a straight line C. For simplicity, the two meridian directions in which the light beam is taken out are made perpendicular to each other on the pupil of the eye to be examined, as shown in FIGS. 1A and 1B. Point 0 is the position of the light beam at 0 diopter. When the distances of movement of points A4 and B4 from 0 diopter in the direction of the straight line C are Xa and Xb, and the distances of movement of these points in a direction perpendicular thereto are Ya and Yb, and the angle formed between a straight line passing through the points A4 and B4 and the straight line C is φ, and the angle constant, i.e., the angle formed between the horizontal direction which is the reference direction in the ophthalmic examination and the measurement meridian direction is β, then the degree of spherical equivalence SPH, the degree of astigmatism CYL and the astigmatic angle Ax are given as follows:
SPH=D·(Xa+Xb)/2
CYL=D√{(Xa-Xb).sup.2 +(Ya+Yb).sup.2 }.sup.1/2
AX=(φ/2)+β=(1/2)·tan.sup.-1 {(Ya+Yb)/(Xa-Xb)}+β
where D is a coefficient corresponding to the diopter of unit distance. Even if the two meridian directions are not made perpendicular to each other, it is easy to calculate these three amounts. Also, it is unnecessary to know the aforementioned four amounts of movement Xa, Xb, Ya and Yb, and it is sufficient to measure three of them.
Now, in the above-described embodiment, the two-aperture stops 4 and 7 have been used to project or take out two light beams, but as shown in FIGS. 8A and 8B and FIGS. 9A and 9B, the number of apertures in one of the stops 4 and 7 may be one. The position of this aperture may be on or off the optic axis.
Where the number of apertures in the stop 4 is one, the deflecting prism 3 becomes unnecessary, and this leads to an optically simple structure. Also, of the light beams in two meridian directions, the light beams passing through the apertures of the stop 4 or the stop 7 are alternately shut off, whereby they are projected or taken out while being distinguished from each other in time, whereby the deflecting prism 3 can be made unnecessary. As shown in FIGS. 10A and 10B, a light beam may be projected from the vicinity of the center of the pupil to the central portion of the eye fundus Er, whereby four light beams may be taken out as the light beams in two meridian directions from two sets of optic-axis symmetrical points around the pupil, i.e., off the optic axis. That is, in this case, the reflecting position of the light beam on the eye fundus Er is always near the center of the eye fundus Er and two pieces of information in two meridian directions are obtained, and in each meridian direction, measurement can be accomplished depending not on the absolute position of a light beam but on the spacing between two light beams, i.e., the relative position of the two light beams, and thus, a highly reliable measured value can be obtained. The incidence and emergence may be reversed to each other as shown in FIGS. 11A and 11B. Further, the light-receiving element 10 need not always be a simple two-dimensional light position detecting element, but may be one-dimensional light position detecting elements 10a and 10b combined together perpendicularly to each other in the measurement meridian directions (the directions la and lb of FIG. 1B) with a beam splitter 13 interposed therebetween, as shown in FIG. 12. For example, two one-dimensional light position detecting elements 10a and 10b may be combined into the shape of a cross, and two cylindrical lenses 14a and 14b whose bus line directions coincide with the measurement meridian directions may be provided in the optical path on this side of the one-dimensional light position detecting elements to thereby enlarge the light-receiving width, and shutters S1 and S2 may be driven by shutter drive means 15 so that light beams may alternately pass through the openings in the respective measurement meridian directions and be projected onto the one-dimensional light position detecting elements, whereby the two-dimensional position may be found.
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The present invention is directed to an eye refractometer, one embodiment of which, includes two-aperture stops positioned substantially conjugate with the pupil of the eye to be examined. Further, a two-dimensional light position detecting device is provided for detecting the two-dimensional positions of two light beams passed through the light beam incidence area of the pupil of the eye to be examined, reflected by the fundus of the eye to be examined and passed through the light exit area of the pupil of the eye to be examined. A processor is provided for obtaining the refractive value of the eye from the output of the two-dimensional light position detecting device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to data analysis of semiconductor tests using a computer and, more particularly to a technique for a software program executed by a computer that combines (1) the measuring results obtained as a combination of arrays from a measuring apparatus and (2) the measuring results obtained as scalar representation data from the measuring apparatus and analyzes thereof.
2. Discussion of the Background Art
When an IC (integrated circuit), whether in a die on a wafer or a package form, referred to hereinafter as measured elements and DUT (device under test), are measured a variety of parameters are set and data are collected. For example, in the semiconductor measuring system described in Japanese Patent Application Publication No. H11[1999]-163,063, a variety of parameters are provided for a test spec 7d and vast amounts of measured data are obtained and evaluated. A combined Agilent 4072 Semiconductor Parameter Tester manufactured by Agilent Technologies Inc. and Semiconductor Process Evaluation Core Software (SPECS) manufactured by the same company or the Agilent 4155 Semiconductor Parameter Analyzer manufactured by Agilent Technologies Inc. and the like may be used for these measurements.
When the current/voltage (I-V) characteristics are measured relative to each of the DUTs under specific conditions using measuring apparatuses, the data are obtained as multiple combinations of arrays that indicate the voltage value relative to the current value under one or more conditions for each DUT and are stored in a file in a format desired by the user. The stored data are calculated using a dedicated data analysis program or Excel® or other all-purpose spreadsheet program. As a result, V TH and other feature values are extracted from the respective array data.
However, when processing was carried out for the obtained array data using a dedicated data analysis program, complicated operations using the array data were needed such that the program had to be revised to handle the quantity of data being processed. Also, the cost of the program increased when a dedicated data analysis program was provided that could handle the data flexibly such that the data were not controlled by the size of the array and the number of combinations of the arrays. Additionally, when the need arose to revise an algorithm used for extracting a feature value during analysis, recompiling had to be carried out and it could not be flexibly revised.
On the other hand, when arithmetic operations were carried out using an all-purpose spreadsheet program, feature value extraction from the multiple array data such as the aforementioned I-V characteristics were executed for each individual spreadsheet. Also, the extracted feature values were inserted in a two-dimensional table, that is, the main spreadsheet which had been displayed for each DUT along with the results of the other measurement items, and were evaluated. However, inserting the feature values obtained for each of the individual spreadsheets mentioned above in a cell on the main spreadsheet is a manual operation which is cumbersome and time-consuming. In addition, the process of debugging between the main spreadsheet and each of the spreadsheets used for feature value extraction is not easily done without sufficient specialized knowledge. Also, when the prior-art all-purpose spreadsheet program was used, there was no function to easily display the array or perform operations for it unless expanding the array to another spreadsheet.
SUMMARY OF THE INVENTION
It is an object of the present invention to address the problems as indicated above and to provide a data analysis environment that comprehensively handles, expresses, and processes measurement items expressed in a single measurement value (scalar representation data) and items expressed in an array of measured values (array representation data).
It is another object of the present invention to provide a data analysis method that provides for the extraction, display, verification and evaluation of feature values from data items expressed in arrays of measurement values of measurement items on a spreadsheet where items expressed in a single measurement value are expressed as measurement items.
It is yet another object of the present invention to provide a mechanism that can be easily handled in the aforementioned data analysis environment without expanding the array data to another part of the spreadsheet and incorporating them.
The present invention provides a method and apparatus for analysis that can comprehensively handle, express, and process measurement items expressed in a single measurement value (scalar representation data) and items expressed in arrays of measurement values (array representation data) in data analysis.
The present invention provides a data analysis method for use on a spreadsheet software having a plurality of cells displayed as a two-dimensional table on a computer comprising (1) assigning to a first cell a definition of array representation data including a single array or multiple arrays of data; (2) displaying to the first cell a first array display button; and (3) selectively displaying the array representation data in a graphical or table format using an array data display device when the array display button is selected.
The present invention comprises an embodiment that comprises (1) assigning to a second cell an expression containing a feature value extraction function for array representation data assigned to the first cell; and (2) selectively displaying and assigning to the second cell an operation result for an expression containing the feature value extraction function.
An embodiment of the present invention is a data analysis apparatus that is provided with (1) a spreadsheet definition device that assigns a definition of array representation data to a first cell on a spreadsheet software having a plurality of cells displayed as a two-dimensional table on a computer; and (2) an array data display device that displays to the first cell a first array display button and selectively displays the array representation data in graphical or table format when the array display button is selected.
Here, the aforementioned spreadsheet definition device is provided with functionality that assigns to the second cell on the aforementioned spreadsheet an expression that contains a feature value extraction function for the array representation data assigned to the aforementioned first cell. The aforementioned data analysis apparatus is also provided with an array data operation device that executes operations for the expression that contains the aforementioned feature value extraction function in the aforementioned second cell. The aforementioned array data display device displays a second array display button when the results of an expression which has been assigned to the aforementioned second cell, and has a function that displays numeric values when the operation results are scalar representation data.
An embodiment of the present invention provides a data analysis method which, when data are displayed to the first cell on the spreadsheet, displays a numeric value when the data assigned to the aforementioned first cell are scalar representation data and displays an array display button when the data assigned to the aforementioned first cell are array representation data.
There is an embodiment in which the data for measurement items expressed in a single measurement value are contained in the aforementioned scalar representation data and the data for measurement items expressed in a single array or multiple arrays of measurement values as measurement items are contained in the aforementioned array representation data; an embodiment in which the array representation data assigned to the aforementioned first cell are displayed in another window in table form or graph form; and an embodiment in which, when an expression that contains a feature value extraction function for the array representation data that have been assigned to the first cell is described in the second cell, the function is calculated and displayed as a numeric value when the calculation results are scalar representation data and an array display button is displayed when the aforementioned calculation results are array representation results.
The present invention also provides a computer program for executing and implementing any of the data analysis methods and data analysis apparatus mentioned above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a preferred embodiment of the present invention;
FIG. 2 is a block diagram of controller 107 in FIG. 1 ;
FIG. 3 is a flowchart indicating the operations involved in an examplary embodiment of the present invention;
FIG. 4 is an example of a display for a spreadsheet of the present invention.
FIG. 5 is an example of a graph display that is indicated when button 410 in FIG. 4 is selected; and
FIG. 6 is an example of a graph display that is indicated when button 412 in FIG. 4 is selected.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, particular attention should be paid to the fact that data analysis carried out for each DUT is divided into two types: (1) scalar representation data (hereinafter also referred to as scalar data) having only a single measurement value (for example, a resistance value when specified terminals are opened) of measurement items or information data for DUT lot/wafer/die, and (2) array representation data (hereafter sometimes referred to as array data) that are expressed as a single array or multiple arrays of measurement items. When these results are arranged and expressed as a two-dimensional table, e.g., a spreadsheet on a computer, an environment is provided in which the measurement items can be displayed and processed comprehensively. More specifically, the array representation data takes single or multiple measurement values obtained for a combination of a single setting value or multiple setting values and retains and handles the features of the measurement items by turning them into data sets. The results can be easily arranged and displayed.
Thus, in the present invention, the array representation data are represented as a single cell in the spreadsheet in the main spreadsheet. Accordingly, a definition of the array representation data assigned to a cell is stored in that cell. By selecting that cell, the user can obtain array data display or array graph display. The array representation data that are related by intuitive operations are referenced and analyzed all the while taking the scalar representation data for each DUT on the main spreadsheet into consideration.
In the analytical environment provided by the present invention, a feature value extraction function that carries out statistical operations and a variety of other operations is prepared for the array representation data represented in the designated cell. Feature values calculated from the designated array representation data can be displayed in the desired cell by using the feature value extraction function in the expression in the definition of the target cell. Therefore, the array representation data and the feature values for these can be easily referenced so that the analytical operations to be executed are significantly simplified.
As an example of the present invention, a spreadsheet in which array representation data have been abstracted and assigned to a cell can be easily understood by calling it a main spreadsheet during analysis. In the present invention, however, this is by no means restricted to cases in which only the main spreadsheet during analysis abstracts the array representation data and assigns them to a cell.
Data analysis apparatus 100 , which is a exemplary suitable embodiment of the present invention, is shown in FIGS. 1 through 3 . As indicated in FIG. 1 , data analysis apparatus 100 is provided with a computer 101 , a display 102 , and an input device 103 . Computer 101 is provided with a storage 108 including memory and a hard disk that stores a variety of programs and data, as well as a controller 107 that executes system control programs, user test programs, and a variety of other programs and includes functionality for controlling the display and the input device. Display 102 comprises a CRT or a liquid crystal display and the like. Computer 101 is provided with functionality for receiving data obtained from a measuring apparatus 104 and stored in a database 105 or a file 106 . Arrows 120 , 122 and 124 indicate the flow of data.
As indicated in FIG. 2 , controller 107 is provided with a spreadsheet definition device 210 , a scalar data display controller 202 , an array data display controller 204 , a scalar data operation device 206 , and an array data operation device 208 . Spreadsheet definition device 210 is provided with functionality that governs the input for the definition of a cell on the spreadsheet. Scalar data display controller 202 is provided with functionality for controlling the display of the scalar data on the spreadsheet. The array data display controller 204 is provided with functionality for displaying and controlling the array data by a control button, in table or graph form. The scalar data operation device 206 is provided with functionality for operating and controlling a cell for the scalar data or an expression that refers to a cell for the scalar data. The array data operation device 208 is provided with functionality for operation and control when a formula has been described in a cell for array representation data defined in the cell.
The controller 107 operates to handle a cell in a spreadsheet according to the flowchart depicted in FIG. 3 . In step 302 , a definition for each of the cells in the spreadsheet displayed is obtained and assigned to each of the cells using the spreadsheet definition device 210 . The process for obtaining the definition from a cell using the spreadsheet definition device 210 may be one in which the user inputs the definition of a cell, as well as one which reads the definition of a cell which has been stored in storage 108 . Further, when array representation data are assigned to a cell, the definition of array representation data that are to be assigned to the cell is coordinated and stored in storage 108 .
When the cell displayed is a scalar data item, the numerical data are displayed to the cell in step 304 of FIG. 3 . When the cell displayed is an array data item, the array display button is displayed in the cell at step 306 .
If an expression defined in the cell displayed contains a feature value extraction function for array data, the function is calculated for the array data to be calculated and the results are displayed to the cell in step 308 .
A numeric value or an array display button is displayed depending on whether the results are scalar data or array data as a means of displaying the results to the cell. Next, if the cell displayed comprises an operation only for scalar data, the operation is carried out and the results are displayed to the cell in step 310 . After the display has been made to the cell as indicated above, controller 107 stands by for key input. When the array display button, displayed in step 306 , is pushed, the array data are displayed in another window in step 312 .
Further, the display configuration for array data may comprise a display means that displays in table form, graph form or both, and an additional display means that displays the remainder from one of the tables or graphs displayed.
Next, there is provided a specific description of the display indicated in FIGS. 4–6 . FIG. 4 is an example of the main spreadsheet that is displayed using data analysis apparatus 100 of the present invention. Display window 400 is a display window for the spreadsheet. The table displayed for the rows is provided with a title line 401 that displays the name of an item displayed for each column and a data display line 402 .
The following items are displayed for the columns in the exemplary window 400 :
(1) information data 403 for specifying measurement objects like the lot ID;
(2) measurement results of scalar data 404 like the resistance value between terminals;
(3) array expression data containing a single two-dimensional array like measurement result of I D V G characteristic 405 ;
(4) array expression data containing multiple two-dimensional arrays like measurement result of I D V D characteristic 407 ;
(5) voltage V TH of scalar data 406 as the results of feature value extraction for single two-dimensional array data 405 ; and
(6) drain current I DS 408 in the saturated regions for each voltage V G that constitutes array representation data for feature values as the results of feature value extraction for multiple two-dimensional array data 407 .
Although it is not shown in the figure, it is also contained in the invention that extracting feature value from specified cells and displaying the result to another cell, of which the scalar data specified for extracting contains array representation data once extracted as feature value.
An array display button is displayed in each of the cells for I D V G characteristic 405 . For example, when the user clicks an array display button 410 for an I D V G characteristic cell for a DUT in which the lot ID is L01, the wafer ID is W05, the die X coordinate is 9 and the die Y coordinate is 9, the data display which is indicated in Table 1 (shown below) or the graph display in FIG. 5 is displayed in another window.
TABLE 1
V G [V]
I D [mA]
0
0
1
2
2
5
3
10
4
40
Likewise, when the user clicks the array display button 412 for the I D V D characteristics which contains multiple two-dimensional array data, the data display indicated in Table 2 (shown below) or the graph display indicated in FIG. 6 is displayed in another window.
TABLE 2
V D [V]
I D (V G = 1V)[mA]
I D (V G = 2V)[mA]
0.0
0
0
0.5
20
40
1.0
30
60
2.0
35
65
3.0
38
68
4.0
40
70
Even when the user pushes (i.e., selects) the array display button for column I DS 408 , which has feature value extraction results containing array representation data, data display or graph display for the array data is carried out as indicated above.
A preferred embodiment of the present invention has been described hereinabove. However, these are only examples used for the sake of explanation and a variety of variants should be appreciated by a person of ordinary skill in the art. For example, when the contents of the cell comprises array representation data, a variant in which characters and symbols are displayed to the cell instead of the button, a variant in which special colors are displayed in the cell, and a variety of other display variants are possible as well. A variety of configurations other than selecting using a mouse can be used as a method for indicating a user selection for displaying the contents of the array representation data from a cell. In the discussion above, the I D V D characteristic 405 was used to represent a single two-dimensional array and the I D V D characteristic 407 was used to represent multiple two-dimensional array data. However, regarding the implementation of the present invention, an embodiment that processes these data by decomposing or integrating them and treating them as one-dimensional or multi-dimensional data is included in the scope of the present invention.
As discussed above, in accordance with the present invention, items expressed by a single measurement value and items that are expressed as arrays of measurement values are integrated and handled in data analysis. Thus, there is provided an analytical environment for representing and processing the items. In addition, feature values can be extracted, displayed, verified, and evaluated from items expressed by an array of measurement values as measurement items and single measurement values as measurement items on a spreadsheet are displayed. Therefore, the user can efficiently analyze and evaluate data that contain an array representation. In addition, since array representation data do not need to be expanded to another part of the spreadsheet and incorporated there, the user can easily make analyses and evaluations which include array representation data.
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A data analysis method, apparatus, and storage medium having computer readable program instructions embodied therein for use on a spreadsheet software having a plurality of cells displayed as a two-dimensional table on a computer including assigning to a first cell a definition of array representation data including a single array or multiple arrays of data, displaying to the first cell a first array display button, and selectively displaying the array representation data in a graphical or table format using an array data display device when the array display button is selected.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] Conventional watercraft, such as recreational powerboats and the like, often generate movement using an inboard/outboard (I/O) propulsion system. These I/O propulsion systems incorporate a stern drive component that typically includes a motor (e.g., a combustion engine), tilt components (e.g., gimbal unit and pivot housing) and an outdrive having a propeller. An opening or passageway is formed in the transom of the watercraft hull so that the stern drive component may be extended therethrough and mounted with the watercraft.
[0004] Complicating the formation of the transom opening is the typical lay-up that forms the watercraft hull. This lay-up includes a number of laminate layers, such as a glass reinforced resin shell and various core materials including plywood, glass reinforced cast composites, and other materials. Cutting and/or drilling through these types of laminate layers to form the transom opening has proven to be quite difficult and time consuming with traditional hand tools; an accurately formed transom opening is therefore hard to achieve. A more precise transom opening outline may sometimes be realized by using automated cutting equipment, but this equipment is often cost prohibitive and requires substantial training to use properly.
[0005] One proposed solution is to form the transom opening by using a reusable cast metal insert, such as one made of aluminum. In this method, the insert is shaped to form the transom opening as a watercraft hull is molded around the perimeter of the insert. In a first step, the insert is attached to a molding tool such that one face of the insert faces inboard and an opposing face of the insert faces outboard with respect to the watercraft hull being formed thereon. Then, a shell layer of the hull is molded onto the molding tool and surrounding the perimeter of the insert. It would seem intuitive at this point just to build the remaining laminate layers onto the shell layer around the insert perimeter, detach the insert from the molding tool, and demold the laminate layers forming the finished watercraft hull from the molding tool (and the insert from the hull) to reveal the transom opening in the hull. However, the rigidity of the metal insert does not promote a tight fit between the insert and the molding tool surface. This allows gel coat or other coatings applied to the layer surfaces to promote lamination thereof to flow between the molding tool and the insert, thereby encapsulating the insert and making removal of the insert and hull from the tool without damaging the hull (and thus damaging the transom opening) very difficult. Also, the lack of a tight fit between the insert and the molding tool facilitates the formation of air voids when the coatings are applied, which impair the structural soundness of the hull and are difficult to remove.
[0006] To solve the problems associated with using the cast metal insert, a raised, curved surface made of clay or wax is formed onto the exposed perimeter of the insert once the insert is installed with the moldling tool. This forms a tighter seal between the insert and the molding tool surface such that the coatings do not pass to the lateral edges of the layers when building up the watercraft hull. Additionally, though, a release agent is usually required to be applied to the perimeter of the case metal insert to thereby form a release film, in order to prevent the laminate from sticking to the insert. Release agents, unfortunately, do not perform ideally when applied to an essentially rigid metal insert. Such agents often form a release film with air voids and damaged spots, resulting in the insert bonding to the molding tool surface and thereby impeding the removal of the insert to expose the finished transom opening.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention overcomes the problems of the prior art by providing an improved insert for use in the fabrication of a watercraft hull to form an inboard/outboard propulsion system passageway, or transom opening. The insert is formed of a semi-rigid body having an inboard surface, an outboard surface, and tapering perimeter sidewalls interconnecting the surfaces. The tapering of the sidewalls facilitates the removal of the insert from the built up layers forming the finished watercraft hull. To provide the semi-rigid body with the desired physical properties, the body may be formed from polyurea, polyurethane, a polyurea/polyurethane compound, or similar materials. Alternatively, the semi-rigid body can be formed of a hybrid structure with a central region formed of a more rigid material (e.g., a metal) and a perimeter region, including the sidewalls, formed of a less-rigid material.
[0008] Before fabrication of a watercraft hull using the insert can begin, a molding tool is manufactured to form the exterior shape of the watercraft hull and the insert is formed with a shape that will define the transom opening to be formed in the hull. In a first step of the process, a release agent is applied to a surface of the tool. The insert is then attached to the transom surface of the molding tool, and the insert and transom surface are coated with a gel that cures into a semi-rigid film that forms the outermost or “painted” surface of the watercraft hull. Subsequently, various layers of laminate material are applied in successive steps on top of one another and over the semi-rigid film (e.g., fiber material in a liquid resin matrix). To form the stiffening structure of the hull, various core layers (e.g., wood, foam, metal, and other materials) may be applied with the layers of laminate material to build the thickness and add strength to the laminate layers. Upon curing of the various laminate layers, the insert is detached from the molding tool transom surface and the finished watercraft hull and insert are demolded from the tool, preferably together. The insert may then be removed from the hull to reveal the transom opening in the hull.
[0009] Because of the semi-rigid nature of the materials forming the insert body—more specifically, the semi-rigid perimeter of the insert body which contacts the laminate layers of the watercraft hull—the insert facilitates an effective seal between the molding tool surface and the insert to prevent gel coat or other coatings from damaging the watercraft hull as the insert is being removed from the transom opening in the hull. The taper of the insert sidewalls also makes for easy insertion and removal of the insert, so that the insert may be reused over and over to form an accurately dimensioned transom opening. Furthermore, the design of the present invention obviates the need to use a release agent, further simplifying the watercraft hull fabrication process.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0010] FIG. 1 is an exploded view showing a finished watercraft hull having a transom opening formed by an insert mounted with a molding tool;
[0011] FIG. 2 is a perspective view of the insert of FIG. 1 ;
[0012] FIG. 3 is a top plan view of the insert of FIG. 1 ;
[0013] FIG. 4 is a bottom plan view of the insert of FIG. 1 ;
[0014] FIG. 5 is a cross-sectional view of the insert of FIG. 1 taken along line 5 - 5 ; and
[0015] FIG. 6 is a cross-sectional view of the insert of FIG. 1 taken along line 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention improves upon previous methods of forming transom openings in watercraft hulls through which stern drive components are mounted. This invention employs a reusable insert design comprised of a semi-rigid body around which the hull can be fabricated. The semi-rigid nature of the body allows for ease of removal of the insert from the finished watercraft hull with the built up laminate layers of the hull surrounding the perimeter of the insert. FIG. 1 shows the insert 10 mounted with molding tool 200 that forms the profile of a watercraft hull 100 . The insert 10 is configured to define the shape of the inboard/outboard propulsion system passageway, in this case, an opening 102 in a transom 104 of the watercraft hull 100 . As the laminate layers of the watercraft hull 100 are applied in successive steps onto a molding tool surface 202 of the tool 200 , the insert extends through the layers in the shape of the transom opening 102 . Upon curing of the laminate layers, the insert 10 is preferably detached from the molding tool 200 , and then the insert 10 and finished watercraft hull 100 are simultaneously demolded from the tool. Finally, the insert 10 is removed from the hull 100 to reveal the finished transom opening 102 .
[0017] As seen in detail in FIGS. 2-6 , the insert 10 , or semi-rigid body, has a base or outboard surface 12 , an inboard surface 14 and a sidewall 16 formed in a perimeter region 17 of the insert and spanning between the surfaces 12 , 14 . The sidewall 16 preferably has a slight taper in the direction moving from the outboard surface 12 to the inboard surface 14 , as best seen in FIGS. 5-6 . This taper increases the ease in removing the insert 10 from the hull 100 to reveal the transom opening 102 . A perimeter lip 18 is also formed at the intersection of the outboard surface 12 and the sidewall 16 in the perimeter region 17 of the insert 10 . When the insert 10 is attached to the molding tool 200 for watercraft hull fabrication, the perimeter lip 18 is flush against the molding tool surface 202 . Thus, the combination of the perimeter lip 18 and the generally semi-rigid nature of the insert 10 facilitate the formation of a seal between the watercraft hull 100 and the insert. This seal impedes the flow of any coatings or laminates applied to the layers forming the watercraft hull 100 between the hull and the insert 10 , which could prevent the hull from being damaged upon removal from the transom opening in the hull. Additionally, the seal provides the edges of the laminate layers with a contour that minimizes the formation of air voids that can otherwise create weak points in the hull and encourage bonding between the insert 10 and the molding tool surface 202 .
[0018] The outlining shape of the insert defined by the sidewall 16 is dependent upon the desired shape of the transom opening 102 accommodating a stern drive component, as those of skill in the art will appreciate. The exemplary insert 10 shown in FIGS. 1-4 has a particular shape that yields a transom opening 102 that is particularly well suited for watercraft in the category of recreational power boats and the like. In the configuration shown, the sidewall 16 has a first set 20 of opposed tapered sections and a second set 22 of opposed tapered sections. The first set 20 comprises generally flat, planar walls 24 having base edges 26 adjoining the perimeter lip 18 and parallel with one another and upper edges 28 adjoining the inboard surface 14 and likewise parallel with one another. The second set 22 comprises planar walls 30 that interconnect the planar walls 24 of the first set 20 . In a preferred arrangement facilitating optimal demolding of the insert 10 and watercraft hull 100 , and subsequent removal of the insert 10 from the hull 100 , the taper of the sidewalls 16 from the outboard surface 12 at the perimeter lip 18 to the inboard surface 14 allows for removal of the insert 10 in a direction from an inboard side 108 to an outboard side 100 of the hull 100 .
[0019] The insert 10 also has a number of voids, preferably through-holes 32 , such that a tool may be inserted therein to manipulate the position of the insert 10 with respect to the watercraft hull 100 and for mounting of the insert 10 with the molding tool surface 202 . The through-holes 32 extend from the outboard surface 12 to the inboard surface 14 . For example, a tool may have a protrusion that is inserted into one through-hole 32 and frictionally fits therewith, or if inserted on the inboard surface 12 side of the insert 10 clamps onto the outboard surface 14 of the insert. A centrally located cavity 34 is also formed in the insert outboard surface 12 to increase the flexibility of the semi-rigid body for insertion with and removal from the watercraft hull 100 .
[0020] In one embodiment, the insert 10 is provided with the desired properties for use in watercraft hull fabrication by being formed of a semi-rigid body made from a somewhat pliable composite such as a polyurethane, a polyurea, a polyurethane/polyurea compound, or another substance that exhibits similar physical properties, including having a degree of flexibility and being chemically inert to the materials used in lamination of the layers during watercraft hull fabrication such that bonding to these layers by the insert does not occur. The insert 10 should also have a hardness value of less than about 90 Shore D but greater than about 65 Shore A when using lamination materials and a transom opening shape common for recreational power boats. In this range, it has been found that the insert 10 has sufficient dimensional stability when lamination layers of the hull are being applied around the sidewall 16 of the insert 10 to generate a structurally sound finished transom opening 102 , but also has enough flexibility to be easily removed from within the opening 102 upon completion of watercraft hull 100 fabrication and to prevent unwanted movement of the gel coatings or other laminate coatings between the insert 10 and the molding tool 200 , or between the insert 10 and lateral side edges 106 of the laminate layers forming the hull 100 . If any heat curing is used during the lamination process of the hull layers, the insert 10 should also be configured to withstand this process without compromising the integrity thereof.
[0021] In another embodiment of the insert 10 semi-rigid body, a metal or other more rigid material (e.g., stiff composite) forms a central region 36 of the insert and the insert perimeter 17 , including the sidewalls 16 and the perimeter lip 18 , is formed of a less rigid material, such as a somewhat pliable composite like a polyurethane, a polyurea, or a polyurethane/polyurea compound or another substance that exhibits similar physical properties. This would aid in providing structural integrity to the insert 10 while ensuring that the sidewalls 16 and perimeter lip 18 , which contact the laminate layers of the watercraft hull 100 , remain flexible enough to facilitate the formation of a seal between the watercraft hull 100 and the insert 10 .
[0022] In use, the molding tool 200 is formed with the surface 202 having a shape that will dictate the shape of the outer layer of the watercraft hull 100 . A release agent is preferably first applied to the molding tool surface 202 to aid in the demolding of the insert 10 and watercraft hull 100 from the tool 200 . The insert 10 is then positioned relative to the tool 200 to align the transom opening 102 on the finished watercraft hull 100 . When the proper position is determined, the insert 10 is attached to the molding tool surface 202 at that location, and with the outboard surface 12 facing the transom of the tool 200 such that the perimeter lip 18 lies against the tool surface 202 . Prior to lamination steps, the molding tool surface 202 and the inboard surface 14 and sidewall 16 of the insert 10 are preferably coated with a liquid gel coat that, upon curing, forms a semi-rigid film that forms the outer or “painted” surface 112 of the watercraft hull 100 . This painted surface 112 is the mirror image of the shape of the molding tool surface 202 and is exposed upon demolding of the insert 100 and hull 100 from the molding tool 200 . Then, various layers of laminate materials are applied in successive steps on top of one another and over the semi-rigid film layer around the sidewall 16 of the insert 10 . The laminate materials typically include a fiber material in a liquid resin matrix that bonds to the semi-rigid film layer and forms a rigid layer upon curing that possesses the desired physical properties (e.g., strength, flexibility) for a watercraft hull. If the lamination process requires, additional actions (applying additional resins, coatings, or other materials, or heat curing) may be undertaken to ensure proper curing of the laminate layers. Additionally, various core layers, such as wood, foam, metals (e.g., aluminum) and the like, may be applied with the fiber and resin to build thickness and add strength to the laminate layers. Finally, upon curing, the insert 10 is detached from the molding tool 200 and the finished watercraft hull 100 —having the insert 10 fit into the transom opening 102 thereof—is demolded from the tool surface 202 . The insert 10 may then be removed towards the outboard direction of the hull 100 and away from the direction of taper thereof to reveal the finished hull having the transom opening 102 formed into the desired shape.
[0023] As can be seen, the insert 10 of the present invention for forming a transom opening in a watercraft hull provides a superior design to the aforementioned prior designs. The insert 10 can be formed in any number of shapes depending on the desired passageway geometry in a watercraft hull, and the durable and chemically inert nature of the design facilitates the repeated use of the insert in large run watercraft hull fabrication. Furthermore, since certain changes may be made in the above invention without departing from the scope hereof, it is intended that all matter contained in the above description or shown in the accompanying drawing be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are to cover certain generic and specific features described herein.
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An insert for use in the fabrication of a watercraft hull to form an inboard/outboard propulsion system passageway. The design of the insert incorporates a semi-rigid body having an inboard surface, an outboard surface, and sidewalls interconnecting the surfaces. The semi-rigid nature of the body facilitates the insert fitting tightly with the build up of laminate layers forming a watercraft hull while maintain dimensional stability during the manufacture of the hull. The insert is further configured to be easily removed from the completed watercraft hull to reveal the finished inboard/outboard propulsion system passageway.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
Reference is made to commonly assigned copending U.S. application Ser. No. 07/478,910 entitled CAMERA WITH FLIP-UP FLASH UNIT, and filed, Feb. 12, 1990 in the names of William L. Burnham et al.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to the field of photography and particularly to a viewfinder for a camera with a flip-up flash unit. More specifically, the invention relates to an optical finder and flash unit combination.
2. Description of the Prior Art
A current trend in camera design is to incorporate an electronic flash unit in the camera housing and yet make such housing relatively small in size in order to increase its ease of storage, portability and handling. Examples of smaller size cameras with built-in electronic flash units are the various disk film cameras, such as previously sold by Eastman Kodak Company and others. As a consequence of making a camera smaller in size, the separation between a built-in flash unit and the taking lens is reduced, thereby possibly creating an undesirable effect commonly known as "red-eye". When using a flash unit and a color print film, red-eye is typified by the pupils in the eyes of a person being photographed coming out red-tinted on a developed color print. Such phenonmenon is attributable to the incidence into the taking lens of the red light reflected from the retinas in the Person's eyes illuminated by the flash light.
Red-eye may be substantially avoided by increasing the separation between the flash unit and the taking lens. As a result, light from the flash unit will reach the eyes of a person being Photographed at too great an angle to be reflected by his retinas into the taking lens. In U.S. Pat. Nos. 4,231,645, granted Nov. 4, 1980, 4,319,818,granted Mar. 16, 1982, 4,557,571, granted Dec. 10, 1985, Des. No. 284,973 granted Aug. 5, 1986, Des. No. 285,087, granted Aug. 12, 1986, and 4,847,647, granted July 11, 1989, red-eye appears to be substantially avoided without increasing the size of a compact 35 mm camera to any great degree by providing a built-in electronic flash unit that is pivotable with respect to the camera housing. The flash unit is pivotable between an inactive folded position in which it forms an integrated part of the camera housing in front of the camera lens and/or the camera viewfinder, and an operative erect position in which it is sufficiently removed from the lens to permit picture-taking substantially without the occurrence of red-eye. In each of these designs, however, some compactness is sacrificed because of the need to include a viewfinder opening in the camera housing.
THE CROSS-REFERENCED APPLICATION
As compared to the prior art examples disclosed in the above cited patents, the cross-referenced application discloses a photographic camera which is relatively more compact. Specifically, there is disclosed a photographic camera comprising a camera housing and a flip-up flash unit. The flash unit includes a head part having a flash emission window and a supporting or neck-like part for the head part. The supporting part is pivotally connected to the camera housing to permit swinging movement of the flash unit to a folded storage position in which the head part and the supporting part cover respective portions of the camera housing and to a non-folded operative position in which the head part and the supporting part are elevated from the camera housing with the flash emission window substantially facing a subject to be photographed. According to the invention, the supporting part has a viewfinder opening for viewing a subject to be photographed when the flash unit is in the non-folded position. Thus, the camera housing can be made relatively compact because a viewfinder opening need not be built into the camera housing.
SUMMARY OF THE INVENTION
According to the invention, a photographic camera comprising (a) a camera housing and (b) a flip-up flash unit including a head part having a flash emission window and a supporting part for the head part connected to the camera housing to permit movement of the flash unit to a folded storage position in which the head part and the supporting Part cover respective portions of the camera housing and to a non-folded operative position in which the head part and the supporting part are elevated from the camera housing with the flash emission window substantially facing a subject to be photographed, is characterized in that:
the supporting part of the flash unit has a viewfinder opening for viewing a subject to be Photographed when the flash unit is in its non-folded position;
a finder objective lens and a finder eyelens are supported for movement relative to the camera housing to individual viewing positions in which the finder lenses are optically aligned with the viewfinder opening of the supporting part when the flash unit is in its non-folded position; and
motion-transmitting means connects the supporting part and the finder lenses for moving the finder lenses to their viewing positions responsive to movement of the flash unit to its non-folded position.
Thus, as compared to the cross-referenced application, the invention provides an optical finder consisting of the finder objective lens and the finder eyelens, without sacrificing compactness of the camera housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a photographic camera with a flip-up flash unit according to a preferred embodiment of the invention, showing the flash unit in a folded storage position;
FIG. 2 is a view similar to FIG. 1, showing the flash unit in a non-folded operative position;
FIGS. 3, 4 and 5 are side elevation section views of the camera, showing progressive movement of the flash unit from its folded position, to an intermediate position and to its non-folded position; and
FIGS. 6, 7 and 8 are respective views similar to FIGS. 3-5, except they show an alternate embodiment of the flash unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is described as being embodied in a compact 35 mm camera with a built-in electronic flash unit. Because such photographic cameras have become well known, this description is directed in particular to camera elements forming part of or cooperating directly with the preferred embodiment. It is to be understood, however, that camera elements not specifically shown or described may take various forms known to persons of ordinary skill in the art.
Referring now to the drawings, FIGS. 1 and 2 show a compact 35 mm camera 1 comprising a contoured housing 3 and a flip-up electronic flash unit 5. The flash unit 5 includes a head part 7 having a flash emission window 9 and a pair of front and rear supporting parts 11 and 13 for the head part. The front supporting part 11 is integrally formed with the head part 7, and is pivotally connected to the camera housing 3 by means of an axial pin 15 extending through an axial opening 17 in the front supporting part and having protruding opposite ends suspended by the camera housing. The pivotal connection of the front supporting part 11 to the camera housing 3 permits the flash unit 5 to be manually swung between a folded storage position, shown in FIGS. 1 and 3, in which the head part 7 fits within a lower recess 19 in the camera housing and the front supporting part fits within a front recess 21 in the camera housing to cover a lens opening 23, and a non-folded operative position, shown in FIGS. 2 and 5, in which the head part and the front supporting part are elevated from the camera housing with the flash emission window 9 substantially facing a subject to be photographed. The rear supporting part 13 is pivotally connected to the camera housing 3 by means of an axial pin 25 extending through an axial opening 27 in the rear supporting part and having protruding opposite ends suspended by the camera housing. The pivotal connection of the rear supporting part 13 to the camera housing 3 permits that part to be located within a top recess 29 in the camera housing when the flash unit 5 is in its folded position, shown in FIGS. 1 and 3, and to be elevated above the camera housing when the flash unit is in its non-folded position, shown in FIGS. 2 and 5. When the flash unit 5 is in its non-folded position, a forward edge 31 of the rear supporting part 13 engages or abuts the front supporting part 11 at a cross-wise edge 33 of the latter part to brace the flash unit in the non-folded position. A relatively light torsion spring 35 urges the rear supporting part 13 to continuously engage the front supporting part 11. See FIGS. 4 and 5.
According to the invention in its preferred embodiment, the front supporting part 11 has a rectangular front viewfinder opening 37 which is empty, and the rear supporting part 13 has a rectangular rear viewfinder opening 39 which contains a biconvex (positive) finder eyelens 41. The finder eyelens 41 is located behind the front viewfinder opening 37 in optical alignment with that opening when the flash unit 5 is in its non-folded position, to permit a subject to be photographed to viewed through the finder lens and the opening. See FIGS. 2 and 5. Similarly, a plano-concave (negative) finder objective lens 43 is pivotally connected to the camera housing 3 by means of an axial pin 45 which extends through an axial opening 47 in a supporting base or frame 49 for the finder objective lens and has protruding opposite ends suspended by the camera housing. The pivotal connection of the supporting base 49 to the camera housing 3 permits the finder objective lens 43 to be swung between a flat storage position shown in FIG. 3, in which the objective lens lies flat at the bottom of the lower recess 19 in the camera housing and an erect viewing position shown in FIGS. 2 and 5, in which the objective lens is located between the front viewfinder opening 37 and the finder eyelens 41 in optical alignment with the latter two elements when the flash unit 5 is in its non-folded position, to permit the subject to be photographed to be viewed through the finder objective lens as well as the finder eyelens and the viewfinder opening. The finder objective lens and the finder eyelens form an optical finder which uses the principle of an inverted or reverse Galilean telescope.
The front supporting part 11 and the supporting base 49 include respective integral gear rings 51 and 53 which continuously engage to swing the finder objective lens 43 from its flat storage position to its erect viewing position responsive to manual swinging of the flash unit 5 from its folded position to its non-folded position. See FIGS. 3-5. Conversely, the gear rings 51 and 53 operate to swing the finder objective lens 43 from its viewing position to its storage position responsive to manual swinging of the flash unit 5 from its non-folded position to its folded position.
The rear supporting part 13 is bowed to arch rearwardly of the camera housing 3 when the flash unit 5 is in its non-folded position, to locate the finder eyelens 41 sufficiently removed from the camera housing to permit a photographer to place one eye at that lens without any interference (obstruction) by the camera housing. See FIG. 5. Conversely, when the flash unit 5 is in its folded position, the rear supporting part 13 is urged by the torsion spring 35 to cover the front viewfinder opening 37 and the finder objective lens 43. See FIG. 3. Thus, in this instance, the rear supporting part 13 serves as a cover part.
Operation
To use the 35 mm camera 1, the flash unit 5 must be manually swung from its folded position, shown in FIGS. 1 and 3, to its non-folded position, shown in FIGS. 2 and 5. As the flash unit 5 is swung to its non-folded position, the front supporting part 11 pushes against the rear supporting part 13 to swing the latter part out of the top recess 29. Similarly, the gear rings 51 and 53 operate to swing the finder objective lens 43 out of the top recess 29. See FIG. 4. Once the forward edge 31 of the rear supporting part 13 and the cross-wise edge 33 of the front supporting part 11 engage, the front part is braced in its non-folded position and the front viewfinder opening 37, the finder objective lens 43 and the finder eyelens 41 37 and 39 are optically aligned. See FIG. 5.
After picture-taking is completed, the flash unit 5 is manually swung from its non-folded position to its folded position. As the flash unit 5 is swung to its folded position, the torsion spring 39 pivots the rear supporting part 13 to maintain the latter part in continuous contact with the front supporting part 11. See FIG. 4. When the flash unit 5 is returned to its folded position, the rear supporting part 13 covers the front viewfinder opening 37 and the finder objective lens 43. See FIG. 3.
Alternate Embodiment
FIGS. 6-8 are respective views similar to FIGS. 3-5, except they show a light-baffle 55 projecting from the inside of the rear supporting part 13 to reduce glare from stray light at the finder eyelens 41.
While the invention has been described with reference to a preferred embodiment, it will be understood that various modifications can be effected within the ordinary skill in the art without departing from the scope of the invention. For example, a 35 mm camera may be devised as in cited U.S. Pats. Nos. 4,557,571; 4,350,420 and 4,319,818, in which the flip-up flash consists of a head part and only one supporting part. This in in contrast to cited U.S. Pats. Des. Nos. 285,087 and 284,973 in which the flip-up flash includes front and rear supporting parts.
According to another example, the flash unit might be a type that pops-up rather than pivots up.
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A flip-up flash unit for a camera has a viewfinder opening for viewing a subject to be photographed when the flash unit is swung to an operative position elevated from the body of the camera. A finder objective lens and a finder eyelens are each swung to individual viewing positions optically aligned with the viewfinder opening, responsive to movement of the flash unit to its operative position. The body of the camera, therefore, can be made more compact because the need for a viewfinder opening and finder lenses built into the body is eliminated.
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CROSS REFERENCE TO RELATED APPLICATION
This is a divisional application of U.S. Ser. No. 14/028,844 filed Sep. 17, 2013 and claims priority from U.S. Provisional Application Ser. No. 61/701,888, filed Sep. 17, 2012; the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of Invention
The current invention relates generally to apparatus, systems and methods for amplifying a signal. More particularly, the apparatus, systems and methods relate to amplifying a radio frequency (RF) power signal. Specifically, the apparatus, systems and methods provide for a power amplifier that uses multiple cascode amplifiers some of which are grouped together and some of which are spaced apart.
2. Description of Related Art
Amplifiers have long been used to amplify a variety of electrical signals. For example, amplifiers can be used to amplify voltage, current, power and the like. Early amplifiers used vacuum tubes to amplify signals. These tubes where large, used high power and often burned out. The invention of the silicon transistor greatly improved amplifier technology and quickly led to the extinction of vacuum tubes. Silicon transistors were much smaller, cheaper, could be more easily mass produced and had a much longer life span than vacuum tubes. Additionally, transistors consume much less power and generate less heat than vacuum tubes.
Because of a transistors small size, it has allowed for more sophisticated amplifiers to be designed. For example, operational amplifiers (Op Amps) contain two or more stages of amplification each with their own bias schemes all implemented with transistors and other discrete components. Op Amps provide excellent common mode rejection so that just a signal of interest is amplified.
One conventional approach to amplifying radio frequencies (RF) is to use a cascade amplifier that has a common gate transistor and a common source transistor. However, these types of amplifiers often have a small operational bandwidth (BW) and cannot handle higher currents/power, Therefore, what is needed is a better amplifier.
SUMMARY
The preferred embodiment includes a cascade power amplifier (PA). The cascode PA is an RE power amplifier (PA) that includes two or more adjacent cascode amplifiers and at least one remote cascode amplifier. The adjacent cascode amplifiers are lined up adjacent each other with inputs of the adjacent cascade amplifiers connected to a common input line and outputs of the of adjacent cascode amplifiers connected to a common output line. The adjacent cascade amplifiers generally operate in parallel. The remote cascade amplifier is spaced apart from the adjacent cascode amplifiers. An input transmission line connects an input of the remote cascade amplifier to the input line and to the common input line. An output transmission line connects an output of the remote cascode amplifier to the output line and the common output line. Amplified outputs of the adjacent cascade amplifiers and amplified outputs of the remote cascade amplifier are all power combined and summed into a coherent amplified output signal that is output on the output transmission line.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
One or more preferred embodiments that illustrate the best mode(s) are set forth in the drawings and in the following description. The appended claims particularly and distinctly point out and set forth the invention.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various example methods, and other example embodiments of various aspects of the invention. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skin in the art will appreciate that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.
FIG. 1 illustrates an example schematic of a preferred embodiment of a cascode radio frequency (RF) power amplifier (PA).
FIG. 2 illustrates an example view looking downward toward a gallium nitride (GaN) chip implementing a Non-uniform Distributed PA (NDPA).
FIG. 3 illustrates an example top view a preferred embodiment of a bias inductor formed in a metal layer and with air bridge connector devices.
FIG. 4 illustrates an example cross-section view a preferred embodiment an air bridge.
FIG. 5 illustrates an example top view of the metal layers of a FRAP circuit.
Similar numbers refer to similar parts throughout the drawings.
DETAILED DESCRIPTION
FIG. 1 illustrates the preferred embodiment of a cascode Power Amplifier (PA) cell 100 that uses a compound transistor. The compound transistors include a common source transistor X 1 and a common gate transistor X 2 . They are connected in series from a DC standpoint but in cascode configuration from an RF standpoint. The advantages to this compound transistor over a conventional single ended common source transistor is that first, it has a high efficiency. Secondly, it a higher voltage and lower current for a given power output which reduces certain power distribution loses both in the power module and in the chip itself due to reduced Ohmic losses operating at higher voltage and lower current. As a result of the higher voltage and lower current, a given power impedances are higher so that they can be matched over a wider bandwidth (BW).
The novelty of this embodiment of the PA cell 100 includes the bias network and how it stabilizes the cascade PA cell 100 . The two left-hand biasing legs of FIG. 1 are the RF cascading and stabliization circuits. These two legs include R 1 -R 3 , C 1 , TL 1 , TL 6 and TL 7 . There is a resistive voltage divider formed with resistors R 1 and R 2 connected to the common gate transistor X 2 through a transmission line that sets the voltage of the compound transistor to half of Vdd across the common gate transistor X 2 and half of Vdd across the common source transistor X 1 . There also is a series RC formed by resistor R 3 and capacitor C 1 combination that allows cascading grounding of the common gate of transistor X 2 , that is essentially an RE ground. Ideally, a large capacitor C 1 is desired but this would require too much area and a small cascode cell is desired. Therefore, in the preferred embodiment C 1 is still made as large as possible within a confined area and R 3 is connected in series with it.
The common gate transistor X 2 makes a very good oscillator configuration so stability can be controlled. The common gate transistor X 2 has its source connected to the drain of the common source transistor X 1 and its drain connected to the output P 1 and resistor R 1 . Common source transistor X 1 has its gate connected to RF ground (capacitor C 2 ). The common transistor X 1 has a gate connected to an input line and has its drain connected to resistor R 2 and capacitors C 1 , C 2 and has its source connected to ground.
In the preferred embodiment, the value of the components in FIG. 1 are now provided. R 1 and R 2 are each 5000 Ohms and have widths of 10 micro meters (um) and lengths of 123 um. Resistor R 3 has a value of 320 Ohms, a width of 12.5 um and a length of 10 um. Capacitor C 1 has a value of 1.0 pF and capacitor C 2 has a value of 0.085 pF. Transmission line TL 1 has a width of 8 um and a length of 155 um, transmission line 112 has a width of 15 um and a length of 105 um, transmission line TL 3 has a width of 10 um and a length of 40 um, transmission line TL 4 has a width of 8 um and a length of 185 um, transmission line TL 5 has a width of 8 um and a length of 58 um. Transmission line T 6 has a width W 1 of 14, a with W 2 of 14 um and a width W 3 12 um, transmission line 17 has a width W 1 of 10 um, a width W 2 of 10 um, a W 3 18 um and transmission line T 8 has a with W 1 of 14 um, a width W 2 of 14 um and a width W 3 12 um.
FIG. 2 illustrates the preferred embodiment of how some components and cells are positioned and laid out on a Salt chip to create a RF PA. The chip can he implemented with GaN or with another type of semiconductor material as understood by one of ordinary skin in the art. FIG. 2 , illustrates both halves 3 A, 3 B of cascaded RF PA 1 that is symmetrical about centerline CL 1 that cuts the RF PA 1 into two halves 3 A, 3 B. Because it has a lot of symmetry, only one half 3 A will be described and that description and labeling will equally apply to the second half 3 B. The PA 1 is a non-uniform distributed PA for two reasons, First the widths of the transmission lines are different resulting in different impedances. Secondly, it is non-uniform because the cascode cells 100 are distributed with a duster eight cascode cells 5 (e.g., eight amplifiers 100 ) clumped together at one location and with two other cascode cells 7 , 9 distributed remotely away from the cluster of eight 5 .
The RF input enters the Non-uniform Distributed PA (NDPA) transmission line TL 10 before passing by capacitor C 1 and onto a tapered transmission line TLT connected to the bank of eight cascaded cells 5 (e.g., eighth amplifiers 100 ). Transmission line TLT is generally tapered so that it becomes smaller in width until the last cascode amplifier 100 of the cluster of eight cascaded cells 5 receives the RF input signal.
Transmission line TL 11 is formed with transmission lines TL 11 A and TL 11 B. Transmission line TL 11 A is connected to the end of the tapered transmission line TLT and is also connected to the remote cascade amplifier 7 . Transmission line TL 11 A includes a generally semicircle portion 21 that is included to increase the length of transmission line TL 11 to make it a proper length. Transmission line TL 11 B is connected between remote cascade amplifier 7 and remote cascade amplifier 9 . Transmission line TL 11 B is straight between remote cascade amplifier 7 and remote cascade amplifier 9 and has a constant width between these two amplifiers.
Transmission line 13 is formed with transmission lines TL 13 A-C. Transmission line 13 A is connected to the outputs of the cluster of eight cascaded cells 5 . This transmission line TL 13 A is slightly tapered beginning at the first cascade amplifier 100 of the bank of eight cascaded cells 5 until it reaches the last cell 100 of the bank of cascaded cells 5 . Transmission line TL 13 B is connected to transmission line TL 13 A at the last cell 100 of the bank of cascaded cells 5 and transmission line TL 13 B is routed from here to the output of remote cascade amplifier 7 . This transmission line TL 13 B is jogged way from transmission line 11 A for shielding reasons. Transmission line 13 C is connected between the outputs of remote cascade amplifier 7 and remote cascade amplifier 9 . This transmission line 13 C is straight with a constant width.
Output transmission line TL 14 is connected between the output of remote cascade amplifier 9 and an output capacitor C 6 . it is also connected to a biasing inductor I 1 . This transmission line TL 14 includes a somewhat semicircular portion 23 that extends its length a desired amount for optimal operation. Bias inductor I 1 is connected/wired to capacitors C 2 and C 3 . The mirrored cacsode RF PA 1 contains other capacitors C 4 , C 5 and other components that are not discussed in detail here as they are not the primary novelty of the preferred embodiment of the cascade RF PA 1 .
FIGS. 3 and 4 illustrated the bias inductor I 1 . The bias inductor I 1 has two levels of metal. One layer of metal is a transmission strip 25 layer of metal in combination with a spiraling octagonal shape metal 31 and the another layer of metal includes metallic air bridge metal structures 27 that air bridge over the transmission strip of 25 metal passing under the air bridge metal 27 . There is actually a gap 41 between the air bridge metal 27 and the transmission strip 25 . This gap can be filled with air, another gas or another material as understood by those of ordinary skill in the art. The air bridge metal 27 can include tab ends 29 A, 29 B that are used to connect it to ends 31 A, 31 B of the spiraled metal 31 . The air bridge metal 27 actually arches upward from the first end 31 A of the spiral metal 31 and has a curved arch that later curves downward toward the second end 31 B of the spiral metal 31 . A central portion 33 of the spiral of the bias inductor I 1 is free of metal. In the preferred embodiment, the spiraled metal 31 almost makes five complete spirals around the central portion 33 . Of course, in other embodiments, a different number of completed spirals may be desired.
It is desired to have an RF PA that has high bandwidth which means that the bias inductor I 1 ideally has high impedances that don't interfere with the desired RE signal. Thus a large inductance is preferred, but a large inductance has a parasitic that is a shunt capacitance that limits the BW. However, the bias inductor of FIGS. 3 and 4 has an overall good geometry that does well to balance these competing design constraints. The conductors are thick and wide enough to handle the high current of the PA 1 . In the preferred embodiment, the width (W) of the metal 31 used to form the octagonal shaped inductor I 1 is about 40 microns wide with about 10 microns of gap (G) between the metal spirals. Of course these measurements can be other values.
FIG. 5 illustrates the details of the fusible link resistive voltage divider “FRAP” device 70 . Before the invention of this FRAP 70 one needed to apply a gate voltage to each individual chip and each individual chip needed to be tracked and the proper voltage applied to power it when it was implemented in a circuit. The FRAP device 70 is used to adjust the bias point of biasing circuits at the time of wafer testing. In the preferred embodiment, the FRAP 70 is on a GaN wafer 71 with conductive electrical routing and pad components. Five resistors R 1 - 5 are provided and are connected to pad devices 77 that are connected to fusible links 73 . In the preferred embodiment, these five resistors can be used to create about 32 different voltages ranging from −9 volts to about −2 volts but other ranges and voltage could be created in other embodiments. Two more resistors R 6 - 7 are also provided that are always used to create a bias voltage. Resistor R 7 is connected by a pad 79 to a reference voltage, that in the preferred embodiment is −9 volts. Resistor R 6 is connected to the other ends of the fusible links by a pad at a ground voltage and conductive routing 75 . In the preferred embodiment, the values of the resistors is as follows: R 1 =75 ohms, R 2 =150 ohms, R 3 =300 ohms, R 4 =600 ohms, R 5 =1200 ohms, R 6 =75 ohms and R 7 =80 ohms. Of course, in other embodiments the resistors can have different values and there may be fewer or more resistors used to implement the FRAP 70 .
At the time of wafer testing, the bias voltage of the RF PA 1 is measured while it being applied to the RF PA circuits themselves. Next, a determination is made as to how much the bias voltage needs to he changed so that the RF PA 1 is biased to a proper value. A calculation is performed to determine which of the five resistors R 1 - 5 connected to the fusible links 73 need to be used to create the proper bias voltage. Once that is determined, the fusible links 73 connected to just the unneeded resistors are broken so that just the required resistors participate in creating the proper bias voltage. In the preferred embodiment, the FRAP is a voltage divider circuit formed by resisters R 1 -R 5 . The fusible links 73 can be broken on the GaN wafer 71 by any method as understood by those of ordinary skill in the art. For example, one way they can be broken is applying a strong enough voltage across them to create the breakage.
The related and co-owned U.S. Applications entitled “TILE ARRAY PA MODULE USING QUADRATURE BALANCED PA MIMICS,” “DIGITALLY CONTROLLED POWER AMPLIFIER,” and “METHOD OF OPERATING A POWER AMPLIFIER IN CLASS F/INVERSE CLASS F,” which are filed contemporaneously herewith, are incorporated as if fully rewritten.
In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. Therefore, the invention is not limited to the specific details, the representative embodiments, and illustrative examples shown and described. Thus, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims.
Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described. References to “the preferred embodiment”, “an embodiment”, “one example”, “an example”, and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in the preferred embodiment” does not necessarily refer to the same embodiment, though it may.
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An amplifier for amplifying signals is presented. A cascode power amplifies includes two or more adjacent cascode amplifiers and at least one remote cascode amplifier. The adjacent cascode amplifiers are lined up adjacent each other with inputs of the adjacent cascode amplifiers connected to a common input line and outputs of the of adjacent cascode amplifiers connected to a common output line. The adjacent cascode amplifiers generally operate in parallel. The remote cascode amplifier is spaced apart from the adjacent cascade amplifiers. An input transmission line connects an input of the remote cascode amplifier to the common input line. An output transmission line connects an output of the remote cascode amplifier to the common output line. Amplified outputs of the adjacent cascode amplifiers and amplified outputs of the remote cascode amplifier are power combined and summed into a coherent amplified output signal that is output on the output transmission line.
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FIELD OF THE INVENTION
The present invention relates to a container handling system and, more particularly, to a container handling system which stacks a predetermined number of containers in a predetermined configuration for shipping and reduces the need for operator involvement.
BACKGROUND OF THE INVENTION
Currently, various packaging and shipping methods are used to transport containers, such as bottles, from one location to another. Such methods include palletizing layers of vertically orientated bottles upon one another to form a shipping package, wherein the shipping package contains a predetermined number of bottles. Subsequently, the stacked layers of bottles are wrapped or otherwise secured to ensure that they withstand the harshness associated with shipping.
Due to inventory and cost, it is critical that the number of bottles shipped in each container is known and consistent. As such, feeding mechanisms have been devised which ensure that the shipping package contains a predetermined number of bottles. Such mechanisms typically have a conveyor on which a pre-selected number of bottles are loaded. The bottles are then transported along the conveyor and loaded onto a pallet.
One conventional method of palletizing bottles is to feed them in from the single lane conveyance onto an accumulation conveyor by use of a slow down module. In this way, the single lane of bottles is changed to a stream of either two wide or three wide, which then hit the back of a previously accumulated pack. When this happens, the stream spreads out over the entire width of the belt to the edges of the accumulator and are patterned. Once the bottles are patterned, a layer is swept onto a pallet. While this method does palletize bottles, it has several drawbacks. Specifically, as the bottles are flowing to the sides of the accumulator, they can either fall over, miss a spot (void), or jumble up such that they are out of pattern. In addition, when a layer is swept off, bottles may be crushed and destroyed. Overall, with these drawbacks an operator is required full time to watch the pattern, fill voids, and make corrections as required.
A second method of palletizing blow molded bottles is to separate the one single lane as described above into six single lanes with automatic divert gates. Once the proper number of bottles are counted, a bottle stop is closed and the six lanes of bottles are run into the sweep mechanism. The sweep mechanism sweeps as many times as it takes to form a complete layer. Once the layer is formed, then it is moved forward and stacked on the pallet. This method also has some drawbacks. Specifically, the bottles are unstable in the sweep mechanism and can tip over during the sweeping process. As a result, the machine is limited in speed and even at a low speed the sweep mechanism is unreliable and thereby requiring an operator. In addition, the entrance of high speed blow molders into the bottling market are too fast for this concept, thereby requiring multiple palletizing machines to be used. The present invention was developed in light of these and other disadvantages.
SUMMARY OF THE INVENTION
It is therefore an advantage of the present invention to provide a container material handling system and method which reduces the amount of container tippage during packaging.
It is yet another advantage of the present invention to provide a container material handling system which quickly and accurately selects and organizes a predetermined number of containers into a layer configuration for stacking.
Another advantage of the present invention is to eliminate the need for a human operator to ensure proper stacking and palletizing.
Yet another advantage of the present invention is the speed at which bottles may be patterned and placed onto a pallet.
An additional advantage of the present invention is that the bottles are held in place until they are palletized, thereby virtually eliminating the possibility of tipping which would destroy the pattern and certainty of the system.
To accomplish these and other advantages, the present invention provides a method and apparatus for packaging a plurality of containers, wherein each container has a body and an engagement lip surrounding a neck portion, which comprises a plurality of steps. First, a set of containers is provided. Next, the containers are loaded on a plurality of neck guides and driven along the neck guides to a gathering area to form a bundle of containers. The containers are patterned and closed into a “nesting” pattern bundle to provide the maximum number of containers per volume. A transfer device then stacks the bundle on a pallet where it is “resquared” to ensure maximum rigidity. In a further aspect of the present invention, the above steps are repeated for a plurality of sequential sets of containers and corresponding bundles until the proper shipping package size is achieved.
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 preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a side elevation view of an palletizing apparatus;
FIG. 2 is a top plan view of a palletizing apparatus;
FIG. 3 is an end view of the palletizing section of the palletizing apparatus with the hoist in a lowered position according to the present invention;
FIG. 4 is an end view of the palletizing section of the palletizing apparatus with the hoist in the fully up position according to the present invention;
FIG. 5A is a detail view of the hoist from FIG. 3 in the uncollapsed position according to the present invention;
FIG. 5B is a detail view of the hoist from FIG. 4 in the collapsed position according to the present invention;
FIG. 6 is a cross-section view of the hoist taken along line 6 — 6 of FIG. 5A;
FIG. 7 is a cross-sectional view of the hoist taken along line 7 — 7 of FIG. 5A; and
FIG. 8 is a detail view of the row opening cylinder and bar according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With particular reference to FIGS. 1 and 2, a bottle or container palletizing apparatus is illustrated generally at 10 . Palletizing apparatus 10 is designed to move bottles or similarly formed containers 12 from a first position to a palletized position. The palletizing apparatus 10 includes several distinct sections to move the bottles 12 from the first position to the palletized position. With reference to FIG. 8 the bottles 12 are held in the neckguides by a lip 12 a formed in an upper portion of the bottle 12 . However, the bottle 12 is able to slide along the neckguide thus being able to move from position to position within the neckguide. Returning reference to FIGS. 1 and 2, generally, bottles 12 are moved in the direction of Arrow A from their initial position in the single lane neck guide 14 through a six lane former 16 . Once the bottles 12 are through the six lane former 16 , they continue down the six lane neck guide 18 . At the end of the six lane neck guide 18 , the bottles encounter an eighteen row indexer 20 . After the bottles 12 have filled the eighteen row indexer 20 , the bottles then move to the palletizing section 22 .
A plurality of air plenum create a jet in the adjacent neckguide which pushes the bottle 12 through the neckguides. An air plenum 24 pushes the bottles 12 along the first single lane neck guide 14 towards the six lane former 16 . A second air plenum 26 pushes the bottles through the six lane former 16 and to the six lane neck guide 18 . The six lane former 16 includes internal passageways 28 and internal gates (not shown) which move the bottles from the single lane neck guide 14 to the six lane neck guide 18 . The bottles 12 then travel along the six lane neck guide 18 toward the eighteen row indexer 20 under the force of the air plenum 26 . The eighteen row indexer 20 is movable from a first position 20 a to a second position 20 b (shown in dashed lines). A final air plenum 30 assists in pushing the bottles 12 along the six lane neck guide 18 into the eighteen row indexer 20 .
The eighteen row indexer 20 fills the first six rows and then indexes from the first position 20 a towards the second position 20 b to fill the next six rows and then indexes a final time to the 20 b position to fill the final six rows. In this way, up to eighteen rows may be formed. However, it is to be understood that this is exemplary only and that more lanes may be included in the eighteen row indexer 20 or fewer than the entire eighteen rows may be filled with bottles 12 . Once the eighteen row indexer 22 has been filled to the desired capacity, then the last air plenum 30 pushes the bottles from the eighteen row indexer 20 into the row closing neck guides 32 .
Continuing reference to FIG. 1 and further reference to FIGS. 3 and 4, the palletizing section 22 of the palletizing apparatus 10 is in greater detail described. The hoist 34 generally includes a plurality of holding members or row closing neck guides 32 which engage the bottles 12 . The bottles 12 from the eighteen row indexer 20 move into the row closing neck guides 32 of the hoist 34 where upon each row of bottles 12 engages a stop 36 to form a first nested pattern. The first nested pattern being where an individual bottle 12 is positioned between two other bottles such as one may stack logs of wood or other round objects. However, when the bottles first engage the stops 36 , they are spaced a distance apart. After the bottles 12 have stopped in the row closing neck guides 32 of the hoist 34 , the row closing neck guides 32 are actuated to compress the bottles. 12 together to form a constricted nested pattern wherein each bottle 12 is nearly touching the adjacent bottle 12 . Once the row closing neck guides 32 have been closed (described herein), the hoist 34 then proceeds down the hoist guides 37 placing that layer of bottles 12 in the constricted nested pattern on a pallet 38 . Each layer of bottles 12 is referenced as a bundle or tier 40 of bottles 12 . Once a tier 40 has been placed upon a pallet 38 , a resquare apparatus 42 constricts the tier 40 further to ensure that the tier 40 is as tightly packed as possible. The resquare apparatus 42 also places a tier sheet 44 on top of the tier 40 . The process of forming, placing, and resquaring tiers 40 is repeated until a full pallet 38 is produced. A pallet 38 is considered full when a predetermined number of tiers 40 has been placed on the pallet 38 which takes into consideration the size and shape of bottles along with other factors. A full pallet 38 may be produced to resemble that illustrated particularly in FIG. 4 . Once a full pallet 38 is produced, the pallet 38 is conveyed along the pallet conveyor 46 where it is bound and removed for shipping or storage.
Now with particular reference to FIGS. 3 and 4, the hoist 34 runs on the hoist guide tracks 37 and is movable from a top position 34 a to a lowered position 34 b , and may be lowered to a position substantially adjacent the pallet 38 (not shown). When the hoist 34 is in the fully upright position 34 a , the hoist 34 engages fixed cams. The fixed cams 48 ensure that the row closing neck guides 32 return to a proper position to receive a new set of bottles 12 from the eighteen row indexer 20 . The fixed cams 48 are necessary to ensure that the row closing neck guides 32 are in proper alignment with the neck guides in the eighteen row indexer 20 so that the bottles 12 will move easily into the row closing neck guides 32 . The hoist 34 is preferably moved on the hoist guide tracks 37 with servo motors, however it is to be understood that any number of means may be used to move the hoist 34 . After the bottles 12 have been moved into the row closing neck guide 32 of the hoist 34 , the hoist 34 moves from the top position 34 a , engaging the fixed cams 48 , to an intermediate position 34 b not engaging the fixed cams 48 so the row closing neck guides 32 may then be closed to form the tier 40 into the constricted nested pattern. The movement of the row closing neck guides 32 is actuated by a driving mechanism, preferably the driving mechanism is an air cylinder 50 that further actuates a first arm 52 . The first arm 52 engages at least one end of the set of row closing neck guides 32 . Each of the row closing neck guides 32 are interconnected to another row closing neck guide 32 through linkages 54 , therefore movement in one of the row closing neck guides 32 creates movement in all of the row closing neck guides 32 . Preferably the row closing neck guides 32 move towards the center most row closing neck guide 32 (process and apparatus described herein).
With particular reference to FIGS. 5A and 5B, the general construction of the hoist 34 including the row closing neck guides 32 is illustrated. In particular, FIGS. 5A and 5B, illustrate the hoist 34 and the row closing neck guides 32 as seen in direction of Arrow A as shown in FIG. 1 . The row closing neck guides 32 as illustrates in FIG. 5A are in their fully extended position, that being a position which the row closing neck guides 32 and the hoist 34 are in the fully up position 34 a and engaging the fixed cams 48 (illustrated in FIG. 3 ). The row closing neck guides 32 may then be moved more adjacent one another to form the constricted nested pattern with the bottles 12 to form a tier 40 . The air cylinder 50 drives the first arm 52 which engages the chain linkages 56 to drive the chain linkages 56 in a chain guide 69 (shown in FIG. 6) around sprockets 58 to move the neck guide engaging arms 60 which in turn moves the row closing neck guides 32 which then constricts a tier 40 into the constricted nested pattern as illustrated particularly in FIG. 5 b.
Each row closing neck guide 32 is pivotally affixed to a first pivot guide 62 , the first pivot guide 62 also engages a linkage 54 . The linkage 54 is further pivotally affixed to an adjacent linkage 54 through a second pivot guide 64 wherein the linkages 54 generally form a V or W pattern along the entire length of the hoist 34 . When the first arm 52 is actuated by the air cylinder 50 , the chain linkages 56 move the neck guide engaging arm 60 which in turn drives the row closing neck guides 32 towards the center. As this happens the individual linkages 54 collapse towards the fixed center 66 .
With continuing reference to FIGS. 5A and 5B, and further reference to FIG. 6, the action of moving the row closing neck guides 32 towards the fixed center point 66 is described in detail. The neck guide engaging arm 60 is affixed at a first end to the chain linkages 56 in the chain guide 69 and a second end the neck guide engaging arm 60 is affixed to the first pivot guide 62 . The first pivot guide 62 is also affixed to the row closing neck guides 32 . The first pivot guide 62 further engages a first lower track 68 on a first side of the hoist 34 and a second lower track 70 on a second side and opposite side of the hoist 34 . Therefore, when the air cylinder 50 is actuated to drive the neck guide engaging arm 60 towards the fixed center point 66 , the neck guide engaging arm 60 moves the first pivot guide 62 along the tracks 68 and 70 thereby moving the new closing neck guides 32 toward the fixed center point 66 by means of the linkages 56 . The amount of movement of the first pivot guide 62 and the row closing neck guides 32 is limited through a second pivot guide 72 and an upper track 74 . The second pivot guide 70 is interconnected to the first pivot guide 62 through the linkages 54 at the point where the linkages 52 are pivotally interconnected. As the neck guide engaging arm 60 is driving the first pivot guide 62 towards the center fixed point 66 , the linkages 54 are compressed therefore driving the second pivot guide 72 towards the center fixed point 66 and upwards. As the second pivot guides 72 are driven upwards, the upper track 74 is also driven upwards. Affixed to the upper track 74 is a pin 76 which is disposed within a stop motion slot 78 . Therefore, as the pin 76 moves within the stop motion slot 78 , the movement of the pin 76 is restricted, thereby restricting the upper track 74 movement as well. Therefore, at a particular point, the linkages 54 can no longer move the second pivot member 72 any further due to the restrictiveness of the track 74 withheld by the pin 76 . At this point, the row closing neck guides 32 can travel no further. The above described interaction allows the driving of the row closing neck guides 32 to be uncontrolled beyond the fact of simply being driven together. However, it is to be understood that the row closing neck guides 32 may also be driven by servo motors or other means to accomplish similar results.
With reference to FIGS. 3, 6 , 7 and 8 , the bottles 12 must be released from the row closing neck guides 32 . Once the bottles 12 and the row closing neck guides 32 are in the first constricted pattern, the hoist 34 moves down the hoist tracks 37 to place the current tier 40 upon the previous tier 40 which is on the pallet 38 . Once the present tier 40 is set upon the previous tier 40 of bottles 12 , the bottles 12 must be released from the row closing neck guides 32 . Each row closing neck guide 32 includes a first side 32 a and a second side 32 b which are interconnected through the first pivot guide 62 at a pivot point 79 . Once the bottles 12 are placed upon the previous tier 40 , the opening cylinder or piston 80 is actuated to press down an opening bar 82 onto the two sections 32 a and 32 b of the row closing neck guides 32 which terminate in an upper part in a first tab 84 a and a second tab 84 b . The tabs 84 a and 84 b cross one another so that the first tab 84 a is over the second side 32 b of the row closing neck guide 32 and the second tab 84 b is over the first side 32 a of the row closing guide 32 . Therefore, when the opening bar 82 is pressed down, it engages the first and second tabs 84 a and 84 b forcing open the neck guide 32 in a scissor fashion where the first side 32 a of the row closing neck guide 32 and the second 32 b of the row closing neck guide 32 open as they rotate above the pivot point 78 . Therefore, when each of the row closing neck guides 32 have been opened, the bottles 12 are released from the row closing neck guides 32 allowing the hoists 34 to again return to the top position 34 a as illustrated in FIG. 4 . After the opening bar 82 has disengaged the tabs 84 a and 84 b , a spring 86 biases the first and second sides 32 a and 32 b of the row closing neck guide 32 together thereby reclosing the row closing neck guides 32 .
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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An apparatus and method for packaging containers, of the type having an engagement lip, wherein the apparatus includes tacks to engage the engagement lip to move the containers from starting point to a delivery point. The containers are moved by the apparatus while being engaged by the track such that the containers are never free from the track until loaded on a pallet. A set of the containers is constricted into a bundle and the bundle is then resquared and set on a pallet. One a pallet includes a sufficient number of bundles the pallet is bound for shipment or storage.
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BACKGROUND OF THE INVENTION
This invention relates to a mangle for pressing damp laundry articles with rotatably mounted padded drums in the form of perforated hollow cylinders connected to a vacuum device. The drum surfaces contact and cooperate with trough shaped hollow bodies heated with high pressure steam, and the used hot air developed inside the drums and/or the condensate accumulating in the trough bodies is used to pre-dry the laundary articles.
With a known mangle the used air from the drums is used to heat a post dryer arranged behind the drums (German AS No. 1,666,740). The post dryer consists essentially of a box shaped heat chamber which works together with the laundry article transport or conveyor bands and which is heated by the used hot air. The transport bands guide the laundry articles into and press them against the heat chamber. The post dryer is arranged at the rear end of the mangle and can be folded up above the drums.
It is also known (German PS NO. 468,074) to channel the used air from the drums through a heat exchanger to heat fresh air, and then to use the warm fresh air to pre- and post-dry the laundry articles. The heated fresh air is supplied to boxes having perforated upper surfaces arranged before and after the mangle drums, and flows through the perforations to the laundry articles which are drawn thereacross.
The hot air and vapor from the drums is reused in these known mangles in order to recycle the exhaust air which would otherwise be released into the atmosphere, but such recycling is problematical in several respects. The post dryer of German AS No. 1,166,740 does not significantly increase the output of the mangle because it is not the conditions at the end but rather at the beginning of the mangle which are decisive. The post dryer also has a negative effect on the smoothing achieved by the mangle itself. When fresh air is blown freely through the laundry articles before and after the mangle, this fresh air being heated by the exhaust air from the mangle drums in a heat exchanger (German PS No. 468,074), this also adversely affects the operation of the mangle. The people working at the mangle are constantly subjected to a hot and steamy environment, and in addition the exhausted hot air from the drums is not effectively utilized.
With another known mangle (German PS No. 182,689) a drum and several trough shaped hollow bodies are spaced slightly apart, the condensate which accumulates in the hollow bodies is fed back through the tubes which serve to heat the air, and the air which is heated in this manner is applied to the laundry articles which move around the drum in the space between the drum and the hollow bodies.
With still another known mangle (German AS No. 2,814,618) having two drums situated one above the other and each having two trough shaped hollow bodies associated with it, the condensate which accumulates in the hollow bodies is taken to a heat exchanger for further heating and added to hot air already heated in a separate heat exchanger. This double heated air is then applied to the laundry articles as in German PS 182,689.
Using the hot condensate to heat air and using this heated air to dry the laundry articles in a press or mangle is disadvantageous in several respects. The utilization of the condensate heat is not optimal, for example, in the mangle of German PS No. 182,689 because a large proportion of the hot air is vented to the atmosphere as a result of the constantly running exhaust associated with the drums.
It is also known to pass the laundry articles for purposes of pre- and post-drying over the outside of the heated trough shaped hollow bodies (Great Britain No. 805,339 and German PS No. 600,141) and to press the laundry articles against the outside of the hollow bodies.
Cylinder mangles are also known in which the outer surface of a steam heated cylinder or drum is provided with pressure rollers, bands or plates which move at the same speed and in the same direction as the drum, and which guide the laundry articles and press them against the drum.
SUMMARY OF THE INVENTION
The object of this invention is to provide a mangle wherein the heat of the exhaust air and/or the condensate is used more advantageously and efficiently than with known mangles without adversely influencing the operation of the mangle.
With a mangle constructed according to the invention the heat contained in the exhaust air and/or condensate is used to heat an unperforated hollow cylinder and cooperating curved guide manifolds arranged in advance of the mangle drums relative to the direction of transport, and the laundry articles are guided around the outer wall of this cylinder and travel substantially around it. The laundry articles are dried only by contact with the heated wall surface, without the blow through of hot air, before the pressing operation, and the pre-drying process is very effective due to an increased length drying run. The laundry articles reach the first mangle drum/trough unit considerably pre-dried, which eliminates to a large extent problems when damper articles are initially fed into the mangle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a longitudinal sectional view through a mangle with a hollow cylinder heated by exhaust air according to the invention,
FIG. 2 shows a top view of the mangle of FIG. 1, and
FIG. 3 shows a longitudinal sectional view through a mangle with a hollow cylinder heated by condensate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The mangle shown in the drawings consists of two spaced, vertical stands 10, 11 between which padded, air permeable drums 12, 13, and 14 are mounted. The drums cooperate with the heated working surfaces of stationary, trough shaped hollow bodies 15, 16, and 17. An unperforated but heated hollow padded cylinder 18 is mounted in advance of drum 12. The drums and cylinder are rotatably mounted in the stands 10, 11 in a known manner, not illustrated, to revolve in the direction of arrows 20, 23, 25, 27. A driven belt infeed 29 is also mounted between the stands in front of the cylinder 18, as are five pressure rollers 30 spaced around the upper periphery of the cylinder and a pair of curved pressure plates 31, 32. The infeed 29 consists of two drive and diverting rollers 33, 34 and a plurality of belts 35 which fit around them. The two pressure plates 31, 32 consist of drive and diverting rollers 36-39 and transport bands 40, 41 which enclose heated guide manifolds 46, 47. The four runs 42-45 of the transport bands are driven such that the laundry articles are conveyed between the runs 42, 45 and the heated manifolds 46, 47. The infeed 29 and the pressure plates 31, 32 are driven in the direction of arrows 19, 20, and 21. The transfer of the laundry articles from the first transport section of plate 31 to the second transport section formed in common with plate 32 is accomplished by a diverter guide 53. The transfer of the articles from between the two pressure plates 31, 32 to the first drum/trough unit 12, 15, and then through the following units 13, 16 and 14, 17 is implemented by curved diverter bridges 54, 55, 56, which are heated with high pressure steam as are the troughs 15-17 and the manifolds 46, 47. Following the last drum/trough unit is a feed out tray 57 which transfers the laundry articles to a table or folding machine.
With the mangle of FIGS. 1 and 2 the steam and used air which accumulates on and inside drums 12-14 is evacuated by fans 58, 59, 60 mounted on the hollow bearings of the drums and fed through the exhaust conduit 61 into the hollow cylinder 18 and, although not shown, into the guide manifolds 46, 47. The cylinder 18 has a hollow bearing neck on the feed side. The removal of the used air from cylinder 18 takes place through a hollow bearing neck on the other side which is coupled to an exhaust conduit 62. The steam supplies to and condensate exhausts from the troughs 15, 16, 17, the bridges 54, 55 and 56 and the manifolds 46, 47 are not shown in FIGS. 1 and 2.
With the mangle according to FIG. 3 special condensate removal lines 63-68 are provided. The condensate which accumulates in these lines is taken through a collection lead 69 to a container 70. From this container the condensate is fed by a pump 71 and lines 72, 73 to a shallow chamber 74 located around the inner periphery of the cylinder 18, which is only partially shown in the drawings. The lines 72, 73 pass through a bore in the hollow bearing 76 of the cylinder. The coupling between lines 72, 73 has a rotating joint in the area of the bearing 76. A line 75 on the other side of the cylinder 18 removes the used condensate from chamber 74 through the hollow bearing 77 via a further rotating joint. The supply and removal of condensate to and from the manifolds 46, 47 is not shown in the drawing.
A cover extending between stands 10, 11 with lids 49-52 is arranged above and thus encloses drums 12, 13, 14, the cylinder 18 and the bridges 54, 55, 56.
The mangles according to FIGS. 1 through 3 have in addition all needed and known but not illustrated devices and parts necessary for operation. For example, the mangle in FIG. 3 also has an electric control device with a float switch in the container 70 which controls the pump 71.
The operation of the mangle is as follows:
The laundry articles, not shown, are delivered to infeed 29 either by hand or by an automatic feeder and are conveyed through the apparatus in the direction of arrows 19-28. The articles are first fed through the pre-dryer, which consists of the heated cylinder 18 and manifolds 46, 47, over a frictionless, elongated transport path defined between the heated surfaces of the cylinder 18 and manifolds 46, 47. The frictionless conveyance of the articles, due to the cylinder 18 and the bands 40, 41 being driven at the same peripheral speeds, prevents blockages and wrinkles from occurring. The laundry articles leave the pre-dryer and slide through mangle bonds, not shown, and over the heated diverter bridge 54 to the first drum/trough unit 12, 15 and from there in a known manner through the rest of the mangle.
As a result of the pre-drying of the laundry articles, at the first drum/trough unit, in contrast to mangles which lack this pre-drying and in which approximately 40% of the moisture must be removed here, considerably less is removed. This lower evaporation at the first drum/trough unit leads, with the same output of the mangle, to a comparably reduced vaporization output compared to the total of the three drum/trough units, and thus enables the output of the mangle to be increased. In both cases, i.e. the heating of the cylinder 18 and the manifolds 46, 47 by the exhaust air removed from the drum/trough units (FIGS. 1 and 2) or by the condensate from troughs 15-17 and the diverter bridges 54-56 (FIG. 3), there is considerable energy saving relative to the vaporization output of the mangles resulting from the dampness of the laundry articles.
Since the amount of condensate accumulating in the steam heated troughs 15-17 and diverter bridges 54-56 is dependent on diverse factors, where the accumulation of condensate is not adequate it is advisable to heat the manifolds 46, 47 of the pre-dryer with steam and to also use the accumulated condensate therefrom to heat the cylinder 18. It is also possible to feed condensate occurring from other steam consuming installations in the laundry to the collection container 70.
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Used hot air exhausted from perforated mangle drums 12-14 and/or steam condensate from curved guide troughs 15-17 cooperating with the drums is passed through the interior of a hollow, unperforated predryer cylinder 18. A pair of curved transport belts 40, 41 surround the bottom half of the cylinder and are driven at the same peripheral speed thereof to press laundry articles against the heated cylinder and to reverse their direction. Heating manifolds 46, 47 are mounted inside the transport belt runs.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device which improves a connection between a bit line and a cell of dynamic access memory.
2. Description of the Related Art
FIGS. 1A and 1B show a memory cell in a dynamic access memory which comprises a capacitor, transistor and bit line contact. FIG. 1B shows a cross-sectional view as taken along line A--A in FIG. 1A. In the memory cell, transfer transistor (MOS transistor) 10 is made up of gate 2, source 4a and drain 4b. With the gate voltage of transfer transistor 10 raised, a signal to bit line 1 is written as data into a capacitor between capacitor plate 3 and substrate 8 via transfer transistor 10 and, with the aforementioned gate voltage lowered and hence MOS transistor 10 OFF, is stored as data. At the read time, on the other hand, the gate voltage of transfer transistor 10 is raised and hence MOS transistor 10 is turned ON. A corresponding voltage is sent to bit line and then amplified by a sense amplifier which is connected to the bit line. It is thus judged whether data is "0" or "1". The semiconductor device of FIG. 1B includes insulating interlayer 5, capacitor gate insulating film 6, transfer transistor insulating film 9 and bit line contact 11.
FIGS. 2A and 2B show a cell array corresponding to the memory as shown in FIGS. 1A and 1B. Bit line 1 extends over cell element area 20 and is connected to bit line contact 11 for each respective cell element area 20. In the cell array, reference numeral 2 shows gate 1 bit line; 4, source and drain regions; 5, an insulating interlayer; 6, a capacitor gate insulating film; 7, a transfer transistor insulating film; 9, a field insulating film; and 11, a bit line contact.
When a greater number of contact holes for bit line contact formation are to be formed in a semiconductor layer structure, some of them are left unopened. In order to raise the electrical conductivity, which is the ratio between an actual number of contact holes as distinct from a total number of holes formed and those contact holes left unopened, it is necessary to form bigger contact holes. As a result, a flat bit line width (twice an X value in FIG. 1A) is narrowed around the contact hole, causing an increase in bit line resistance and hence a margin drop in the memory cell's sense amplifier operation.
In order to cope with the aforementioned drawback, an attempt has been made to thicken bit line 1 around bit line contact 11, that is, to increase the X value. In the conventional cell pattern, however, if the aforementioned X value is increased, then the distance between bit lines 1 is decreased, causing the occurrence of a short between the bit lines. In the cell pattern, it appears possible to increase the X value if an alternate array of bit line contact 11 on upper bit line 1 and bit line contact 11 on lower bit line 1 is employed. It is, however, difficult to change the cell array shown in FIGS. 2A and 2B, because the cell array of FIG. 2 is of a folded bit line type.
The following explains why the bit lines' resistance rises in the conventional system.
It is necessary to lower the bit lines' resistance because a rise in the bit line's resistance occurs due to the deposition of a silicide film by an ordinary sputtering method. That is, this occurs due to the prominent thinning of the silicide film at the contact site resulting from a poor converage rate at the contact area, that is, the ratio between the vertical thickness of the bit line at the contact site and the thickness of the flat area of the bit line relative to the contact site. In order to solve the problem, it is preferable that the silicide film be deposited on the associated semiconductor structure by virtue of a vacuum CVD method by which a high degree of coverage is obtained at the corner site and groove area. However, the method is now at the development stage and cannot be introduced in the production line of LSI's.
SUMMARY OF THE INVENTION
It is accordingly the object of the present invention to provide a semiconductor device which optimizes a pattern of bit lines and bit line contacts and a resultant construction to adequately lower a bit line's resistance.
According to the present invention, a semiconductor device is disclosed which connects a bit line via a bit line contact to cells in a dynamic access memory, the device including a first conductive layer connected via the bit line contact to the cells of the memory cell array and a second conductive layer connected to the first conductive layer via a contact hole which is formed over the first conductive layer. By providing the first conductive layer between the bit line contact and the bit line it is possible to increase a flat line width around the contact of the bit line and hence to adequately lower the bit line's resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a conventional semiconductor device and FIG. 1B is a cross-sectional view taken along line A--A in FIG. 1A;
FIG. 2A is a plan view showing a memory array of the conventional semiconductor device and FIG. 2B is a cross-sectional view taken along line B--B in FIG. 2A;
FIGS. 3A to 3D show plan views and associated cross-sectional views showing the manufacturing process of a semiconductor device according to an embodiment of the present invention;
FIG. 4A is a plan view showing a memory cell array pattern of the semiconductor device of the present invention and FIG. 4B is a cross-sectional view taken along line C--C in FIG. 4A; and
FIG. 5 is a plan view showing another array pattern of the semiconductor device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the present invention will be explained below with respect to the accompanying drawings.
FIGS. 3A and 3B, respectively, show a plan view and associated cross-sectional view of a semiconductor device according to one embodiment of the present invention. Specifically, as shown in FIG. 3A, cell element area 120 is formed by a LOCOS method in silicon substrate 101, and field oxide film 102 is formed as thermal oxidation film about 5000Å thick for an element isolation area on the resultant semiconductor structure. Then first oxide film 103 is formed as a 100Å thick thermal oxidation film on cell element area 120 and a poly-Si film, containing a first N type impurity for first gate electrode 100, is formed on the whole surface of the resultant structure. A poly Si silicon, containing a first N type impurity, is patterned by a photoetching method on the resultant structure to provide gate electrode 100. First gate oxide film 103 is formed by an etching step on the semiconductor structure with first gate electrode 100 as a mask to expose part of silicon substrate 101.
As shown in FIG. 3B, second gate oxide film 104 is formed on the exposed part of silicon substrate 101 at which time oxide film 104 is formed on the side surface and upper surface of first gate electrode 100. A poly-Si film, containing a second N type impurity for second gate electrode 105, is deposited on the whole surface of the semiconductor structure. Second gate electrode 105 is formed by the photoetching method on the surface of the semiconductor structure so as to obtain a gate electrode for a transfer electrode. With second gate electrode 105 as a mask, arsenic ions are implanted, at 5×10 15 cm -2 and 50 KV, into those regions corresponding to source and drain diffusion layers 106 and 106a.
As shown in FIG. 3C, first CVD SiO 2 film 107 is deposited to a depth of about 3000Å, on the whole surface of the resultant structure. The structure is heat-treated for about 30 minutes within an N 2 atmosphere to provide source and drain diffusion layers 106 and 106a. Contact hole 108 is so formed in first CVD SiO 2 film 107 as to correspond to a bit line contact site. A third poly-Si film is deposited on the whole surface of the semiconductor structure and, after heat treatment of the structure in a POCl 3 atmosphere, an N type impurity is diffused down into the third poly-Si film and silicon substrate 101. In this way, ohmic contact is made across the third poly-Si film and N-type source diffusion layer 106. Third poly-Si pattern is formed as first conductive film 109 to obtain bit line contact with the near-by cell.
As shown in FIG. 3D, second CVD SiO 2 film 111 is deposited, as a 5000Å film, on the whole surface of the semiconductor substrate and a contact hole is formed in the exposed surface part of third poly-Si pattern 109. An MoSi film is deposited by a sputtering method on the structure. Then the MoSi 2 pattern is formed by the photoetching method to provide bit line 112 for the formation of a second conductive layer.
FIGS. 4A, 4B and 5 show one form of a cell array as shown in FIG. 3A to 3D. As shown in FIGS. 4A, 4B and 5, a bit line is formed between cell arrays. FIG. 4B shows a cross-sectional view taken along line C--C in FIG. 4A. In this pattern array, a capacitor plate electrode pattern (first gate electrode 100) is omitted in FIGS. 4A, 4B. In the arrangement of FIGS. 4A, 4B, bit line 112 is located over an element isolation field (field oxide film 102) where, for example, a cell transistor and capacitor are not formed. Therefore, an underlying step coverage for bit line 112 becomes smaller as its extent of "step" and, as a result, a high coverage rate is obtained at a location of the semiconductor structure overlying the step coverage of bit line 112 preventing an increase in bit line resistance. C 1 , C 2 and C 3 are contacts between bit line 112 and third poly-Si pattern 109.
FIG. 5 shows an array pattern for preventing an increase in bit line resistance. By changing the array of third poly-Si pattern 109 it is possible to increase the flat line width of bit line 112 which is located around the contact (C 11 , C 21 , C 31 ) between bit line 112 and third poly-Si pattern 112. As can be seen from FIG. 5, the bit margin Y value of the contact (C 11 , C 21 , C 31 ) over third poly-Si pattern 109 can be taken as a greater value than in the conventional pattern. In this case, however, a decrease in the line width of bit line 112 corresponds to a (Y-X) value, but if the bit line margin X value of the bit line contact site as in FIGS. 4A, 4B takes a greater value it is necessary to make the (Y-X) value twice that value. Contacts (C 11 , C 21 , C 31 ) of FIG. 5 are displaced in a corresponding relation to contacts (C 1 , C 2 , C 3 ) in FIG. 4A.
FIG. 5 shows an array pattern for suppressing an increase in bit line resistance. By improving the array of third poly-Si pattern 109 it is possible to increase the line width of bit line 112 around the contact (C 11 , C 21 , C 31 ) between bit line 112 and third poly-Si pattern 109.
That is, in the array pattern shown in FIG. 5, third poly-Si pattern 109 is formed as a rectangle with a square attached as a projection to the vertical side face of the first-mentioned rectangle in which case adjacent third poly-Si pattern 109 is formed in the same shape as that of the first-mentioned third poly-Si pattern 109 except that a projection of adjacent poly-Si pattern 109 extends in a direction opposite to that in which the first-mentioned projection extends. At a location of projection 109a, contact is made between Poly-Si pattern 109 and bit line 112 to provide contact C 11 , C 21 and C 31 . It is thus possible to increase the line width of bit line 112 around each contact (C 11 , C 21 , C 31 ). In the case where, in order to increase the line width of bit line 112 around the contacts (C 11 , C 21 , C 31 ), provided enlarged spot 112a, and hence to suppress an increase in bit line resistance there, it is necessary that, in order to prevent a shorting between the adjacent bit lines, cutout 112b be provided just beneath or over the contact (C 11 , C 21 , C 31 ) around the bit line which is located adjacent to bit line 112 around the contact (C 11 , C 21 , C 31 ).
In the array pattern shown in FIG. 5, since projections 109a are provided vertically around contacts C 11 , C 21 , C 31 in the aforementioned opposite relation, it is not necessary to form the cutout at each side of bit line 112. It is possible to increase the flat line width of bit line 112 around the contacts (C 11 , C 21 , C 31 ), that is, the Y value of enlarged site 112a.
In the array pattern shown in FIG. 5, the width of cutout 112b of bit line 112 corresponds to the (Y-X) value. The X value corresponds to a distance from the side of the contact to the side of bit line 112.
In the array pattern shown in FIG. 5, since contacts C 11 , C 21 , C 31 are formed in the aforementioned opposite relation, the cutout of the adjacent bit line which corresponds to contacts C 11 , C 21 , C 31 is provided at only one side of the bit line, thus assuring a greater Y value.
Furthermore, a MoSi film which contains a low-ohmic metal, such as molybdenum, is formed by a sputtering method to provide bit line 112 as the second conductive layer. In this case, bit line 112 which is formed of the MoSi film is employed as an input line which is connected to a sense amplifier.
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A semiconductor device is disclosed which connects a bit line via a bit line contact to cells in a dynamic access memory which are constructed of a transistor and capacitor. The semiconductor device includes a first conductive layer connected to the cell of a cell array via a bit line contact and a second conductive layer connected to the first conductive layer via a contact hole which is formed over the first conductive layer. By providing the first conductive layer between the bit line contact and the bit line, it is possible to increase a flat line width around a bit line contact and hence to adequately lower the bit line's resistance.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method and apparatus for boosting the pressure of the air charge to an internal combustion (IC) engine which has an exhaust gas recirculation (EGR) system, and in particular to such an engine having a combined EGR/turbocharger bypass control valve for controlling the amount of recirculated exhaust gas and the power of a turbocharger compressor. The invention is particularly although not exclusively for use in a diesel engine.
[0003] 2. Related Technology
[0004] One way of boosting the pressure of the air charge to an IC engine is to use a turbocharger, which typically has a rotary compressor for compressing the intake air driven by a turbine wheel powered by engine exhaust gas. The result is that more air is sent into an engine's combustion chamber, increasing engine power.
[0005] When air is compressed, it is simultaneously heated. So, compressing engine intake air raises the temperature of air sent into the engine's combustion chamber. The raised air temperature increases the temperature of the combustion chamber and the surrounding engine components, which can increase thermal stress and reduce engine lifetime. Compressed intake air is often therefore cooled to increase the amount by which it can be compressed without detrimentally increasing combustion chamber temperature. This cooling can also generally increase the amount of air provided in the combustion chamber at a given intake pressure, as cool air is denser than hot air. Intake air cooking can therefore help to increase engine power.
[0006] Emission regulations are now beginning to dictate that many automotive engines mix intake air with recirculated exhaust gas, as this can reduce NOX (e.g. Nitrogen Dioxide etc.) emissions. NOX is formed in far higher quantities above certain combustion temperatures. Mixing recirculated exhaust gas with engine intake air can lower the combustion temperature and therefore reduce NOX formation. However, exhaust gas is hot. Like compressed intake air, it therefore benefits from cooling before it enters an engine's combustion chamber. In particular, cooling recirculated exhaust gas can increase the amount of exhaust gas that can be provided in the combustion chamber at a given intake pressure (e.g. improve mass flow).
[0007] Coolers for cooling compressed intake air are usually referred to as charge air coolers or intercoolers. Intercoolers can be cooled by engine coolant or other liquids, but are more commonly air cooled. An air cooled intercooler typically comprises an arrangement of tubes through which the compressed intake air can flow. For most car and light truck engines, intercoolers can provide sufficient cooling capacity without being inconveniently large and have relatively straightforward, robust and maintenance free designs. They are typically make from aluminum or plastics, as they only have to deal with relatively low temperatures (less than around 200° C.).
[0008] Coolers for cooling recirculated exhaust gas are usually referred to as Exhaust Gas Recirculation (EGR) coolers. An EGR cooler typically comprises a cylindrical shell containing one or more heat exchange tubes through which the exhaust gas can flow. Liquid coolant is passed through the shell around the tubes. The coolant is therefore in a heat exchange relationship with the exhaust gas and can cool it. Liquid cooling is used as it can typically provide greater cooling capacity than air cooling for a given heat exchange surface area. Thus, the heat exchange tubes can have a relatively large diameter and small surface area, which makes the EGR cooler tolerant to the build up of soot inside the tubes. EGR cooler are typically made from steel. One reason for this is that exhaust gas can be hot enough to damage other materials such as aluminum and plastics, but steel is more tolerant to high temperatures.
[0009] So, when it is desired to cool both engine intake air and recirculated exhaust gas, two separate coolers are conventionally provided; an intercooler and an EGR cooler. An example of such an arrangement is disclosed in patent document EP 1,138,928 A2. However, it is possible to use a combined EGR and inlet air cooler, for example as disclosed in U.S. Pat. No. 6,167,703 B1.
[0010] All such prior art systems entail a significant amount of cost, owing to the provision of conduits between the inlet and exhaust sides of the engine, and also valves to control the flow of exhaust gasses and the control systems associated with the operation of such valves. It is therefore desirable to minimize, as far as possible, the costs associated with such hardware.
BRIEF SUMMARY OF THE INVENTION
[0011] According to the invention, there is provided a compressor and exhaust gas recirculation (EGR) apparatus for an internal combustion engine (ICE). The apparatus includes a turbine impeller, and exhaust gas inlet leading to the impeller for providing exhaust gas from one or more combustion chambers of an ICE to drive the impeller, an exhaust gas outlet for venting exhaust gas from the impeller, a compressor arranged to be driven by the impeller, an air inlet for supplying inlet air to the compressor, a compressed air outlet leading from the compressor for providing compressed air to one or more combustion chambers of an IC engine, an exhaust gas bypass passage for controlling the amount of exhaust gas used to drive the impeller, and EGR passage for recirculating exhaust gas from the exhaust gas inlet to the compressed air outlet, and a combined turbine impeller and EGR control valve arranged to receive exhaust gas from the exhaust gas inlet and to control the relative proportions of exhaust gas flowing to: the compressed air outlet via the EGR passage; the exhaust, gas outlet via the exhaust gas bypass passage; and the impeller.
[0012] According another aspect of the invention, there is provided an IC engine having one or more combustion chambers, and engine air inlet passage leading to the combustion chambers, an engine exhaust outlet passage leading from the combustion chambers, a turbocharger with a turbine impeller arranged to be driven by exhaust gas from the engine exhaust outlet passage and a compressor driven by the impeller for compressing air admitted to the engine air inlet passage, an EGR system arranged to recirculate exhaust gas from the engine exhaust outlet passage to the engine air inlet passage, and an exhaust gas bypass passage arranged to divert exhaust gas that would otherwise reach the impeller, a control valve with a valve inlet arranged to receive exhaust gas from the engine outlet passage, and three valve outlets, a first one of the valve outlets providing exhaust gas to the EGR system for recirculation to the engine air inlet passage, a second one of the valve outlets providing exhaust gas to the exhaust gas bypass passage and a third one of the outlets providing exhaust gas to the impeller.
[0013] Also according to the invention, there is provided a method of operating an IC engine, the engine including a turbocharger having a linked turbine impeller/compressor and an exhaust gas impeller bypass, an EGR system, an a combined turbine impeller and EGR control valve, said method comprising the steps of:
i) providing exhaust gas from the engine in order to drive the impeller and power the compressor; ii) using the compressor to compress inlet air supplied to the engine; iii) using the bypass to divert exhaust gas from reaching the impeller; iv) using the EGR system to recirculate a portion of exhaust gas produced by the engine; v) using the combined turbine impeller and EGR control valve to control both the amount of the exhaust gas diverted by the bypass and recirculated by the EGR system, and the amount of exhaust gas reaching the impeller.
[0019] The use of a combined turbine impeller and EGR control valve provides significant benefits. In particular, the arrangement permits a more efficient routing of conduits around an internal combustion engine for the exhaust gas recirculation from the outlet side of the engine to the inlet side of the engine. The turbocharger will normally be situated at a side of the engine convenient to receive from the engine the exhaust gas used to drive the impeller and to provide compressed inlet air to the engine. The use of the combined valve therefore allows the minimal use of conduits for exhaust gas recirculation which are in any event required to provide exhaust gas to the impeller and to provide compressed air to the engine. The invention therefore helps conserve space in the crowded environment of a typical internal combustion engine for a motor vehicle, as well as allowing a reduction in the complexity and number of components used in routing recirculated exhaust gas between the outlet and inlet sides of the engines.
[0020] The apparatus may advantageously include a housing which surrounds the impeller, compressor and control valve. This can help provide a compact unit which is easier to install during manufacture, and which has fewer components exposed to the harsh environment of a motor vehicle engine compartment.
[0021] The control valve, exhaust gas bypass passage and EGR passage are therefore preferably integrated within a unitary apparatus.
[0022] The EGR passage may be arranged to recirculate un-cooled exhaust gas from the exhaust gas inlet to the compressed air outlet, and the compressor is arranged to provide un-cooled compressed air to the compressed air outlet. By providing cooling separates from the turbocharger apparatus, the cooling may be provided at any convenient location with respect to the engine or engine compartment.
[0023] In a preferred embodiment of the invention, the control valve prevents exhaust gas from being recirculated whenever exhaust gas is allowed to bypass the impeller. This is useful in simplifying the design and operation of the combined control valve as exhaust gas recirculation is generally not desired at high engine speeds, when the turbocharger boost is significant and being limited by use of the bypass.
[0024] Alternatively, the control valve may control the proportions of exhaust gas being recirculated as exhaust gas bypasses the impeller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will now be further described, by way of example only, and with reference to the accompanying drawings, in which:
[0026] FIG. 1 is a block diagram of a conventional boosted IC engine utilizing a turbocharger unit with a conventional intercooler and conventional EGR system and EGR cooler.
[0027] FIG. 2 is a schematic illustration of a boosted IC engine according to a first embodiment;
[0028] FIG. 3 is a schematic illustration of a boosted internal combustion engine according to a second embodiment of the invention of the invention similar to the first embodiment in which the combined turbine impeller and EGR valve is integrated within the turbocharger unit;
[0029] FIG. 4 is a plot showing the proportion of recirculated exhaust gas in the total gasses admitted in the air inlet to the engine in the embodiments of the invention; and
[0030] FIG. 4 is a plot showing the proportions of exhaust gas directed by the combined turbine impeller and EGR valve to EGR and the turbine impeller bypass in the embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1 illustrate in schematic form a prior art turbocharged engine 1 utilizing exhaust gas recirculation (EGR). The engine 1 incorporates conventional compressed intake air cooling using a conventional air cooled intercooler 2 and conventional EGR cooling via an EGR cooler 4 . The coolers 2 , 4 may be formed from aluminum or steel, and the EGR cooler 4 may employ engine coolant through coolant inlets and outlets (not shown) to cool recirculated exhaust gas.
[0032] A main engine exhaust gas passage 6 leads from an exhaust manifold 8 on the output side of one or more combustion chambers 10 of the engine 1 . The engine exhaust gas passage 6 conveys exhaust gas 12 from the exhaust manifold 8 towards a turbocharger exhaust gas inlet 13 that leads to a turbine impeller 14 of a turbocharger 16 . Exhaust gas 18 exits the turbocharger 16 via a turbocharger exhaust outlet passage 20 . An upstream EGR passage 22 branches from the main engine exhaust gas passage 6 to the EGR cooler 4 . The upstream EGR passage 22 forms together with the EGR cooler 4 and a downstream EGR passage 37 an EGR path between the outlet and inlet sides 8 , 34 of the combustion chambers 10 .
[0033] The impeller 14 of the turbocharger 16 is coupled by a shaft 24 to a rotary compressor 26 for compressing engine intake air 28 received at a turbocharger air inlet 27 from an upstream air inlet passage 29 . The impeller 14 can therefore drive the rotary compressor 26 under power of exhaust gas inlet 13 . A turbocharger air outlet 31 from the compressor 26 is connected to a compressed air outlet passage 33 for conveying hot compressed engine intake air 30 to the intercooler 2 . Although not shown, a compressor bypass and bypass control valve may be provided between the upstream air inlet passage 29 and the compressed air outlet passage 33 in order to help regulate the compressed inlet air 30 .
[0034] The intercooler 2 is arranged to receive the hot compressed engine intake air 30 from the rotary compressor 26 , cool it, and provide cooled compressed air 36 to an engine air inlet passage 35 that leads to an inlet manifold 34 on the intake side of the combustion chambers 10 .
[0035] Similarly, the EGR cooler is arranged to receive a portion 38 of the hot exhaust gas 12 output by the combustion chambers 10 via the EGR branch passage 22 , cool it, and to provide cooled recirculated exhaust gas 40 to the downstream EGR passage 37 which meets the engine air inlet passage 35 at a confluence point or mixing point 32 , at which the cooled recirculated exhaust gas 40 is mixed with the cooled compressed air 36 prior to admission to the combustion chambers 10 .
[0036] An EGR regulator valve 42 is positioned between the EGR cooler 4 and the mixing point 32 to control the amount of cooled exhaust gas 40 that is recirculated to the mixing point 32 to control the amount of cooled exhaust gas 40 that is recirculated to the mixing point 32 and hence provided to the intake manifold 34 and combustion chamber 10 .
[0037] In order to control and limit the exhaust gas portion 25 provided to the impeller 14 and hence the power drawn from the total exhaust gasses 12 , a turbocharger exhaust gas bypass passage 44 is provided between a branch point 46 on the downstream exhaust gas outlet passage 20 . Flow of bypass exhaust gas 50 along the bypass passage 44 is controlled by a wastegate valve 52 .
[0038] One or more engine control units (ECU) 54 is arranged to control via control lines 56 , 58 the operation the valves 42 , 52 and hence the amount of recirculated exhaust gas 50 and the power boost provided by the turbocharger 16 .
[0039] FIG. 2 illustrates in schematic for a turbocharged engine 101 having EGR, according to a first embodiment of the invention. For convenience, features corresponding with those of the prior art engine 1 are indicated using the same reference numerals.
[0040] The invention differs from the prior art in that there is just one, unitary EGR/bypass control valve 60 for controlling the flow the engine exhaust gas 12 to the turbocharger impeller 14 , a turbocharger bypass 144 , and an exhaust gas recirculation path comprising an upstream EGR passage 122 , and EGR cooler 104 and a downstream EGR passage 137 .
[0041] The control valve 60 is a three-way rotary valve that has one inlet 61 into which the exhaust gas 12 from the main exhaust passage 6 flows. The valve has three outlets, a first one of which 62 is connected to the turbocharger exhaust gas inlet 13 , a second one of which 63 is connected to the upstream EGR passage 122 and a third one of which is connected to the bypass passage 144 . The control valve 60 is configured to control the relative proportions of exhaust gas 125 , 138 , 150 supplied to the impeller 14 , the EGR system 122 , 104 , 137 and the exhaust gas bypass passage 144 .
[0042] As with the first embodiment 1, compressed air 30 from the turbocharger air outlet 31 from the compressor 26 is connected to a compressed air outlet passage 33 for conveying the hot compressed engine intake air 30 to the intercooler 2 . The cooled compressed air 36 in the engine air inlet passage 35 is then mixed with cooled recirculated exhaust gas 140 are mixed at a confluence point 132 upstream of the inlet manifold 34 .
[0043] The mixing point 132 comprises a venturi (not shown). More specifically, the mixing point 132 has a constricted throat for passing the cooled compressed engine intake air 36 . An inlet is provided in the side wall of the constricted throat for admitting the cooled exhaust gas 140 , after which the gas combination 36 , 140 is provided to the inlet manifold 34 on the intake side of the combustion chambers 10 .
[0044] An engine control unit (ECU) 154 is arranged to control, via a control line 156 , the operation the control valve 60 and hence the amount of recirculated exhaust gas 140 , bypass exhaust gas 150 and exhaust gas 125 provided to the impeller 14 , and hence the power boost provided by the turbocharger 16 .
[0045] The amount of exhaust gas that is recirculated 138 to the mixing point 132 is controlled by varying the amount of exhaust gas that flows through the various valve outlets 62 , 63 , 64 of the control valve 60 . The amounts of both compressed intake air 30 and recirculated exhaust gas 138 that pass through, respectively the intercooler 2 and the EGR cooler 104 are varied depending on engine load, as shown in FIG. 4 , which shows a plot of the proportion of recirculated exhaust gas 140 in the total gas combination 36 , 140 provided to the inlet manifold 34 . As can be seen, the proportion is a maximum of about 40% at a minimum engine load of 10%, and declines to zero at an engine load of about 50%.
[0046] FIG. 5 shows how the control valve 60 under the control of the ECU 154 determines the proportions of exhaust gas flowing to the three valve outlets 62 , 63 , 64 . At a minimum engine load of 10%, about 20% of the exhaust gas 12 is provided to the EGR path 122 , 104 , 137 , none is provided to the bypass passage 144 , meaning than 80% flows 125 to the impeller 14 .
[0047] As engine load increases up to about 50%, there is still no exhaust gas provided to the bypass passage 144 , and the proportion of the exhaust gas 12 provided to the EGR path 122 , 104 , 137 drops steadily to zero, at which point all of the exhaust gas 12 flows 125 to the turbocharger impeller 14 .
[0048] Above 50% engine load, the amount of exhaust gas provided 125 to the bypass 144 increases in order to limit the speed of the turbocharger 16 , and hence the engine power, while none of the exhaust gas 12 is provided to the EGR path 122 , 104 , 137 . Above an engine speed of 90%, all the exhaust gas 12 bypasses the impeller 14 .
[0049] FIG. 3 shows a boosted internal combustion engine according to a second embodiment 210 of the invention. The second embodiment 201 differs from the first embodiment in having a unitary EGR/bypass control valve 160 that is integrated within a turbocharger unit 116 . Again for convenience, features corresponding with those of the prior art engine 1 or engine according to the first embodiment 101 are indicated using the same reference numerals as before.
[0050] As with the second embodiment 101 , the control valve 160 is a rotary valve which has a single valve inlet 161 that receives all the engine exhaust gas 12 , and three outlets 162 , 163 , 164 that convey varying proportions of exhaust gas 225 , 238 , 250 to the impeller 114 , an EGR passage 222 , and a turbocharger bypass passage 244 . These exhaust gas proportions 225 , 238 , 250 are controlled as described above with reference to FIGS. 4 and 5 in order to control the amount of recirculated exhaust gas 238 and the power of a compressor 126 in the turbocharger unit 116 .
[0051] The second embodiment 201 of the invention results in significant benefits in terms of a reduction in the number of components and exhaust gas connections which need to be provided. Because the valve 160 is internal to the turbocharger 116 , so are the EGR passage 222 , the bypass passage 244 and the confluence points 232 , 248 .
[0052] As with the first embodiment, the EGR confluence point 232 comprises a venturi (not shown) that has a constricted throat for passing un-cooled compressed engine intake air 130 . An inlet is provided in the side wall of the constricted throat for admitting the un-cooled exhaust gas 238 , after which the un-cooled gas combination 130 , 238 is provided to a turbocharger compressed air outlet 131 and into an un-cooled compressed air passage 133 upstream of a combined intercooler 65 for cooling the mixture of compressed air 130 and exhaust gas 238 . The combined intercooler may employ engine coolant through coolant inlets and outlets (not shown) to cool the mixture of compressed air 130 and recirculated exhaust gas 238 .
[0053] The combined intercooler 65 provides a cooled gas mixture 136 into to an engine air inlet passage 135 that leads to the inlet manifold 34 on the intake side of the combustion chambers 10 .
[0054] The invention therefore also facilitates the use of a single combined intercooler 65 , rather than two separate coolers for the compressed air and recirculated exhaust gas, thus providing further benefits in terms of reduced part count and space consumed within a motor vehicle engine compartment.
[0055] The control valve 160 , EGR passage, bypass passage 244 , and EGR and bypass confluence points 232 , 248 are preferably all housed within a turbocharger housing (not shown), for example a machined casting. More specifically, the control valve 160 may have a body cast in a casing of the turbocharger 116 around the impeller 114 .
[0056] In the illustrated embodiments 101 , 201 , all the gas combination, that is, all the intake air and recirculated exhaust gas always passes through separate or combined coolers. However, in another embodiment (not shown), a bypass passage is connected from upstream of the EGR or combined cooler 104 , 65 to a point downstream of the cooler 104 , 65 . For example, in the second embodiment, such a bypass passage can be connected from between the mixing point 232 or the compressor outlet 131 and the air inlet passage 135 to the intake manifold 34 of the combustion chambers 10 . This bypass passage allows EGR or combined gas cooling to be bypassed during engine warm up and such like.
[0057] The engine 101 , 201 of the described embodiments is preferably a diesel engine. However, the invention can equally be applied to a petrol (or “gasoline”) engine, Liquid Petroleum Gas (LPG) engine or such like. Similarly, the described engines 101 , 201 are intended for automotive applications, usually for cars and light trucks. However, it may of course be used in a broad range of other applications, such as for an electrical generator.
[0058] In the foregoing description, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without using these specific details. In other instances, well-known methods and structures have not been described in detail so as not to unnecessarily obscure the present invention.
[0059] For example, it may in some applications of the invention be desirable to simultaneously direct some of the exhaust gas through the bypass while some gas is directed through the EGR system. Similarly the recirculated exhaust gas need not be directed through a venturi in the mixing of the recirculated exhaust gas and the inlet air.
[0060] Likewise, the described embodiments of the invention are only examples of how the invention may be implemented. Modifications, variations and changes to the described embodiments will occur to those having appropriate skills and knowledge. These modifications, variations and changes may be made without departure from the scope of the invention defined in the claims.
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A method and apparatus for boosting the pressure of the air charge to an internal combustion engine, which has an exhaust gas recirculation (EGR) system and a turbocharger. The EGR system is arranged to recirculate exhaust gas from an engine exhaust outlet passage to the engine air inlet passage. An exhaust gas bypass passage arranged to divert exhaust gas that would otherwise reach the turbocharger's impeller. The engine has a single, unitary control valve with a valve inlet arranged to receive exhaust gas from the engine exhaust outlet passage, and three valve outlets. A first of said valve outlets provides exhaust gas to the EGR system for recirculation to the engine air inlet passage, a second of said valve outlets provides exhaust gas to the exhaust gas bypass passage and a third of said outlets provides exhaust gas to the impeller.
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BACKGROUND OF THE INVENTION
Class III antiarrhythmic agents may be categorized as having the ability to markedly prolong Purkinje fiber action potential duration without producing significant changes in maximal upstroke velocity. Unlike Class I antiarrhythmic agents, a pure Class III agent displays no effect on cardiac sodium channels. The electrophysiologic properties of a compound possessing a Class III activity profile are observed in vivo as negligible effects on atrial, ventricular and H-V conduction times while producing a marked increase (greater than 20 percent) in both the atrial and ventricular refractory period. In contrast, Class I agents will demonstrate a marked slowing of ventricular conduction velocity, with variable effects on the refractory period. Recent reviews of these agents are by: Brexton et al., Pharmac. Ther. 17, 315-55 (1982); Vaughan-Williams, J. Clin. Pharmacol. 24, 129-47 (1984); Steinberg et al., Ann. Rep. Med. Chem. 21, 95-108 (1986).
The following workers have reported the selective Class III antiarrhythmic activity of the dextro enantiomer of 4-(2-isopropylamino-1-hydroxyethyl)-methane-sulfonamide (MJ-1999, Sotalol): Taggart, et al., Clin. Sci. 69, 631-636 (1985) and McComb, et al., J. Am. Coll. Cardiol. 5, 438 (1985).
Silberg et al., ACAD Rep. Populace Romire, Fillala Clug, Studee Cercetari Med., 10244-52 (1959) disclose p-acetylamino-N-(2-diethylaminoethyl)benzenesulfonamide and compare its antiarrhythmic properties with procainamide.
Wohl et al. disclose N-[2-(diethylamino)ethyl]-4-[(methylsulfonyl)amino]-benzamide hydrochloride as a potential class III antiarrhythmic agent in U.S. Pat. No. 4,544,654, Oct. 1, 1985.
Cross et al. have reported various (phenyl(carbonyl)alkyl)-4-(pyridinyl or imidazolyl)piperazines as useful antiarrhythmic agents in European Patent 0233051, June 19, 1987. A series of phenylpiperazinyl-propranol derivatives are disclosed in U.S. Pat. 4,428,950 by Franke et al., however, the antiarrhythmic activity (if any) is not discussed.
DESCRIPTION OF THE INVENTION
In accordance with this invention, there is provided a group of antiarrhythmic agents classified by their pharmacological profile as Class III antiarrhythmic agents of the formula (I) ##STR1## wherein R 1 is alkylsulfonamido of 1 to 6 carbons, arylsulfonamido of 6 to 10 carbons, perfluoroalkylsulfonamido of 1 to 6 carbon atoms, alkylsulfone or alkylsulfoxide of 1 to 6 carbon atoms, NO 2 , CN, or 1-imidazolyl; R 2 is hydrogen or straight or branched alkyl chain of 1 to 6 carbon atoms; X is O, S, or NR 3 wherein R 3 is H or a straight or branched alkyl chain of 1 to 6 carbon atoms; Y is CH 2 or CHOH; Het is selected from the group consisting of ##STR2## wherein R 4 is H, --NHSO 2 (C 1 to C 6 alkyl) or NO 2 ; Z is O, S, NR 5 wherein R 5 is H or alkyl of 1 to 6 carbon atoms and the pharmaceutically acceptable salts thereof.
The preferred compounds of the present invention are of formula (II) ##STR3## wherein R 1 is methylsulfonamido, or nitro; Y is CH 2 or CHOH; Het is selected from the group consisting of ##STR4## and the pharmaceutically acceptable salts thereof.
The preferred compounds of the present invention are
α-[(4-nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazineethanol;
N-[4-[2-hydroxy-3-[4(2-piperazinyl]propoxy]phenyl]methanesulfonamide;
N-[4-[2-hydroxy-3-[4-(2-pyrimidinyl)-1-piperazinyl]propoxy]phenyl]methanesulfonamide;
(S)-α-[(4-nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazineethanol;
(R)-α-[(4-nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazineethanol;
and the pharmaceutically acceptable salts thereof.
It is to be understood that the definition of the compounds of Formula (I) encompasses all possible stereoisomers and mixtures thereof which possess the activity discussed below. In particular, it encompasses racemic modifications and any optical isomers which possess the indicated activity.
The pharmaceutically acceptable salts of the antiarrhythmic agents of this invention are prepared directly by neutralization of the free base. These physiologically acceptable salts may be formed with organic or inorganic acids, such as hydrochloric, hydrobromic, phosphoric, sulfuric, sulfamic, nitric, methylsulfonic, acetic, maleic, succinic, fumaric, tartaric, citric, salicylic, lactic, napthalenesulfonic acid and the like.
The compounds of this invention of formula (I) wherein Y is CHOH may be prepared by reaction of an appropriately substituted epoxide of formula (III) ##STR5## wherein R 1 and X are as defined above with the required N-substituted piperazinyl moiety of formula (IV) wherein Het is as defined above in solvents such as acetone or acetonitrile. The latter may in turn be prepared from a halo-substituted heterocycle and a suitably protected derivative of piperazine.
When Y is CH 2 , the compounds of formula (I) can be prepared by the reaction of an appropriately substituted aryl compound of formula (V) ##STR6## wherein R 1 and X are as defined above with the required N-substituted piperazinyl moiety of formula (IV) wherein Het is as defined above in the presence of a suitable base in solvents such as acetone or acetonitrile. These reactants are generally known compounds and otherwise are routinely prepared by techniques well within the skill of the chemist.
CORONARY OCCLUSION--REPERFUSION
The compounds of this investigation demonstrate antiarrhythmic activity when tested in the standard experimental animal in accordance with the following procedure.
Pigs (Durrock-Landrace cross) of either sex weighing 12 to 24 kg were anesthetized by administration of sodium pentobarbital. (35 mg/kg i.p. and supplemented with 5 mg/kg/hr. i.v.) and ventilated with room air following tracheotomy (minute volume: 200 mL/kg). The left femoral artery and vein were cannulated for the recording of blood pressure and for drug administration, respectively. Blood pressure and lead II EKG were recorded on a chart recorder.
The heart was exposed by a left thoracotomy performed at the fifth intercostal space. A silk ligature was placed beneath the left anterior descending coronary artery (LAD) about 1.5 cm from its origin and distal to the septal artery branch. The artery was occluded by lifting the vessel with the ligature and quickly placing a bull-dog clamp (3×12 mm padded jaws) over the artery. The clamp remained in place for a period of 20 minutes. Removal of the clamp produced a rapid reperfusion of the ischemic myocardium as evidenced by the return of normal color to the myocardium distal to the site of occlusion. Ectopic activity was monitored during occlusion and reperfusion by recording the lead II EKG at chart speeds of 5 to 25 mm/second. Animals were allowed to stabilize for at least 30 minutes prior to drug administration.
Pigs were randomized into groups receiving either vehicle or test drug at a given dose (1-5 mg/kg i.v.) 20 minutes before LAD occlusion. Animals surviving the period of occlusion were subsequently reperfused. No attempt was made to resuscitate animals experiencing ventricular fibrillation (VF) at any time following occlusion. In the absence of treatment, less than 30 percent of the animals survive the 20 minute period of occlusion, with a mean time to death onset of 8 to 12 minutes. Effective compounds either prevent death due to VF or prolong survival time.
Fraction of pigs surviving occlusion and reperfusion:
______________________________________ Cmpd 1 Cmpd 1 Vehicle 2.5 mg/Kg 5 mg/Kg______________________________________20 min. occlusion 0/4 1/4 4/4Reperfusion -- 0/4 2/4______________________________________
CARDIAC ELECTROPHYSIOLOGY
The compounds of this invention display a Class III antiarrhythmic profile. The Class III antiarrhythmic activity was established in vitro and in vivo in accordance with the following standard test procedures.
In Vitro:
Bundles of free-running Purkinje fibers with attached myocardium obtained from either ventricle of adult dog heart were pinned without stretching to the bottom of a 10 mL tissue chamber and continuously superfused with oxygenated Tyrode's solution at a flow rate of 5 mL/min. The composition of the Tyrode's solution was (mM): NaCl, 138; KCl 4; CaCl 2 , 2; MgCl 2 0.5; NaHCO 3 , 24; dextrose, 5.5. The solution was aerated with 95% O 2 -5% CO 2 at 37° C. Bath temperature was maintained at 37±0.5° C. by circulating the pre-warmed superfusate through a thermostatically controlled water bath immediately prior to entering the tissue chamber.
The preparations were stimulated through bipolar Teflon-coated silver wires, bared at the tips, placed on the endocardial surface of the attached myocardium, using a digital stimulator set to deliver constant current pulses 1.5-msec in duration at cycle lengths of 300 or 1000 msec. Stimulus strength was set at approximately 2×diastolic threshold, and adjusted as required throughout the experiment. All preparations were allowed to equilibrate in the tissue chamber for at least 1 hour before measurements were begun. Subsequently, a minimum of 60 minutes were allowed for equilibration with each drug-containing superfusate before post-drug measurements were made. Impalements were made at 6 to 10 sites throughout the preparation before and after drug exposure. Offset potentials were rechecked after each impalement.
Glass microelectrodes filled with 3M KCl were coupled to high impedance negative capacitance electrometers and Ag/AgCl half-cells used as reference electrodes. The first derivative of the action potential upstroke (V max ) was obtained using an analog differentiator circuit, coupled to a peak-hold circuit that retained the recorded value of V max for 30 to 70-msec. Action potential and V max tracings were displayed on a storage oscilloscope, and photographed for later analysis. In addition, chart paper recordings of Vmax were obtained using the peak-hold device output.
Fresh stock solutions of drug were prepared for each experiment. Compounds were dissolved in distilled water at total concentrations of 1 to 10 mg/mL, and subsequently diluted to a final concentration of 3 to 10 μM in appropriate volumes of normal Tyrode's solution for evaluation.
Action potential (AP) parameters measured included: diastolic take-off potential or activation voltage, (V act ); AP overshoot (V os ); AP duration measured as the time taken to repolarize to -20 mV (APD -20 ), -60 mV (APD -60 ), and -80 mV (APD -80 ); and maximal upstroke velocity (V max ). An increase in APD -60 that occurred without a significant change in V max was taken, by definition, to indicate Class III antiarrhythmic activity "in vitro".
In Vitro:
Mongrel dogs of both sexes weighing 12 to 18 kg were anesthetized with sodium pentobarbital (35 mg/kg i.v. supplemented with 5 mg/kg/h) and artificially ventilated with room air (minute volume: 200 mL/kg).
The heart was exposed by a right thoractomy performed at the fifth intercostal space and suspended in a pericardial cradle. Epicardial electrodes for stimulation and recording were sutured to the free wall of the lower right atrium and near the base of the right ventricle. Each electrode set contained a linear array of electrodes consisting of 1 bipolar stimulating electrode and 2 bipolar recording electrodes embedded in a rigid acrylic matrix. The stimulating bipole was 7 mm from the proximal recording electrode, which in turn was 10 mm from the distal recording bipole. Each electrode array was oriented to be parallel to the epicardial fiber axis.
Arterial blood pressure and lead II ECG were displayed on a chart recorder and monitored on an oscilloscope. Conduction times and refractory periods were measured during pacing at a cycle length of 300 msec. The dog heart was paced by a stimulator driving a constant current isolation unit. Electrical signals from the atrial and ventricular electrodes were displayed on a digital oscilloscope and recorded by a ink-jet recorder. Diastolic threshold was determined before and after each trial.
Refractory periods of the right atrium and right ventricle (AERP and VERP) were determined by introducing an extrastimulus (S 2 ) every 8 paced beats (S 1 ). The extrastimulus was followed by a 4-second rest interval during which no pacing occurred. Both S 1 and S 2 were of identical intensity (twice threshold) and duration (2 msec). The S 1 -S 2 interval was gradually decreased in 2-msec steps until the extra-stimulus failed to induce a propagated response. This S 1 -S 2 interval was considered to define effective refractory period.
Atrial and ventricular (ACT and VCT) conduction times were measured as the time interval between the 2 electrograms recorded at the proximal and distal sites of the recording electrode array. The time of activation for electrograms with predominantly biphasic complexes was taken as the moment when the trace crossed the zero reference line, and for triphasic complexes, as the peak of the major deflection.
Animals received the test compound by i.v. injection. Drugs were administered cumulatively at the following dose levels: 1, 2.5, 5, 7.5, 10 mg/kg. Each dose was administered over a 3 minute period. Electrophysiologic testing was performed 15 minutes following the end of dosing. Every 30 minutes the dog received the next incremental dose.
Vehicle-treated animals did not show any significant change of the electrophysiologic parameters. An increase in ERP that occurred without a significant decrease of CT was taken, by definition to indicate "in vivo" Class III antiarrhythmic activity.
The biological data is set forth in the table below.
__________________________________________________________________________Biological DataPurkinje Fiber 3 μM Anesthetized Dog (5 mg/kg)BCL = 300 BCL = 1000 BCL = 300ExampleAPD.sub.-60 V.sub.max APD.sub.-60 V.sub.max AERP VERP ACT VCT HR BP__________________________________________________________________________1 15 -19 29 ± 6 -8 ± 5 69 ± 7 25 ± 3 16 ± 1 -7 ± 9 -33 ± 1 -33 ± 9(n = 2) (n = 3) (n = 3) (n = 3)5 30 7 50 14 56 13 6 3 -15 -254 16 -12 33 -17 24 13 -4 0 -14 -16__________________________________________________________________________
Based upon the activity profile elicited by the compounds of this invention in the above-described standard scientifically recognized test models, the compounds are established as antiarrhythmic agents useful in the treatment of cardiac arrhythmia and conditions characterized by coronary arteries vasospasm. For that purpose, the compounds may be administered orally or parenterally in suitable dosage forms compatible with the route of administration, whether oral, intraperitoneal, intramuscular, intravenous, intranasal, buccal, etc. The effective dose range determined in the animal test models has been established at from about 1 to about 5 milligrams per kilogram host body weight (preferably from 2 to 10 mg/kg) i.v., and from about 2 to about 10 mg/kg (preferably 5 to 20 mg/kg) p.o., to be administered in single or plural doses as needed to relieve the arrhythmatic dysfunction. The specific dosage regimen for a given patient will depend upon age, pathological state, severity of dysfunction, size of the patient, etc. Oral administration is performed with either a liquid or solid dosage unit in any conventional form such as tablets, capsules, solutions, etc., which comprise a unit dose (e.g. from about 50 milligrams to about 400 milligrams) of the active ingredient alone or in combination with adjuvants needed for conventional coating, tableting, solubilizing, flavoring or coloring. Parenteral administration with liquid unit dosage forms may be via sterile solutions or suspensions in aqueous or oleaginous medium. Isotonic aqueous vehicle for injection is preferred with or without stabilizers, preservatives and emulsifiers.
The following examples illustrate the preparation of a representative number of compounds of this invention.
EXAMPLE 1
α-[(4-Nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazineethanol Dihydrochloride
Step (1) Preparation of 1-p-Nitrophenoxy-2,3-propene
To a solution of p-nitro sodiumphenoxide (30 g, 0.186 mol) in DMF (400 mL) was added allyl bromide (24 mL, 0.28 mol). The reaction mixture was stirred under a nitrogen atmosphere at room temperature for 48 hours, then diluted with water (300 mL) and extracted with ether (3×100 mL). The combined organic fraction was diluted with pentane until it became turbid. It was then washed with water (2×100 mL), dried (MgSO 4 ), and concentrated to afford 27.5 g of product (83%) as a red oil of sufficient purity to use in the next step.
1 H NMR (CDCl 3 ): δ 8.19 (d, 2H, J=8 Hz, ArH), 6.97 (d, 2H, J=8 Hz, ArH), 6.17 (m, 1H,--CH═CH 2 ),5.40 (m, 2H,--CH═CHH 2 ), 4.65 (d, 2H, J=6 Hz, O--CH 2 --).
Step (2) Preparation of 1-p-Nitrophenoxy-2,3-propeneoxide
To a solution of 1-p-nitrophenoxy-2,3-propene (19.25 g, 0.107 mol) in dry methylene chloride (300 mL) was slowly added meta-chloroperbenzoic acid (24.13 g, 0.14 mol). The reaction mixture was stirred under a nitrogen atmosphere for 48 hours. The mixture was filtered and the filtrate was concentrated to afford a yellow residue. Trituration of the yellow residue with ether, yielded the crude product as yellow crystals. Purification by flash chromatography afforded 11.75 g (56%) of product as a light yellow solid, m.p. 63°-65° C.
1 H NMR (CDCl 3 ): δ 8.15 (d, J=8.2 HZ, 2 ArH), 6.95 (d, J=8.2 Hz, 2 ArH), 4.36 and 3.98 (2m,--OCHH 2 --CH), 3.36 (m, 1H, epoxide methine), 2.92 and 2.76 (2m, 2H, epoxide methylene)
Anal. Calcd.: C, 59.19; H, 5.87; N, 6.27. Found: C, 59.51; H, 5.84; N, 6.31.
Step (3) Preparation of α-[(4-Nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazineethanol Dihydrochloride
To a stirred solution of 1-p-nitrophenoxy-2,3-propeneoxide (4.00 g, 20.49 mmol) in acetonitrile (50 mL) was added 1-(2-pyridinyl)piperazine (6.24 mL, 40.98 mmol). The resulting mixture was stirred at reflux for 18 hours, cooled to 20° C., and filtered. The collected solid was treated with ethanolic HCl and ether to afford 6.10 g (69%) of analytically pure dihydrochloride salt as a white powder, m.p. 244°-246° C. (dec.).
1 H NMR (DMSO-D 6 ): δ 10.9 (m, 2H, N⊕H), 8.22 (d, J=9.21 Hz, 2H, ArH), 8.12 (dd, J 1 =1.2 Hz, J 2 =5.4 Hz, 1H, ArH), 7.87 (m, 1H, ArH), 7.21 (m, 1H, ArH), 7.17 (d, J=9.27 Hz, 2H ArH), 6.91 (t, J=6.19 Hz, 1H, ArH), 4.50-4.42 (m, 4e,uns/H/ , --OCH 2 --CH--OH), 4.15 (brd, 2H, --CHOH--CH 2 --N), 3.89-3.15 (brm, 8H, piperazine H's)
IR (KBr): cm -1 3320 (OH), 1600-1500 (NO 2 ).
MS (m/e): 358 (18%), 107 (100%).
Anal. Calcd.: C, 50.12; H, 5.61; N, 12.99. Found: C, 49.96; H, 5.67; N, 12.92.
EXAMPLE 2
(S)-α-[-(4-Nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazine Ethanol Dihydrochloride
Step (1) Preparation of 2-(S)-1,2-Epoxy-3-(p-nitrophenoxy)propane
To a solution of sodium 4-nitrophenoxide (3.18 g, 19.74 mmol) in DMF (20 mL) at 0° C. was added 2-(S) (+)glycidyl-3-nitrobenzenesulfonate (4.00 g, 15.43 mmol). The mixture was stirred for 18 hours under N 2 at 20° C. The reaction mixture was diluted with brine (50 mL) and extracted with ethyl acetate. The combined organic phase was washed with cold 0.1N NaOH water, and brine. The extract was dried (MgSO 4 ) and concentrated to afford 3.0 g of product which was purified by flash column chromatography using 2:1 hexane/ethyl acetate to afford 2.49 g (83%) of product as a white solid, m.p. 73°-75° C.
1 H NMR (CDCl 3 ): δ 8.20 (d, J=9 Hz, 2H, ArH), 7.00 (d, J=9 Hz, 2H, ArH), 4.39 and 4.00 (2m, --OCH 2 --CH), 3.38 (m, 1H, epoxide methine), 2.90 and 2.80 (2m, 2H, epoxide methylene)
[α] D 25 =+10.6° (MeOH).
Step (2) Preparation of (S)-α-[(4-Nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazine Ethanol Dihydrochloride
1-(2-Pyridinyl)piperazine (1.56 mL, 10.26 mmol) was added to a stirred solution of 2-(S)-1,2-epoxy-3-(p-nitrophenoxy)propane (1.00 g, 5.13 mmol) in acetonitrile (15 mL). The resulting mixture was refluxed for 18 hours, cooled, and the precipitated solid was collected by filtration to afford 1.14 g (62%) of product. The material was treated with ethanolic HCl to afford its dihydrochloride salt which was recrystallized from ethanol/ether to afford 1.20 g of analytically pure product as a white solid m.p. 239°-240° C. (dec.) which was identical with the racemate except for rotation.
Anal. Calcd.: C, 50.12; H, 5.61; N, 12.99. Found: C, 49.82; H, 5.49; N, 12.62.
[α] D 25 =-5.88° (DMSO).
EXAMPLE 3
(R)-α-[(4-Nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazine Ethanol Dihydrochloride
Step (1) Preparation of 2-(R)-1,2-Epoxy-3-(p-nitrophenoxy)propane
To a solution of sodium 4-nitrophenoxide (2.38 g, 13.30 mmol) in DMF (15 mL) at 0° C. was added 2-(R)(-)glycidyl-3-nitrobenzenesulfonate (3.00 g, 11.57 mmol). The mixture was stirred for 18 hours under N 2 at 20° C. The reaction mixture was worked up and purified as in Example 2, Step 1 to afford 1.83 g (81%) of epoxide as a white solid, m.p. 75°-76° C.
1 H NMR (CDCl 3 ): δ 8.20 (d, J=9 Hz, 2H, ArH, 7.00 (d, J=9 Hz, 2H, ArH), 4.39 and 4.00 (2m,--OCH 2 --CH), 3.38 (m, 1H, epoxide methine), 2.90 and 2.79 (2m, 2H, epoxide methylene)
[α] D 25 =-11.0° (MeOH).
Step (2) Preparation of (R)-α-[(4-Nitrophenoxy)methyl]-4-(2-pyridinyl)-1-piperazine Ethanol Dihydrochloride
1-(2-Pyridinyl)piperazine (1.56 mL, 10.26 mmol) was added to a stirred solution of 2-(R)-1,2-epoxy-3-(p-nitrophenoxy)propane (1.00 g, 5.13 mmol) in acetonitrile (15 mL). The resulting mixture was refluxed for 18 hours, cooled, and the precipitated product was collected by filtration. Yield: 1.15 g (63%). The dihydrochloride salt was prepared by treatment with ethanolic HCl and was recrystallized from ethanol/ether to afford 1.20 g of analytically pure white solid, m.p. 242°-244° C. (dec.) which was identical with the racemate except for rotation.
Anal. Calcd.: C, 50.12; H, 5.61; N, 12.99. Found: C, 49.70; H, 5.53; N, 12.66.
[α] D 25 =+6.50° (DMSO).
EXAMPLE 4
N-[4-[2-Hydroxy-3-[4-(2-pyrimidinyl)-1-piperazinyl]-propoxy]phenyl]methanesulfonamide
Step (1) Preparation of α-[(4-Nitrophenoxy)methyl]-4-(2-pyrimidinyl)-1-piperazineethanol Dihydrochloride
1-(2-Pyrimidinyl)piperazine (1.65 g, 10.06 mmol) and 1,2-epoxy-3-(p-nitrophenoxy)propane, prepared by the process of Example 1, Step 2, (1.31 g, 6.71 mmol) were refluxed in acetonitrile (30 mL) for 5 hours. The reaction was subsequently stirred at 25° C. for 24 hours, concentrated to dryness, and the resulting residue was triturated with ether/hexane to afford 1.57 g (62%) of product as a white solid which was taken on without further purification. A small amount was converted into its dihydrochloride salt for analysis.
1 H NMR (DMSO-D 6 ): δ 10.69 (br s, 2H, N.sup.⊕ H), 8.44 (d, J=4.67 Hz, 2H, ArH), 8.22 (d, J=9.27 Hz, 2H, ArH), 7.17 (d, J=9.26 Hz, 2H, ArH), 6.76 (m, 1H, ArH), 4.85 (br m, 1H, --OH), 4.66 (m, 2H, --OCH 2 --CHOH), 4.49 (m, 1H, OCH 2 --CHOH), 4.15 (br d, 2H, CH 2 N), 3.70-3.10 (br m, 8H, piperazine H's)
IR (KBr, cm -1 ): 3300 (OH).
MS (m/e): 359 (M.sup.⊕, 60%), 177 (100%).
Step (2) Preparation of α-[(4-Aminophenoxy)methyl]-4-(2-pyrimidinyl)-1-piperazineethanol
α-[(4-Nitrophenoxy)methyl]-4-(2-pyrimidinyl)-1-piperazineethanol dihydrochloride (1.32 g, 3.68 mmol) was hydrogenated in a Parr reactor using 5% Pd/C (0.198 g, 15% by wt) in ethyl acetate (40 mL). After 5 hours, the mixture was filtered through solka floc and the filtrate was concentrated to afford 1.2 g (100%) of product as a pale oil of sufficient purity for use in the next step.
1 H NMR (CDCl 3 ): δ 8.25 (d, J=5.4 Hz, 2H, ArH), 6.72 (d, J=9.0 Hz, 2H, ArH), 6.59 (d, J=9.2 Hz, 2H, ArH), 6.45 (m, 1H, ArH), 4.10 (m, 1H, --CHOH), 3.90 -3.50 (m, 9H, OCH 2 -CHOH, NH 2 , 4 piperazine CH 2 ), 2.80-2.40 (m, 6H, CH 2 --N, 4 piperazine CH 2 ).
Step (3) Preparation of N-[4-[2-Hydroxy-3-[4-(2-pyrimidinyl)-1-piperazinyl]propoxy]phenyl]methanesulfonamide
Methanesulfonyl chloride (0.31 mL, 4.01 mmol) was added dropwise to a stirred solution of α-[(4-aminophenoxy)methyl]-4-(2-pyrimidinyl)-1-piperazine-ethanol (1.20 g, 3.65 mmol) in pyridine (15 mL) at -30° C. under N 2 . The reaction was stirred at 25° C. for 1.5 hours. Ice water was added, and the resulting mixture was extracted with ethyl acetate. The organic phase was dried (MgSO 4 ), decolorized (charcoal), and concentrated to afford a residue. Trituration followed by recrystallization from methanol/ethyl acetate/hexane afforded 0.65 g (44%) of analytically pure product, m.p. 143°-146° C. as a tan solid.
1 H NMR (DMSO-D 6 ): δ 9.35 (s, 1H, CH 3 SO 2 NH), 8.35 (d, J=4.77 Hz, 2H, ArH), 7.15 (d, J=8.72 Hz, 2H, ArH), 6.93 (d, J=8.72 Hz, 2H, ArH), 6.61 (m, 1H, ArH), 4.92 (m, 1H, OH), 3.98 (m, 2H, OCH 2 CHOH), 3.87 (m, 1H, OCH 2 CHOH), 3.71 (m, 4H, piperazine CH 2 ), 2.88 (s, 3H, CH 3 SO 2 NH), 2.49 (m, 6H, CH 2 N and piperazine CH 2 )
IR (KBr, cm -1 ): 3120 (OH).
MS (m/e): 407 (M.sup.⊕, 10%), 177 (100%).
Anal. Calcd.: C, 53.06; H, 6.18; N, 17.19. Found: C, 52.81; H, 5.84; N, 16.84.
EXAMPLE 5
N-[4-[2-Hydroxy-3-[4-(2-pyridinyl)-1-piperazinyl]propoxy]phenyl]methanesulfonamide
Step (1) Preparation of 3-[(4-Amino)phenoxy]-1-propene
To 3-[(4-nitro)phenoxy]-1-propene prepared by the process of Example 1, Step 1, (12.65 g, 70.67 mmol) in concentrated HCl (85 mL) at 0° C. was slowly added stannous chloride (48 g, 212 mmol). After stirring for 20 minutes at 55° C., the mixture was cooled to 0° C. and carefully basified with 50% NaOH. The cloudy mixture was extracted with ether. The organic phase was decolorized (charcoal), dried (MgSO 4 ), and concentrated to afford product (8.50 g, 81%) as a yellow oil which was used directly in the next step.
1 H NMR (CDCl 3 ): δ 7.05 (m, 4H, ArH), 6.4 (m, 1H, OCH 2 --CH═CH 2 ), 5.70 (m, 2H, CH 2 CH═CH 2 ), 4.80 (d, 2H, OCH 2 CH═CH 2 ).
Step (2) Preparation of N-[4-(2-Propeneoxy)phenyl]methanesulfonamide
Methanesulfonyl chloride (5.06 mL, 65.32 mmol) was added to a stirred solution of 3-[(4-amino)phenoxy]-1-propene (8.11 g, 54.43 mmol) in pyridine (80 mL) at 0° C. The mixture was stirred for 72 hours and was then poured slowly into ice-water and extracted with ether. The organic phase was washed with cold 1N HCl and was then extracted with 1N NaOH solution. The aqueous phase was acidified and the product (9.05 g, 73%) precipitated out as a white solid.
1 H NMR (CDCl 3 ): δ 7.18 (d, J=6.75 Hz, 2H ArH), 6.88 (d, J=8.94 Hz, 2H ArH), 6.00 (m, 1H, CH 2 CH═CH 2 ), 5.40 and 5.30 (2m, OCH═CH 2 ), 4.50 (m, OCH 2 CH═CH 2 ).
Anal. Calcd.: C,52.85; H,5.76; N,6.16.
Found: C,52.80; H,5.63; N,5.99.
Step (3) Preparation of 1-[(4-Methanesulfonamido)phenoxy]-2,3-propeneoxide
m-Chloroperoxybenzoic acid (12.16 g, 70.48 mmol) was added to a solution of N-[4-(2-propeneoxy)phenyl]methanesulfonamide (8.00 g, 35.24 mmol) in methylene chloride (120 mL). The mixture was stirred overnight at reflux, cooled, and filtered. Concentration afforded crude product which was purified by flash chromatography using 1:1 hexane/ethyl acetate. Yield 5.55 g (65%) of white solid.
1 H NMR (CDCl 3 ): δ 7.17 (d, J=6.87 Hz, 2H ArH), 6.90 (d, J=8.93 Hz, 2H, ArH), 6.40 (br s, NHSO 2 CH 3 ), 4.20 (dd, J 1 =5.54 Hz, J 2 =2.98 Hz, 1H, epoxide CH 2 ), 3.90 (dd, H 1 =5.54, J 2 =5.78 Hz, 1H, epoxide CH 2 ), 3.35 (m, 1H, epoxide CH), 2.94 (s, 3H, NHSO 2 CH 3 ), 2.90 and 2.76 (2m, OCH 2 ).
IR (KBr): 3240 (NH).
MS (m/e): 243 (60% M + ), 164 (100%).
Step (4) Preparation of N-[4-[2-Hydroxy-3-[4-(2-pyridinyl)-1-piperazinyl]propoxy]phenyl]methanesulfonamide
To a stirred solution of 1,2-epoxy-3-(p-methanesulfonamidophenoxy)propane (2.00 g, 8.22 mmol) in acetonitrile (18 mL) was added 1-(2-pyridinyl)piperazine (2.50 mL, 16.44 mmol) and the resulting mixture was refluxed for 18 hours. Upon cooling, 1:1 hexane/ether (30 mL) was added and the resulting mixture was filtered. The collected product was continually triturated with ether and then dried overnight in vacuo to afford 2.19 g (66%) of analytically pure product as an off-white solid, m.p. 131°-132° C.
1 H NMR (DMSO-D 6 ): δ 9.33 (br s, 1H,--NHSO 2 CH 3 ), 8.08 (m, 1H, ArH), 7.50 (m, 1H, ArH), 7.13 (d, J=8.91 Hz, 2H, ArH), 6.92 (d, J=9.01 Hz, 2H, ArH), 6.78 (d, J=8.62, 1H, ArH), 6.61 (m, 1H, ArH), 4.89 (br d, J=4.12 Hz, 1H, --OH), 3.95 (m, 2H, --OCH 2 CHOH), 3.85 (m, 1H, --OCH 2 CHOH), 3.44-3.30 (m, 10H, CH 2 N), 2.86 (s, 3H, --NH SO 2 CH 3 )
IR (KBr, cm -1 ): 3200 (OH).
MS (m/e): 407 (MH.sup.⊕, 40%).
Anal. Calcd.: C, 56.14; H, 6.45; N, 13.78.
Found: C, 55.90; H, 6.56; N, 13.93.
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This invention relates to certain substituted piperazines possessing anti-arrhythmic activity, to pharmaceutical compositions and to methods for production thereof.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of Ser. No. 11/698,141 filed on Jan. 26, 2007 and entitled “Wastewater Flow Equalization System and Method” and now U.S. Pat. No. ______.
BACKGROUND OF THE INVENTION
[0002] This invention is an improvement in wastewater treatment plants or systems, particularly home aeration systems, which experience periodic process upsets of varying load conditions which reduce efficiency. Heretofore the assignee of the present invention patented a wastewater treatment system under U.S. Pat. No. 5,413,706 issued on May 9, 1995 which particularly provided novel flow equalization ports so as to maintain efficiency of the wastewater treatment system even during process upsets or varying load conditions.
[0003] In the latter patent the wastewater treatment mechanism 250 of FIGS. 10 through 17 is most representative of prior art and reflects flow equalization provided by three diametrically opposite pairs of vertically spaced flow equalization ports defined by (i) a lowermost diametrically opposite pair of design flow equalization ports, thereabove (ii) a pair of diametrically opposite sustained flow equalization ports, and (iii) a pair of uppermost diametrically opposite peak flow equalization ports. Two or more of the latter pairs of flow equalization ports build up a static head of the wastewater on the upstream side of the wastewater treatment mechanism when the incoming wastewater flow rate exceeds the ability of the flow equalization ports to pass the wastewater at the given static head. The elevation of the lowest pair of diametrically opposite design flow equalization ports determines the normal operating wastewater level of the entire wastewater plant. The second next upper pair of diametrically opposite sustained flow equalization ports are located approximately 3½″ above the first diametrically opposite design flow equalization ports and come into play as the induced stream static head continues to increase as liquid level rises upstream. The higher the hydraulic head, the greater the pressure and, therefore, the more water which will proportionately flow out of the lower pair of design flow equalization ports until the next upper pair of sustained flow equalization ports come into operation. In this manner the demand rate flow is achieved at minimal wastewater level fluctuation and minimum hydraulic currents. Finally, should prolonged and excessive incoming wastewater flow exceed the ability of both lower levels of flow equalization ports to pass the wastewater, the pair of uppermost diametrically opposite large size peak flow equalization ports become effective to pass the remaining flow. Over many years the latter wastewater flow equalization mechanism has assured efficient operation, particularly with respect to installation as part of a typical residential/home wastewater aeration system.
[0004] The assignee's U.S. Pat. No. 5,413,706 was designed to afford optimum flow equalization for a wastewater treatment plant receiving flow according to a pattern devised by NSF International which was industry developed and accepted to represent a “typical” residential wastewater flow pattern. Most of the data used to derive this wastewater flow pattern came from studies of flow patterns of municipal collecting systems receiving residential wastewater. As such, this pattern represents collective flows, in toto, from a number of residences and small commercial installations. However, each installation has its own unique individual flow pattern based upon a variety of factors. These factors are made up of an infinite number of variables including the number of residents or visitors, the number of plumbing fixtures, lifestyles, etc. However, once these factors are established for each installation, they are likely to stay relatively stable over a time and are generally repeatable. Therefore, having this ability to adapt the flow equalization equipment to the individual characteristics of each wastewater flow pattern allows optimum flow equalization for each unique installation. Such has been provided by the assignee of the latter patent over years of its manufacture and installation of the subject matter thereof.
SUMMARY OF THE INVENTION
[0005] Through many years of sales, installation and servicing of the wastewater treatment system of U.S. Pat. No. 5,413,706, the assignee has found that no matter how carefully one might engineer and install the wastewater treatment mechanism 250 of the latter patent and particularly the sizes of the three diametrically opposite pairs of vertically spaced flow equalization ports 267 , 268 and 269 formed in a peripheral wall 256 of an outer unit 251 of the wastewater treatment mechanism 250 , optimum equalization of wastewater flow or demand rate flow may not necessarily occur. As an example of one problem, a residential or home wastewater treatment installation with which the wastewater treatment mechanism is installed might have, for example, three bedrooms, two baths and typically clothes and dish water outlets. If, at the time of installation, the house is occupied by a husband, wife and two children, the sizing of the flow equalization ports based upon past experience can be readily determined with a high degree of accuracy and, barring changes in usages, no future problems should be expected. However, should this hypothetical family grow to include an additional four children, the original wastewater treatment installation might be severely taxed and, instead of operating at its most efficient level (design flow equalization ports), it might operate predominantly under overflow conditions (peak flow equalization ports) which is highly undesired. If the original house assumed to have the three bedrooms, four occupants, etc. was expanded to include further bathroom facilities and should bathroom, shower and clothes washing increase as children grow older and/or the number of children increase the original wastewater treatment installation would most definitely be pushed to the extreme and process failure could occur.
[0006] In keeping with the foregoing, the present invention is directed to a novel wastewater treatment mechanism which includes at a minimum at least one, though preferably two, design flow equalization ports. In the case of a single design flow equalization port, the design flow equalization port would be located at the design flow level of the wastewater treatment mechanism, as is now located the pair of design flow equalization ports of the latter patent. Instead of the single design flow equalization port and no other ports, the wastewater treatment mechanism might instead include a pair of diametrically opposite design flow equalization ports, just as in the latter patent, though no other ports thereabove. In each case the wastewater treatment mechanism would include a container having a peripheral wall and a bottom wall with the peripheral wall being exteriorly surrounded by one or more filters and the peripheral wall including means cooperative with the design flow equalization port or ports to effect relative insertion, removal and/or replacement therebetween.
[0007] As one example of the present invention, the peripheral wall of the container might be provided with a pair of diametrically opposite openings which are relatively large and into each of which can be removably secured a flow port member which itself includes a single design flow equalization port of a particular size and specifically a size smaller than the peripheral wall opening. The design flow equalization port of the diametrically opposite flow port members includes an axis below the axis of the peripheral wall opening and the size of each design flow equalization port would be selected so as to accommodate the design flow characteristics of wastewater from a particular single family home wastewater treatment installation, such as that earlier first assumed. Under the previously assumed initial conditions of two adults and two children and based upon past experience of the assignee, there would be little doubt that the wastewater treatment mechanism as just described would be highly efficient. However, as is customary during scheduled maintenance and inspection of wastewater treatment mechanisms or upon automatically generated alarms therefrom, it might well become apparent that the design flow equalization ports are operating inefficiently, particularly years after installation and as the hypothetical family has grown, its numbers increase and wastewater flow correspondingly appreciably increases.
[0008] In keeping with the present invention, under physical inspection during scheduled maintenance or repair or upon an automatic alarm, the less than desired efficiency of the design flow equalization ports is readily observed, particularly by the maximum height or maximum range of heights of wastewater reflected upon an exterior surface of the filter member surrounding the peripheral wall containing the flow equalization ports. Solids filtered from the wastewater which do not pass through this filter accumulate upon the exterior thereof to a greater or lesser degree depending upon the upstream head as induced by the pair of design flow equalization ports. If the pair of flow equalization ports are undersized, the “normal” operating liquid level of the wastewater will rise together with solids which accumulate on the upstream side (outside) of the filter. If upon examination of the filter, an extremely high liquid level is observed because of the large amount of solids/sludge/biosolids/scum layer or mat deposited upon the exterior of the filter above the design flow equalization ports, the service personnel knows intuitively and through experience that the design flow equalization ports are undersized. The flow port members are simply removed and both are replaced by a flow port member having a larger flow equalization port than those first installed in the wastewater treatment mechanism. As one example, each of the initial flow port members might have a flow equalization port of ¼″ diameter which might be considered, for example, the “standard” design flow equalization port size formed in a “standard” flow port member of a “standard” 1¾″ outer diameter accommodated in like sized openings of the container peripheral wall. The service personnel, having quickly recognized from the observed high level or high range of levels of the solids/particulates/scum upon the filter would therefrom necessarily determine that the original design flow equalization ports are now “undersized” to achieve present day (increased family size) flow demands. The pair of flow port members would be removed and, based upon judgment and experience, would each be replaced by another flow port member having a larger design flow equalization port, such as 5/16″, ⅜″, 7/16″, and in reality any diameter up to and virtually including the 1¾″ diameter of the peripheral wall openings. By so readily and easily removing and replacing one, two or more flow port members with desired sizes/diameters of flow equalization ports otherwise inefficient flow equalization of the wastewater treatment system is rendered very efficient in an inexpensive and rapid fashion.
[0009] In further accordance with this invention, the flow port members are each preferably cup-shaped and each includes a peripheral wall and an end wall with a flow equalization port being formed in the end wall thereof. In addition, the opening in the peripheral or cylindrical wall of the wastewater treatment container is also circular, but the latter and the peripheral wall of the flow port member preferably include a registrable radial projection and slot which assures that each flow port member is properly oriented and inserted into the wastewater treatment container wall opening with the flow equalization port thereof disposed bottommost (six o'clock position) in every installation and for every size of flow equalization port.
[0010] In further accordance with the invention, there is preferably one diametrically opposite pair of flow port members associated with each wastewater treatment container wall and an identical diameter flow equalization port associated with each. However, in accordance with the present invention, additional flow equalization ports can be provided in diametrically opposite pairs, preferably above the removable flow port members of the present invention, and the uppermost flow equalization ports may be stationary or removable and may be of the same or varying sizes, depending upon the particular design liquid level of a particular wastewater treatment installation.
[0011] With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 is a fragmentary longitudinal cross-sectional view of a novel wastewater treatment plant constructed in accordance with this invention, and illustrates a clarification chamber housing a novel wastewater treatment mechanism of the present invention.
[0013] FIG. 2 is an enlarged axial cross-sectional view taken through the wastewater treatment mechanism of FIG. 1 , and illustrates an outermost micronically molded filter media or wall, a next inner molded filter media retainer and spacer housing or container, and in an upper portion of a peripheral wall of the latter at least one opening housing an insertable and removable flow port member having a design flow equalization port therein.
[0014] FIG. 3 is an exploded perspective view of the wastewater treatment mechanism of FIGS. 1 and 2 , and illustrates the major components thereof including chlorination and de-chlorination tubes, an exterior uppermost cover, and a plurality of outwardly projecting integral wall portions of the molded filter media retainer and spacer housing for spacing the outermost filter media relative thereto.
[0015] FIG. 4 is an exploded partial fragmentary view of the upper wall portion of the peripheral or cylindrical wall of the molded filter media retainer and spacer housing, and illustrates a circular opening therein prior to the insertion of the flow port member and its associated design flow equalization port.
[0016] FIG. 5 is a perspective view similar to FIG. 4 , and illustrates the inside of the retainer and spacer housing cylindrical wall after the design flow equalization member has been inserted therein with a locating rib and locating recess of the latter elements being interlocked to accurately locate the design flow equalization port at a lowermost portion of the flow port member.
[0017] FIG. 6 is a fragmentary elevational view looking from the inside of the retainer and spacer housing cylindrical wall, and illustrates the diametrically opposite relationship between the locating rib and locating recess and the design flow equalization port.
[0018] FIG. 7 is an enlarged cross-sectional view taken generally along line 7 - 7 of FIG. 6 , and illustrates details of the locating rib of the flow port member snap-secured into the locating recess or slot in a peripheral edge portion of the circular opening.
[0019] FIG. 8 is a fragmentary elevational view of the outside of the molded filter media or wall, and illustrates in the background an upper peak flow equalization port, a next lower sustained flow equalization port, and in the broken away portion, the flow port member and the design flow equalization port thereof, and with an exterior of the filter media or wall being stippled to indicate an undesirably high accumulated scum layer above the peak flow equalization port evidencing the necessity of increasing the size of the design flow equalization port.
[0020] FIG. 9 is a fragmentary elevational view of the outside of the molded filter media of FIG. 8 , and illustrates in the background the upper peak flow equalization port, the next lower sustained flow equalization port, and illustrates through stippling a lowering of the scum line of the scum layer of FIG. 8 upon utilizing a larger design flow equalization port in a flow port member of FIG. 9 substituted for the flow port member of FIG. 8 .
[0021] FIG. 10 is a fragmentary elevational view of the outside of the molded filter media of FIGS. 8 and 9 , and illustrates in the background the upper peak flow equalization port, the next lower sustained flow equalization port, and an acceptable height of the scum line of the scum layer after a yet larger design flow equalization port of another flow port member was substituted in FIG. 9 for the flow port member of FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
[0022] The novel apparatus, mechanism and method disclosed specifically hereinafter includes improvements in the wastewater treatment plant of U.S. Pat. No. 5,413,706 dated May 9, 1995 in the name of Jan D. Graves and assigned to Norwalk Wastewater Equipment Company (NORWECO), and the totality of the disclosure of the latter patent is incorporated herein by reference. Much of comparable elements of the latter patent which correspond to elements herein will be described briefly utilizing identical reference numerals to thereby assure compliance with 35 U.S.C. § 112, the first paragraph thereof.
[0023] In keeping with the present invention, a novel wastewater treatment plant ( FIG. 1 ) is generally designated by the reference numeral 10 and is normally designed for residential use, such as individual homes, although the same is readily adapted to many other facilities and utilizes well known digestion processes of wastewater or like fluid treatment.
[0024] The wastewater treatment plant 10 includes an upper concrete casting 11 having two cylindrical risers or castings 12 of which only one is illustrated and which defines a generally cylindrical chamber 14 closed by a cover 16 providing access above finished grade G.
[0025] The riser 12 projects upwardly from a top wall 20 of the upper casting 11 which is bound by a peripheral wall 21 , closed by a bottom wall (not shown) and includes intermediate walls (also not shown) to form various chambers of the wastewater treatment plant 10 , such as a pretreatment chamber (not shown) into which wastewater is introduced, an aeration chamber 35 and a final clarification chamber 36 . Incoming wastewater (organic flow and solids) is introduced into the pretreatment chamber, flows into the aeration chamber 35 and exits the aeration chamber through a transfer port (not shown) in the bottom of a wall 29 separating the aeration chamber 35 from the clarification chamber 36 , as is fully described in patentee's U.S. Pat. No. 5,667,689 granted on Sep. 16, 1997. Wastewater flow currents are created in the bottom of the clarification chamber 36 through a flow augmenting device 37 having an inlet portion 38 opening into the bottom of the clarification chamber 36 adjacent the earlier mentioned transfer port in the wall 29 resulting in the agitation of solid particles in the lower portion of the clarification chamber 36 , as fully disclosed in U.S. Pat. No. 5,667,689 and U.S. Pat. No. 5,868,172 granted on Feb. 9, 1999. The wastewater W, including scum, biosolids, etc. enters the clarification chamber 36 and rises upwardly along the exterior of a novel wastewater treatment mechanism 50 of the invention eventually departing therefrom through a discharge effluent pipe 41 ( FIGS. 1 and 2 ).
[0026] The wastewater treatment mechanism 50 will now be described with particular reference to FIGS. 1 through 3 of the drawings with the direction of wastewater/effluent flow into, through and out of the wastewater treatment mechanism 50 being evident therefrom and as more specifically described in U.S. Pat. No. 5,413,706.
[0027] The individual major components of the wastewater treatment mechanism 50 includes filtering means 70 , housing means 80 inboard thereof for retaining and spacing the filtering means 70 , an innermost housing 90 which houses therein a baffle plate assembly 110 closed by an upper closure assembly 120 upon which is supported a dry tablet chlorination tube 140 and a dry tablet de-chlorinization tube 180 , and an uppermost and outermost closure or cover 60 ( FIG. 2 ).
[0028] The filtering means 70 is a one-piece cylindrical micronically molded polymeric/copolymeric flow filter media or wall formed as two cylindrical filters of different meshes, namely, a lower relatively fine mesh cylindrical filter media wall 71 and thereabove a more coarse cylindrical filter media wall 72 .
[0029] The filtering means 70 is conventionally secured to the exterior of the housing means 80 which is also molded from synthetic polymeric/copolymeric material to define a retainer and spacer housing or container 80 having lower circular bottom wall 81 , a cylindrical wall 82 , a single radially inwardly directed cylindrical rib or multiple radially inwardly directed cylindrically spaced ribs or supporting portions 83 , a plurality of outwardly directed vertically and circumferentially spaced filter media retainer and spacer ribs or projections 85 ( FIG. 3 ), an uppermost radially outwardly directed peripheral rim 86 having a plurality of locking lugs 87 for conventionally locking thereto the uppermost closure 60 ( FIG. 2 ), and an uppermost cylindrical wall portion 88 .
[0030] Most importantly, the present invention includes the utilization of at least one but preferably two diametrically opposite means 260 ( FIGS. 1 through 8 ) in the upper cylindrical wall portion 88 of the filter media retainer and spacer housing 80 for achieving design wastewater flow equalization when the wastewater W is at or somewhat above the liquid level L in accordance with pre-established design flow characteristics. The upper portion 88 of the cylindrical retainer and spacer housing 80 also includes a diametrically opposite pair of sustained flow equalization ports 261 and thereabove another and somewhat larger diametrically opposite pair of peak flow equalization ports 262 which will be described more fully hereinafter. However, subsequent to achieving desired flow equalization and wastewater treatment, the treated wastewater is discharged from the wastewater treatment mechanism 50 via effluent line 41 through the intermediary of a two-part relatively sliding flange coupler 450 ( FIG. 2 ) including a first flange coupler 451 retained in the peripheral wall 21 of the upper casting 11 ( FIG. 1 ) and sealingly bonded to the discharge effluent pipe 41 , and a second flange coupler 452 connected to the retainer and spacer housing 80 and having a vertical flange 456 all cooperatively functioning as specifically set forth in U.S. Pat. No. 5,413,706. The latter vertical sliding arrangement between the flange couplers 451 , 452 permits the wastewater treatment mechanism 50 to be vertically inserted in and withdrawn from the clarification chamber 36 upon removing the outermost cover 16 ( FIG. 1 ). Upon removing the entire wastewater treatment mechanism 50 to a point above finished grade G, the exterior of the filtering means 70 is readily visible for the purpose heretofore described which will be more fully described hereinafter to determine whether the wastewater treatment mechanism 50 is operating efficiently and within desired flow characteristic design parameters.
[0031] The hydraulic head of the wastewater is, as was heretofore briefly described, determined by the wastewater level L ( FIG. 1 ) and the rate of flow of the wastewater/effluent through the wastewater treatment mechanism 50 will depend upon the head or height of the wastewater W in the wastewater clarification chamber 36 , the rate of flow of the wastewater through the lower filter wall or media 71 , the upper filter wall or media 72 , etc., the size of the solids or particulates involved during filtration, settling, etc., and most importantly the pairs of flow equalization ports 261 , 262 and a design flow equalization port 263 in each of a pair of diametrically opposite flow port member 260 . Under “normal” hydraulic head, the level L of the wastewater W is generally at, slightly below or slightly above the level L of FIG. 1 which approximates the position of the one or a diametrically opposite pair of flow port members 260 , each of which includes the design flow equalization port 263 ( FIGS. 1 , 2 and 4 through 7 ) located in a circular end wall 264 which merges with a peripheral wall 265 and terminates in a radially outwardly directed peripheral flange 266 . Under the first assumed residential installation, each flow equalization port 263 is ¼″ diameter. Each flow port member 260 further includes a circumferential radially outwardly directed securing rib 267 and diametrically opposite the design flow equalization port 263 is a radially outwardly directed locating wall portion, projection or rib 268 . The outermost diameter of the peripheral or circumferential rib 267 is slightly greater than the diameter of an opening 165 ( FIG. 7 ) in the upper portion 88 of the retainer and spacer housing 80 , and is slightly smaller than the diameter of the rib 267 and appreciably smaller than the maximum diameter of the peripheral wall 265 and the terminal peripheral flange 266 . The openings 165 , 165 are diametrically opposite each other in the upper wall portion 88 of the retainer and spacer housing 80 and each opening 165 includes a locating slot or notch 168 which registers with the locating rib or projection 268 , as is most evident in FIGS. 5 and 6 . The rib 268 and slot 168 thereby cooperatively define locating means for assuring that the design flow equalization port 263 is at a lowermost position of the circular end wall 264 with an axis Ap ( FIG. 6 ) of the design flow equalization port 263 being in vertical alignment with a central axis Ao of the opening 165 and in a plane vertically bisecting the slot or notch 168 and the rib 268 . The latter locating means thereby locates volute V, which is the lowest portion of each design flow equalization port 263 , in horizontal alignment or in the same horizontal plane as the design flow line or liquid level L ( FIG. 1 ). Accordingly, in the scenario heretofore described of a residence or house occupied initially by two adults and two small children, a single properly sized design flow equalization port 263 in a single flow port member 260 would efficiently achieve desired wastewater treatment and no additional flow equalization ports, such as the flow equalization ports 261 , 262 , disposed each individually or in diametrically opposite pairs would be required.
[0032] However, in one preferred embodiment of the invention, there are two diametrically opposite circular openings 165 formed in the upper wall portion 88 of the retainer and spacer housing 80 with each of the openings receiving in snap-secured relationship thereto one of the flow port members 260 with its associated design flow equalization port 263 located with its volute V in the horizontal plane of the design flow line L ( FIG. 1 ). In this case, the opposite pairs of sustained flow equalization ports 261 and peak flow equalization ports 262 could be totally eliminated (not shown) or retained, as illustrated in FIGS. 1 and 2 . Alternatively, the diametrically opposite pair of flow equalization ports 261 , 261 could be eliminated, leaving only the flow equalization ports 262 , 262 and 263 , 263 or, alternatively, the pair of diametrically opposite flow equalization ports 262 , 262 can be eliminated leaving only the diametrically opposite pairs of flow equalization ports 261 , 263 . If all three pairs of flow equalization ports 261 , 262 and 263 are retained, the diameter of all is preferably the same and preferably corresponds to the diameter of the design flow equalization ports 263 , 263 of the wastewater treatment mechanism 50 when initially installed. This initial sizing of all three pairs of flow equalization ports 261 , 261 ; 262 , 262 and 263 , 263 is possible because each of the flow port members 260 can be subsequently removed at any time, even after years of initial installation, to be replaced by like flow port members except each would include a larger diameter flow equalization port in each wall 264 thereof, as will be more apparent hereinafter.
[0033] Under the first assumed residential installation occupied by two adults and two children, the level L of the wastewater W would be clearly reflected upon the exterior of the lower cylindrical filter wall 71 and would under perfect flow conditions vary in vertical height ranging two to three inches above the level L ( FIG. 1 ), perhaps at times approaching the sustained flow equalization ports 261 , 261 but rarely reaching the same.
[0034] Since the clarification chamber 36 receives settled, but not filtered, treated wastewater, the outer surface of the filter media 70 below a particular liquid level L or a range of varying liquid levels takes on a “dirty brown” appearance from the presence of solids, solid particulates, sludge, scum, etc. If a surge occurs raising the liquid level in the clarification chamber 36 beyond a single design flow equalization port or a pair of diametrically opposite ports 263 and the liquid is metered out therethrough over time and eventually returns the liquid level to the design flow level L, under such circumstances, there is usually a corresponding staining of the filter wall 70 and an upper visually apparent brown line or sludge line SL forms on the exterior of the filter wall 70 above the design flow liquid level ( FIG. 1 ). The density of this sludge line SL and/or the amount of solids retained on the exterior surface of the filter wall 70 is usually directly proportional to the volume or duration of such surges. Visual inspection of this darkened area above the design flow level L up to the brown line or sludge line SL dictates that the system would benefit from a larger design flow port to allow such surges to exit the system more quickly and not raise the liquid level L in the clarification chamber 36 to an undesired vertical height or for an undesired long period of time. Thus, by providing a removable/adjustable design flow equalization port member or insert 260 of a single generally standard exterior diameter, but with different diameter design flow equalization ports 263 , better efficiency and lower operational life between service visits can be readily accomplished which, of course, is not provided by the system of U.S. Pat. No. 5,413,706.
[0035] Returning to the first assumed residential installation, during regular servicing when the wastewater treatment mechanism 50 is removed from the final clarification chamber 36 , the location of the scum line SL of FIG. 1 is readily apparent to the service person. Since the scum line SL is within the desired design wastewater flow characteristics (between the design and sustained flow equalization ports 263 , 261 , respectively), no change is required with respect to the size of the design flow equalization ports 263 , 263 of the flow port members 260 , 260 . The entire wastewater flow mechanism 50 can under these assumed conditions be thoroughly clean, rinsed, flushed and otherwise serviced and then replaced to the original position illustrated in FIG. 1 of the drawings.
[0036] Assuming, as was done earlier, that the number of children increase, additional bathroom facilities are added, etc., a time may come when desired design minimal wastewater level fluctuations and minimum hydraulic currents are appreciably exceeded to the extent that the level L of the wastewater W ( FIG. 1 ) not only rises above the sustained flow equalization ports 261 , 261 but extends well above the same even beyond the filter wall 71 and to the filter wall 72 eventually forming another scum line SL′ ( FIG. 8 ) The scum line SL′ is undesirably vertically beyond the design flow equalization ports 263 , 263 , the sustained flow equalization ports 261 , 261 and, well beyond even the peak flow equalization port 262 , 262 and well within the coarse filter wall 72 , as is reflected by stippling appearing thereon. Trained service personnel during regular maintenance would first observe the undesirably high location of the scum line SL′ ( FIG. 8 ), and thereafter thoroughly clean the exterior surface of the filter walls 71 , 72 , as well as the totality of the interior, exterior and all components of the wastewater treatment mechanism 50 . However, recognizing that the location of the scum line SL′ visually depicts inefficient operation of the wastewater treatment mechanism 50 specifically because of the now recognized undersizing of the original design flow equalization ports 263 , 263 /flow port members 260 , 260 relative to present increased flow, the latter would each be removed and replaced by another flow member 260 ′ ( FIG. 9 ) having a design flow equalization port 263 ′ larger than the design flow equalization port 263 . The particular new diameter size of the design flow equalization port 263 ′ of each flow port member 260 ′ would be based upon the experience of the service personnel, particularly in recognizing the height of the scum line SL′ of FIG. 8 and the change in wastewater flow characteristics from the original installation to date as, for example, increased numbers and ages of adults and/or children, added bathroom facilities, etc. As one specific example, initially the diametrically opposite pairs of design equalization ports 263 ( FIGS. 1 and 8 ) might be ¼″ diameter. However, if at service it appears that the overall system would benefit from a different flow equalization pattern, as is evident from the height of the scum line SL′ of FIG. 8 , the service personnel would simply remove the diametrically opposite pair of flow port members 260 , 260 and replace either or preferably both with a flow equalization member 260 ′ and its larger diameter design equalization port 263 ′ ( FIG. 9 ), such as a diameter of 5/16″, ⅜″, 7/16″ or up to a diameter substantially approaching the diameter of the diametrically opposite openings 165 in the upper wall portion 88 of the filter media retainer and spacer housing 80 , namely, 1¾″.
[0037] With respect to FIG. 9 , it is assumed that during regular scheduled service or maintenance, the design flow equalization port members 260 , 260 of FIG. 8 were replaced by the flow port members 260 ′, 260 ′ of FIG. 9 with the larger design flow equalization port 263 ′ being ⅜″ in diameter. During such replacement, the service person would merely snap-out each flow port member 260 and its ¼″ diameter flow equalization port 263 ( FIG. 8 ), snap-insert each flow port member 260 ′ and its ⅜″ diameter flow equalization port 263 ′ into its opening 165 , reinstall the wastewater treatment mechanism 50 and its components, and subsequently observe height changes of the scum line SL′. Perhaps three months, six months or a year later upon such inspection or because of an automatic wastewater level sensing alarm, the service person might find, as is illustrated in FIG. 9 , that the larger diameter (⅜″) of the diametrically opposite design flow equalization ports 263 ′, 263 ′ has reduced the height of the scum line SL′ of FIG. 8 to a lower and more acceptable scum line level SL″, namely, specifically appreciably below the coarse filter wall 72 and, should the upper portion 88 of the retainer and spacer housing 80 include one or more peak flow equalization ports 262 , well below the latter ( FIG. 9 ).
[0038] Though the service personnel might find acceptable the level of the scum line SL″ of FIG. 9 , nonetheless if there were concerns over high use surges, each of the flow port members 260 ′, 260 ′ ( FIG. 9 ) could be removed and replaced by an identical snap-in flow port member 260 ″ ( FIG. 10 ) differing from the flow port members 260 ′, 260 ′ only in that the design flow equalization port 263 ″ thereof is of a larger diameter, as, for example, 7/16″. Thereupon the wastewater treatment mechanism 50 would be completely serviced and reinserted into the clarification chamber 36 and when next inspected three months, six months or more later, the scum line SL′″ might be observed to have dropped appreciably and to a very acceptable level never having reached during wastewater equalization or surging either the diametrically opposite pair of sustained flow equalization ports 261 , 261 or the diametrically opposite pair of peak flow equalization ports 262 , 262 thereabove.
[0039] In a working embodiment of the present invention, the wastewater treatment mechanism 50 is constructed substantially as herein described and illustrated including the diametrically opposite pair of flow port members 260 , 260 ( FIGS. 1-3 and 8 ) each with a design flow equalization port 263 therein, diametrically opposite sustained flow equalization ports 261 , 261 and opposite diametrically opposite peak flow equalization ports 262 , 262 . The flow equalization ports 261 , 263 are each of the same diameter, namely, ¼″ while the diameter of each of the peak flow equalization ports 262 is preferably 1″. The volute-to-volute (bottommost portion-to-bottommost portion) vertical distance between the flow equalization ports 261 , 262 is 2½″ while the volute-to-volute vertical distance between the flow equalization ports 261 , 263 is 3½″. The vertical distance between the volute of each flow equalization port 261 to the axis A 0 ( FIG. 6 ) of the opening 165 in the upper cylindrical portion 88 of the filter media retainer and spacer housing 80 is approximately 2⅝″.
[0040] Though the latter working embodiment of the invention is presently preferred, in keeping with the present invention the flow equalization ports 261 , 261 and 262 , 262 can be totally eliminated, and in such a case, only the design flow equalization ports 263 , 263 of the flow port members 260 , 260 would be utilized, preferably in diametrically opposite pairs, though, as latter noted, depending upon wastewater flow input and surges, a single, albeit larger, design flow equalization port 263 can be utilized in but a single flow port member 260 of the wastewater flow mechanism 50 .
[0041] Though the method of removing and replacing one or one pair of flow port members 260 , 260 with another one or pair of flow port member 260 ′, 260 ′; 260 ″, 260 ″ has been described with respect to on-site inspection by service personnel, the clarification chamber 36 can as well be provided with wastewater level detecting means of a conventional construction which through conventional electronics, phone lines, the Internet, etc., can provide an alarm reflective of undesired wastewater level/surges and the subsequent dispatch of service personnel to proceed in accordance with the servicing/maintenance heretofore described, including removal and reinsertion of appropriate flow port members and their associated design flow equalization ports.
[0042] Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined by the appended claims.
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A method of effecting efficient flow equalization in a settling and retention basin having a peripheral wall housing a removable design flow equalization port and a filter member exteriorly of the peripheral wall by (a) observing the height of liquid level induced during wastewater flow upon the filter member relative to the flow equalization port. Thereafter (b) determining whether the observed height of step (a) is outside a desired optimum height range reflective of meeting the design flow characteristics of the design flow port. Thereafter (c) replacing the design flow equalization port with a different size flow equalization port based upon the performance of step (b).
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[0001] The invention provides CD4 + CD25 − T cells and Tr1-like regulatory T cells (i.e., contact-independent Type 1-like regulatory T cells), processes for their production and their use for regulatory purposes.
[0002] Introduction
[0003] There is now compelling evidence that CD4 + T cells specialized for the suppression of immune responses play a critical role in immune regulation. It has been convincingly demonstrated in rodents, that cells with this function are enriched within the CD4 + CD25 + subset (Asano et al., J. Exp. Med. 184:387-396 (1996); Takahashi et al., Int. Immunol. 10:1969-1980 (1998); Thornton et al., J. Exp. Med. 188:287-296 (1998)). Recent studies demonstrate, that CD4 + CD25 + T cells are also relevant as an immune regulator in humans (Jonuleit et al., J. Exp. Med. 193:1285-1294 (2001); Levings et al., J. Exp. Med. 193:1295-1302 (2001); Dieckmann et al., J. Exp. Med. 193:1303-1310 (2001); Taylor et al., J. Exp. Med. 193:1311-1318 (2001)). It was shown, that CD4 + CD25 + T cells, similar to their rodent counterpart, constitute a small fraction of CD4 + T cells (average 6%). They are naturally anergic to mitogenic stimuli, inhibit the proliferation of CD4 + and CD8 + T cells after stimulation via their TCR and do so in a cytokine-independent yet cell contact-dependent manner (Jonuleit et al., J. Exp. Med. 193:1285-1294 (2001); Levings et al., J. Exp. Med. 193:1295-1302 (2001); Dieckmann et al., J. Exp. Med. 193:1303-1310 (2001); Taylor et al., J. Exp. Med. 193:1311-1318 (2001)).
[0004] Progress has been made to elucidate the mechanisms by which CD4 + CD25 + T cells exert their regulatory function. It has been suggested, that CD4 + CD25 + T cells bind transforming growth factor β on their cell surface and thereby mediate contact dependent suppression of other T cells (Nakamura et al., J. Exp. Med. 194:629-644 (2001)). Two groups have described the increased expression of glucocorticoid-induced TNF receptor (GITR) on CD4 + CD25 + T cells compared to resting CD4 + CD25 − T cells and they show, that anti-GITR antibodies abrogate CD4 + CD25 + mediated suppression (Shimizu et al., Nat. Immunol. 3:135-142 (2002); McHugh et al., Immunity. 16:311-323 (2002)).
[0005] Very little is still known about requirements for the development and physiological regulation of CD4 + CD25 + T cell function. Survival and/or expansion of CD4 + CD25 + T cells in the periphery seems to be dependent on IL-2 and costimulatory molecules, as mice lacking these components show major deficiencies in CD4 + CD25 + T cells (Papiernik et al., Int. Immunol. 10:371-378 (1998); Salomon et al., Immunity. 12:431-440 (2000); Kumanogoh et al., J. Immunol. 166:353-360 (2001)). It is difficult to understand, how CD4 + CD25 + T cells exert their suppressive function in vivo, as they constitute only 6% of CD4 + T cells and need direct cell contact and activation via their TCR to suppress other T cells. In in vitro experiments usually rather high ratios of CD4 + CD25 + T cells have to be employed to potently suppress proliferation of CD4 + CD25 − T cells. These are conditions, that probably would not occur in vivo, as CD4 + CD25 + T cells even if antigen-specifically activated do not expand and proliferate well due to their anergic state. It has been shown before, that anergized T cells can mediate regulatory function on other T cells (Jooss et al., Proc. Natl. Acad. Sci.U.S.A. 98:8738-8743 (2001)). It was now found that CD4 + CD25 + T cells do not only anergize other CD4 + T cells, but that they also induce high level production of IL-10 in the cells they suppress. The resulting IL-10 producing anergized T cells are then able to suppress T cell proliferation in an IL-10 dependent fashion. These findings give insight into the mechanisms utilized by CD4 + CD25 + T cells to execute their important in vivo function.
SUMMARY OF THE INVENTION
[0006] It has been recently demonstrated that regulatory CD4 + CD25 + CD45RO + T cells are present in the peripheral blood of healthy adults and exert regulatory function similar to their rodent counterparts (PCT/EP02/02671). It remains difficult to understand how the small fraction of these T cells, that regulate via direct cell-to-cell contact and not via secretion of immunosuppressive cytokines, could mediate strong immune suppression.
[0007] It was now found that human CD4 + CD25 + T cells induce long lasting anergy and production of Interleukin-10 in CD4 + CD25 − T cells. These anergized CD4 + CD25 − T cells then suppress proliferation of syngeneic CD4 + T cells via Interleukin-10 but independent of direct cell contact, similar to the so-called type 1 regulatory T cells (Tr1). This “catalytic” function of CD4 + CD25 + T cells to induce Tr1-like cells helps to explain their central role for the maintenance of immune homeostasis. The invention thus provides
[0008] (1) CD4 + CD25 − T cells being able to exert contact-independent regulatory functions;
[0009] (2) Tr1-like regulatory T cells (also designated “contact-independent Type 1-like regulatory T cells”) which are obtainable by anergizing the CD4 + CD25 − T cells according to (1) above, preferably by contact with CD4 + CD25 + T cells, and exert contact-independent regulatory functions;
[0010] (3) a method for expanding CD4 + CD25 − T cells as defined in (1) above or Tr1-like regulatory T cells as defined in (2) above, which method comprises stimulating the T cells with a T cell stimulating agent or with antigen-presenting cells ex vivo and in vivo;
[0011] (4) a method for producing the Tr1-like regulatory T cells of (2) above, which method comprises anergizing CD4 + CD25 − T cells as defined in (1) above or as obtained by the method of (3) above by contacting the CD4 + CD25 − T cells with an anergic state inducing agent ex vivo and in vivo;
[0012] (5) Expanded CD4 + CD25 − T cells and expanded Tr1-like regulatory T cells obtainable by the method according to (3) above and Tr1-like regulatory T cells obtainable by the method according to (4) above;
[0013] (6) a pharmaceutical composition comprising the human CD4 + CD25 − T cells or Tr1-like regulatory T cells according to (1), (2) or (5) above;
[0014] (7) the use of CD4 + CD25 − T cells or of Tr1-like regulatory T cells according to (1), (2) or (5) above
[0015] (a) for preparing a regulatory medicament;
[0016] (b) in assays that will allow to identify other regulatory factors;
[0017] (c) for identifying molecules expressed by the CD4 + CD25 − T cells or by the Tr1-like regulatory T cells including identification of novel molecules on said cells;
[0018] (d) for identifying precursor cells or progeny of the regulatory CD4 + CD25 − T cells or of the Tr1-like regulatory T cells;
[0019] (e) for preparing an agent for adoptive transfer therapy, an agent for treating diseases with enhanced immunity including but not limited to autoimmune diseases, or an agent for preventing/treating transplantation reactions such as graft versus host disease, graft rejections, etc;
[0020] (8) the use of an anergic state inducing agent as defined in (4) above for preparing an agent to induce Tr1-like regulatory T cells in vivo, preferably for preparing an agent for treating autoimmune diseases in a patient;
[0021] (9) a method for adoptive transfer therapy which comprises injecting/infusing back into the patients enriched/expanded autologous or non-autologous Tr1-like regulatory T cells according to (2) or (5) above;
[0022] (10) a method for preparing CD4 + CD25 − T cells and Tr1-like regulatory T cells with a particular desired antigen-specific T cell receptor which comprises
[0023] (i) activating/stimulating/expanding the CD4 + CD25 − T cells according to (1) above or the Tr1-like regulatory T cells according to (2) above with antigen presenting cells, preferably immature or mature dendritic cells (DC), presenting said antigen in vitro or in vivo, or
[0024] (ii) utilizing a ligand/antibody to a particular T cell receptor expressed on (subsets of) CD4 + CD25 − regulatory T cells or Tr1-like regulatory T cells, or a MHC-peptide complex binding to a particular T cell receptor on (subsets of) CD4 + CD25 − T cells or Tr1-like regulatory T cells, and optionally, in case of CD4 + CD25 − T cells, anergizing said CD4 + CD25 − T cells by contacting them with an anergic state inducing agent;
[0025] (11) CD4 + CD25 − T cells and Tr1-like regulatory T cells having a particular desired antigen-specific T cell receptor and being obtainable by
[0026] (i) the method of (10) above, or by transfection of a T cell receptor of desired antigen specificity into ex vivo isolated or expanded T cells; or
[0027] (ii) by the method of (10) above, and which have been brought in anergic state according to the method of (4) above;
[0028] (12) a pharmaceutical composition comprising the T cells of (11) above, preferably said pharmaceutical composition being suitable to treat diseases with enhanced immunity including, but not limited to, autoimmune diseases, graft versus host disease and graft rejections; and
[0029] (13) the use of agents specifically binding to defined entities on the Tr1-like regulatory T cells, including but not limited to ligands/antibodies, such as monoclonal antibodies or MHC-peptide complexes or other ligands binding to T cell receptors on (subsets of) the Tr1-like regulatory T cells for preparing a medicament for removal or functional impairment of Tr1-like regulatory T cells in vivo in order to enhance immune responses, including dampen regulation by and Tr1-like regulatory T cells in vivo, for example, to enhance tumor immunity.
DESCRIPTION OF THE FIGURES
[0030] [0030]FIG. 1: Coculture of CD4 +CD 25 + and CD4 + CD25 − T cells results in high level IL-10 production. CD4 +CD 25 + and CD4 + CD25 − T cells were MACS® sorted from PBMC of healthy individuals. These cells were either cultured alone or at a 1:1 ratio and activated with platebound anti-CD3 and soluble anti-CD28 (10 μg/ml respectively).
[0031] (A) After various time points supernatants were analyzed for cytokine production by ELISA. IL-10 production peaked 48 h after onset of culture and was markedly higher in the coculture of CD4 +CD 25 + and CD4 + CD25 − T cells then in the cultures of each of the cell types alone. A representative out of 5 independent standardized experiments is shown. No elevated levels of INF-α or TGF-β could be measured (data not shown).
[0032] (B) The different T cell populations were also activated with mature allogeneic DC (DC:T cell ratio 1:20) compared to anti-CD3 and anti-CD28 (10 μg/ml respectively). Cytokines were measured 48 h after onset of culture. Results were similar in 5 independent experiments.
[0033] (C) For the last 6 h of activation with anti-CD3 and anti-CD28 2 μM Monensin was added to the cultures. Staining of CD4 surface expression was performed. Cells were washed, fixed, permeabilized and stained for intracellular IL-10 using PE-conjugated specific Abs. One of 5 independent experiments is shown.
[0034] [0034]FIG. 2: Activated fixed CD4 + CD25 + T cells show similar regulatory potential as viable CD4 + CD25 + T cells and can induce IL-10 production in CD4 + CD25 − T cells.
[0035] (A) CD4 + T cell subpopulations were sorted by MACS® CD4 + CD25 + T cells were divided into 3 fractions. One part was activated with platebound anti-CD3 (10 μg/ml) and soluble anti-CD28 (10 μg/ml) over night and fixed next day with paraformaldehyde 2% (activated-fixed). The second part was fixed with paraformaldehyde without activation (resting-fixed) and the second part was left untreated (viable). Each fraction was mixed with syngeneic CD4 + CD25 − T cells at a 1:1 ratio (10 5 T cells per 96 well) and stimulated with platebound anti-CD3 (10 μg/ml) and soluble-anti-CD28 (10 μg/ml). Proliferation was determined by [ 3 H]Tdr incorporation after 5 d. Results are representative of 5 independent experiments, shown as mean cpm of triplicate cultures. Similar results were observed, when T cells were stimulated with mature allogeneic DC (DC/T cell ratio of 1:20; data not shown).
[0036] (B) CD4 +CD 25 + and CD4 + CD25 − T cells were either cultured alone or CD4 + CD25 − T cells were mixed at a 1:1 ratio with activated-fixed, resting-fixed or viable CD4 + CD25 − T cells. T cells were stimulated with mature allogeneic DC at the same ratio as in (A). In a parallel transwell approach CD4 + CD25 + T cells were stimulated with allogeneic DC (DC/T ratio 1:20) in a transwell chamber, and CD4 + CD25 − T cells were placed in the well together with allogeneic DC again at a DC/T ratio of 1:20. IL-10 production was measured by ELISA 48 h after onset of culture. Results were similar in 5 independent experiments.
[0037] [0037]FIG. 3: CD4 + CD25 − T cells anergized by CD4 + CD25 + T cells suppress proliferation of CD4 + T cells in a IL-10 dependent manner. MACS® sorted CD4 +CD 25 + and CD4 + CD25 − T cells were either cultured alone or mixed at a 1:1 ratio (2×10 6 T cells/24 well) and stimulated with mature allogeneic DC (DC/ T cell ratio 1:20) or immobilized anti-CD3/soluble anti-CD28. After 48 h of culture cells were harvested and one fraction of each population was fixed with paraformaldehyde for 1 h. Viable and fixed cells were cocultured with syngeneic resting CD4 + CD25 − T cells at a 1:1 ratio (10 5 T cells per 96 well) and stimulated as before with immobilized anti-CD3/soluble anti-CD28 (lower panel) or mature allogeneic DC (upper panel) in the presence or absence of 10 μg/ml anti-IL-10 antibodies. In a parallel transwell approach the three different T cell populations were placed in a transwell chamber and resting CD4 + CD25 − T cells were stimulated with DC (DC/T cell ratio 1:20; upper panel) or platebound anti-CD3/soluble anti-CD28 (lower panel) in the well. Proliferation after 5 d was determined by [ 3 H]Tdr incorporation. One out of 4 independent experiments is shown.
[0038] [0038]FIG. 4:
[0039] (A) Anergized CD4 + CD25 − T cells predominantly secrete IL-10. CD4 + CD25 + and CD4 + CD25 − T cells were isolated as described and stimulated alone or at a 1:1 ratio with anti-CD3/anti-CD28. 48 h after stimulation supernatant was harvested and analyzed by a cytometric bead array for IL-2, IL-4, IL-5, TNF-αand INF-γ. Results were similar in 5 independent experiment. (B) Before mixing CD4 + CD25 − and CD4 + CD25 + T cells at a 1:1 ratio, CD4 + CD25 + T cells were labeled with CFSE (0,5 μM) for 15 min. Cells were then mixed and stimulated with immobilized anti-CD3/soluble anti-CD28. After 48 h cells were harvested and sorted on a FACS Vantage®. The positive and the negative fraction were then cocultured with syngeneic resting CD4 + CD25 − T cells (10 5 T cells per 96 well). Proliferation was measured after 5 d by [ 3 H]Tdr incorporation. One out of 5 independent experiments is shown.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The important in vivo function of CD4 +CD 25 + regulatory T cells has been thoroughly demonstrated in rodents (Asano et al., J. Exp. Med. 184:387-396 (1996); Takahashi et al., Int. Immunol. 10:1969-1980 (1998); Thornton et al., J. Exp. Med. 188:287-296 (1998)). Recent studies demonstrate, that CD4 + CD25 + T cells are also relevant as an immune regulator in humans (Jonuleit et al., J. Exp. Med. 193:1285-1294 (2001); Levings et al., J. Exp. Med. 193:1295-1302 (2001); Dieckmann et al., J. Exp. Med. 193:1303-1310 (2001); Taylor et al., J. Exp. Med. 193:1311-1318 (2001)). Lately we and others have shown that a similar population of regulatory T cells also exists in humans (PCT/EP02/02671). These findings have been confirmed and extended by several groups up to now (Jonuleit et al., J. Exp. Med. 193:1285-1294 (2001); Levings et al., J. Exp. Med. 193:1295-1302 (2001); Dieckmann et al., J. Exp. Med. 193:1303-1310 (2001); Taylor et al., J. Exp. Med. 193:1311-1318 (2001); Nakamura et al., J. Exp. Med. 194:629-644 (2001); Ng et al., Blood 98:2736-2744 (2001); Iellem et al., J. Exp. Med. 194:847-853 (2001); Yamagiwa et al., J. Immunol. 166:7282-7289 (2001); Stephens et al., Eur. J. Immunol. 31:1247-1254 (2001); Taams et al., Eur. J. Immunol. 31:1122-1131 (2001)). Still numerous characteristics of CD4 + CD25 + T cells need to be explained. One important question that has to be answered is how CD4 + CD25 + T cells execute their important function in vivo, as they only constitute a small population of peripheral CD4 + T cells (average 6%), that need direct cell contact as well as stimulation via the TCR to suppress unwanted T cell activation. In vitro studies usually employ high ratios of CD4 +CD 25 + /CD4 + CD25 − T cells, a situation that is hard to imagine at an inflammatory site in vivo. As described, coculture of CD4 +CD 25 + and CD4 + CD25 − T cell leads to marked reduction of T cell proliferation (Dieckmann et al., J. Exp. Med. 193:1303-1310 (2001)). This effect is stable for several days (data not shown). Although CD4 + CD25 + T cells produce sizeable quantities of IL-10 this cytokine does not seem to be responsible for the regulatory effects (Dieckmann et al., J. Exp. Med. 193:1303-1310 (2001)). The supernatant of CD4 +CD 25 + and CD4 + CD25 − cocultures were analyzed and it was found that high levels of IL-10 are produced, peaking after 48 h. IL-10 levels in the coculture were markedly higher than IL-10 produced by CD4 + CD25 + T cells alone, suggesting that it was not only attributable to CD4 + CD25 + T cells. This was further confirmed by intracellular FACS® analysis. IL-10 is known to inhibit cytokine production from T cells (Moore et al., Science 248:1230-1234 (1990)) and exert anti-inflammatory and suppressive effects on most haematopoeitic cells. It is also involved in the induction of peripheral tolerance via effects on T-cell-mediated responses (Moore et al., Science 248:1230-1234 (1990)). IL-10 indirectly suppresses T-cell responses by potently inhibiting the antigen-presenting capacity of APC, including DC (Steinbrink et al., J. Immunol. 159:4772-4780 (1997), Langerhans cells and macrophages (Romagnoli et al., J. Immunol. 168:1644-1648 (2002)). In addition, IL-10 directly regulates T cells by inhibiting their ability to produce IL-2, TNF-α (De Waal et al., J. Immunol. 150:4754-4765 (1993)), IL-5 (Schandene et al., J. Immunol. 152:4368-4374 (1994)) and to proliferate Bejarano et al., Int. Immunol. 4:1389-1397 (1992)). It was important to rule out, that the effects seen were not only due to CD4 + CD25 + cells in the coculture. In a set of pilot experiments we could show, that CD4 + CD25 + T cells when paraformaldehyde-fixed after polyclonal activation have similar regulatory properties as viable CD4 + CD25 + T cells. In coculture experiments, employing activated-fixed and viable CD4 + CD25 + T cells together with CD4 + CD25 − T cells, it turned out, that IL-10 production remained high, even if activated-fixed CD4 + CD25 + T cells were used. This showed, that IL-10 production was not attributable to increased production by CD4 +CD 25 + but due to the anergized CD4 + CD25 − T cells. In a parallel transwell approach we showed, that direct cell contact between CD4 + CD25 + and CD4 + CD25 − T cells is necessary to prime CD4 + CD25 − T cells to become IL-10 producers.
[0041] Further experiments were performed to analyze, which effect this high level of IL-10 might have on T cell proliferation. Indeed it was shown, that proliferation of syngeneic CD4 + T cells could be markedly decreased by anergized CD4 + CD25 − T cells. Addition of anti-IL-10 abolished the suppressive effects of anergized CD4 + CD25 − T cells, while a transwell setting, permitting the free exchange of soluble factors, but no cell contact, did not change suppression. Furthermore, we CSFE-labeled CD4 + CD25 + T cells and separated them from CD4 + CD25 − T cells after 48 h of coculture by FACS® sorting. Both populations strongly inhibited CD4 + T cell proliferation which was almost abolished in the unlabeled e.g. CD4 + CD25 − fraction by the addition of anti-IL-10, demonstrating that IL-10 indeed is crucial for the suppressive function of energized CD4 + CD25 − T cells. This is not surprising, as other reports have shown, that activation of human CD4 + T cells in the presence of IL-10 results in a state of functional unresponsiveness without death, termed anergy (Iellem et al., J. Exp. Med. 194:847-853 (2001)). CD4 + T cells with low proliferative capacity, that are generated in the presence of IL-10 have been termed type 1 T regulatory cells (Tr1). The cells that are generated in the presence of CD4 + CD25 + T cells show some characteristics resembling Tr1 cells, especially their low proliferative capacity and the high level production of IL-10. But in some instances they differ, as Tr1 are also defined by their ability to produce TGF-β and anergized CD4 + CD25 − T cells did not produce significant amounts of TGF-β at least by the assay used. Further on we clearly demonstrate, that cell contact between CD4 +CD 25 + and CD4 + CD25 − T cells and not IL-10 is crucial for the induction phase of inhibitory, anergized, IL-10-producing, CD4 + CD25 − T cells. But as coculture of anergized CD4 + CD25 − with syngeneic resting CD4 + CD25 − T cells results in anergic, IL-10 releasing CD4 + CD25 − T cells this IL-10 production may then also contribute to the generation of Tr1-like cells as described for Tr1 cells. To distinguish between indirect effects via APC modulation and direct effect on T cells we used as a stimulus not only allogeneic DC but also immobilized anti-CD3/soluble anti-CD28 as a cell free T cell stimulation system. As the effects seen were independent of the stimuli used, a direct effect on T cells is most likely. The data presented here may serve as an explanation of how CD4 + CD25 + T cells fulfill their important in vivo function. At sites of inflammation if activated they would anergize CD4 + T cells in their lose environment in an antigen-unspecific bystander effect fashion (Thornton et al., J. Immunol. 164:183-190 (2000)). Our findings suggest, however, that anergized CD4 + T cells (including pathogenic ones) in turn will produce high levels of IL-10 thereby creating an immunosuppressive environment either by indirect effect via influence on APC (Steinbrink et al., Blood 93:1634-1642 (1999)) or via direct effects on other T cells thereby effectively abrogating unwanted T cell activation.
[0042] The invention is further explained by the following examples, which are, however, not to be construed as to limit the invention.
EXAMPLES
[0043] Abbreviations: CFSE, 5-carboxyfluorescein diacetat succinimdyl ester; CTLA-4, cytotoxic T lymphocyte antigene 4; DC, dendritic cell; MACS®, magnetic activated cell sorting; Tr1, T regulatory cell 1.
[0044] Material and Methods
[0045] Culture Medium: RPMI 1640 (Bio Whittaker) supplemented with 1% heat-inactivated autologous plasma, 20 μg/ml gentamicin (Merck) and 2 mM glutamine (Bio Whittaker) was used for the generation of dendritic cells (DC), X-VIVO-20 (Bio Whittaker) supplemented with 1% heat-inactivated single donor human serum, 20 μg/ml gentamicin (Merck) and 2 mM glutamine (Bio Whittaker) for T cell culture.
[0046] Cytokines: All cytokines used in this study were recombinant human proteins. Final concentrations were: GM-CSF 1,000 U/ml (Leukomax TM; Novartis), IL-4 800 U/ml (Sandoz) and IL-2 (Proleukin; Chiron Corp.) were used at the concentrations indicated; for DC maturation we used a cocktail consisting of IL-1β 2 ng/ml (Sigma); IL-6 1000 U/ml (Sandoz); TNF-α 10 ng/ml (Bender, Vienna), and PGE 2 1 μg/ml (Sigma).
[0047] Antibodies: For immunostaining PE- and FITC-conjugated Antibodies (Ab) (all from BD Pharmingen) against CD3 (UCHT 1), CD4 (RPA-T4), CD5 (UCHT 2), CD8 (RPA-T8), CD14 (M5E2), CD19 (HIB 19), CD25 (M-A251), CD28 (CD28.2), CD45 RA (HI 100), CD45 RO (UCHL 1), CD56 (B159), CD62L (DREG-56), CD80 (L307.4), CD83 HB15e), CD86 (FUN-1), CD95 (DX 2), CD95L (G247-4), CD122 (MiK-02), CD152 (BNI3.1), CD154 (TRAP 1), HLA-DR (G46-6), and respective mouse and rat isotype controls were employed. Ab used for intracellular cytokine staining were FITC- and PE-conjugated anti-IL-2 (MQ1-17H12), anti-IL-4 (8D4-8), anti-IL-10 (JES3-19F1) and anti-IFN-γ (45.B3), all from BD Pharmingen. Unconjugated anti-IL-10 (JES3-19F1) (Pharmingen) was used for neutralization experiments, anti-CD3 (UCHT1) and anti-CD28 (CD28.2) for polyclonal activation of T cells.
[0048] Cytokine Assays: T cells were stimulated with allogeneic DC or with platebound anti-CD3 (10 μg/ml)+soluble anti-CD28 (10 μg/ml) in X-VIVO-20+1% serum. Cytokine analysis was performed at different time points by analysis of supernatants with commercially available ELISA kits for human IL-10, IFN-β (Biosource International) and TGF-β (BD Pharmingen). IL-2, IL-4, IL-5, IFN-γ and TNF-α were measured by a cytometric bead array (Th1/Th2 Cytokine CBA 1; BD Pharmingen) according to the manufacturers instructions. For analysis of intracellular cytokine production T cells were either stimulated with PMA 20 ng/ml and Ca 2+ionophore A23187 500 μg/ml (both from SIGMA) for 6 hours or with platebound anti-CD3 and soluble anti-CD28 Ab for 6 hours. Monensin, 2 μM (SIGMA) was added for the last 5 hours of culture. Cells were collected, washed, fixed and saponine permeabilized (Fix/perm solution, BD Pharmingen) and stained with cytokine specific Ab or isotype.
[0049] Cell isolation and DC Generation: DC were generated from buffy coats orleukapheresis products (both obtained from the Department of Transfusion medicine, University of Erlangen, from healthy donors after informed consent was given) as described in Romani et al, J. Immunol. Methods 196:137-151(1996) and Thurner et al., J. Immunol. Methods 223:1-15(1999). In brief, PBMCs were isolated by Ficoll density gradient centrifugation. Monocytes were isolated by plastic adherence and cultured in RPMI Medium, supplemented with IL-4 and GM-CSF. At day 6, a maturation cocktail (IL-1β, IL-6, PGE 2 and TNFα) was added. At day 7 nonadherend cells were harvested and constituted mature DC that were>90% double positive for costimulatory molecules (CD80, CD86) and CD83.
[0050] CD4 + T cells were isolated from PBMC with a negative CD4 + T cell isolation kit (Miltenyi Biotech). CD4 + CD25 + T cells were isolated from the pure, untouched CD4 + T cells using CD25 Microbeads (Miltenyi Biotech). Purity was assessed by FACS®.
[0051] Flow Cytometric Analysis: For immunofluorescence staining cells were washed and stained for 20 min at 4° C. with optimal dilution of each Ab. Cells were washed again and analyzed by flow cytometry (FACS Scan® and CELLQuest® software; Becton Dickinson). For analysis of intracellular CD152 cells were stained for CD4 expression, fixed and saponine permeabilized (Fix/perm solution, BD Pharmingen) and stained with CD152 specific Ab or isotype.
[0052] Fixation of CD4 +CD 25 + and CD4 + CD25 − T cells: For fixation experiments CD4 +CD 25 + and CD4 + CD25 − T cells were isolated and divided into three fractions. One part of each was activated with platebound anti-CD3 and soluble anti-CD28 over night. Next day the stimulated parts and one resting part were fixated with 2% paraformaldehyde for 1 h at 4° C. Thereafter fixated cells were washed extensively and used in regulation assays together with the untreated fraction.
[0053] Induction of anergized T cells: To induce anergized CD4 + CD25 − T cells with CD4 + CD25 + T cells, both populations were isolated as described. They were either used directly or fixated as described above. 5×10 5 of CD4 +CD 25 + and CD4 + CD25 − T cells were cultivated either with platebound anti-CD3 and soluble anti-CD28 (10 μg/ml each) or with allogeneic mature DC (5×10 4 ) for 48 h in 48 well plates. Thereafter cells were harvested, washed and used in proliferation experiments.
[0054] Proliferation Assays: To assess proliferation of the differently cultured CD4+subtypes 10 5 sorted T cells were incubated in X-VIVO-20 with 5×10 3 DC in 96 well U-bottom plates or 10 μg/ml of platebound anti-CD3+10 μg/ml soluble anti-CD28 in 96-well flat-bottom plates. For assessment of regulatory properties 10 5 resting CD4 + CD25 − autologous T cells were cultured with 5×10 3 DC or platebound anti-CD3 and soluble anti-CD28 in 96-well U-bottom plates. Purified CD4 +CD 25 + and CD4 + CD25 − T cells, anergized CD4 + CD25 − T cells or fixated CD4 +CD 25 + and CD4 + CD25 − T cells were added usually at a 1:1 ratio, if not indicated differently. After 4-5 days of culture [ 3 H]Tdr (37 kBq/well) was added for additional 16 h. Proliferation was measured using a liquid scintillation counter.
[0055] Transwell Experiments: Transwell experiments were performed in 24-well plates. 10 6 CD4 + CD25 − T cells were stimulated with 5×10 4 DC. In addition, 10 6 CD4 +CD 25 + , CD4 + CD25 − and anergized CD4 + CD25 − T cells were either added directly to the culture or were placed in transwell chambers (Millicell, 0.4 μm; Millipore). After 5 days of coculture T cells were transferred to 96-well plates (10 5 cells/well) in triplicates. Proliferation was measured after 16 h pulse with [ 3 H]Tdr using a liquid scintillation counter.
[0056] CFSE labeling and sorting: CD4 +CD 25 + and CD4 + CD25 − T cells were labeled with 0.5 μM of CFSE (Molecular Probes) for 15 minutes at 37° C. Reaction was stopped with ice-cold PBS buffer and cells were washed extensively. 5×10 5 CD4 +CD 25 + CFSE labeled T cells were then cultured with 5×10 5 unlabeled CD4 + CD25 − T cells (and vice versa) with platebound anti-CD3 and soluble anti-CD28 in 48 well plates. Proliferation was controlled by FACS® for different time points. After 48 h cells were harvested and sorted on a FACS Vantage® (Becton Dickinson). Sorted cells were used for further regulation assays.
Example 1
Coculture of CD4 +CD 25 + and CD4 + CD25 − T Cells Yields Low Proliferating, IL-10 Producing T Cells
[0057] CD4 +CD 25 + and CD4 + CD25 − subpopulations were separated by magnetic cell sorting from healthy donors. Separately or mixed at a 1:1 ratio the cells were stimulated polyclonally with platebound anti-CD3 and soluble anti-CD28 or with mature allogeneic DC. As shown before coculture of CD4 +CD 25 + and CD4 + CD25 − T cells results in a constantly low proliferating T cell population (data not shown). The supernatant of this coculture was analyzed after various time points for different cytokines and a high level of IL-10 production was found (peaking 48 h after onset of culture (FIG. 1A)). As shown before CD4 + CD25 + T cells alone also produce sizeable amounts of IL-10 (˜200 pg/ml). One might speculate, that IL-10 production was only attributable to CD4 + CD25 + T cells, but IL-10 production in the coculture was 2-4 times higher then production of CD4 + CD25 + T cells alone (FIGS. 2A & B). Intracellular FACS revealed, that the number of IL-10 producing cells more then doubled (FIG. 1C). High IL-10 production after 48 h of coculture was observed regardless if polyclonal activation (platebound anti-CD3 and soluble anti-CD28) or allogeneic mature DC were used (FIG. 1B). In none of the cultures increased production of TGF-β or Inf-α could be observed (data not shown). CD4 + CD25 − T cells alone did not produce significant amounts of IL-10 (FIG. 1 A-C)
Example 2
Activated, Paraformaledhyd-Fixed CD4+CD25+ T Cells Show Similar Regulatory Capacity as Viable Cells
[0058] It is known, that CD4 + CD25 + T cells exert their regulatory function in a cell contact-dependent yet cytokine-independent manner. To further analyze their regulatory function, isolated CD4 + CD25 + T cells were divided into three parts. One was activated over night polyclonally with platebound anti-CD3 and soluble anti-CD28 and fixed thereafter with paraformaldehyde (“activated-fixed”), the second part was fixed with paraformaldehyde without prior activation (“resting-fixed”) and the third part was left untreated (“viable”). After this procedure the three differently treated fractions of CD4 + CD25 + cells were used in regulation assays with syngeneic CD4 + CD25 − T cells. As shown in FIG. 2A activated-fixed CD4 + CD25 + T cells had a similar regulatory capacity as their normal viable counterpart. This is in sharp contrast to resting-fixed CD4 + CD25 + T cells which do not show any regulatory function at all.
[0059] Activated-fixed and viable CD4 + CD25 + T cells almost completely suppressed proliferation of CD4 + CD25 − T cells when a 1:1 ratio was used. This underlines and extends prior findings on the regulatory function, demonstrating that surface molecules, induced after activation of CD4 +CD 25 + are responsible for the regulatory capacity of these cells.
Example 3
CD4 +CD 25 + Regulatory T Cells Induce IL-10 Production in Anergized CD4 + CD25 − T Cells in a Cell Contact-Dependent Manner
[0060] In further experiments the above mentioned findings were used to analyze the requirements for induction of IL-10 producing anergized CD4 + CD25 − T cells. CD4 +CD 25 + and CD4 + CD25 − T cells were either cultured alone or at a 1:1 ratio with normal viable CD4 + CD25 + T cells, activated-fixed CD4 + CD25 + cells, resting-fixed CD4 + CD25 + T cells or in a transwell setting. IL-10 production was measured 48 h after onset of culture. As shown in FIG. 2B a high level IL-10 production was achieved in coculture either with viable CD4 +CD 25 + or activated-fixed CD4 + CD25 + T cells. In Transwell experiments IL-10 production, similar to that of CD4 + CD25 + T cells alone was observed and CD4 + CD25 − T cells alone produced negligible amounts of IL-10.
Example 4
CD4+CD25− T Cells Anergized by CD4+CD25+ T Cells Suppress Activation of Syngeneic CD4+ T Cells in an IL-10 Dependent Manner
[0061] IL-10 is known as a cytokine with potent immunosuppressive function. It was therefore tempting to speculate, that the high IL-10 production of anergized CD4 + CD25 − T cells would lead to secondary suppression of other T cells. In a next set of experiments we sought to investigate this matter. As it is known, that IL-10 can act indirectly on T cells, via influence on APC, we choose a polyclonal, cell free T cell stimulus (platebound anti-CD3 and soluble anti-CD28) and mature allogeneic DC, because they are known as the most powerful APC and largely resistant to IL-10 17. CD4 +CD 25 + and CD4 + CD25 − T cells alone or at a 1:1 ratio were stimulated with allogeneic DC (FIG. 3, upper panel) or with bound anti-CD3 and soluble anti-CD28 (FIG. 3, lower panel) for 48 h. Thereafter cells were either fixed with paraformaldehyde or used viable. As expected activated CD4 + CD25 + T cells induced strong suppression of CD4+ proliferation and at a 1:1 ratio almost abolished it, whereas activated CD4 + CD25 − T cells did not alter proliferation of syngeneic CD4 + T cells. When the cocultured CD4 +CD 25 + and CD4 + CD25 − T cells were used in regulation assays, they mediated a strong inhibition of CD4 + T cell proliferation (FIG. 3). This phenomenon was seen, regardless of the stimulus used (FIG. 3, upper and lower panel). We further added anti-IL-10 Ab to the regulation assay or performed it in a transwell setting. As shown before anti-IL-10 did not alter suppressive function of pure CD4 + CD25 + T cells, whereas in a transwell setting CD4 + CD25 + T cells could not mediate suppression. The opposite was true for regulation by anergized CD4 + CD25 − T cells. Addition of IL-10 antibodies almost completely abolished inhibition, whereas a transwell setting did not markedly change the regulatory function of these cells. Suggesting, that inhibition is mediated dominantly by secretion of IL-10 (FIG. 3). Similar effects were seen with polyclonally or allogeneic stimulated cells (FIG. 3, upper and lower panel).
[0062] To further exclude that the observed effects are mediated by CD4 + CD25 + cell directly we performed CFSE labeling and FACS® sorting experiments. CD4 + CD25 − T cells were labeled with CFSE and then mixed with CD4+CD25+unlabelled T cells at 1:1 ratio. This mixture was stimulated with immobilized anti-CD3/soluble anti-CD28 for 48 h. Thereafter cells were sorted by FACS® and used in regulation assays with syngeneic CD4 + CD25 − T cells. As shown in FIG. 4, regulation was mediated by both, the labeled and unlabeled fractions, which was abolished by addition of anti-IL-10 in the case of unlabeled (anergized CD4 + CD25 − T cells). Not surprisingly activated CD4 + CD25 + T cells showed inhibition of T cells proliferation themselves. This could not be abolished by anti IL-10, clearly demonstrating, that anergized CD4 + CD25 − T cells mediate suppression via IL-10 which is distinct from the mechanisms utilized by CD4 + CD25 + T cells.
Example 5
Anergized CD4 + CD25 − T Cells Predominantly Produce IL-10
[0063] To analyze the cytokine secretion pattern of anergized CD4 + CD25 − T cells, CD4 +CD 25 + and CD4 + CD25 − T cells were sorted and stimulated alone or at a 1:1 mixture as described before. After 48 hours of culture supernatants were analyzed for the cytokines IL-2, IL-4, IL-5, TNF-α and INF-γ by a cytometric bead array, which allows multiparameter analysis in a single sample. As shown in FIG. 4, anergized CD4 + CD25 − T cells similar to CD4 + CD25 + T cells do only produce very low levels of TNF-α and INF-γ and no IL-2,-4 or IL-5. CD4 + CD25 − T cells on the other hand produce high levels of IL-2, TNF-α and INF-γ and low to moderate levels of IL-4 and IL-5, resembling a TH1 phenotype. Surface phenotyping with the Abs mentioned in material and method did not reveal striking differences between activated CD4 +CD 25 + , activated CD4 + CD25 − and cocultured CD4 +CD 25 + /CD4 + CD25 − T cells after 48 h of activation (data not shown).
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The invention provides CD4 + CD25 − T cells and Tr1-like regulatory T cells (i.e., contact-independent Type 1-like regulatory T cells), processes for their production and their use for regulatory purposes.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a braiding machine, and more particularly to a braiding machine having a plurality of bobbin supports which are movable along a track. The invention is suitable with particular advantage, although not exclusively, to a braiding machine which applies braid onto a hose. Such braiding machines are shown in German Pat. No. 517,586 of Feb. 5th, 1931.
Braiding machines of this type have bobbin supports which carry respective supply bobbins, that is bobbins carrying a supply of filament, bead, thread, wire or the like. The bobbin supports are movable along a track and are advanced along the track by an arrangement whose operation is similiar to that of a Geneva motion.
The problem with the prior-art machines of this type is that the bobbin supports alternately engage and disengage a plurality of rotary drivers which are arranged along the track and which serve to engage the motion-transmitting portion of the bobbin supports in order to advance the latter along the track. The engagement of the motion-transmitting portions with the drivers involves entry of a motion-transmitting portion into one of a plurality of circumferentially spaced recesses on the respective driver, advancement with the rotating driver through a portion of arc, movement outwardly of the recess and into engagement with the periphery of an adjacent driver, movement along this periphery through a small distance and entry into a recess in the periphery of the adjacent driver, whereupon the operation repeats with respect to a further driver.
Braiding machines are widely known for the very considerable noise level which they develop in operation, and which results from the contact of the motion-transmitting portions of the bobbin supports with the respective drivers. It has been proposed to line the recesses in the peripheries of the drivers with synthetic plastic material, but it was then discovered that this does not materially aid in reducing the noise level during operation. Moreover, it is not advisable to use any significant amount of synthetic plastic material for the movable components of the braiding machine, such as the motion-transmitting portions of the bobbin supports, because such synthetic plastic material tends to wear quite rapidly and this leads to frequent repairs with the necessary machine downtime.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of this invention to overcome the disadvantages of the prior art.
More particularly, it is an object of the invention to provide an improved braiding machine which is not possessed of the aforementioned disadvantages, particularly of the high noise level in operation.
A further object of the invention is to provide such a braiding machine which is reliable in operation and which has an improved lifetime due to reduced wear.
In keeping with these objects, and with others which will become apparent hereafter, one feature of the invention resides, in a braiding machine, in a combination which, briefly stated, comprises guide means defining an endless track, and a plurality of bobbin supports movable along the track and each having a guide portion engaging the track, and a motion-transmitting portion. Means is provided for advancing the bobbin supports along the track and includes a plurality of rotary drivers arranged along the track and each having an angularly movable circular plate provided in a circumferential margin therof with angularly spaced recesses each located in a sector of the plate. The margins of adjacent ones of the plates overlap one another and the motion-transmitting portions are engageable in the recesses so as to share part of the angular movement of the respective plate prior to engaging the margin of the adjacent plate and entering into a recess of the latter. Sound-damping means is provided at these margins at least in that region of each sector which is located forwardly of the respective recess with reference to the angular movement, so as to reduce the noise resulting from engagement between the margins and the bobbin supports.
The invention is based upon the realization that the main reason for the high noise level of a braiding machine in the prior art is the impacting of the edges of the guide plates on the base of the bobbin supports with the radially outer edge of the circular plate of the rotary drivers. The reason for this is that the guide plates as well as the circular plates are not always very precisely positioned, or else can move out of their original precisely positioned location to a slight extent, and then can contact one another. The result of this is that at the transfer point where a bobbin support begins to be transferred from one driver to another, the guide plate of the bobbin support tends to assume a position which is conformed to that of the new rotary driver to which the bobbin support is being transferred. At the time at which a recess of the new driver engages the motion-transmitting portion of the bobbin support, in order to start advancing the bobbin support along the guide track, the undesired noise has already occurred.
The invention eliminates the problem at its root, so to speak, in that it provides the sound-damping means at the location of the respective rotary driver where the first contact occurs between the driver and the bobbin support, i.e., where in the prior art the noise develops as a result of such contact. Since the engagement is only brief and no particular stresses act in the regions in question, it has been quite surprisingly found that the sound-damping means of the present invention is subject to very little wear and therefore has a considerable lifetime.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary top-plan view illustrating components of a braiding machine which are necessary for an understanding of the invention, other components having been omitted for the sake of clarity and only a single bobbin support being shown;
FIG. 2 is a vertical section taken on line II--II of FIG. 1, including components which are omitted in FIG. 1;
FIG. 3 is an axial section through a rotary driver according to the present invention, as used in FIGS. 1 and 2;
FIG. 4 is a top-plan view of FIG. 3;
FIG. 5 is a sectioned detail view illustrating a detail of further embodiment of the invention on an enlarged scale; and
FIG. 6 is a top-plan view illustrating two adjacent rotary drivers of the machine according to the present invention at the time of transfer of a bobbin support from one to the other driver.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-4 and 6 illustrate an embodiment of the invention; FIG. 5 illustrates a detail of a modified embodiment.
The braiding machine in which the present invention is incorporated has not been shown in detail, because such braiding machines are well known to those having skill in the art. For this reason, only those components have been illustrated and will be described which are essential for an understanding of the invention.
The braiding machine has a plurality of bobbin supports 10 each of which supports one or more spools or bobbins of filaments, and the associated control devices for setting and regulating the filament tension. Neither the bobbins nor the regulating and control devices are illustrated, because they also are conventional. In FIGS. 1, 2 and 6 only a single bobbin 10 has been shown, because the invention can be explained with reference to a single bobbin, since evidently this explanation will be applicable to all of the bobbins 10.
The bobbin 10 which is shown by way of example has a bottom 11 provided with a guide portion 12 which engages into a rail or track 13 that is composed of a plurality of arcuate portions which are shown particularly clearly in FIG. 1 wherein the rotary drivers have been omitted for the sake of clarity. Since the guide portion 12 is guided by and moves along the rail 13, it is the rail which determines the movement to be performed by the respective bobbin support 10. The track formed by the rail 10 has two portions; the bobbin support 10 will first move in one of the portions in one direction and then in the other portion in the opposite direction. Where the two portions of the track cross one another, connecting portions 14 are inserted which serve the purpose of permitting the bobbin supports 10 to move across these junctions.
Upwardly of the guide portion each bobbin support 10 is provided with a drive section 15 composed of an upper plate 16 and a lower plate 17 which are connected by a pin 18 that constitutes a motion-transmitting portion. The diameter of the upper plate 16 is slightly in excess of that of the lower plate 17.
The movement of the bobbin supports 10 along the track defined by the rails 13 is effected by a plurality of rotary drivers 20 which are arranged along the track at the locations 19 shown in FIG. 1 and which cooperate with the motion-transmitting portions 18 of the respective bobbin supports 10 in the manner of a Geneva motion. FIG. 3 shows clearly that the illustrated rotary driver 20 (which is representative of all of the others) has a circular plate 21 at the exterior of the machine and a gear plate 22 in the interior of the machine and provided with a circumferentially extending annulus of gear teeth. The plate 22 is located below the level of the track 13 and its teeth engage with a drive gear (not illustrated) so that the rotary driver 20 is rotated. The gear plates 22 of the adjacent rotary drivers 20 mesh with one another. Each driver 20 further has a hub 23 whose configuration is shown in FIG. 3.
As FIG. 4 shows more clearly, the circular plate 21 of the respective driver 20 is provided with a plurality of marginal recesses 24 which are equiangularly spaced from one another. In the illustrated embodiment, four of the recesses 24 are provided, but a larger number, such as eight, could also be provided.
In operation, the upper plate 16 of the respective bobbin support 10 moves onto the exposed side of the circular plate 21 of the rotary driver 20 with which the bobbin support 10 cooperates at the particular moment; at the same time the plate 17 of the bobbin support 10 engages the lower or inner side of the plate 21. Also at this time the motion-transmitting portion 18 of the bobbin support 10 enters into one of the recesses 24 of the plate 21 and is taken along as the driver 20 is rotated, thus causing the bobbin support 10 to travel along the track defined by the rail 13 in the direction of rotation of the respective driver, by sharing part of the angular (i.e., rotary) displacement of the plate 21 thereof.
FIG. 2 shows that the circumferential margins of the plates 21, 21' of adjacent drivers 20, 20' overlap one another; for this purpose the circumferential margins are stepped in a complementary manner, as illustrated at 25 and 25'. The plates 21, 21' assume during their rotation respective positions in which the recesses 24, 24' of the adjacent plates 21, 21' are located opposite one another so that the motion-transmitting portion 18 of a bobbin support 10 can leave the recess 24 of the plate 1 and enter into a recess 24' of the plate 21'.
FIG. 6 shows how the transfer of a bobbin support 10 from one driver 20 to an adjacent driver 20' is accomplished. It will be seen that the drivers 20 and 20' rotate in mutually opposite directions, as indicated by the arrows 26 and 26'. The solid-line showing of the plate 16 of the bobbin support 10 shows that a portion 30 of the periphery of the plate 16 at this time overlaps the margin of the plate 21' of the driver 29' to which the bobbin support 10 is to be transferred from the driver 21. At this time, however, the motion-transmitting portion 18 of the bobbin support 10 is still spaced by a significant distance from the circumference of the plate 21', and is still received in the associated recess 24 of the plate 21. This means that at this time the advancement of the bobbin support 10 is dictated exclusively by the angular motion of the plate 21. At the time at which the plate 16 assumes the full-line position in FIG. 6, the transfer of the bobbin support 10 from the driver 20 to the driver 20' presents no problem in terms of the development of noise.
However, the noise problem occurs at the time at which the plate 16 is in the broken-line position 16a, shown in FIG. 6. At this time at which the closest recess 24' of the plate 21' which can and eventually will engage the motion-transmitting portion 18 of the bobbin support 10 is still spaced by a significant angular distance from the point of transfer, a contact already exists between the peripheral portion 30 and a circumferential contact location 32 of the plate 21'. Because of unavoidable deviations in the relative positions of bobbin support 10 and plate 21', a noisy engagement between bobbin support 10 and plate 21' will result, be it because of contact of the plate 21' with the plate 16 or with the plate 17. The sectors 27 between the recesses 24 or 24' of a respective plate 21 or 21' are the portions which support the plates 16 and 17 of the bobbin support 10. In order to avoid the undesired noise, the invention provides for the provision of a zone or portion of noise-damping material, particularly synthetic plastic material which is elastically yieldable, at that marginal portion 33 of a respective sector 27 of the plate 21 or 21', where the contact point 32 is located. It has been found that a plastic material available commercially under the tradename "Vulkollan" * is especially suitable, although other materials of synthetic plastic and having the requisite capability of elastically yielding can also be used.
The portion 33 is always located ahead of (in the direction of rotation) the respective recess 24 or 24'. There is therefore obtained a good buffer effect at the location 32, which is especially advantageous if the entire outer radial edge 28 of the plates 21 or 21' is provided with this zone, as illustrated in FIG. 4.
It is currently preferred if the entire plate 21 or 21' is surrounded by a rim 29 of such synthetic plastic damping material. The rim 29 has a width 34 so selected that the steps 25, 25' can be formed in the rim. Moreover, the recesses 24 and 24' are advantageously also lined with a curved portion 35 of the frame 29. The flanks of the recesses 24 are bounded by this portion of the frame.
FIG. 3 shows the exact configuration of the frame 29. The plate 21 (and, of course, the plate 21') has a metallic center or core 36 which is provided in its outer circumferential edge face in the region of the respective sector 27 with a radial groove 37 which is so shallow that in the region of the recesses 34 it does not extend into the core 36. It extends parallel to the surface 38 and is located substantially midway between the opposite end faces of the plate 21 or 21'. The frame 29 is advantageously produced by forming it directly onto the core 36 in appropriate form, so that its material enters into the groove 37 and couples the frame 29 with the core 36.
The embodiment which is illustrated in FIG. 5 corresponds in all details to that of FIGS. 1-4 and 6, except that the radial groove 37 is replaced by a radially projecting rib 39 which also extends parallel to the surface 38 and in this case is embedded in the material of the frame 29. The rib 39 may be provided with a plurality of axially extending holes or bores 40 into which the synthetic plastic material of the frame 29 can enter. It is advantageous to locate the rib 39 in the region of the projecting portion 41 of the step 25, so that the profiling in the frame 29 will be located at the same level as the rib 39.
Of course, as pointed out before, the frame 29 need not be continuous but instead the damping could also be applied in individual portions on the respective sectors 27.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the type described above.
While the invention has been illustrated and described as embodied in a braiding machine, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A plurality of bobbin supports is movable along an endless track and each has a guide portion which engages the track, and a motion-transmitting portion. An arrangement is provided for advancing the bobbin supports along the track and includes a plurality of rotary drivers which are arranged along the track and which each have an angularly movable circular plate provided in a circumferential margin thereof with angularly spaced recesses each located in a sector of the plate. The margins of adjacent ones of the plates overlap one another and the motion-transmitting portions are engageable in the respective recesses so as to share part of the angular movement of the respective plate prior to engaging the margin of the adjacent plate and entering into a recess of the latter. A sound-damping arrangement is provided at the margins so as to dampen sound when the margins are engaged by the bobbin supports.
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BACKGROUND OF THE INVENTION
This application is an improvement on the current garment supports located on the inner waistband of pants, shorts, skirts, trousers and the like. The purpose for such supports is to hold up the garments without the necessity of an external belt.
Because clothing is sized for an "average" person, many people have difficulty finding a garment that will fit the proportions of their body. Something which fits a person's hips or thighs may be too large for their waist. Clothing manufacturers lose countless sales due to this very problem. It may be necessary to buy numerous belts to coordinate with the many different garment fabrics and patterns. Some garment bottoms do not even come with belt loops so they may need to be altered at an additional expense.
Depending on, among other things, the thickness of the garment fabric and the fluctuations in a person's weight, a belt which fits one day may not fit on the same or another garment the next day. Furthermore, if the waist of a garment is a lot larger than the person's waistline, the use of an external belt will cause uncomfortable and unsightly bulges of fabric beneath the belt which in turn tends to push the belt upwards in the spaces between the belt loops.
The current garment supports which attach to the inside waistband do solve some of the above-mentioned problems in that they may eliminate the need for external belt loops and a multiplicity of belts since they are out of site. However, these current garment supports consist of one or more elastic strips somehow attached to the inner waistband. The problem with elastic strips is that they are of limited stretchability. Beyond a certain point, usually less than one half their resting circumference, they become uncomfortably tight, constricting, and may possibly break. Thus, there may still be a need to buy a number of different lengths of this elastic material to fit all of a person's garments. Furthermore, this type of garment support does not eliminate the fabric bulges around the waistband.
For the foregoing reasons, there is a need for a single garment support which will accommodate substantial fluctuations in waist size while remaining comfortable and look good.
SUMMARY OF THE INVENTION
The present invention is directed to a garment support that satisfies this need for substantial waist size adjustability, yet maintaining comfort and style. A garment support having features of the present invention comprises a flexible, expandable, inner tube-type device to which an air intake and release mechanism will be attached. The present invention can be built into the inner waistband of garments or can be made detachable therefrom.
OBJECTS OF THE INVENTION
Therefore, it is an object of this invention to provide for a garment support which can be adjusted to fit a wide range of waist sizes, even when there are fluctuations in the user's weight.
It is another object of this invention to provide for a comfortable garment support that does not become too loose or restricted depending on garment to which it is attached.
It is a further object of this invention to provide for a comfortable fit while maintaining the smooth appearance of the garment such that no bulges in fabric appear due to the support.
It is yet a further object of this invention to provide for a single support which will coordinate with the garment regardless of its type of fabric, pattern, or size.
It is still a further object of this invention to provide a means for either permanent or removable attachment.
BRIEF DESCRIPTION OF THE INVENTION
These and other intended objects, features, and advantages of the invention will become more readily apparent form the following with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of one embodiment of the invention located within the inner lining of the waistband of a garment;
FIG. 2 is a perspective view of a second embodiment of the invention attached to the inner waistband of a garment by belt loops; and
FIG. 3 is a close-up view of a third embodiment of the invention being attached to the inner waistband of a garment by strips of velcro.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a garment support which may be permanently attached to the inner waistband of a garment or be removable therefrom. The inner tube-like body will be made of rubber, plastic, or any other suitable material which allows for flexibility, elasticity, and expandability. Attached to the this inner tube-like body will be a small button to pump air into the tube and a release valve to let the air out of the tube.
Referring now to FIGS. 1 and 2, the inflatable, flexible belt 14 is shown attached to the inner waistband 12 of the garment 10. The belt 14 can be attached to the inner waistband 12 either by being sewn into the inner lining 13 of the garment 10 as shown in FIG. 1, or by belt loops 20 as shown in FIG. 2. The belt 14 may also be attached to the inner waistband 12 by using a hooks and loops mechanism 22, such as velcro strips, as shown in FIG. 3.
The invention may be permanently attached to the garment such that the invention is located within the inner lining of the waistband. The air intake and release mechanisms may be positioned through the material of the garment such that the wearer can have access from outside the garment.
If as shown in FIG. 1 the belt 14 is attached to the garment 10 by the inner lining 13, the air intake button 18 can be attached to one end of the belt 14 and extend through the waistband 12 to be accessible from outside the garment 10. The air release valve 16 is then attached to the far end of the belt 14 and likewise protrudes from the waistband 12 of the garment 10 to accessible from outside the garment.
Clothing manufacturers may have the option of attaching the present invention to their garments upon production to insure that their product will fit the not-so-average person's proportions. Depending on the means of attachment, the manufacturer could make the product either permanently attached or removable.
If it is desired to make the invention removable from the garment, the air pump and release valve can be located anywhere on the side of the tube facing the garment. Thus, the slightly raised surface of either pump or valve will not be touching the wearer. The wearer need only reach slightly into his waistband to adjust the amount of air in the tube. The whole apparatus may be attached to the inner waistband of a garment by a variety of means, such sewn in belt loops, or a self adhesive hooks and loops mechanism of which velcro strips is an example.
If the belt 14 is attached by belt loops 20 as shown in FIG. 2, a hooks and loops mechanism 22 as shown in FIG. 3, or any other means of attachment, the air intake button 18 and release valve 20 do not protrude through the waistband 12. As shown in FIG. 2, the air intake button 18 is attached to the surface of belt 14 which faces the inner waistband 12 of garment 10 such that it does not touch the wearer's body. The release valve 16 is likewise attached to the same inward surface of belt 14 as shown in FIG. 2. The air intake button 18 and release valve 16 are located at the front of the wearer's body where the stomach is so that they can be easily accessible.
The placements of the air intake button and release valve disclosed above are the suggested placement, however, the intake and release buttons could be placed anywhere along the length of the belt. They could even be placed side by side, on the inside or outside of the belt.
With the air pump and release valve, a person can adjust the amount of air inside the tube to fit their waist size. The more air that is pumped into the tube, the tighter the garment becomes, while the less air in the tube, the looser the garment becomes.
The present invention eliminates the frustration of having to forego the otherwise perfect pair of pants, shorts, skirt, etc. because of the waist size. The present invention also reduces the need for multiple external belts, costly alterations, external belt loops, and eliminates uncomfortable and unsightly bulges of fabric.
It is understood that the above description is illustrative only, small variations in the structure components could be made without departing from the intended scope of the claim.
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The present invention is directed to a garment support that satisfies this need for substantial waist size adjustability, yet maintaining comfort and style. A garment support having features of the present invention comprises a flexible, expandable, inner tube-type device to which an air intake and release mechanism will be attached. The present invention can be built into the inner waistband of garments or can be made detachable therefrom.
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BACKGROUND OF THE INVENTION
This invention relates to a method of and an apparatus for piecing up the broken yarn in an open-end spinning system.
Heretofore, in the open-end spinning system, the operation of piecing up the broken yarn could be accomplished up to about 30,000 r.p.m. of the rotor without the necessity of making any special contrivance. However, the rate of success in piecing up the broken yarn was generally low for high speed rotation of say about 50,000 to 60,000 r.p.m. of the rotor, because the setting of the correct timing for supplying the separate fiber material for piecing up with the broken yarn or the supply quantity thereof and that of the correct timing for starting the winding operation or withdrawal of the piecing up yarn from the rotor will become progressively difficult with increase in the number of revolutions of the rotor. To cope with such difficulties, the number of revolutions of the rotor had to be reduced to say about 30,000 r.p.m. for performing the yarn piecing up operation. In such a case, not only the production efficiency was lowered due to the reduced speed of rotation of the rotor but the spinning unit assembly was generally complicated in its structure because of the annexed variable speed devices and sensing devices for the rotational speed of the rotor.
SUMMARY OF THE INVENTION
When a yarn end is thrown into the inside of a revolving rotor for piecing up, it is twisted under the effect of a centrifugal force and thus reduced in length. At this time, some tension is produced on the yarn end. According to the present invention, this phenomenon is utilized advantageously so that such tension on the yarn end is sensed by a sensor or a feeler and the delivery of the separated fiber material into the rotor is started depending on the output of the sensor.
The winding operation or withdrawal of the pieced up yarn from the rotor is started after a predetermined time as set on a timer has elapsed since the start of delivery of the separated fibers, or as a sensor or feeler has sensed that the tension on the end yarn has increased with the progress of delivery of the separated fiber material and attained a predetermined value.
According to the present invention, the percentage of successful yarn piecing up operation may be improved drastically, and the yarn piecing up operation can be performed with the spinning system running at its elevated speed, without it being necessary to lower the rotational speed of the rotor for yarn piecing up. According to the experiment conducted by the applicant with the use of cotton yarn, of which diameter is 0.012-0.070 inch, the rate of successful yarn piecing up operation has attained nearly 100% for 50,000 r.p.m. of the rotor and exceeded 80% for 60,000 r.p.m. of the rotor. Moreover, the separated fiber material can be supplied in an optimum quantity, and the pieced up portion of the yarn may be twisted satisfactorily and have a smooth appearance. In the conventional open-end spinning machine, the pieced up portion is generally thicker by more than 400% than the remaining portion of the yarn. In accordance with present invention, the bulging rate of the pieced up yarn portion can be reduced to less than 200%, thus making it possible to dispense with the step of unwinding the yarn by using a winder so as to remove the bulged portion from the yarn. Moreover, the present apparatus is simple and inexpensive because each spinning unit is provided with separate feed clutch and take-up clutch means. The electrical circuit and the timer are also inexpensive. The apparatus can be made more simple in structure and inexpensive by providing a single set of the electrical circuit and the timer for a group of spinning units. In addition, according to the present invention, the delivery of the separated fiber material and the restart of the winding operation can be accomplished automatically if only the proper timer setting is made in advance and the yarn end is, pulled out from the winding package and thrown into a guide pipe at the time of breakage of the yarn.
While the method of the present invention described above provides a pieced up portion of even thickness and smooth appearance, a second electrical signal to be described later may occasionally be produced from the yarn tension sensor in case the sufficient quantity of the fiber material is not supplied into the rotor but the yarn end portion YF is given a sufficient twist, or the separated fiber material are supplied in an excess quantity and yet the sufficient twist is not given to the yarn end portion. In this instance, the spinning unit may be so constructed that the winding operation is started after lapse of time set on the timer and after transmission of the second signal from the yarn tension sensor. The rate of successful yarn piecing up operation can then be increased further, the pieced up portion will have an improved appearance and more uniform thickness.
According to a further feature of the present invention, the separated fiber material can be supplied in a controlled quantity during the normal winding of spun yarn, owing to the provision of the yarn tension sensing means in a control unit for controlling the number of revolutions of the feed roller. When the quantity of the separated fibers is changed during the normal winding operation for some reason, the resistance offered by the yarn being intertwined with the fiber material is also changed, resulting in the fluctuations in the yarn tension. These fluctuations are sensed by the yarn tension sensor for changing the number of revolutions of the feed roller so as to adjust the supply of the fiber material to effect more uniform spinning.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an explanatory view of a spinning unit including the present apparatus;
FIG. 2 is a front sectional view of the traverse drum;
FIG. 3 is a perspective view of a rotor including a yarn tension sensor and a yarn breakage sensing rotor; and
FIG. 4 is a diagram showing the timing relationship between the delivery of the fibers and the winding of the spun yarn.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, C designates an electric circuit connected to a timer TX. Although each spinning unit is provided with one such circuit C and timer TX in FIG. 1 for ease of understanding, plural spinning units may be arranged into one group and associated with one circuit C and timer TX for economy sake. This electric circuit C is further connected electrically with a yarn breakage sensor or feeler F, a sliver feed clutch FC and a take-up clutch TC enclosed in a winding drum D.
The yarn breakage feeler F is designed to sense the tension applied to the yarn as conventionally so as to make or break an electrical contact included in the circuit, and is mounted intermediate a winding package P and a rotor R.
The sliver S is pinched between a feed roller 1 and a pressure plate 2 and supplied into an opening unit 6 where it is opened by the rotating opening roller 3 into one or more separate fibers. These separate fibers are carried by an air stream through a channel insert 4 into the inside of a rotor R where they are blown towards and transferred on the receiving surface 5 under the effect of a gyrating air current in the revolving rotor R. And then the fibers are collected on the collecting surface 7 under the effect of centrifugal force upon the rotation of the rotor R.
A feed shaft 9 is mounted in common to the group of spinning units longitudinally of the machine frame and adapted to drive a feed roller through a worm 10, a helical gear 11 and the feed clutch FC. A transmission belt B is mounted in common to the group of spinning units and adapted to drive the rotor R into rotation.
The fibers collected on the collecting surface 7 are twisted into a yarn Y and delivered through a guide pipe G and wound on the package P rotated by frictional contact with the winding drum D.
The winding drum D is mounted to each spinning unit and fitted to a drum shaft 8 mounted in common to the group of the spinning units longitudinally of the machine frame. The take-up clutch TC is mounted inside the winding drum D as an electromagnetically operated clutch brake means and operates to establish or interrupt the driving connection between the drum shaft 8 and the winding drum D.
The device operates as follows: When the feeler F senses the yarn breakage in a spinning unit, the electrical contact is turned off to disengage the feed clutch FC and the take-up clutch TC. Thus the feed roller 1 and the winding package P of the spinning unit are immediately brought to a stop.
When piecing up the broken yarn, the end of the yarn wound on the package is thrown as a yarn end into the inside of the rotor R manually or by a device designed to hold or release the yarn in a freely suspended position. The yarn end charged into the rotor R is revolved therewith and placed under a tension under the centrifugal force and the shrinkage in length of the yarn caused by twisting. This tension is sensed by the feeler F which acts immediately to engage the feed clutch FC, thereby driving the feed roller 1 into rotation so as to supply the fibers into the rotor.
These fibers are accummulated uniformly on the inner wall surface 7 of the rotor R. At this time, the yarn end is secured fixedly at the winding side and placed flat at the other side on the inner wall 7 of the rotor and revolved together with the rotor. The yarn end is twisted as a result and the end part of the yarn is rotated about its axis. The yarn end is now intertwined with the free ends of the fibers about to be heaped on the wall 7 of the rotor. The twisting movement is transmitted to the thicker fiber bundle already heaped on the inner wall 7 of the rotor. When the fibers are supplied into the rotor in a sufficient quantity to be intertwined with the end yarn for piecing up, and the yarn continuous to the ended portion becomes thicker and twisted to the required degree, the yarn is lifted as spun yarn endowed with sufficient strength, and the spinning operation is started again. According to the present embodiment, the optimum time interval To since the injection of the fibers into the rotor until the taking up of the pieced up yarn is set on the timing relay TX. Thus, after lapse of this time interval To since the start of injection of the separated fibers, the take-up clutch TC is engaged to drive the winding package P into rotation so as to wind up the yarn.
Referring to FIG. 2 showing an embodiment of the take-up clutch, the numeral 12 denotes a drum body mounted on the drum shaft 8 by means of a bearing 13, the numeral 14 a drum tube secured to the drum body 12, the numeral 15 a pin secured to the drum tube 14 and to which an armature 16 is fitted axially slidably on a splined shaft 19 secured in turn to the drum shaft 8, and the numeral 20 a coil casing secured to a fixed bracket 21 and enclosing a coil 23 connected to leads 22. When the current is not supplied to the leads 22, the armature 16 is biased towards right in the drawing under the force of a spring 24 and the disc 17 fitted on both sides with the linings 18 is clinched by and between the armature 16 and a friction surface 25 provided to the drum body. At this time, the drum body 12 is united as one with the disc 17 and revolved with rotation of the drum shaft 8. When the current is supplied to the leads 22, the coil 23 is energized and the armature 16 is displaced towards left in the drawing. Thus, the connection between the drum body 12 and the drum shaft 8 is interrupted, at the same time that the armature 16 is pressed onto a brake shoe 26 of the coil casing 20 for braking the drum body 12. The take-up clutch thus operates to start or stop the rotation of the drum body 12 immediately according as the current is applied to the leads 22 or not.
In the present embodiment, rotation or cessation of rotation of the drum is transmitted to the package P. In the modified embodiment wherein the package is supported on a pivotally movable cradle and designed to be contacted with and displaced away from the drum surface, the take-up clutch way be omitted and a solenoid may be provided in the electric circuit C to effect the pivotal displacement of the cradle.
In the preceding embodiment, the feeler F adapted to sense the occurrence of the yarn breakage and to stop the feed roller and the winding package is used at the same time for sensing the tension placed on the end yarn. In the modified embodiment shown in FIG. 3, a separate sensing means is provided for sensing the end yarn tension for controlling the time of supplying the separated fibers and starting the wind-up operation.
Referring to FIG. 3 showing this modified embodiment, the fibers are introduced into the rotor R through a supply conduit 4, and taken out from the rotor R in the form of spun yarn through a guide pipe G. The yarn breakage feeler F and a yarn sensor T are mounted at the exit side and towards the winding package not shown in FIG. 3. The feed roller and the winding package, also not shown in FIG. 3, are adapted to be driven into rotation or stopped in the same way as in the preceding embodiment. The yarn tension sensor may be of the electrically operated type and designed as conventionally so that the electrical current or voltage may be generated in varying intensity depending on the sensed yarn tension.
When piecing up the broken yarn, the yarn end is thrown into the guide pipe G by way of the yarn tension sensor T and the yarn breakage feeler F. When thrown into the guide pipe, the yarn end is twisted by rotation of the rotor R. The yarn end portion YF intermediate the lower end of the guide pipe G and the inner wall of the rotor is shrunk in length as a result of twisting, and the increasing tension is placed on the yarn end as a whole. The amount of twist given to the yarn end may thus be known from the measured tension on the yarn end. According to the present embodiment, a first electrical signal is produced by the yarn tension sensor as the yarn end tension has reached a proper value for intertwining the yarn end with the free end of the fiber to be supplied subsequently into the rotor, and the feed clutch FE is engaged upon reception of this first signal to start the delivery of the separated fibers into the rotor.
As the fibers are intertwined with the free end of the yarn end, the tension placed on the yarn end is increased further due to the resistance offered by the intertwined fibers. According to the present embodiment, a second electrical signal is generated as the yarn end tension has reached a proper value such that the yarn end is intertwined with the fiber ends to the optimum degree and the pieced up portion has become tolerably thick, and the take-up clutch TC is engaged upon reception of this second signal to start the winding operation.
In these two embodiments, when piecing up the yarn at the number of revolution of the rotor and that of the feed roller commonly employed for spinning, the time interval necessary for twisting the yarn to the optimum degree for the subsequent yarn piecing up tends to be shorter than that required for feeding the fibers in an optimum quantity for piecing up.
For instance, it was observed experimentally that, when spinning the cotton yarn, of which diameter is 0.0121 inch, at a 40,000 r.p.m. of the rotor, the optimum time for twisting the yarn end was approximately 0.4 second, while the proper time interval for feeding the separated fibers was approximately 0.2 second.
In such a case, as shown in FIG. 4, the feed clutch FC is engaged after lapse of a time interval T 2 since the time T 1 at which the yarn end is thrown into the rotor. Then, after lapse of a time interval T 3 since the charging of the end yarn, the feed clutch FC is disengaged. Then, the take-up clutch TC as well as the feed clutch FC is engaged after the lapse of a time interval T 4 since the disengagement of the feed clutch TC to start the winding operation.
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A method of and apparatus for piecing up the broken yarn in an open end spinning machine wherein the yarn breakage that has occurred in a spinning unit of the machine is pieced up or jointed with the fiber material supplied into a rotor while the spinning unit is operated at the ordinary high spinning speed and while the various elements of the spinning unit are driven at the same speed as the high spinning speed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Application Ser. No. 61/860,759 filed Jul. 31, 2013 the entire contents of which is hereby expressly incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] This invention relates to improvements in a projectile. More particularly, the present reusable projectile is fabricated from a casting process that can be used in a bullet cartridge and inserted into a gun. The reusable projectile conforms to the rifling of the barrel. After the projectile hits a target the projectile can be reused with limited degradation.
[0007] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98.
[0008] Most projectiles that are fired out of a gun, cannon or other firing armament that uses black powder or gun powder use a single use projectile. The projectile is deformed with the rifling of the barrel, and is further deformed when the projectile makes impact with a target. Either of both of these impacts deforms the projectile to a condition that the only way to re-use the projectile is to melt the projectile and reform the projectile. A number of other projectiles are made for non-lethal purposes, but these projectiles are custom designed to the firearm or operate outside of the firearm.
[0009] A number of patents and or publications have been made to address these issues. Exemplary examples of patents and or publication that try to address this/these problem(s) are identified and discussed below.
[0010] U.S. Pat. No. 6,295,933 issued on Oct. 2, 2001 to Bernard Dubocage discloses a Non-Lethal Projectile For Firearms. The projectile is a soft and elastic material that is formed into a ball, compressed pushed in a deformed condition into a cartridge. While the ball can be deformed and inserted into another cartridge, the ball is not in the shape of a bullet where the rifling of the barrel improves accuracy of the projectile. Because the projectile fit entirely within the cartridge, using the cartridge in a non-shotgun application would not allow the cartridge to automatically feed from a clip.
[0011] U.S. Pat. No. 7,278,358 issued Oct. 9, 2007 to Rick Huffman discloses a Non-Lethal Marking Bullet for Related Training Cartridges. The bullet has an outer casing that seals the inner marking material. Once the bullet hits a target the outer casing is compromised to allow the marking material to leave a visible indicator of the point of impact. The bullet operates in a shotgun and upon impact there are limited components that can be reused.
[0012] U.S. Pat. No. 7,063,021 issued on Jun. 20, 2006 and U.S. Pat. No. 7,237,490 issued on Jul. 3, 2007, both to Neil Keegstra et al., disclose an Expanded Volume Less Lethal Ball Type Projectile. The ball is deformed and pressed into a hull that guides the ball through the barrel of the firearm. The ball can then be collected and used in a future hull and base, but the ball requires an expendable hull to guide the ball through a shotgun barrel.
[0013] U.S. Pat. No. 8,312,812 issued on Nov. 20, 2012 to John A Kaples and U.S. Pat. No. 8,316,769 issued on Nov. 27, 2012 to Chris Wilson both disclose a training or non-lethal ammunition projectile. The reloadable training monition has a reusable shell base with a projectile that simulates the weight of an actual monition. The projectile is used for hand loading into a cannon for training purposes. While the projectile is reusable it is not used in in small arms guns and rifles where it is automatically loaded into the firearm for rapid shooting where the projectiles can be easily collected and reused.
[0014] What is needed is a reusable polyurethane projectile that approximates the size and shape of a bullet or other projectile. The proposed reusable polyurethane projectile provides a solution to this problem.
BRIEF SUMMARY OF THE INVENTION
[0015] It is an object of the reusable polyurethane projectile to be reusable. Because the projectile is reusable it can be pushed or inserted into a cartridge, fired, collected and reused with minimum degradation. The projectile follows the rifling of the firearm to improve the accuracy to a target. Upon impact the projectile will flatten and then rebound to the original shape. Standard re-loading mechanisms can be used to install the projectile back into a prepared cartridge. This reduces the cost to firing a cartridge to just the cost of the primer and the gunpowder.
[0016] It is an object of the reusable polyurethane projectile to be operable at high temperatures. The reusable projectile is fabricated from a casting process that increases the resistance of the polyurethane from melting when the hot gun gunpowder pushes the reusable projectile out of the barrel of the gun as well as the heat from frictional forces as the projectile moves through the barrel. Projectiles made from some molding operations can melt or leave residue within the barrel of the firearm that can increase over time and cause harm when an actual lethal projectile is fired.
[0017] It is another object of the reusable polyurethane projectile to be less lethal. Because the projectile can deform or flatten and then return to the original shape the projectile is less lethal than a hard bullet or other metallic projectile. The amount of gunpowder can be adjusted to reduce the velocity and impact force when the projectile reaches a target. The size of the projectile is easy to fabricate based upon the bore of the firearm and the desired length to diameter ratio.
[0018] It is still another object of the reusable polyurethane projectile to perform like a bullet or projectile. This performance has multiple benefits. Because the projectile is essentially the same size and shape of a bullet it can be fed through a normal bullet clip into the breach of a gun, fired and ejected. Another benefit of the projectile having the same size and shape of a bullet is that the projectile will conform to the rifling of the barrel of the firearm to spin the projectile and provide equivalent accuracy to a metallic bullet.
[0019] Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0020] FIG. 1 shows a reusable projectile in a cartridge.
[0021] FIG. 2 shows a matrix of reusable projectiles after casting.
[0022] FIG. 3 shows the process of manufacturing the reusable projectiles.
[0023] FIG. 4 shows the process of using the reusable projectiles.
[0024] FIG. 5 shows a cross-sectional view of the reusable projectile.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a reusable projectile 10 in a cartridge. Polyurethane is a polymer resin widely used in molding because of its many material qualities. Its hardness can range from 10 shore A to 80 shore D, so polyurethane can simulate many production materials, from hard plastics, to soft rubbers. Urethanes are known as room temperature volcanizing materials because they can be created at room temperature. The mainstay of RTV molding is the ability to closely match parts production material characteristics. In the preferred embodiment the polyurethane is shore A 40 to 99, or shore D 10 to 50, but could be fabricated beyond the provided values depending upon the desired performance of the projectile. Modern urethanes can also withstand heat up to 220 F., making them functional in a wide range of environments and especially in the preferred embodiment where the projectile is briefly subjected to high temperatures of expanding gun powder and frictional forces as the projectile moves through the barrel.
[0026] This figure shows the reusable projectile 10 with a cylindrical mid-section 20 having a first end that is captured in a shell casing 19 . The second end is shown as an elliptical taper 22 . While an elliptical taper is shown, the second end could be configured as a round, flat, hollow point or other shape depending upon the desired flight and impact characteristics. The shell is essentially a common or standard shell casing, but can be a custom shape to fit a particular firearm or armament. The shell is cylindrical is shape, but can have a step such as a 0.30-6 or other similar shell. A typical shell has a rim 18 for either a rim fire or can be loaded with a primer in the central bottom of the rim 18 .
[0027] FIG. 2 shows a matrix of reusable projectiles after casting. In the preferred embodiment the projectiles are cast, poured or molded in a collective group as shown after the collective group is removed from a mold. The mold shows two different size and or shapes of projectiles 41 and 42 . The projectiles can be formed in an oriented matrix 43 of rows and columns, circular, spiral or randomly placed to provide the best fabrication density. or can be just a single projectile. In this figure shows the multiple projectiles after mold has been inverted and the projectiles have been removed from the mold. The projectiles are created by pouring liquid polyurethane into a mold and the polyurethane fills the projectile voids to create the projectiles. Excess polyurethane is poured into the mold and the excess polyurethane creates a sprue, runner or gate 40 .
[0028] FIG. 3 shows the process of manufacturing the reusable projectiles. Before creating a mold the desired profile and shape of the projectile(s) is determined and a master pattern or mold is created. Depending upon the desired casting, molding or pouring process a master pattern, or mold of the projectile is created 50 . Producing cast urethane parts starts with the creation of a master pattern. SLA rapid prototypes are typically used for the patterns, but SLS and Polyjet prototypes work as well. In one embodiment to make the mold, silicone rubber is poured around the pattern. Once the silicone has set the pattern is removed, leaving a negative image which polyurethane can then be cast into. Because silicone molds are flexible, they tend to be more forgiving, and slides are usually not required for minor undercuts.
[0029] In another contemplated embodiment, insert or over molding is created with silicone molds. To make over molded parts two patterns are made, one with the over mold, and one without. Then the two molds are made from the masters, and the urethane parts are cast. First, the base part is cast using the mold without the over mold. Then, the part is moved into the second mold, so that the second casting can be poured over it. The Urethane Casting process is capable of reproducing small details. Due to the flexibility of the molds, draft angles and undercuts are not as critical as it is in other molding processes.
[0030] The chemical formula for the compound polyurethane is ROC(O)N(H)R. The molecular formula for urethane, also known as ethyl carbamate, is C 3 H 7 NO 2 . Polyurethane is a polymer which is made up of several organic units which are joined by urethane or carbamate links. Polyurethane bridges the gap between rubber and plastics by combining rubber's characteristics with the cut, tear, and abrasion resistance of plastics,
[0031] Polyurethane is a mixture of urethane resin and hardener. The accuracy of the mixture is important to the success of the resulting projectile. The urethane resin and the hardener are thoroughly mixed 51 and the mixture is poured, injected or otherwise introduced into the mold 52 . A vacuum can be applied to the mixture 57 to remove bubbles from the mixture before the mixture is deposited into the cavity. When the vacuum is applied to the mixture prior to depositing the mixture into the cavities, step 53 to remove bubbles is typically not applied during the process. The master pattern is attached to a gate assembly and suspended into either a frame or a box or simply poured into the pattern or mold. In the preferred embodiment the mold can be placed in a vacuum 53 chamber to allow air bubbles to float to the surface and improve the homogeneous nature of the resulting projectile. Once the urethane has hardened or cured 54 , it is removed and the process can be repeated using the same mold to cast additional parts.
[0032] In the embodiment shown in FIG. 2 the mold in inverted and the polyurethane projectile array is pulled from the mold 55 . Individual or collective projectiles are cut, trimmed, or otherwise removed 56 from the surrounding gate, sprue or runner 40 to result in individual projectiles. One or multiple dispensing heads can dispense material directly into the cavities and fill each cavity with the desired amount of material thereby eliminating any sprue or runner and thereby eliminating any need to trim the projectiles.
[0033] FIG. 4 shows the process of using the reusable projectiles, and FIG. 5 shows a cross-sectional view of the reusable projectile. At the beginning of the process the shell or brass is prepared 60 . In an optimal situation the brass casing 19 is tumbled, wiped clean and inspected for splits, cracks, or bulging. Any defective cases should be deformed and thrown away to prevent confusion between a good casing and an uninspected or bad case. The brass should be lightly lubricated. A sizing die is used to ensure that the diameter is correct. The length and width should also be measured to ensure optimal operation because cases will always stretch, becoming longer after several firings, you must check the length and trim to size for proper chambering and safety. The outer edge 21 should be de-burred and often bevels the case for easier seating of the bullet. It is also contemplated that the polyurethane projectile can have an insert 25 or be insert cast to achieve a desirable weight or mass.
[0034] The case is primed 61 by inserting a primer 17 into bottom of case. A good way is to use a hand held priming tool to insert primers into the case. This provides a better feel for the primer being inserted. The other method is to use the reloading press and a priming tool attachment for seating primers.
[0035] The powder charge 16 is poured or packed into the case 19 . Because the projectile is polyurethane the powder charge 63 can be adjusted to the desirable projectile velocity. A user can consult a reputable reloading manual and look up your load and learn which powder and what charge amount to fill the shell 19 . The shell should again be inspected to ensure even charges in each case 19 .
[0036] The polyurethane projectile is the seated in the case 19 using a seater die. Because the projectile is polyurethane the projectile 10 can be manually pushed into the case 19 such that the cylindrical body 23 of the polyurethane projectile is essentially concentric with the inside diameter 24 of the case 19 . When using a seater die, the case 19 is placed into the shell holder and the handle of the press in lowered, thereby, running the case 19 to the top of the press stroke. When the polyurethane projectile is properly seated the projectile can be used in a firearm or armament.
[0037] After the polyurethane projectile is fired 65 the polyurethane projectile will follow the rifling of a barrel and with approximate the accuracy of a non-polyurethane projectile. The polyurethane projectile can be retrieved for use again. This operation can take place as many times as the projectile retains its initial size and shape. There can be some degradation with the polyurethane projectile makes contact with abrasive surface.
[0038] Thus, specific embodiments of a reusable polyurethane projectile have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.
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Improvements in a reusable polyurethane projectile are presented. The reusable polyurethane projectile performs like a bullet or projectile because the projectile is essentially the same size and shape of a bullet and can be fed through a normal bullet clip into the breach of a gun, fired and ejected. The reusable polyurethane projectile conforms to the rifling of the barrel of the firearm to spin the projectile and provide equivalent accuracy to a metallic bullet. Upon impact the projectile will flatten and then rebound to the original shape. Standard re-loading mechanisms can be used to install the projectile back into a prepared cartridge. The reusable projectile is fabricated from a casting process that increases the resistance of the polyurethane from melting when the hot gun gunpowder pushes the reusable projectile out of the barrel of the gun.
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TECHNICAL FIELD
[0001] The present invention relates generally to underwater mining, and in particular relates to a system and method for seafloor stockpiling. In particular the invention relates, but is not limited, to mining, gathering, and stockpiling resources on the seafloor using a plurality of cooperating seafloor tools.
BACKGROUND OF THE INVENTION
[0002] Seabed excavation is often performed by dredging, for example to retrieve valuable alluvial placer deposits or to keep waterways navigable. Suction dredging involves positioning a gathering end of a pipe or tube close to the seabed material to be excavated, and using a surface pump to generate a negative differential pressure to suck water and nearby mobile seafloor sediment up the pipe. Cutter suction dredging further provides a cutter head at or near the suction inlet to release compacted soils, gravels or even hard rock, to be sucked up the tube. Large cutter suction dredges can apply tens of thousands of kilowatts of cutting power. Other seabed dredging techniques include auger suction, jet lift, air lift and bucket dredging.
[0003] Most dredging equipment typically operates only to depths of tens of metres, with even very large dredges having maximum dredging depths of little more than one hundred metres. Dredging is thus usually limited to relatively shallow water.
[0004] Subsea boreholes such as oil wells can operate in deeper water of up to several thousand metres depth. However, subsea borehole mining technology does not enable seafloor mining.
[0005] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.
[0006] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
SUMMARY OF THE INVENTION
[0007] According to a first aspect, the present invention provides a system for seafloor stockpiling, the system comprising:
a flexible transfer pipe for carrying slurry from a slurry inlet to a slurry outlet; wherein the slurry inlet receives slurry from a seafloor collection machine; and the slurry outlet, positioned at a desired location distal from the slurry inlet, delivers the slurry to a seafloor site.
[0011] According to a second aspect, the present invention provides a method for seafloor stockpiling, the method comprising:
capturing seafloor material in a slurry form; carrying captured slurry through a flexible transfer pipe to a slurry outlet; and positioning the slurry outlet at a desired seafloor site distal from the slurry inlet.
[0015] Preferably the outlet is mounted in a seafloor stockpiling hood. The seafloor stockpiling hood preferably has an open bottom and preferably captures and contains the slurry on a seafloor surface of the seafloor site. The seafloor stockpiling hood preferably allows egress of water from the slurry in the hood.
[0016] The flexible slurry transfer pipe permits the slurry outlet to be moved relative to the slurry inlet, for example to accommodate varied seafloor topography, environmental conditions and/or seafloor device operating conditions. Embodiments of the first and second aspects of the invention may thus be applied in a broad range of seafloor mining applications in which it is desired to transfer a slurry from one seafloor site to another.
[0017] In embodiments of the first and second aspects of the invention the slurry inlet may be mounted upon a seafloor gathering tool configured to gather slurry from more than one seafloor location for delivery to the slurry outlet.
[0018] In embodiments of the first and second aspects of the invention, the desired location to which the slurry outlet delivers the slurry may comprise a naturally occurring seafloor site at which the slurry is released. In such embodiments the slurry outlet may simply be anchored at or proximal to the desired location to deliver slurry. The desired location may comprise a naturally occurring seafloor depression in order to promote settling of solids in the slurry into the depression.
[0019] The desired location could be artificially formed and could for example be a walled area with the walls comprising solid material placed in order to form walls. The walled area could have an open wall and for example may have a wall only to a downstream side of the desired location when a prevailing current is known to occur, such that solids settling out of the slurry delivered to the desired location will tend to gather against the open wall and thus tend to remain at the desired location. Alternatively, the walled area could be substantially surrounded by the wall and function as a settling tank for slurry delivered into the desired location. In further embodiments the desired location may comprise a substantially enclosed volume into which the slurry is pumped so as to capture solids in the slurry.
[0020] The slurry may contain waste material which is desired to be relocated on the seafloor. Alternatively, the slurry may comprise valuable solids which are desired to be recovered from the seafloor to a surface vessel, via a seafloor stockpiling site at the desired location.
[0021] According to a third aspect, the present invention provides a system for seafloor mining, the system comprising:
at least one seafloor tool that captures seafloor material in a slurry form; a seafloor stockpiling hood for receiving seafloor material in slurry form that captures and contains seafloor material present in the slurry at a seafloor site while permitting egress of water present in the slurry from the hood; at least one flexible stockpiling transfer pipe for transport of slurry from the seafloor tool to the seafloor stockpiling hood;
a gathering tool for extracting seafloor material captured by the hood and delivering the gathered seafloor material to a riser and lifting system that lifts the seafloor material to the surface; and
a surface vessel for receiving the seafloor material from the riser and lifting system.
[0027] According to a fourth aspect, the present invention provides a method for seafloor mining, the method comprising:
at least one seafloor tool capturing seafloor material in a slurry form; a seafloor stockpiling hood receiving the seafloor material in slurry form from the seafloor tool and capturing and containing seafloor material present in the slurry at a seafloor site while permitting egress of water present in the slurry from the hood; extracting seafloor material from the hood and delivering the gathered seafloor material to a riser and lifting system; and a surface vessel receiving the seafloor material from the riser and lifting system.
[0032] Preferably the seafloor material is extracted in slurry form. Preferably the seafloor material extracted in slurry form is delivered to the riser and lifting system via a riser transfer pipe.
[0033] The third and fourth aspects of the present invention recognise that slurry flow rates desired for capturing seafloor material can be significantly different to the slurry flow rates desired for lifting a slurry in a riser and lift system, and thus provides for decoupling of these flow rates by use of a seafloor stockpiling hood. The respective flow rates may thus be separately optimised.
[0034] Moreover, significant operational benefits result from removing the dependence of the gathering system from the operation of the seafloor tool, such that the gathering of stockpiled material for delivery to the riser and lift system may occur even when the seafloor tool is not capturing seafloor material. This is particularly important for seafloor tools with highly variable production capacity, such as a peak capacity of around 10,000 tonnes per day but an average production of 3,000 tonnes per day, as the present invention permits a gathering system and riser and lift system to be designed to meet the average production value rather than the peak production value.
[0035] Moreover, in the case of small seafloor sites, the use of stockpiling can afford particular operational benefits in permitting a single tool to work a bench for extended lengths of time, reducing the need for multiple seafloor tools to co-habit a small bench or the need for large number of tool movements to permit alternating tools to work the small site. With use of seafloor stockpiling and suitable stockpiling transfer pipes each seafloor tool can work with considerably reduced interdependence at varying sites in the proximity of the stockpile. For example, in some embodiments the, or each, stockpile pipe may be configured to permit the associated seafloor tool to work up to 200 m away from the stockpile and up to 50 m above or below the stockpile in elevation.
[0036] The hood preferably has an open bottom and is configured such that, when positioned on a relatively flat portion of the seafloor, the hood and seafloor define a stockpiling cavity. The walls of the hood preferably completely enclose a stockpiling volume in a manner to minimise the loss of slow-settling fine particles (referred to herein as “fines”). In such embodiments, to accommodate large volumes of slurry inflow, the hood preferably permits the egress of water from the stockpiling volume so as to filter and capture the seafloor material from the slurry. To this, end, preferably a significant surface area of the walls of the hood are formed of filter material which contains fines while permitting egress of water from the hood.
[0037] A grade of the filter material, being a dimension below which solid particles can pass through the filter material, is preferably selected in order to maximise fines containment while permitting the necessary water flow rate out of the hood to accommodate slurry inflows into the hood. For example the filter material may comprise a silt curtain of 50 micron grade. The seafloor hood preferably comprises a space frame supporting the filter material, with the walls of the hood being formed by the filter material.
[0038] Capture of fines from a slurry inflow into the hood can be advantageous both environmentally in avoiding escape of plumes of the seafloor material, and operationally as such fines may represent 30% or more of the seafloor material desired to be gathered.
[0039] The, or each, seafloor tool delivering captured seafloor material to the stockpiling hood may comprise an auxiliary cutter, a bulk cutter, or a collection machine.
[0040] The gathering tool for delivering seafloor material from the seafloor hood to the riser and lift system may extract seafloor material directly from the hood. The gathering tool may be a portion of the seafloor hood, for example a suction inlet positioned within the hood and connected to a suitable transfer pipe and slurry pumping system. Additionally or alternatively, the gathering tool for delivering seafloor material from the seafloor hood to the riser and lift system may be a collection machine separate to the hood, the collection machine having a collection head configured to be brought within the hood via a collection port in the hood, the collection head comprising a suction inlet. Alternatively there may be no gathering tool of the hood, and the hood may simply be removed to leave the seafloor ore pile freely accessible to a gathering machine.
[0041] The slurry flow rate in the stockpiling transfer pipe may for example be about 3,000 m 3 /hour, with an ore concentration of about 3%. In contrast, in such an embodiment the flow rate in the riser transfer pipe may be around 1000 m 3 /hour at an average ore concentration of about 12%.
[0042] The stockpile hood may have angled walls forming a substantially frustoconical or frustopyramidal shape, the walls being at an angle to approximate the expected rill angle of an ore heap so as to avoid a stockpiled ore heap exerting significant outward pressure on the walls.
[0043] In alternative embodiments the seafloor stockpiling hood may comprise a settling tank with an encircling wall, whereby delivery of a slurry into the settling tank permits gathered material to settle to the base of the settling tank and permits water of the slurry to rise out of the tank, the tank having a sufficient cross section that a flow rate of water out of the tank is slow, to permit fines to settle. Preferably, the cross sectional area of the tank is sufficient, relative to an inlet slurry flow rate, that the flow rate out of the tank is about 12 m/hour or less, so that fines settling in water at a rate greater than 12 m/hour are captured.
[0044] Further, the present invention provides a system adaptable in some embodiments to deployment at significant water depths. For example some embodiments may be operable at depths greater than about 400 m, more preferably greater than 1000 m and more preferably greater than 1500 m depth. Nevertheless it is to be appreciated that the multi-tool system of the present invention may also present a useful seafloor mining option in water as shallow as 100 m or other relatively shallow submerged applications. Accordingly is to be appreciated that references to the seafloor or seabed are not intended to exclude application of the present invention to mining or excavation of lake floors, estuary floors, fjord floors, sound floors, bay floors, harbour floors or the like, whether in salt, brackish, or fresh water, and such applications are included within the scope of the present specification.
[0045] The, or each, seafloor tool may be an untethered remotely operated vehicle (ROV), or may be a tethered vehicle operated by umbilicals connecting to the surface.
[0046] The seafloor gathering tool preferably comprises a mobile slurry inlet which can be controllably positioned proximal to stockpiled material to be gathered. Thereby, suction at the slurry inlet causes water and proximal solids to be drawn into the inlet in the form of a slurry. The seafloor gathering tool preferably has a remote attachment and disconnection system for connection of a riser transfer pipe for transfer of the slurry from the stockpile to the riser base. In such embodiments, the remote connection system enables deployment and recovery of the gathering machine to and from the seafloor without recovery of the slurry riser system. The suction at the slurry inlet may be generated by a pump of the gathering tool, or alternatively may be generated by a subsea transfer pump at the riser base.
[0047] The riser and lift system preferably comprises a subsea slurry lift pump to pump slurry to the surface through a riser pipe. In preferred embodiments the seafloor stockpiling hood receives seafloor material in slurry form from the seafloor tool via a flexible stockpile transfer pipe. The stockpile transfer pipe preferably has remote connection/disconnection ability at both the seafloor tool and the hood.
[0048] The surface vessel may be a navigable vessel, a platform, a barge, or other surface hardware. The surface vessel preferably comprises dewatering equipment to dewater the slurry received from the riser, and may further comprise ore transfer and/or processing facilities such as an ore concentrator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] An example of the invention will now be described with reference to the accompanying drawings, in which:
[0050] FIG. 1 is a simplified overview of a subsea system in accordance with one embodiment of the present invention;
[0051] FIG. 2 illustrates another embodiment involving simultaneous operation of seafloor tools sharing a single stockpiling device;
[0052] FIGS. 3 a to 3 d illustrate the example operational positions of the stockpiling system;
[0053] FIG. 4 illustrates the seafloor mining system of FIG. 2 from an elevated perspective;
[0054] FIGS. 5 a - 5 d illustrate the collection machine in greater detail;
[0055] FIG. 6 illustrates the collection machine dredge pumping system;
[0056] FIG. 7 illustrates another embodiment in which the stockpiling device is a settling tank; and
[0057] FIG. 8 illustrates fluid flows and settling rates in the embodiment of FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] The following abbreviations and acronyms are used throughout the following detailed description:
[0000]
m
Metres
PSV
Production Support Vessel
RALS
Riser and Lifting System
ROV(s)
Remotely Operated Vehicle(s)
RTP
Riser Transfer Pipe
SMS
Seafloor Massive Sulphide
SMT(s)
Seafloor Mining Tool(s)
SSLP
Subsea Slurry Lift Pump
CM
seafloor Collecting and cutting Machine
AM
seafloor Auxiliary Mining machine
BC
seafloor Bulk Cutting machine
[0059] FIG. 1 is a simplified overview of a subsea system 100 in accordance with one embodiment of the present invention. A derrick 102 and dewatering plant 104 are mounted upon an oceangoing production support vessel 106 . Production support vessel (PSV) 106 has ore transfer facilities to load retrieved ore onto barge 108 . The present embodiment provides a system 100 operable to 2500 m depth, however alternative embodiments may be designed for operation to 3000 m depth or greater. During production operations, one or more seafloor mining tools (SMTs) are used to excavate ore from the seabed 110 . The SMTs comprise a seafloor bulk cutting (BC) machine 112 , a seafloor collection machine (CM) 114 and a seafloor auxiliary mining (AM) machine 116 .
[0060] Ore mined by the BC 112 is gathered upon being cut and pumped, in the form of slurry, from the BC through a stockpile transfer pipe (STP) 128 to a seafloor stockpiling device 124 a , which captures ore from the slurry while releasing water from the slurry. CM 114 inserts a boom-mounted suction inlet into stockpile 124 a to gather ore in slurry form and transfers this slurry to the base of the riser 122 . A subsea lift pump 118 then lifts the slurry via a rigid riser 122 (shown interrupted in FIG. 1 , and may be up to 2500 m long in this embodiment). The slurry travels to the surface support vessel 106 where it is dewatered by plant 104 . The waste water is returned under pressure back to the seafloor to provide charge pressure for the subsea lift pump 118 . The dewatered ore is offloaded onto transport barge 108 to be transported to a stockpile facility before being transported to a processing site. AM 116 works another area of the mine site and delivers it's cuttings to the stockpile device 124 a or to another stockpile device 124 b for later gathering by CM 114 .
[0061] An inlet grizzly sizing screen is used on the CM 114 inlet to prevent over-size particles being introduced into the slurry system 120 , 118 , 122 , 104 . The system 100 is designed so that this grizzly screen size is interchangeable.
[0062] The CM 114 , the BC 112 and the AM 116 each have a pump and control system which maintains the integrity of slurry flow and accounts for anticipated variability in inlet slurry conditions. The pump/gathering system incorporates automatic slurry inlet dilution and bypass valves to prevent loss of flow integrity associated with blockages and/or instantaneous changes in slurry intake density outside of the system's specified operating limits. Alternative slurry density control systems may be employed in other embodiments.
[0063] In order to minimise risk of blocking the riser transfer pipe (RTP) 120 and/or CM 114 , in this embodiment the CM 114 has a dump valve that is activated when the slurry flow integrity is compromised. In alternative embodiments of the invention a dump valve may be omitted. The CM 114 of this embodiment further incorporates a back flow system to assist in clearing any slurry system blockages within the CM 114 . This system is a configuration of pipes and valves that direct high pressure water from the slurry discharge line back to the suction head of the gathering machine 114 . Dump valves and backflow systems are similarly provided for the stockpile hoses 126 , 128 and stockpile system 124 in this embodiment.
[0064] The Riser and Lift System (RALS) 118 , 122 lifts the seawater-based slurry containing the mineral ore particles to the Production Support Vessel (PSV) 106 at the surface via a vertical steel riser 122 suspended from the vessel. The ore particles mined by the SMT are collected using suction, and the particles thus become entrained in seawater-based slurry which is then pumped to the base of the riser via a Riser Transfer Pipe (RTP) 120 in a “lazy-S configuration”. A Subsea Slurry Lift Pump (SSLP) 118 suspended below the base of the riser 122 will drive the slurry from the base of the riser 122 to the vessel 106 , which will be over a height of up to 2500 m in this embodiment. Once at the surface, the slurry passes through a dewatering process 104 . The solids are transferred to a transport barge 108 for shipment to shore. The waste water, topped up with additional seawater as required, is passed through a header tank system onboard the PSV 106 and pumped back down to the base of the riser 122 via auxiliary seawater pipelines clamped to the main riser pipe 122 . The return seawater, on arrival at the base of the riser 122 , is then used to drive the positive-displacement chambers of the SSLP 118 prior to being discharged into the sea close to the depth at which it was originally collected. Alternative means to drive the SSLP 118 can also be provided, for example electric, hydraulic, pneumatic or electro-hydraulic systems, among others.
[0065] The riser 122 is supplied in sections (joints), each joint being made up of a central pipe for the transportation of slurry mix from the base of the riser to the surface, together with two water return lines for powering the Subsea Slurry Lift Pump 118 from the surface. Plus, a Dump Valve System to enable all slurry in the Riser pipe 122 to be flushed from the system in the event of unexpected shut down, to prevent blockages.
[0066] The Subsea Slurry Lift Pump (SSLP) 118 is suspended at the bottom of the riser 122 and receives slurry from the CM 114 via the riser transfer pipe 120 . The SSLP 118 subsequently pumps the slurry to the Production Support Vessel 106 . The pump assembly 118 comprises two pump modules, each module containing a suitable number of positive displacement pump chambers driven by pressurised water delivered from surface pumps via seawater lines attached to the riser 122 . The pump 118 is controlled from the surface vessel 106 by a computerised electronic system which passes control signals through umbilical cables to a receiving control unit on the pump 118 . Functions are operated hydraulically with a bank of dual redundancy electro-hydraulic power packs located on the pump 118 . The electrical power to drive the power packs is fed through the same umbilical cables which carry the control data signals from the surface to the pump 118 . The two (dual redundancy) umbilicals for control of the SSLP 118 are secured to clamps on the riser 122 with the weight of the umbilical distributed along the riser joints.
[0067] The main function of the surface pumps is to provide pressurized water to drive the Subsea Slurry Lift Pump 118 . Multiple triplex or centrifugal pumps will be installed on the Production Support Vessel 106 , all taking water removed from the slurry mix (<0.1 mm residues) in the dewatering process, made up with surface seawater to the required volume before being pumped down the water return lines to the SSLP 118 at depth. The surface system incorporates a return water header tank fed from the dewatering system and topped up with the required volume to drive the SSLP 118 using centrifugal pumps extracting filtered surface seawater via a sea chest in the vessel hull. The water in the header tank is delivered to a bank of charge pumps which boost the pressure for delivery to the inlet of the surface pumps.
[0068] A derrick and draw-works system 102 is installed on the support vessel 106 in order to deploy and recover the riser 122 and subsea lift pump 118 . In addition handling systems within the area of the derrick 102 move the SSLP 118 into a designated maintenance area.
[0069] A surge tank is incorporated between the RALS discharge and the dewatering plant 104 to moderate instantaneous slurry variability prior to feed into the dewatering plant. The dewatering system 104 will receive ore from the RALS 122 as mineral slurry. To ensure that the ore is suitable for transport, the large volume of water within the slurry must be removed. The dewatering process of this embodiment uses three stages of solid/liquid separation:
Stage 1—Screening—using vibrating twin double deck screens Stage 2—De-sanding—using hydro cyclones and centrifuges Stage 3—Filtration—using disk filters
[0073] Vibrating screen decks are used to separate the coarse particles from the slurry stream. These coarse particles are considered to be free draining and will not require any mechanical dewatering to achieve the required moisture limit. A vibrating basket centrifuge is used to provide mechanical dewatering of the medium particle size fraction to ensure the required moisture limit is reached.
[0074] Hydro cyclones are then used to separate the valuable fine particles (>0.006 mm) from the slurry feed which have not been removed by the screen decks. Disk filters are used to dewater the valuable fines (between 0.5 mm and 0.006 mm) prior to loading on to the transport barge 108 . This ore size fraction requires greater mechanical input (vacuum) to remove moisture. The ore/slurry waste water is then returned to the seafloor via a pump-set and piping system. A dewatering plant 104 is installed on the topsides surface facilities, in this case the PSV 106 , to reduce the moisture content of the ore to below the transportable moisture limit (TML) of the ore. Reducing the moisture content below the TML allows safe carriage of the ore by ship. It also reduces the cost of transport due to the reduced volume of material being shipped. Alternative embodiments may utilise any suitable other configuration of dewatering plant.
[0075] In the case of dewatering plant 104 failure, the gathering machine 114 will disengage the seafloor 110 and continue pumping seawater. The volume of the surge tank is sufficient to accommodate the volume of slurry in the RALS 122 , 118 in the case of any dewatering plant 104 failure. The slurry in the RALS 118 , 122 will be discharged to the surge tank, or vibrating screens and surge tank, until seawater only is discharged to surface, at which time the dewatering plant 104 by-pass will be engaged and water circulated back to the subsea lift pump or the RALS/gathering machine shut down.
[0076] The PSV 106 remains on location for the duration of mining and supports all mining, processing and offshore loading activities to enable safe and efficient mining of the seafloor deposits 110 , recovery of cut ore to the surface, treatment (dewatering, including return of treated water to seafloor) and off-loading of the dewatered ore into the transportation barges 108 for onward shipment to stockpiling and subsequent treatment facilities. Station holding capability for the vessel is via dynamic positioning. Alternative station holding may be by mooring the vessel, or by a combination of both dynamic positioning and mooring depending on site specific conditions.
[0077] The system 100 of the present embodiment thus provides a means and method for achieving steady state seafloor mining and gathering production, such as seafloor massive sulphide (SMS) production.
[0078] FIG. 2 illustrates simultaneous operation of BC 112 , AM 116 and CM 114 , as made possible by the use of a single shared stockpiling device 124 . Cuttings from BC 112 and AM 116 are simultaneously delivered in slurry form into stockpiling hood 124 . As shown, new stockpiles of ore are built up within hood 124 , and on top of previously formed stockpiles. CM 114 simultaneously works to collect stockpiled cuttings and deliver them in slurry form vie RTP 120 to RALS 118 , 122 .
[0079] STPs 128 and 126 may be configured to take any suitable shape while in use, whether an inverted catenary as shown in FIG. 2 , an “M” shape, or otherwise.
[0080] FIGS. 3 a to 3 d illustrate example operational positions of the system 100 , primarily determined by the stockpiling hose 128 of the seafloor tool 112 , which together define an operational envelope of the system. With a STP 128 having a length of approximately 320 m and a hose inner diameter of approximately 425 mm, the horizontal freedom of movement of the BC 112 relative to a stockpiling site of the hood 124 is 50 to 200 m, in any direction, and the vertical freedom of movement of the BC 112 relative to the stockpile site of the hood 124 is +/−50 m. FIG. 3 a illustrates the BC 112 in a position that is higher than, but relatively close to, the hood 124 . FIG. 3 b illustrates the BC 112 in a position that is lower than, but still relatively close to the hood 124 . FIG. 3 c illustrates the BC 112 in a position that is higher than, but relatively far away from, the hood 124 . FIG. 3 d illustrates the BC 112 in a position that is lower than, but still relatively far away from, the hood 124 .
[0081] In one seafloor mining embodiment, it is desired that both the auxiliary cutter (AC) 116 and a bulk cutter (BC) 112 are able, at certain times, to simultaneously work respective sites within a mine area, each producing a slurry flow of up to 3,000 m 3 /hour. The present invention offers a significant benefit in avoiding the need for two respective RALSs each capable of transferring 3,000 m 3 /hour. Instead, the slurry flows from the AC 116 and the BC 112 may be delivered to one or more seafloor stockpiling hoods 124 , and a single RALS 118 , 122 may extract stockpiled ore in a slurry at around 1000 m 3 /hour. In a mine site with relatively small benches, it is to be expected that the BC 112 and AC 116 will not operate continuously due to inter-site movement, so that operation of the RALS 118 , 122 at a lower rate for a greater period of each day can be expected to roughly maintain site throughput, with the, or each, stockpile 124 operating as an operational buffer.
[0082] FIG. 4 illustrates an example of the seafloor mining system of the present embodiment from an elevated perspective.
[0083] FIGS. 5 a - 5 d illustrate an example collection machine (CM) 114 in greater detail. The CM 114 has a crown cutter collector 502 , a boom/ladder 504 , a chassis 506 , a slew yoke 508 , crawler assembly 510 and lift point 512 . In this configuration the crown cutter has a suction head grid at 50 mm working as a rock guard, a collection range height of −2 m to 5 m, and a collection range width of +/−4 m (8 m total width). Such a CM 114 can be utilised in the present invention to extract seafloor material in slurry form from and/or adjacent to the stockpile device 124 .
[0084] FIG. 6 illustrates an example dredge pumping system 600 of the CM 114 . The dredge pumping system 600 has three pumps 602 , 604 , and 606 that generate a combined outlet pressure of approximately 1750 kPa above ambient pressure. The pumping system 600 has an outlet 608 which is fluidly connected to the riser transfer pipe (RTP). A dump valve 610 is provided adjacent the outlet 608 that is activated when the slurry flow integrity is compromised. A back flush system 610 is also provided which can be used to back flush the crown cutter collector 502 , particularly when the crown cutter collector 502 is clogged or has a blockage. The back flush system 610 can also be used as a dilution system to dilute the seafloor material being extracted if desired.
[0085] FIGS. 7 and 8 illustrate an alternative embodiment of the invention in which the stockpiling device 124 is, or at least includes, a settling tank 700 with open top. Slurry from the BC 112 and/or the AM 116 is delivered into the top of the tank 700 by a delivery inlet 702 . The slurry is typically delivered at up to 6000 m 3 /hour, at which rate the flow rate upwards out of the tank is 12 m/hour. In this configuration, particles less than approximately 69 micrometres in size will settle too slowly and will exit the tank, but all fines larger than approximately 69 micrometres will have suitable conditions for settling in a heap 704 and will thus be captured and contained in the settling tank 700 .
[0086] The stockpiling system of the present invention could be used as part of alternative offshore system designs. For example, while the described embodiment addresses seafloor material of value which is to be recovered to a surface vessel, in accordance with the first and second aspects of the invention the slurry may simply be delivered to a desired location at a site distal from the slurry inlet, for example to relocate waste to another seafloor site distal from a site of interest. The present invention also recognises that a range of costs and losses arise from the double handling of seafloor material involved in such a stockpiling method, but recognises that such costs and losses can by use of the present systems and techniques be minimised while affording a significant net operational benefit to some seafloor mining applications.
[0087] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
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A system and method for stockpiling material on the seafloor, the system and method using seafloor collection machines, such auxiliary or bulk cutters or collection machines, to capture seafloor material to be stockpiled. The captured seafloor material is carried in slurry form over a flexible transfer pipe to an outlet at a desired seafloor site. In a preferred form the outlet is mounted in a seafloor stockpiling hood that sits on the seafloor at the desired seafloor site and captures and contains slurry from the outlet while allowing egress of water. The captured seafloor material can then be extracted to a surface vessel.
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This is a continuation of copending application Ser. No. 07/744,183 filed Aug. 8, 1991, abandoned.
BACKGROUND OF THE PRESENT INVENTION
1. Field of Invention
The present invention relates generally to computer disk drives and specifically to solutions to the problem of zone misses in optical disk drive systems that depend on a modified constant angular velocity (MCAV) method of data recording.
2. Prior Art
Optical disk drives are susceptible to seek errors because track densities are usually very high. After a head seek operation, it is often necessary to do a seek verification that quickly reads the present track address and computes any error distance that must be crossed to get to a target track. To read the track address, a reference synchronizing frequency used in the data readout circuitry must correspond to a data recording frequency for the recording zone in which the head(s) actually landed. When a zone miss occurs, the two frequencies will not match, because the actual zone differs from the target zone, and the data in the tracks cannot be read.
A popular method used in prior art magnetic disk drive systems to increase the recording capacity of optical disk and optomagnetic disk drive systems is a modified constant angular velocity (MCAV) method. This kind of method partitions the media into a number of concentric circular zones, and changes the data recording frequencies in the respective zones with the objective of making the line density of data recording uniform over the media's entire surface. This method has the advantage of allowing very high recording densities. It requires switching a reference synchronizing frequency to an appropriate data recording frequency for the zone in which the head(s) is/are positioned.
Moving a head to a target track in optical disk drive systems requires about ten times the precision of magnetic disk drives because of the much higher track densities. So most optical disk drives use a two-stage method that consists of a rough seek to moves the head(s) near a target track, followed by a fine seek to position the head(s) precisely on the target track. A typical program sequence, implemented as drive firmware, is as follows:
(1) reference a conversion table in a read only memory of a disk drive to find a target zone that contains a target track;
(2) read a first track address to identify where a head is/are presently positioned and calculate a seek distance to the target track;
(3) set a reference synchronizing frequency to the data recording frequency of the target zone;
(4) move the head(s) to the vicinity of the target track with a rough seek;
(5) read a second track address to identify where the head(s) has/have been positioned after the rough seek and calculate any error relative to the target track; and
(6) do a fine seek based on the error.
A rough seek in an optical disk drive will generally get as close as several tracks to several tens of tracks of a target track. If the target track is near the zone boundaries, a "zone miss" phenomena may occur, the head(s) slips out of the target zone after the rough seek to an adjoining zone. The reference synchronizing frequency that is set will probably differ from the data recording frequency of the zone where the head(s) is/are actually positioned, so the optical disk drive circuit cannot read the track address of the track because it cannot synchronize to it. The present track address also cannot be read, so the head(s) is/are effectively lost. There is no way of knowing what the reference synchronizing frequency of the optical disk drive circuit was supposed to be.
The prior art typically uses procedures similar to the following steps to recover from a zone miss:
(1) increase (or decrease) the zone address setting of the disk drive circuit by one from the present address setting;
(2) switch the reference synchronizing frequency to the data recording frequency of the new zone address;
(3) re-read the track address;
(4) repeat steps (1), (2), and (3) when the track address cannot be read; and
(5) change the zone address to zero (or to the highest zone address) and return to step (2) when the zone address setting of the disk drive circuit reaches the highest zone address (or the address zero) of the media.
A prior art zone access method is flowcharted in FIG. 19. In step 1900, a logical address of a seek target sector of a command from a host computer is converted to a physical address. In step 1901, a address for a target zone corresponding to a physical track is indexed from a zone parameter table that has been pre-recorded in a memory within the optical disk system. In step 1902, the current track address is read before doing a rough seek. The difference in distance between the current track address and the target track address is computed to get the head(s) seek distance for a rough seek. In step 1903, the zone address setting is set to equal the address for a target zone. In step 1904, a reference synchronizing frequency is set to the data recording frequency of the target zone obtained in step 1901. In step 1905, the head(s) is/are moved to near the target track in a rough seek according to the seek distance computed in step 1902. In step 1906, a track address identifying where the head(s) is/are after the rough seek is read. In step 1907, the result of the track address reading operation is tested. If it succeeded, the reference synchronizing frequency of the optical disk drive circuit is set to the data recording frequency of the target zone in steps 1909 and 1910, and a fine seek occurs in step 1911. If unsuccessful in step 1907, the drive checks in step 1908 whether or not the present zone setting in the optical disk drive circuit is a maximum zone address for the media. If so, the new zone address setting of the optical disk circuit is set to address zero in step 1913. If the zone address is not a maximum, a new zone address setting is incremented by one, in step 1912. In step 1914, the new zone address setting is tested to see if it has returned to an initial zone address at start of zone access processing. When it does, a media error is reported in step 1916. If not, then in step 1915 the reference synchronizing frequency of the optical disk drive circuit is set to the data recording frequency of the zone that was new in steps 1912 or 1913, and control returns to the track address reading operation of step 1906.
Prior art zone access processing uses simple algorithms, it typically does not take into account any information concerning the conditions under which errors occur, and correct the reference synchronizing frequency usually in only one direction. Consequently, when a head is/are in an adjoining zone because of a zone miss and the zone switching direction is just the opposite, it takes a very long time for the optical disk drive circuit to get to a proper reference synchronizing frequency, and this significantly decreases the processing speed of the drive to a host computer.
There are other means of dealing with zone misses, including one of supplying a new zone in the area between adjacent zones and pre-recording the track address in this new zone with two types of data recording frequencies corresponding to both adjacent zones. (See, Japanese Patent Early Disclosures 1990-189769 and 1990-189742) A method of dividing each zone into a data zone and two buffer zones, one on each side of a data zone, so the buffer zones are sufficiently larger than the estimated seek error is described in Japanese Patent Early Disclosure 1990-183475. These methods are more-or-less effective in cases where comparatively small seek errors have been made. However, track address information must be pre-recorded on the media with two types of frequencies, so mastering of media becomes difficult, thus cost increases are inevitable. Also, the typical phase-locked loop (PLL) circuit becomes complicated, and this also makes higher costs unavoidable. Both methods are not interchangeable with the popular MCAV media now on the market, and is a great impediment in the optical disk drive market. Another problem with these methods is that the data recording area of the media is drastically reduced to make room for the buffer zones, the recording capacity per one media becomes smaller, and the principal advantages of the MCAV media are lost.
The present invention is one that resolves such prior art problems, and its object lies in offering a zone access means that recovers from zone misses quickly, and it is capable of using the MCAV media in the market without sacrificing any of the recording capacity.
SUMMARY OF THE PRESENT INVENTION
According to an embodiment of the present invention, a disk drive zone access method to be used when a head misses a target zone during a seek operation comprises:
switching a reference synchronizing frequency to the data recording frequency of an adjacent zone nearest to the seek target track; and
switching a reference synchronizing frequency to the data recording frequency of an adjacent zone second nearest from the seek target track.
According to an alternative embodiment of the present invention, a disk drive zone access method to be used when a head misses a target zone during a seek operation comprises:
defining a memory space in which to store a zone miss history;
referencing the zone miss history as a basis for estimating a candidate zone where the head(s) is/are likely to be presently positioned;
setting a reference synchronizing frequency to the data recording frequency of the candidate zone; and
updating the zone miss history with current zone miss data.
According to another alternative embodiment of the present invention, a disk drive zone access method to be used when a head misses a target zone during a seek operation comprises:
defining a memory space to stores zone miss history in alternative memory spaces according to the head(s) seek direction at the time of a zone miss;
referencing the one zone miss history that corresponds to the present head(s) seek direction;
estimating a candidate zone where the head(s) is/are most likely to be positioned after the zone miss;
setting a reference synchronizing frequency to the data recording frequency of the candidate zone; and
updating zone miss history in the memory space with the present zone miss data.
According to another alternative embodiment of the present invention, a disk drive zone access method to be used when a head misses a target zone during a seek operation comprises:
measuring the number of mirror marks in a track where the head(s) is/are; and
using the number measured to set a reference synchronizing frequency.
According to another alternative embodiment of the present invention, a disk drive zone access method to be used when a head misses a target zone during a seek operation comprises:
measuring the frequency period of mirror marks in a track where the head(s) is/are; and
using the frequency period measured to set a reference synchronizing frequency.
An advantage of the present invention is that embodiments of it can be implemented by merely modifying the firmware of the drive, without requiring great modifications or supplemental additions to prior art systems.
Another advantage of the present invention is that recovery after a zone miss is quick because the processing method most suitable to the situation is used, which is based on the available information, and that prevents disk drive response time slowdowns.
Another advantage of the present invention is that available information when zone misses occur is used, and is therefore able to reliably estimate the zone in that the head(s) is/are presently positioned and determines the reference synchronizing frequency in a short time.
Another advantage of the present invention is that it can be realized by modifying the only firmware in an existing drive. There is need to change the media format or to make substantial modifications to the drive's circuitry. In this manner the present invention does zone access processing simply and efficiently, thus preventing a slowdown to a host computer.
Other objects and attainments together with a fuller understanding of the present invention will become apparent and appreciated to those skilled in the art by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart for a zone miss recovery method, according to a first embodiment of the present invention;
FIG. 2 is a flowchart of an exemplary zone access order control process that can be used to implement step 102 of FIG. 1;
FIG. 3 is a flowchart of another exemplary zone access order control process that can be used to implement step 102 of FIG. 1;
FIG. 4 is a flowchart for a zone miss recovery method, according to a second embodiment of the present invention;
FIG. 5 is a flowchart of an exemplary adjacent zone access order control process that can be used to implement step 403 of FIG. 4;
FIG. 6 is a flowchart of another example of adjacent zone access order control process that can be used to implement step 403 of FIG. 4;
FIG. 7 is a flowchart for still another alternative adjacent zone access order control process that can be used to implement step 403 of FIG. 4;
FIG. 8 is a flowchart for a zone miss history updating process;
FIG. 9 is a flowchart of a zone access method, constructed according to a fourth embodiment of the present invention;
FIG. 10 is a flowchart of track inquiry process that can be used to implement step 904 of FIG. 9;
FIG. 11 is a flowchart of an example of zone access process that can be used to implement step 1000 of FIG. 10;
FIG. 12 is a flowchart of a zone access process, constructed according to a fifth embodiment of the present invention;
FIG. 13 is a layout of the sectors for a zone recording type optical media;
FIG. 14 illustrates a pregrooved optical media;
FIG. 15 diagrams the structure of a typical sector;
FIG. 16 is a block diagram complete system, according to an embodiment of the present invention;
FIG. 17 is a diagram of various signal waveforms;
FIG. 18 is a timing diagram for example index and mirror mark detection signals; and
FIG. 19 is a flowchart of a prior art zone access method.
DETAILED DESCRIPTION OF THE EMBODIMENTS
First Embodiment
FIG. 1 flowcharts an exemplary zone access method, according to a first embodiment of the present invention. In step 100, a logical address for a target sector called for in a seek command from a host computer is converted into a physical address that depends on a disk drive's configuration. The physical address is conventionally calculated taking into account the number of heads in the disk drive, the number of sectors per track, and the number of defective sectors in the media. The physical address consists of both a physical track address and a physical sector address. In step 101, the address for a target zone to which the physical track address belongs is determined. This can be done, e.g., by referencing a zone parameter table prerecorded in the memory space. In step 102, the zone access order of the two adjacent zones comprising the inner adjacent zone and the outer adjacent zone adjoining the address for a target zone obtained in step 101 is determined by the following means. In step 103, the track address where the head(s) is/are presently positioned is read as a preliminary stage of the seek. The difference in distance between the track address of this readout and the target track address is computed, to get the distance required for the seek. In step 104, the zone address is set to the address for a target zone, and in step 105 the reference synchronizing frequency of the circuit switches to the data recording frequency of the zone address set in step 104. In step 106, the head(s) does a rough seek to near the target track based on the seek distance computed in step 103. In step 107, the track address identifying where the head(s) is/are after the rough seek is read. Here, it will be necessary to synchronize the data recording frequency of the track address with the reference synchronizing frequency, to detect the sector and address marks, and to read the track address within a predetermined time. After a rough seek, there is ordinarily an error of several tracks to several tens of tracks between the target track and the track where the head(s) actually is. If the actual after-seek track is in the same media zone as the target track, the track address can be read by synchronizing the reference synchronizing frequency to the data recording frequency for the whole zone. However, when a target track is near or at a media zone boundary, there is a chance that the actual after-seek track will not correspond to the right zone, but to an adjacent one. Since the data recording frequency of the adjacent zone will differ, it cannot be synchronized and its track address cannot be read within the time allowed. In step 108, the success or failure of the track address readout in step 107 is checked. If successful, step 109 issues a seek correction (a fine seek) after computing a position error between the actual after-seek track address and the target track address. If a failure is discovered in step 108, then a branch is made to step 110, where the zone address is set to the primary zone address, based on the zone access order determined in step 102. In step 111, a reference synchronizing frequency is set to the data recording frequency of the new zone. In steps 112 and 113, a track address is read again in the same manner as steps 107 and 108, and the result is checked. If the result indicates success, the zone access process ends. The target zone becomes the new zone setting in step 119. The reference synchronizing frequency is set to the data recording frequency of the target zone in step 120. And the fine seek starts in step 109. When a failure is discovered in step 113, then step 114 sets the zone in the disk drive's circuitry to the adjacent zone second address determined in step 102. In step 115, it corresponds to the reference synchronizing frequency of the circuit. In steps 116 and 117, a track address readout is similar to steps 107 and 108, and the result is checked. If successful, the zone access process ends. In steps 119 and 120 the secondary zone address becomes the target zone setting, the reference synchronizing frequency is set to the data recording frequency of this target zone, and the fine seek starts in step 109.
Ordinarily, the number of tracks per zone is on the order of several hundred, so a head almost never misses an adjoining zone in a rough seek. But if step 117 determines there to be a failure, further zone access process is done in step 118, for outside the target zone and the two adjacent zones, followed by passing through steps 119 and 120 to do the fine seek in step 109.
FIG. 2 is a flowchart of an exemplary adjacent zone access process. Media track address zero is on the inside and track addresses increase stepping out toward the outer perimeter. In step 200, the address of the first track of the target zone is determined. In step 201, an offset value between the address of the first track and the target track is computed. In step 202, the track offset value is compared to one half of the number of tracks per zone. When the target track is nearer the inside of the target zone, step 204 chooses the inner adjacent zone to be the primary zone, and the outer adjacent zone to be the secondary one. When the target track is nearer the outside of a target zone, step 203 chooses the outer adjacent zone to be the primary zone, and the inner adjacent zone to be the secondary one. When a address for a target zone is set to either extreme of the media, only one adjacent zone exists, so the only zone that is adjacent is set to be the primary zone.
FIG. 3 flowcharts another example of an adjacent zone access process for FIG. 1. The track address layout is assumed to be the same as that described above for FIG. 2. In step 300, the address of the first track of the target zone is determined. In step 301, a first offset value of the address of the first track to the target track is determined. In step 302, the address of the first track of the zone adjoins the outer side of the target zone is determined. The address of this adjacent zone is the address for a target zone plus one. In step 303, a second offset value of the address of the first track to the target track is calculated. In step 304, the first and second offsets are compared. When the first offset is equal to or less than the second offset, step 305 sets the inner adjacent zone to be accessed first, and the outer one second. When the first offset is greater than the second offset, step 306 sets the outer adjacent zone to be accessed first and the inner secondary zone. When the address for a target zone is at either extreme of the media, there is only one adjacent zone, and that becomes the primary zone to access.
Second Embodiment
FIG. 4 flowcharts a zone access method, according to a second embodiment of the present invention. In step 400, the logical address of a target sector is converted into a physical address, according to the organization of the particular disk drive. In step 401, an address for a target zone containing the physical track is determined. In step 402, the current track address is read before doing a rough seek. The distance from the present track address to the target track address is calculated to get the distance needed for a rough seek. In step 403, the zone access sequence is determined, as in FIGS. 2 and 3, and is based on the address for a target zone and the physical track address. In step 404, the zone address the drive is set to is made the address for a target zone. In step 405 the circuit reference synchronizing frequency switches to the data recording frequency of the zone address set in step 404. In step 406, the head(s) does a rough seek to get near the target track, based on the computation of the seek distance done in step 402. In step 407, the actual after-seek track address is read to identify where the head(s) actually is after a rough seek. The reference synchronizing frequency must be set to match the data recording frequency of the actual after-seek track. A specified time period is allowed to read the track address. If the actual after-seek track is within the same zone as the target track, the track address can be read by synchronizing the reference synchronizing frequency to the data recording frequency of the present track. However, when the actual after-seek track is not in the same zone, the data recording frequency of the adjoining zone will be too different from the reference synchronizing frequency (set in step 405), and the track address cannot be read. In step 408, the results of the track address readout operation are determined. When it has been successful, step 409 computes the position error between the actual after-seek track address and the target track address, in order to do a fine seek. But if there has been a failure, a zone access process begins, starting with step 410. In step 410, the zone address the drive is set to is made the primary zone address. In step 411, the reference synchronizing frequency is set to the data recording frequency for this zone. In steps 412 and 413, a track address readout precedes as in steps 407 and 408, and a result is determined. If the readout was successful, the zone access process ends. Control branches to step 419. The original target zone becomes the target zone. In step 420, the reference synchronizing frequency is set to the data recording frequency for this target zone. A history variable is updated, based on the results of this zone access procedure in step 421 (described below), and a fine seek (step 409) begins. If a failure is detected in step 413, control passes to step 414 where the zone value in the disk drive is set to equal the secondary zone address determined in step 403. In step 415, the reference synchronizing frequency is set to the data recording frequency of the target zone. In steps 416 and 417, a track address is readout, similar to how it was done in step 408, and the results are checked. If the results indicate success, the zone access process ends. In steps 419 and 420 the target zone set in the disk drive becomes the original target zone, and the reference synchronizing frequency is set to the data recording frequency of the target zone. In step 421, a history variable is updated, and a fine seek of in step 409 begins. If the track address readout fails in step 417, then step 418 begins further zone access processing for other than the target zone or the two adjacent zones, and passes through 419, 420 and 421 to start the fine seek in step 409 (no zone miss history updating occurs).
FIG. 5 is a flowchart of an exemplary adjacent zone access order process (sub-routine) for step 403 of FIG. 4. The more positive a zone miss history is, the stronger will be the tendency of the actual after-seek track to be in the outer adjacent zone of the target zone. Conversely, the more negative the zone miss history, the stronger the tendency is for the adjacent zone inside the target track to be the right one. In step 500, the zone miss history is tested for sign.
When positive, step 501 makes the outer adjacent zone the primary zone and the inner adjacent zone the secondary zone. When the zone miss history is not positive, step 502 makes the inner adjacent zone the primary zone and the outer adjacent zone the secondary zone.
FIG. 6 is an alternative process to that of FIG. 5. A first zone miss history stores the number of times that the actual after-seek track was in the adjacent zone outside the target zone. A second zone miss history similarly stores the number of times it was in the adjacent zone inside. In step 600, the first and second zone miss histories are compared. If the first is larger than the second, step 601 sets the outer adjacent zone to be the primary zone and the inner adjacent zone to be the secondary zone. If the first zone miss history is equal to or smaller than second zone miss history, step 602 sets the inner adjacent zone to be the primary zone and the outer adjacent zone to be the secondary zone.
Third Embodiment
FIG. 7 is an alternative process to that of FIGS. 5 and 6, and represents a third embodiment of the present invention. As above, the first and second zone miss histories respectively store the number of times the actual after-seek track was in the inner adjacent zone of the target zone after inward seeks and the number of times it was in the outer adjacent zone after inward seeks. A third and a fourth zone miss history similarly hold the number of times the actual after-seek track was in the inner adjacent zone of a target track after outward seeks and the number of times in the outer adjacent zone after outward seeks. (Put another way, the four zone miss histories keep seek statistics to help predict the best direction to try an adjacent zone access first.) In step 700, a decision is made whether to seek-in or seek-out. This may be decided by comparing the present track address and the address of the target track. If a seek-in is decided in step 700, then step 701 references a seek-in zone miss history table (the first and second zone miss histories) is referenced. In step 702, the first zone miss history is compared with the second zone miss history. When the first is not larger than the second, step 703 sets the outer adjacent zone to be the primary zone and the inner adjacent zone to be the secondary zone. If the first zone miss history is larger than the second zone miss history in step 702, step 706 sets the inner adjacent zone to be the primary zone and the outer adjacent zone to be the secondary zone.
When a seek-out is determined in step 700, step 704 references a seek-out zone miss history table (the third and fourth zone miss histories). In step 705, the third zone miss history and the fourth zone miss history are compared. If the third is larger than the fourth, step 706 sets the inner adjacent zone to be the primary zone and the inner adjacent zone to be the secondary zone. If the first zone miss history is equal to or smaller than the second zone miss history in step 705, step 703 sets the outer adjacent zone to be the primary zone and the inner adjacent zone to be the secondary zone.
FIG. 8 flowcharts an exemplary zone miss history update process (sub-routine) for step 421 in FIG. 4. This zone miss history update process suits the adjacent zone access sequence control process of FIG. 5. In step 800 a determination is made as to whether the reference synchronizing frequency has successfully synchronized by using the outer adjacent zone. If so, step 801 increments by one the respective zone miss history. If not, step 802 determines whether the reference synchronizing frequency has successfully synchronized using the inner adjacent zone. If so, the zone miss history is decremented by one. Otherwise, this means that neither the outer nor the inner adjacent zone resulted in a good readout, so no updating of the zone miss history is warranted.
Fourth Embodiment
FIG. 9 flowcharts a head seek process for a zone access method, according to a fourth embodiment of the present invention. Beginning in step 900, a logical address for a target sector is converted into a physical address, according to the organization of the particular disk drive. In step 901, the address for a target zone containing the physical track is determined from the physical track address. In step 902, a current track address is read before doing a seek. In step 903, the results of the read are judged. If the read was successful, step 905 determines the head(s) seek distance needed to do a seek. If unsuccessful, step 904 begins a track inquiry process (described below).
External shocks or vibrations inflicted on a disk drive can cause the head(s) to be moved inadvertently to another zone. Consequently, the data recording frequency of the zone and the reference synchronizing frequency of the drive's circuitry will not match, and the correct zone will be unknown and harder to determine. In step 904, the zone in which the head(s) is/are actually positioned is found by stepping through all the possible reference synchronizing frequencies until a frequency that works is found. In step 906, the reference synchronizing frequency is set to the data recording frequency of the target zone based on the result in step 901. In step 907, the head(s) is/are moved. In step 908, the track address is read where the head(s) is/are actually positioned after the seek. In step 909, the result of the readout operation is analyzed. If the head(s) has/have entered an adjacent zone that is not the target zone, the data recording frequency of the adjacent zone will differ from the reference synchronizing frequency set in step 906. So the track address cannot be read. If the readout operation is successful in step 909, step 911 compares the actual after-seek track address with the target track address. If they agree, the process ends in step 912. If not, any remaining position error between the target track address and the actual after-seek track is computed, and the seek is repeated. If the readout operation is unsuccessful in step 909, step 910 does a track inquiry process similar to step 904, the track address is read, and control passes to to step 911.
FIG. 10 is an exemplary track inquiry process (sub-routine) that implements step 904 (FIG. 9). Step 1000 is a zone access process (described in detail, below). In step 1001, the reference synchronizing frequency is set based on the process results obtained earlier. In step 1002, the track address is read.
FIG. 11 flowcharts an exemplary zone access process that implements step 1000 (FIG. 10). Determining the zone address for a track is done by counting the number of mirror marks that have been placed in the particular track. ("Mirror marks" are used in patterns of dull and shiny spots on a disk that can be seen by photodetectors mounted near the head[s], e.g., mirror mark 1404, below.) In step 1100, a mirror mark count register is initialized to zero. Steps 1101 and 1102 wait for and confirm receipt of an index pulse that is generated by the drive each disk rotation. After the index pulse is detected, steps 1103 and 1104 recognize individual mirror marks by using a total sum signal output from the head(s). In step 1105, the mirror mark count register is incremented by one. Steps 1103 through 1105 are repeated until the next index pulse arrives. Thus the number of mirror marks in one track are counted (the result is retained in the mirror mark count register). Then step 1107 uses the mirror mark number to index a pre-recorded table in memory to get the number of sectors per track in each zone and the zone address of the head(s).
Fifth Embodiment
FIG. 12 flowcharts a zone access method, according to a fifth embodiment of the present invention, that measures the time periods between mirror marks to identify the current zone address. In step 1200, a mirror mark period register is initialized to zero. In steps 1201 and 1202 mirror marks are detected and confirmed. Step 1203 starts a mirror mark timer, which keeps on running until the next mirror mark in the following sector is received in steps 1204 and 1205. Step 1206 stops the timer. Step 1207 uses the mirror mark period to index a pre-recorded table in memory to get the number of sectors per track in each zone and the zone address of the head(s).
FIg. 13 shows how a typical optical disk sector is laid out when using the zone recording method. There are three zones, namely zones 1300 to 1302. (Describing only three zones here is meant to make the description clearer, an actually implementation will use many more zones.) A sector 1303 is typical of all the sectors on the disk. The number of sectors per single track varies depending on where a zone is located, fewer sectors can be accommodated in the inner zones. Zone 1300 has 12 sectors per track, zone 1301 has eight sectors per track, and zone 1302 has six sectors per track. Mirror marks are associated with sectors on a one-for-one basis, and the number of mirror marks in a track also varies.
FIG. 14 illustrates an optical media with continuous grooves. A distance 1400 indicates the length of one sector. The media has a groove 1401, a land 1402 that serves as a data recording area, a pit 1403 which stores a sector address, and a mirror mark 1404. Groove 1401 is separated by mirror mark 1404 so a laser beam will reflects differently between them. The reflectance differs from other parts, and the drive's circuitry can easily discriminate the mirror mark 1404 by observing the reflected beam.
FIG. 15 illustrates the structure of a typical sector comprising a sector mark 1500 identifying the start of the sector, a VFO1 data 1501, a VFO2 data 1504, a VFO2 data 1506, a VFO3 data 1511, and an address mark 1502 that identifies the start of the sector address recording zone. And ID1 data 1503, ID2 data 1505, and ID3 data 1507 are for when the sector addresses are recorded with pits (e.g., pit 1403). A preamble zone 1508, a mirror mark 1509, a gap flag or an automatic laser power control zone ALPC 1510, a synchronizing zone 1512, a data zone 1513, and a buffer zone 1514 are also included. One mirror mark 1509 only is present between a pit zone and a data zone in each such sector.
FIG. 16 shows a block diagram an alternative embodiment of the present invention. A system comprises a host computer interface (I/F) 1600, an interface controller 1601, a drive controller 1602, a mirror mark sensor 1603, a read/write (R/W) signal processor 1604, a PLL controller 1605, optical head(s) 1606, a disk media 1607, a magnetic field generating coil 1608, a spindle motor 1609, a pit read signal 1610, a differential data readout signal 1611, a head position signal 1612 used for tracking and focusing control of the optical head(s), an index signal 1613 generated from the spindle motor once each revolution, a mirror mark detection signal 1614 that is generated each time mirror mark signal sensor 1603 detects the mirror marks via signal 1610, and a read data signal 1615 by the optical head(s) 1606 that use a laser beam for reading. Signal 1610 has a different signal level for the mirror mark regions versus the other regions, as will be illustrated in the discussion of FIG. 17, below. Mirror mark sensor 1603 does signal level discrimination and generates mirror mark detection signal 1614 when it senses a mirror mark. Drive controller 1602 is notified of the mark detection. Index signal 1613 is output from spindle motor 1609 once each rotation of media 1607. When drive controller 1602 receives index signal 1613, it counts the individual pulses belonging to mirror mark detection signal 1614 to determine what zone the head(s) is/are in. Drive controller 1602 can also determine the zone of the current track by measuring the frequency or period of the pulses belonging to mirror mark detection signal 1614. This does not require using index signal 1613. When drive controller 1602 has determined the zone of the track, it sends PLL controller 1605 a command to change the reference synchronizing frequency to the frequency corresponding to the zone of the track where head(s) 1606 is/are presently positioned.
FIG. 17 illustrate a typical waveform for signal 1610 (FIG. 16). It comprises a sector mark pulse 1700, a VFO pulse 1701, an address mark pulse 1702, and a mirror mark pulse 1703. Because the signal level of the mirror mark pulse is the highest, as compared to signal waveforms of the other regions, it is easy to detect.
FIG. 18 is an exemplary set of timing diagrams for an index signal and a mirror mark detection signal in one part of a track. Time 1800 is one complete track rotation long. A first sector 1801 begin the track and a final sector 1802 ends it. A pit zone 1803 is contained in each sector, as are a mirror mark zone 1804, a data zone 1805. An index signal 1806 is output from the spindle motor and compresses an index pulse 1807 that is generated once for each cycle of the media. A mirror mark detection signal 1808 has a mirror mark pulse 1809. Signal 1806 is representative of the index signal 1613 (FIG. 16). Similarly, signal 1808 is representative of mirror mark detection signal 1614 (FIG. 16). The position of index pulse 1807 does not necessarily agree with the start of first sector 1801. Since index pulse 1807 is always generated at the same point, measuring mirror mark pulses 1809 for one rotation of a track will not be difficult. Drive controller 1602 starts to count mirror mark pulses by first recognizing the leading index pulse 1807 at the left of FIG. 18. The count starts at the second from the left mirror mark pulse 1809, and a total of seven (in this example) mirror mark pulses are counted before the index pulse 1807 on the right is received.
While the present invention has been described in conjunction with several specific embodiments, it is evident to those skilled in the art that many further alternatives, modifications and variations will be apparent in light of the foregoing description. Thus, the present invention described herein is intended to embrace all such alternatives, modifications, applications and variations as may fall within the spirit and scope of the appended claims.
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A disk drive zone access method for recovering from a zone miss of a disk drive head(s) is used with media that has a plurality of zones each having different data recording frequencies. Data is read with a variable reference synchronizing frequency that can be set to match any one of the data recording frequencies. The method comprises 1) defining a memory space to stores zone miss history in alternative memory spaces according to the head seek direction at the time of a zone miss; 2) referencing the one zone miss history that corresponds to the present head seek direction; 3) estimating a candidate zone where the head is/are most likely to be, based on the zone miss history; 4) setting the variable reference synchronizing frequency to the data recording frequency of the candidate zone; and 5) updating zone miss history in the memory space with the present zone miss data according to the head seek direction at the time of the zone miss.
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[0001] This application claims the priority date of provisional application Ser. No. 60/234,057, filed Sep. 20, 2000.
TECHNICAL FIELD
[0002] This invention relates in general to electrical submersible pumps and in particular to a restrictor for reducing downward flowing casing annulus well fluid during the initial start-up.
BACKGROUND
[0003] In a well, a static fluid level is established while the well is not being produced. This level is a function of the reservoir pressure at the well bore perforations. If this level is above the wellhead (ground level), it is a flowing well. If the level is below the wellhead, it is a dead well and requires artificial lift to flow.
[0004] [0004]FIG. 8 represents an example of an inflow performance relationship. It plots pressure at the perforations versus flow from the well. The pressure at the perforations could also be plotted as a fluid level (or fluid over the perforations ratio), as shown on the right scale of FIG. 8.
[0005] When an artificial lift system, such as an electrical submersible pump (ESP) is started, it adds pressure to the fluid so that it flows to the surface at a predicted flow rate. Before start-up of the ESP, the well bore is at a static condition with the well bore fluids stabilized in the well bore at a static fluid level. After the ESP is started and it has reached its design point, the well bore fluids are stabilized at a flowing fluid level. This drawdown follows the IPR curve in FIG. 8.
[0006] Between start and well bore stabilization, the fluid level is moving form the static level to the flowing level. This is called “annulus drawdown”. Therefore, the annulus volume has to be reduced or pulled down to its flowing fluid level. On start-up, almost all of the fluid being pumped is from the annulus above the pump intake, with only a small amount coming through the well bore perforations. As the annulus is drawn down, the flow from the annular volume decreases and the flow from the well bore perforations increases. The rate of this transfer is dependent upon the well annular volume (casing ID to tubing and equipment OD and the annular drawdown length) and the pumping flow rate.
[0007] At startup, the flow from the perforations upward past the motor to the pump intake will be zero or very low. The motor depends upon fluid flow by its skin to carry heat away. If this flow is too low, for too long a period, excessive heat can build up internally in the motor, causing damage or failure. This is especially true in wells which produce heavy, or viscous oil.
[0008] [0008]FIG. 9 shows graphically the heat rise in the motor, flow from perforations (flow by the motor), and annular flow to the surface versus time. In this example, the reduced cooling flow by the motor causes the motor to reach 480+ degrees F. in about 33 minutes. The drawdown to well bore stabilization takes over 583 minutes. In some wells, the transition time from start-up to steady state conditions may be as long as two days.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a schematic side view of an electrical submersible pump assembly, showing a tubing annulus flow restrictor in accordance with this invention.
[0010] [0010]FIG. 2 is a view of an upper portion of the pump assembly of FIG. 1, showing a first alternate embodiment of a restrictor.
[0011] [0011]FIG. 3 is a schematic view of an upper portion of the pump assembly of FIG. 1, showing a second alternate embodiment of a restrictor.
[0012] [0012]FIG. 4 is sectional view of an upper portion of the pump assembly of FIG. 1, showing a third alternate embodiment of a restrictor.
[0013] [0013]FIG. 5 is a sectional view of an upper portion of the pump assembly of FIG. 1, showing a fourth alternate embodiment of a restrictor.
[0014] [0014]FIG. 6 is a sectional view of an upper portion of the pump assembly of FIG. 1, showing a fifth alternate embodiment of a restrictor.
[0015] [0015]FIG. 7 is a sectional view of an upper portion of the pump assembly of FIG. 1, showing a fifth alternate embodiment of a restrictor.
[0016] [0016]FIG. 8 is a graph of pressure of a typical well at the perforations versus flow from the pump.
[0017] [0017]FIG. 9 is a graph of a typical rise in temperature of an electrical motor of an electrical submersible pump of a prior art assembly and installation.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring to FIG. 1, the well has a casing 11 containing perforations 13 . Well fluid flows in through perforations 13 , and if not pumped, will reach a static level 15 below the top of the well. Static level 15 could be only a short distance above perforations 13 , or it could be thousands of feet above perforations 13 .
[0019] An electrical submersible pump assembly (“ESP”) 17 is installed in casing 11 . ESP 17 includes a centrifugal pump 19 . Pump 19 is made up of a large number of impellers and diffusers in a conventional manner. Pump 19 has an intake 21 at its base. An electrical motor 23 is part of ESP 17 and drives pump 19 . Motor 23 is normally a three-phase induction electrical motor that drives a shaft in pump 19 . A seal section 25 locates between pump 19 and motor 23 for equalizing the hydrostatic pressure of the well fluid with internal lubricant located in the motor. ESP 17 may also have a gas separator (not shown) that separates gas from well fluid and discharges it into casing 11 .
[0020] ESP 17 is suspended on tubing 27 that secures to the upper end of pump 19 . Tubing 27 is normally production tubing, made up of sections of steel pipe screwed together. A power cable 29 extends from the surface to motor 23 for supplying power. Power cable 29 will extend alongside and be strapped to tubing 27 . A tubing annulus 30 is located around tubing 27 within casing 11 . Similarly, a pump annulus 32 surrounds pump 19 within casing 11 . Normally, pump 19 is of larger diameter than tubing 27 , thus pump annulus 32 will be smaller in cross-sectional flow area than tubing annulus 30 . Pump annulus 32 and tubing annulus 30 maybe considered to be separate parts of a well annulus.
[0021] A flow restrictor 31 is placed in tubing annulus 30 for restricting flow of well fluid down pump annulus 32 into intake 21 during start-up. Restrictor 31 is a blocking member sized so that the suction created by the start-up of pump 19 will draw more well fluid from perforations 13 than from the well fluid in tubing annulus 30 . In the embodiments of FIGS. 1 - 3 and 5 - 7 , the restrictor is placed about 50 to 100 feet above pump 19 . Restrictor 31 , as well as those in the other embodiments, provides a downward flow area that is less than the minimum flow area in pump annulus 32 . The minimum flow area in pump annulus 32 is normally around motor 23 , which is typically larger in diameter than pump 19 . The maximum downward flow rate through restrictor 31 , as well as the restrictors of the other embodiments, is a fraction of the discharge flow rate of pump 19 , preferably about 5% to 50%.
[0022] In the embodiment of FIG. 1, restrictor 31 is similar to a swab cup, having an elastomeric portion that slidingly engages the inner wall of casing 11 while ESP 17 is being lowered into the well. The orientation of restrictor 31 allows upward flow past the sealing surfaces as it is being lowered, but not downward flow. However, it has a plurality of orifices or passages 33 that extend through it for allowing a maximum flowrate of downflow from tubing annulus 30 . The flowrate is selected to be small enough such that most of the well fluid flowing into pump intake 21 will be from perforations 13 . Additionally, passages 33 allow any gas that is discharged by a gas separator (not shown in FIG. 1) into casing 11 to flow up past restrictor 31 . There are no check valves in passages 33 , allowing fluid flow in both upward and downward directions.
[0023] In operation, there will be a static fluid level 15 when pump 19 is not operating. Static fluid level 15 will normally be above restrictor 31 . Once pump 19 begins operating, formation fluid from perforations 13 will begin flowing into pump intake 21 . At the same time, static fluid level 15 will begin dropping. Well fluid in tubing annulus 15 will flow downward through passages 33 toward intake 21 , but at a lower flow rate than would exist if no restriction were present. The restriction provided by restrictor 31 enhances flow out of perforations 13 over the prior art, which has no type of restrictor 31 . The decreased downward flow rate increases the drawdown period before the well fluid in tubing annulus 30 reaches a constant fluid level with pump 19 operating, but increases cooling flow by motor 23 during the initial starting period. Eventually, static fluid level 15 will drop to a constant level even though pump 19 is operating, with downward flow from tubing annulus 30 ceasing. This constant level while pump 19 is operating may be either above restrictor 31 or below.
[0024] Rather than a swab cup type restrictor 31 , various other blocking members could be utilized. For example, the diameter of tubing 27 between the discharge of pump 19 and the static fluid level could be increased. This decreases the cross-sectional flow area of tubing annulus 30 in that area, reducing the downward flow during start-up. Also, as shown in FIG. 2, an inflatable packer 35 could be utilized having orifices 37 for upward and downward flow. Packer 35 would be inflated in a conventional manner during installation of ESP 17 .
[0025] In the embodiment of FIG. 3, a rigid plate 39 is mounted to tubing 27 above pump 19 (FIG. 1) and below static fluid level 15 . An annular clearance 41 is located between plate 39 and the inner diameter of casing 11 . Annular clearance 41 allows some downward flow of fluid from tubing annulus 30 . Furthermore, plate 39 has orifices 43 sized for allowing only a selected rate of downward flow during start-up. Orifices 43 also allow upward flow.
[0026] In the embodiment of FIG. 4, the restriction comprises aggregate 45 placed in tubing annulus 30 . Aggregate 45 , basically gravel, could also be placed around pump 19 in pump annulus 32 . Aggregate 45 reduces the flow rate of well fluid in tubing annulus 30 .
[0027] The embodiment of FIG. 5 is particularly useful for wells that produce significant amounts of gas. Blocking member 47 may be either a packer such as packer 35 of FIG. 2, or it may be a swab cup type elastomer such as elastomer 31 of FIG. 1. Blocking member 47 has at least two passages, with passage 46 being primarily for upward gas flow and passage 48 being for downward liquid flow of well fluid in the tubing annulus. Gas flow passage 46 is connected to a tube 49 that extends upward, and well fluid passage 48 is connected to a tube 51 that extends downward. Preferably, tube 49 extends above the static fluid level 15 (FIG. 1), although this is not necessary. Tube 51 extends downward far enough to be below any gas cap 52 that may form below the lower end of blocking member 47 . Tube 51 serves to bleed off gas in gas cap 52 to prevent it from growing to a size large enough to affect the intake of liquid into the pump intake 21 (FIG. 1). Locating the upper end of tube 49 above restrictor 47 reduces the amount of liquid flowing downward in tube 49 , which might otherwise impede the upward flow of gas. Similarly, tube 51 reduces downward flowing liquid in the vicinity of the inlet to gas flow passage 46 , which might otherwise obstruct the flow of gas. There are no valves in either passage 46 , 48 that would prevent upward or downward flow of fluid.
[0028] [0028]FIG. 6 also discloses an embodiment for facilitating the upward flow of gas while restricting the downward flow of liquid. Blocking member 53 is an annular member mounted to tubing 27 so as to provide a lower end that is configured to create a gas pocket 57 along one side. In this embodiment, gas pocket 57 is created by tilting blocking member 53 so that portion of the lower end is higher than another portion. A gas flow passage 55 extends upward through blocking member 53 from the portion above gas pocket 57 . A well fluid passage 59 extends through a lower portion of blocking member 53 for the downward flow of well fluid. Both passages 55 and 59 are capable of two-way flow, however gas will tend to flow through gas flow passage 55 because of its location over gas pocket 57 .
[0029] [0029]FIG. 7 shows another embodiment for restricting downward flow. Blocking member 61 may be either a packer such as in FIG. 2 or an elastomer as in FIG. 1. Blocking member 61 has one or more passages 63 that allow downward flow of well fluid as well as upward flow. A pressure responsive variable orifice valve 65 is in each passage 63 . Each valve 65 will reduce the flow area through passage 63 in response to an increase in differential pressure across blocking member 61 . Valve 65 constricts the flow rate of downward flowing well fluid in proportion to the extent of draw down due to the initial operation of pump 19 (FIG. 1). If there is a fairly high static fluid level, when pump 27 starts to operate, a fairly large pressure differential across blocking member 61 may occur. If so, valves 65 will reduce the flow area accordingly to prevent a high flow rate of well annulus fluid from flowing downward. Valve 65 preferably is not electrically actuated. Rather it preferably has a resilient portion within its passage that deforms in response to pressure differential to reduce and increase the passage.
[0030] The invention has significant advantages. Restricting downward flow of well annulus fluid allows more flow through the perforations. The increased flow through the perforations flows past the motor, cooling it.
[0031] While the invention has been shown in several of its forms, it should be apparent that the invention is not so limited, but is susceptible to various changes without departing from the scope of the invention.
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A method of pumping well fluid from a well having casing with perforations includes connecting an electrical motor to a lower end of a pump and securing the pump to tubing. A restrictor is mounted to the tubing above the pump, the restrictor having a restrictor passage. The well annulus contains a well fluid with a static level under static conditions. When the motor is started to cause the pump to operate, downward flow of well fluid contained in the well annulus flows through the restrictor passage. This reduces the amount of downward flow to increase well fluid flow through the perforations.
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FIELD OF THE INVENTION
The present invention relates to a rubbing-contact fluid sealing structure for use with a rotatable heat regenerative core incorporated in, for example, a rotary, counter-flow heat-regenerative heat exchanger for use in, for example, a gas turbine for use, typically, as a prime mover for a land transportation vehicle such as an automotive vehicle.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a rubbing-contact sealing structure for a heat regenerative core rotatable within a stationary housing structure having high-pressure and low-pressure fluid chambers arranged in counter-flow relationship adjacent one face of the heat regenerative core and a high-pressure space surrounding the heat regenerative core and communicating with the high-pressure fluid chamber, comprising a main seal element having an inner end face to be in rubbing contact with the aforesaid face of the heat regenerative core, and an elastic, substantially flat pressing member provided in sealing engagement between the main seal element and the housing structure and at least in part elastically deformable toward and away from the aforesaid face of the heat regenerative core, the pressing member having an outer face at least in part exposed to the aforesaid fluid space and laterally extending substantially in parallel with the aforesaid face of the heat regenerative core in the absence of a differential fluid pressure between both sides of the pressing member, viz., between the low-pressure fluid chamber and the high-pressure fluid space.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the sealing structure according to the present invention as compared to prior art sealing structures will be understood more clearly from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a sectional view showing the general arrangement of a prior-art sealing structure provided in a rotary, counter-flow heat-regenerative heat exchanger for a gas turbine which is shown schematically;
FIG. 2 is a view showing, to an enlarged space, a portion indicated by II in FIG. 1;
FIG. 3 is a fragmentary perspective view showing, to a further enlarged scale, a portion of the pressing member incorporated in the prior-art sealing structure illustrated in FIGS. 1 and 2;
FIG. 4 is a cross sectional view showing a preferred embodiment of the sealing structure according to the present invention;
FIG. 5 is a fragmentary cross sectional view showing a modification of the pressing member in the embodiment of FIG. 4;
FIG. 6 is a cross sectionsl view showing another preferred embodiment of the sealing structure according to the present invention; and
FIG. 7 is a cross sectional view showing part of still another preferred embodiment of the sealing structure according to the present invention.
DESCRIPTION OF THE PRIOR ART
Referring first to FIG. 1 of the drawings, a prior-art fluid sealing structure of the type to which the present invention appertains is assumed to be incorporated in a rotary, counter-flow heat-regenerative heat exchanger of a gas turbine to be used as, for example, a prime mover for a land transportation vehicle such as an automotive vehicle. As is well known in the art, a gas turbine of such a nature is usually constructed as a series-flow two-shaft type and generally comprises two sections which are arranged in series with each other. The two sections consist of a gasifier and impeller section and a power section. The gasifier and impeller section comprises an air compressor 10 having a bladed compressor rotor (not shown), a compressor turbine 12 axially positioned in alignment with the air compressor 10 and including a bladed compressor turbine rotor (not shown) connected to the bladed rotor of the compressor 10 by a compressor drive shaft 14, and a combustor 16 including a combustion chamber (not shown) which is arranged to intervene, in effect, between the air compressor 10 and the compressor turbine 12. The combustion chamber forming part of the combuster 16 is usually formed around the compressor rotor and is arranged with a fuel nozzle and an igniter project into the combustion chamber though not shown in the drawings. When the bladed rotor of the air compressor 10 is driven to rotate by the compressor turbine 14 through the compressor drive shaft 14, air sucked into the compressor 10 through an air intake (not shown) of the gas turbine is carried around the compressor rotor and is blown under compression into the combustion chamber of the combustor 16. Into the compressed air thus injected into the combustion chamber of the combustor 16 is sprayed fuel ejected from the fuel nozzle so that a hot combustion gas is produced in the combustion chamber by the combustion of the fuel with the agency of the compressed air. The high-pressure, high-temperature gas thus produced in the combustion chamber of the combustor 16 is directed against the bladed rotor of the compressor turbine 12 and causes the compressor turbine rotor to spin at high speed. The rotation of the compressor turbine rotor is transmitted through the compressor drive shaft 14 to the rotor of the compressor 10 and drives the compressor rotor for rotation with the compressor turbine rotor and the shaft 14, thereby enabling the air compressor 10 to continuously supply fresh compressed air into the combustion chamber of the combustor 16. The igniter forming part of the combustor 16 plays the part of firing the mixture of the fuel and compressed air initially introduced into the combustion chamber but, once such a mixture is fired at an initial stage of a gas turbine operation, the combustion flame produced in the combustion chamber of the combustor 16 continues as long as fuel is thereafter continuously supplied into the combustion chamber. On the other hand, the power section of the gas turbine shown in FIG. 1 is positioned downstream of and axially in alignment with the compressor turbine 12 of the gasifier and impeller section thus arranged generally and comprises a power turbine 18 including a bladed rotor rotatable with a turbine output shaft 20 which is axially in line with the compressor drive shaft 14. The turbine output shaft 20 is secured at one end thereof to the bladed rotor of the power turbine 18 and at the end thereof to a suitable driven member such as, for example, a gear forming part of a power transmission gear assembly (not shown) for an automotive vehicle. The high-pressure, high-temperature gas which has driven the compressor turbine rotor as above described enters the power turbine 18 and causes the bladed rotor of the power turbine 18 to spin about the center axis thereof. The rotation of the power turbine rotor is transmitted through the turbine output shaft 20 to the power transmission gear assembly and is further transmitted, upon reduction of the speed in the transmission gear assembly, to the driving road wheels of the vehicle through, for example, a final drive gear unit (not shown) forming part of the vehicle driveline.
The rotary, counter-flow heat-regenerative heat exchanger provided in the gas turbine engine thus constructed and arranged comprises a generally drum-shaped housing structure 22 having enclosed therewithin a generally disc-shaped heat regenerative core 24 securely mounted on a drive shaft (not shown) for rotation about the center axis of the shaft and having axially outer and inner or cold-side and hot-side faces 24a and 24b which are perpendicular to the axis rotation of the regenerative core 24. Though not shown in the drawings, the drive shaft for the heat regenerative core 24 is journaled in suitable bearings supported on the housing structure 22 and is usually arranged to be driven by the compressor drive shaft 14 through a suitable reduction gear unit. The heat regenerative core 24 is usually constructed of alternate spiral layers of flat and corrugated sheets of metal or ceramic and, thus, has a multicellular matrix structure formed with a multiplicity of pores or fine passageways (not shown) extending in parallel with the axis of rotation of the core and open at the opposite cold-side and hot-side faces of the core. The heat regenerative core 24 may have a non-porous outer rim defining the outer circumference of the core and a nonporous inner rim constituting a hub by means of which the core is secured to the drive shaft for the core.
The housing structure 22 having the heat regenerative core 24 thus accommodated therewithin is formed with a cold air inlet chamber 26 contiguous to at least a portion of one semicircular half of the cold-side face 24a of the regenerative core 24, a preheated air outlet chamber 28 contiguous to at least a portion of one semicircular half of the hot-side face 24b of the regenerative core 24, a hot exhaust gas inlet chamber 30 contiguous to at least a portion of the other semicircular half of the hot-side face 24b of the regenerative core 24, and a cooled exhaust gas outlet chamber 32 contiguous to at least a portion of the other semicircular half of the cold-side face 24a of the core 24. The term "semicircular half" of the cold-side or hot-side face 24a or 24b as above mentioned does not necessarily mean that such an area of the cold-side or hot-side face of the heat regenerative core 24 has a geometrically exact semicircular configuration but may imply any of acute-angle or obtuse-angle sector-shaped configurations largely similar to a semicircular configuration. The cold air inlet chamber 26 and the preheated air outlet chamber 28 are substantially coextensive in cross section with each other across the heat regenerative core 24 and, likewise, the hot exhaust gas inlet chamber 30 and the cooled exhaust outlet chamber 32 are substantially coextensive in cross section with each other across the the regenerative core 24, as will be seen from FIG. 1. The cold air inlet chamber 26 is in constant communication with the discharge end of the air compressor 10 through a compressed air conducting passageway 34 so that the compressed air delivered from the air compressor 10 is constantly directed through the passageway 34 into the cold air inlet chamber 26 and is passed to the preheated air outlet chamber 28 through the pores or passageways in the regenerative core 24. The preheated air outlet chamber 28 is in constant communication with the combustion chamber of the combustor 16 through a suitable air passageway formed in part in the housing structure 22. The air inlet and outlet chambers 26 and 28 longitudinally aligned with each other across one semicylindrical half of the heat regenerative core 24 thus constitute passageway means defining an incoming fluid a path for the unidirectional stream of the compressed air to be passed through the heat regenerative core 24 in one direction parallel with the axis of rotation of the core 24. On the other hand, the hot exhaust gas inlet chamber 30 of the heat exchamger is in constant communication with the discharge end of the power turbine 18 through a suitable passageway (not shown) formed in part in the housing structure 22 so that the high-temperature, high-pressure exhaust gases which have been discharged from the power turbine 18 are constantly directed into the hot exhaust gas inlet chamber 30 and are passed to the cooled exhaust gas outlet chamber 32 through the pores or passageways in the heat regenerative core 24. The cooled exhaust gas outlet chamber 32 is open to the outside of the gas turbine or, usually, to the atmosphere through a suitable exhaust gas discharge passageway (not shown). The air inlet and outlet chambers 30 and 32 longitudinally aligned with each other across the other semicylindrical half of the heat regenerative core 24 thus constitute passageway means defining an outgoing fluid path for the unidirectional stream of the exhaust gases to be passed through the heat regenerative core 24 in the other direction parallel with the axis of rotation of the core 24. The paths of the incoming and outgoing fluids to be passed through the heat regenerative core 24 are thus in counterflow relationship to each other. The housing structure 22 is further formed with an annular space 36 surrounding the outer peripheral surface of the heat regenerative core 24 and formed in part by a partition member 38 secured to or forming part of the housing structure 22. The annular space 36 is open to the cold air inlet chamber 26 or otherwise in constant communication with the discharge end of the air compressor 10 so that the compressed air delivered from the air compressor 18 is in part passed through the chambers 26 and 28 to the combustion chamber of the combustor 18 and in part admitted into the annular space 36 for the reason that will be explained later.
Throughout operation of the gas turbine, the heat regenerative core 24 of the heat exchanger above described is continuously driven to rotate about the axis of rotation thereof. Thus, portions of the heat regenerative core 24 alternately traverse the incoming fluid path between the air inlet and outlet chambers 26 and 28 and the outgoing fluid path between the exhaust inlet and outlet chambers 30 and 32 and are thereby alternately heated by the hot exhaust gases passed from the chamber 30 to the chamber 32 and cooled by the fresh, compressed air passed from the chamber 26 to the chamber 28. The heat in the hot exhaust gases being passed from the hot exhaust gas inlet chamber 30 to the cooled exhaust gas outlet chamber 32 is therefore partially transferred to a portion of the rotating heat regenerative core 24 and is thereafter further transferred through the portion of the core to the fresh, compressed air being passed from the cold air inlet chamber 26 to the preheated air outlet chamber 28 through the portion of the core 24. The useable heat in the exhaust gases to be discharged is in these manners recovered to preheat the compressed air to be fed to the combustor 18.
In order to recover useable heat at a satisfactory efficiency in a heat exchanger of the nature above described, it is important that the counterflow streams of the fluids in the incoming and outgoing fluid paths in the housing structure 22 be hermetically isolated from each other. For this purpose and also to prevent each of the fluids from bypassing the heat regenerative core 24, the heat exchanger in the gas turbine illustrated in FIG. 1 further comprises two rubbing-contact fluid sealing structures 40 and 42 are provided on the cold and hot sides, respectively, of the heat regenerative core 24. The sealing structure 42 provided on the hot side of the heat regenerative core 24 is securely attached to the housing structure 22 and comprises an annular outer strip portion contacting an outer circumferential portion of the hot-side face 24b of the heat regenerative core 24 and two radial strip portions (not shown) extending radially inwardly from the annular strip portion and joined together through an annular inner strip portion contacting a center portion of the hot-side face 24b of the core 24. The radial strip portions may be arranged in diametrically opposite relationship to each other or may be angled to each other so as to define therebetween two generally sector-shaped open areas one of which has an acute central angle and the other of which has an obtuse central angle about the center axis of the sealing structure 42. The two discrete open areas thus defined by the individual strip portions constituting the hot-side sealing structure 42 are preferably such that are conforming to the respective sectional areas of the preheated air outlet and exhaust gas inlet chambers 28 and 30, respectively, in the housing structure 22.
On the other hand, the rubbing-contact fluid sealing structure 40 provided on the cold side of the heat regenerative core 24 is arranged to be in elastically pressing contact with the cold-side face 24a of the heat regenerative core 24 so that a wear to be caused in each of the sealing structures 40 and 42 during use of the heat exchanger can be automatically compensated for by an elastic deformation or displacement of the cold-side sealing structure 40 in the axial direction of the regenerative core 24. In the arrangement shown in FIG. 1, the cold-side sealing structure 40 is assumed, by way of example, to have a generally semicircular or sector-shaped configuration largely conforming to a semicircular or sector-shaped half of the cross sectional configuration of the heat-regenerative core 24 and is located between the cold-side face 24a of the regenerative core 24 and the cooled exhaust gas outlet chamber 32.
As illustrated to an enlarged scale in FIG. 2, the cold-side sealing structure 40 comprises a generally sector-shaped support member 44 consisting of a flat base wall portion spaced apart in parallel from the cold-side face 24a of the heat regenerative core 24 and securely attached to a correspondingly shaped internal surface portion 22a of the housing structure 22 and an inner side wall portion perpendicularly upstanding from the base wall portion toward the cold-side face 24a of the regenerative core 24. A generally sector-shaped pressing member 46 constituted by a Belleville (initially coned or dished) spring is securely attached along its inner peripheral end to the flat base wall portion of the support member 44 and has an outer peripheral end portion spaced apart from and extending over the base wall portion of the support member 44 as shown. Between the pressing member 46 thus arranged and the cold-side face 24a of the heat regenerative core 24 is positioned a combination of a generally sector-shaped seal element 48 and a generally sector-shaped seal retaining member 50 formed with a continuous groove 50a having the seal element 48 closely received therein. The seal retaining member 50 has a flat outer face contacted by the outer peripheral end portion of the pressing member 46 and an inner peripheral surface contacted by or slightly spaced apart from the outer peripheral surface of the inner side wall portion of the support member 44. The seal element 48 axially protrudes from the groove 50a in the seal retaining member 50 and is slidably contacted by the cold-side face 24a of the heat regenerative core 24 by the spring force of the pressing member 46 which elastically presses the combination of the seal retaining member 50 and the seal element 48 toward the cold-side face 24a of the heat regenerative core 24. As illustrated to a further enlarged scale in FIG. 3, the pressing member 46 is formed with a series of slits 52 which are arranged at suitable regular intervals along the pressing member and which extend perpendicularly to and termenate at the outer peripheral end of the pressing member so that the pressing member functions effectively as a Belleville spring. In a modified version of the sealing structure, the pressing member 46 is secured along its outer peripheral end to the flat outer face of the seal retaining member 50 and has its inner peripheral end portion held in pressing contact with the inner surface of the base wall portion of the support member 44.
When the gas turbine is in operation, the seal element 48 forming part of the cold-side sealing structure 40 thus constructed and arranged is held in rubbing contact with the cold-side face 24a of the rotating heat regenerative core 24 so that the exhaust gases which have left the heat regenerative core 24 are confined in the outgoing fluid path thereof and are thereby precluded from being admixed to the fresh air flowing through the cold air inlet chamber 26 into the heat regenerative core 24. Throughout operation of the gas turbine, a differential pressure is established across the cold-side sealing structure 40 by the high-pressure air in the annular space 36 surrounding the heat regenerative core 24 and the low-pressure exhaust gases in the cooled exhaust gas outlet chamber 32. The differential pressure acts on the flat outer face of the seal retaining member 50 of the sealing structure 40 partially through the slits 52 in the pressing member 46 and, in cooperation with the pressing member 46, presses the seal element 48 against the cold-side face 24a of the heat regenerative core 24 for enhancing the sealing effect between the seal element 48 and the regenerative core 24.
When the seal element 48 is in rubbing contact with the cold-side face 24a of the heat regenerative core 24, the pressing member 46 thus pressing the seal element 48 against the cold-side face 24a of the regenerative core 24 is forced to expand outwardly with its slits 52 wider open. This not only results in leakage of the high-pressure air from the cold air inlet chamber 26 and the annular space 36 into the cooled exhaust gas outlet chamber 32 through the enlarged slits 52 in the pressing member 46 but is sometimes causative of cracks in an outer peripheral portion of the pressing member as indicated at 54 in FIG. 3 due to the production of unusual and localized stresses in the regions of the slits 52. The present invention aims at provision of an improved rubbing-contact fluid sealing structure free from these disadvantages.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 4 to 7 show some preferred embodiments of the present invention to achieve such an end. In each of these embodiments of the present invention, the sealing structure is assumed to be incorporated into a rotary, counter-flow heat-regenerative heat exchanger similar to that shown in FIG. 1 and is, thus, shown to be provided in conjunction with a rotatable heat regenerative core enclosed within a housing structure essentially similar to the housing structure 22 of the heat exchanger illustrated in FIG. 1. In each of FIGS. 4 to 7, therefore, the members, elements and structures similar to those shown in FIG. 1 are designated by the same reference numerals as those denoting such members, elements and structures in FIG. 1 and will be presented in the following description without having recourse to rpeated description of the constructions and functions thereof.
Referring to FIG. 4 of the drawings, a sealing structure embodying the present invention is shown to be used as a cold-side sealing structure positioned on the downstream side of the outgoing fluid path of the exhaust gases to flow through the heat regenerative core 24 and is designated as a whole by reference numeral 56. The cold-side sealing structure 56 comprises a stationary support member 58 having a generally L-shaped cross section and made up of a flat base wall portion securely sttached to the internal surface portion 22a of the housing structure 22 of the heat exchanger and an inner side wall portion projecting from the inner peripheral or lateral end of the base wall portion toward the cold-side face 24a of the heat regenerative core 24. A main seal element 60 formed of a ceramic or a suitable ceramic composition and having a rectangular cross section is closely received in part in a shallow groove formed in a seal retaining member 62 having a substantially flat outer face. A resilient auxiliary seal element 64 having a protruded longitudinal edge or rib portion 64a and formed of rubber for example is closely attached to the flat outer face of the seal retaining member 62 by suitable fastening means such as a plurality of bolts 66 screwed through a substantially flat portion of the seal element 64 into the seal retaining member 62 so that the rib portion 64a extends along the inner peripheral or lateral end of the seal element 64 and protrudes toward the internal surface portion 22a of the housing structure 22. The rib portion 64a of the auxiliary seal element 64 thus attached to the seal retaining member 62 is spaced apart a suitable distance from the outer surface of the inner side wall portion of the support member 58. A substantially flat pressing member 68 constructed of an elastic sheet metal such as a spring steel is securely attached to the inner surface of the flat base wall portion of the support member 58 by suitable fastening means and extends away from the outer surface of the side wall portion of the support member 58 substantially in parallel with the flat outer face of the seal retaining member 62 and in such a member as to be in contact with the rib portion 64a of the auxiliary seal element 64. The fastening means thus securing the pressing member 68 to the support member 58 is shown comprising a plurality of bolts 70 screwed to the flat base wall portion of the support member 58 and a substantially flat clamping member 72 closely interposed between the pressing member 68 and the heads of the bolts 70. The width of the clamping member 72 from the inner peripheral end thereof is such that the clamping member leaves the pressing member 68 uncovered over its area contacting the rib portion 64a of the auxiliary seal element 64 as shown. The cold-side sealing structure 56 shown in FIG. 1 further comprises adjusting means adapted to manually adjust the axial position of the rotatable assembly of the main seal element 60, seal retaining member 62 and auxiliary seal element 62 with respect to the housing structure 22 and the heat regenerative core 24. Such adjusting means is shown comprising a plurality of studs 74 which are fitted by means of nuts 76 to the housing structure 22 through tapped holes formed in the housing structure. The studs 74 extend substantially perpendicularly toward the flat outer face of the seal retaining member 62 and about at their respective leading ends against the flat portion of the auxiliary seal element 64 for limiting the displacement of the rotatable assembly of the seal elements 60 and 64 and the seal retaining member 62 away from the cold-side face 24a of the heat regenerative core 24.
Each of the support member 58, main seal element 60, seal retaining member 62, auxiliary seal element 64, pressing member 68 and clamping member 72 is assumed to have a generally semicircular sector-shaped configuration and, thus, defines an outgoing fluid path between the cold-side face 24a of the heat regenerative core 24 and the cooled exhaust gas outlet chamber 32 formed in the housing structure 22. In FIG. 4 is further shown a hot-side sealing structure 78 comprising a seal element 80 similar in configuration to the seal element 60 of the above described cold-side sealing structure 56 and in contact with the hot-side face 24b of the heat regenerative core 24 and a seal retaining member 82 formed with a groove having the seal element 78 in part received therein.
When the gas turbine having the seal structures 56 and 78 incorporated in the heat exchanger thereof is in operation, there is a differential fluid pressure produced by the relatively high pressure of the compressed air in the annular space 36 surrounding the heat regenerative core 24 and the relatively low pressure of the exhaust gases issuing from the heat regenerative core 24 into the cooled exhaust gas outlet chamber 32. The differential fluid pressure acts on both of the auxiliary seal element 64 and the pressing member 68 so that the pressing member 68 is elastically pressed against the rib portion 64a of the auxiliary seal element 64, which is as a consequence pressed against the outer face of the seal retaining member 62 by the differential pressure acting thereon and the pressing thus imparted from the pressing member 68 to the seal element 64. The main seal element 60 is therefore feld in pressing and rubbing contact with the cold-side face 24a of the rotating heat regenerative core 24 and, accordingly, the heat regenerative core 24 is forced against the seal element 80 of the hot-side sealing structure 78 as long as a differential fluid pressure is maintained between the cooled exhaust gas outlet chamber 32 and the space 36 in the housing structure 22. As abrasion proceeds on the rubbing contact surfaces of the seal elements 60 and 80 of the cold-side and hot-side sealing structures 56 and 78, respectively, the pressing member 68 is caused to wrap toward the cold-side face 24a of the heat regenerative core 24 and automatically takes up the wears of the seal elements 60 and 80.
One of the outstanding advantages of the cold-side sealing structure 56 thus constructed and arranged is that the pressing member 68 to maintain the seal between the seal element 60 and the cold-side face 24a of the heat regenerative core 24 is constructed of an initially flat sheet metal which is arranged substantially in parallel with the flat outer face of the seal retaining member 62 and which is devoid of slits or slots similar to the slits 52 formed in the pressing member 46 of the previously described prior-art sealing structure. Being thus constructed of an initially flat sheet metal and arranged in parallel with the outer face of the seal retaining member 62, the pressing member 68 functions as an excellent spring when subjected to a fluid pressure on its outer face and is, thus, adapted to achieve proper sealing effected between the seal element 60 and the cold-side face 24a of the heat regenerative core 24 and the seal element 80 and the hot-side face 24b of the core 24. Being devoid of slits or slots, furthermore, the pressing member 68 is free from leakage of fluid therethrough and from localized stresses which would otherwise lead to production of cracks in the pressing member.
The pressing member 68 used in the seal structure 56 shown in FIG. 4 is assumed to be constructed of a unitary metal plate but, if desired, such a member may be composed of a laminar structure of two or more leaves or segments of elastic sheet metal. FIG. 5 shows a pressing member 68' consisting of a laminar structure of three metal segments 68a, 68b and 68c. The metal segments 68a, 68b and 68c constituting the pressing member 68' have different widths smaller than each other toward the axially innermost one 68a of the segments and have outer peripheral or lateral edges which are arranged in tier. The metal segments 68a, 68b, 68c are secured along their inner peripheral or lateral edges to the support member 58 (FIG. 4) by suitable fastening or clamping means arranged similarly to the bolt 70 and clamping member 72 in the sealing structure 56 shown in FIG. 4 and are successively in contact with the protruded longitudinal edge or rib portion 64a of the auxiliary seal element 64 at the respective outer peripheral or lateral edges of the segments. The segments 68a, 68b and 68c may be bonded or otherwise secured together by adhesive or mechanical fastening means or may be simply superposed on each other without being secured together. An advantage of the pressing member 68' thus composed of the different metal segments 68a, 68b and 68c thus arranged is that, since the outer peripheral or lateral edges of the segments are successively in contact with the rib portion 64a of the auxiliary seal element 64 at the respective outer peripheral or lateral edges of the segments, an enhanced sealing effect can be achieved between the auxiliary seal element 64 and the pressing member 68'.
FIG. 6 shows another modification of the cold-side sealing structure 56 illustrated in FIG. 4. In the sealing structure shown in FIG. 6, a pressing member 68" is composed of a laminar structure of two, axially inner and outer leaves or metal segments 68d and 68e. The inner metal segment 68d is smaller in width and thickness than the outer metal segment 68e as shown and the outer metal segment 68e is formed with perforations 84 in its outer peripheral or lateral end portion so that a fluid pressure to be developed in the annular space 36 surrounding the sealing structure acts not only on the outer face of the outer metal segment 68e but on the outer face of the inner metal segment 68d through these perforations 84. The inner and outer metal segments 68d and 68e are secured along their inner peripheral or lateral ends to the support member 58 by means of the bolt 70 and clamping member 72 as in the sealing structure 56 illustrated in FIG. 4 and are in contact with the resilient auxiliary seal element 64 at the outer peripheral or lateral edges of the segments. The auxiliary seal element 64 in the sealing structure herein shown has a thickness substantially uniform throughout the width thereof and is securely attached to the flat outer face of a base plate 86 which is fastened to the outer face of the seal retaining member 62 by means of bolts 88 screwed through the base plate 86 into the seal retaining member 62. The rotatable assembly thus composed of the main seal element 60, seal retaining member 62, auxiliary seal element 64 and base plate 86 is position adjusted with respect to the housing structure 22 and the heat regenerative core 24 by adjusting means which comprises a plurality of screw threaded members such as bolts 90 fitted to the housing structure 22 through tapped holes in the housing structure and arranged to perpendicularly abut at their respective leading ends against the outer face of the outer metal segment 68e of the pressing member 68'. The reason why the inner metal segment 68d is made thinner than the outer metal segment 68e is to enable the segment 68d to properly warp about the outer peripheral or lateral edge of the clamping member 72 when the segment 68d is forced to warp toward the outer face of the seal retaining member 62.
FIG. 7 shows still another modification of the sealing structure 56 illustrated in FIG. 4. The embodiment herein shown is characterized specifically by adjusting means comprising a plurality of studs 92 each having a bored shank portion formed with an annular flange 92a and an axial bore 92b which is open at the leading end of the shank portion. Each stud 92 is screwed through a wall portion of the housing structure 22 in such a manner that the flange 92a of the shank portion is positioned between the internal surface 22a of the housing structure 22 and the auxiliary seal element 64 attached to the flat outer face of the seal retaining member 62 and the axial bore 92a in the shank portion is open perpendicularly to the flat portion of the auxiliary seal element 64 as shown. The stud 92 is secured to the housing structure 22 by means of a nut 92. A spring seat element 96 having an elongated rod portion terminating in a disc portion 96a has its rod portion axially slidably inserted in part into the axial bore 92b in the shank portion of each of these studs 92 so that the disc portion 96a of the spring seat element 96 is axially movable between the flat portion of the auxiliary seal element 64 and the inner face of the flange 92a of the stud 92. A preloaded helical compression spring 98 is seated at one end on the flange 92a of each stud 92 and the disc portion 96a of the spring seat element 96 and thus urges the spring seat element 96 to move toward the seal element 64 so that the disc portion 96a of the spring seat element 96 is pressed against the outer face of the flat portion of the auxiliary seal element 64. The auxiliary seal element 64 and accordingly the main seal element 60 are therefore constantly forced toward the cold-side face 24a of the heat regenerative core 24 (FIG. 4) by the forces of the compression springs 98 respectively provided in association with the individual studs 92 and automatically adjust the pressure by which the heat regenerative core is pressed upon by the main seal element 60. The force of each of the springs 98 can be manually adjusted by turning the stud 92 on the housing structure 22 so as to cause the flange 92a of the stud 92 to move toward or away from the disc portion 96a of the spring seat element 96 pressed onto the auxiliary seal element 64.
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A rubbing-contact sealing structure for use in a rotary, counter-flow heat-regenerative heat exchanger having a heat regenerative core rotatable with a housing structure having high-pressure and low-pressure fluid chambers arranged in counter-flow relationship adjacent one face of the core, comprising a main seal element to be in rubbing contact with the particular face of the regenerative core, and a pressing member supported on the housing and in pressing engagement with the main seal element for pressing the main seal element in rubbing contact with the heat regenerative core, the pressing member being substantially flat and parallel with the aforesaid face of the heat regenerative core.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a washing machine, especially, to a washing machine and method for manufacturing door thereof reinforcing the rigidity of a cabinet as well as improving a fine view around a door as installing a door ring on a cabinet around a door, and preventing the glaring as well as improving a fine view of a door as forming a decoration part which is continued by reflection/irreflection or intaglio/relief patterns on the front surface of a door.
2. Description of the Conventional Art
Generally, a washing machine is a machine which removes dirt, etc. stuck on the clothes as providing a mechanical action as using electricity; a drum washing machine has effects which hardly damage the laundry, the laundry does not get tangled, and a strike and rub washing effect.
FIG. 1 is a perspective view that a drum washing machine is illustrated in accordance with the conventional technique, FIG. 2 is a side cross-sectional view that a drum washing machine is illustrated in accordance with the conventional technique, and FIG. 3 is a plane cross-sectional view according to the A-A line of FIG. 2 .
As illustrated on the FIGS. 1 and 2 , a conventional drum washing machine is composed as including: a cabinet ( 2 ), forming the external aspect of a washing machine; a tub ( 4 ) installed to be hung by a spring ( 3 ) in the inside of a cabinet ( 2 ); a drum ( 5 ) installed on the inner aspect of the tub ( 4 ) and the laundry is washed; a lift ( 6 ) installed on the inner aspect of a drum ( 4 ) and drags the laundry up to be fell on a certain height by gravity; a motor ( 7 ) which is installed on the rear part of the tub ( 4 ) and occur a power; a cabinet cover ( 17 ) installed on the front and a laundry entrance ( 18 ) capable of inputting and taking out of the laundry is formed on the center; a door ( 20 ) as installed on the cabinet cover ( 17 ) capable of opening and closing the laundry entrance, preventing the laundry breaking out of the laundry entrance.
Between a tub ( 4 ) and a door ( 20 ), a gasket ( 8 ) which is moderating the impulse from the rotation of a drum ( 5 ) as well as being a packer preventing the washing water flooding to outside is installed.
And, a top plate ( 9 ) and a base ( 10 ) which are formed of a superior surface and a inferior surface are installed on the upper part and lower part of the above-mentioned washing machine; a draining pump ( 11 ) and a draining hose ( 12 ) which drain or circulate the washing water are installed on the lower part of a tub ( 4 ); a water supply hose ( 13 ), a water supply valve ( 14 ), and a detergent box ( 15 ) which supply the washing water and the detergent into the inner part of a tub ( 4 ) are inner packed on the lower side of a top plate ( 9 ).
Also, a door ( 20 ) of a drum washing machine in accordance with the conventional technique is composed as including: a ring-shaped door frame which is installed to be possible to be rotated; a door hinge ( 24 ) that each of either ends are installed on a door frame ( 21 ) and a cabinet cover ( 17 ), and supporting a door frame to be rotated; a door glass ( 25 ) installed on the opened center hole ( 21 a ) of a door frame( 21 ) so as to look at the inner situation of a drum ( 5 ).
A door frame ( 21 ), generally, is an injection of a plastic quality, and composed of: a front door frame ( 22 ) placed on the front and has a handle ( 29 ) on an aspect; a rear door frame ( 23 ) installed on the rear surface of a front door fame ( 22 ), one of the ends of the door hinge ( 24 ) is placed. A hook is formed protruded on an aspect on a rear door frame ( 23 ), a hook hole ( 28 ) to be united with a hook ( 27 ) is formed on a cabinet cover ( 17 ).
On a door glass ( 25 ), an edge part is fixed between a front door frame ( 22 ) and a rear door frame ( 23 ), so a center hole ( 21 a ) of a door frame ( 21 ) is installed to be closed.
On the other hand, recently, as the design has become an important element deciding the marketability of a product besides the performance and endurance; developing a new model as giving a suitable specific gravity for contour, colors, and texture when developing a new product so as to satisfy the consumer's aesthetical desire has been becoming a trend.
However, a drum washing machine in accordance with a conventional technique, a door frame ( 21 ) is an injection of plastic quality, so it becomes an occasion declining the marketability of a product as unable to give the consumers an impression of high classic on a fine view.
Also, recently, gradually being large-sized of the drum washing machines has been becoming a trend, the above-mentioned laundry entrance ( 18 ) and a door ( 20 ) become large-sized. Accordingly, a door frame ( 21 ) has to be formed with an enough strength to support the load of an enlarged door glass ( 2 ), but because a door frame ( 21 ) is an injection molded with a plastic quality, the insurance of the strength isn't easy.
To improve the above-mentioned problems; forming a door frame ( 21 ) with a metallic texture which is capable of creating a high classic image and has an excellent strength is possible; but in this case, the material cost is increased, the total weight of a door is increased, and the surface processing to improve the texture is difficult.
Especially, a door ( 20 ) is installed on a cabinet cover ( 17 ) which is composing a cabinet ( 2 ) so as to be opened and closed; because any particular intermediate member isn't installed around a laundry entrance ( 18 ) on a cabinet cover ( 17 ), the insurance of the enough strength to support the gradually enlarged doors is difficult.
Also, because the front surface of a cabinet cover ( 17 ) is usually formed as a single plane structure, there is a limit on improving the whole of front external aspect of a washing machine.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to solve the problems of the conventional technique and providing a washing machine which is improving the strength of the structures around a door and the external fine view as installing a ring around a door.
Another object of the present invention is to provide a manufacturing method of washing machine and a washing machine door capable of intermediating the strength of a door frame, and exchanged just a front element easily according to the needs as installing a front element on a door frame of a door.
Another object of the present invention is to provide a manufacturing method of washing machine and a washing machine door capable of improving the entire sense of beauty as well as preventing the glaring as forming a decoration part which is continued by reflection/irreflection or intaglio/relief patterns on the front surface of a door frame or a front element of a door.
To achieve these and other advantages in accordance with the purpose of the present invention, as embodied and broadly described herein, there is a washing machine comprising: a door rotatably installed on a cabinet, and open and close a laundry entrance; a door ring placed on a cabinet to be belted on the circumference of the external aspect of a door.
A door ring is formed as more bulgily protruded than other parts of a cabinet, and a door ring is united with a hook or a adhesion element on a cabinet, or formed to be one as bended on a cabinet and a gliding layer is formed on the external surface.
Also, a front element that the strength is excellent and the external aspect is fine is installed on the front surface of a door, and a front element has a decoration part that reflection and irreflection patterns are repeatedly formed as intaglio and relief form. A decoration part that reflected and irreflection patterns are formed as intaglio and relief form by an etching method; at least one of the reflection and irreflection patterns is being formed as a lattice shape, round shape, quadrilateral shape , or a trilateral shape.
Or differently with the above-mentioned, a decoration part that the intaglio and relief patterns are formed repeatedly on the front surface of a door ; at least, metal gliding layer is formed on the front surface of a door.
Or differently with the above-mentioned, a decoration part that the reflection and irreflection patterns are formed repeatedly on the front surface of a door; a metal gliding layer is formed on the front surface of a door; a decoration part is formed on the metal gliding layer; a protection film which of transparent material is worn on the surface of a metal gliding layer.
A decoration part that reflection and irreflection patterns are formed as intaglio and relief forms; at least one of the reflection and irreflection patterns is being formed as a lattice shape, round shape, quadrilateral shape , or a trilateral shape.
On the other hand, a manufacturing method of a door of a washing machine comprising; a cutting step which is cutting out a front element from a metal plate body; a material feel forming step which is forming a decoration part on a front element; and on forming a material feel forming step, the reflection and irreflection patterns are arranged repeatedly.
The decoration patterns on a material feel forming step are composed of the forms of intaglio and relief.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view illustrating a drum washing machine in accordance with the conventional technique;
FIG. 2 is an aspect cross-sectional view illustrating a drum washing machine in accordance with the conventional technique;
FIG. 3 is a plane cross-sectional view cording to the line A-A of FIG. 2 ;
FIG. 4 is a perspective view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 1 of the present invention;
FIG. 5 is a plane cross-sectional view according to the line B-B direction of FIG. 4 ;
FIG. 6 is a perspective view illustrating a door of a drum washing machine according to the preferred embodiment No. 1 of the present invention;
FIG. 7 is a disassembled perspective view illustrating a door and a door ring of a drum washing machine according to the preferred embodiment No. 1 of the present invention;
FIG. 8 is a flow chart illustrating the manufacturing method of a front element used on a door of a drum washing machine according to the preferred embodiment No. 1 of the present invention;
FIG. 9 is a drawing illustrated orderly the manufacturing method of a front element used on a door of a drum washing machine according to the preferred embodiment No. 1 of the present invention;
FIG. 10 is a plane cross-sectional view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 2 of the present invention;
FIG. 11 is a plane cross-sectional view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 3 of the present invention;
FIG. 12 is a plane cross-sectional view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 4 of the present invention;
FIG. 13 is a plane cross-sectional view according to the line C-C direction of FIG. 12 ;
FIG. 14 is a plane cross-sectional view illustrating a major part of a door of a drum washing machine according to the preferred embodiment No. 5 of the present invention;
FIG. 15 is a disassembled perspective view of a door not showing some parts of a drum washing machine according to the preferred embodiment No. 5 of the present invention;
FIG. 16 is a plane diagram illustrating an afore state of a front element bended according to the preferred embodiment No. 5 of the present invention;
FIG. 17 is a plane diagram illustrating a superior surface of a door that a front element is operated according to the preferred embodiment No. 5 of the present invention;
FIG. 18 is a plane cross-sectional view illustrating a door of a drum washing machine according to the preferred embodiment No. 6 of the present invention;
FIG. 19 is a plane diagram illustrating the inner side of a mold for molding a door frame according to the preferred embodiment No. 6 of the present invention;
FIG. 20 is a flow chart illustrating the manufacturing method of a door having a decoration part according to the preferred embodiment No. 6 of the present invention;
FIG. 21 is a plane cross-sectional view illustrating a door of a drum washing machine according to the preferred embodiment No. 7 of the present invention;
FIG. 22 is a flow chart illustrating the manufacturing method of a door having a decoration part according to the preferred embodiment No. 7 of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
Hereinafter, preferred embodiments of a washing machine and the manufacturing method according to the present invention will be explained.
FIG. 4 is a perspective view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 1 of the present invention; FIG. 5 is a plane cross-sectional view according to the line B-B direction of FIG. 4 ; FIG. 6 is a perspective view illustrating a door of a drum washing machine according to the preferred embodiment No. 1 of the present invention; FIG. 7 is a disassembled perspective view illustrating a door and a door ring of a drum washing machine according to the preferred embodiment No. 1 of the present invention;
As illustrated on FIG. 4 to 7 , a drum washing machine according to the preferred embodiment is composed as including: a ring-shaped door frame ( 70 ) which is installed to be rotated on a cabinet cover ( 62 ) that a laundry entrance ( 64 ) is formed; a door hinge ( 80 ) that each of either ends are installed on a door frame ( 70 ) and a cabinet cover ( 62 ), and supporting a door frame ( 70 ) to be rotated; a door glass ( 90 ) installed on the opened center hole ( 70 A) of a door frame ( 70 ) so as to look at the inner situation of a drum; a front element ( 100 ) installed on the front surface of a door frame ( 70 ), and have a seat structure to intermediate the strength of a door ( 60 ).
A door frame ( 70 ) is composed of: a front door frame ( 72 ) placed on the front and has a handle ( 76 ) on an aspect; a rear door frame ( 74 ) installed on the rear surface of a front door fame ( 72 ), one of the ends of the door hinge ( 80 ) is placed.
A hook ( 77 ) is formed protruded on an aspect on the rear surface of a rear door frame ( 74 ); a hook hole ( 78 ) to be united with a hook ( 77 ) is formed on a cabinet cover ( 62 ); a door ( 60 ) is fixed on the state that a laundry entrance ( 64 ) is closed as a hook ( 77 ) is fixed as being inserted on a hook hole ( 78 ).
It is accurate that a front door frame ( 72 ) and a rear door frame ( 74 ) are formed with the plastic texture which is light and the injection performance is excellent.
On a glass ( 90 ), an edge part is placed between a front door frame ( 72 ) and a rear door frame ( 74 ), and an opened center hole ( 70 A) of a door frame ( 70 ) is closed according to a front door frame ( 72 ) is united with a rear door frame ( 74 ).
On the other hand, a decoration part (D) is formed to give the front a high-classic textured sense on a front element; on this preferred embodiment, a decoration part (D) is formed as a lattice patterned as illustrated on FIG. 5 to 6 . A front element ( 100 ) is installed as inserted on a install groove ( 92 ) which is formed on the front part of a door frame ( 70 ).
A install groove ( 92 ) is formed that a front element ( 100 ) is placed as being inserted on the front surface of a door frame ( 72 ), and a install groove ( 92 ) is formed as a ring shape along a front door frame.
A front element is a ring-shaped panel formed of the stainless steel texture which is thin, the strength, external aspect, corrosion resistance are excellent, and a decoration part (D) is formed to express a high classic textured sense and prevent the glaring. a front element is directly cut out from a stainless steel plate as a complete ring shape, or can be united each other after cut out as several divided shape.
Especially, a decoration part (D) is composed as a reflection and irreflection patterns are continually placed, and the reflection/irreflection patterns are possible as forming an irreflection pattern as a relief pattern by an etching process.
That is, an irreflection pattern is relatively formed as a relief pattern that the roughness is higher, and a reflection pattern is a surface which is not etched, and relatively formed as an intaglio form which is smooth and the roughness is low.
A decoration part is formed with a lattice pattern structure that a quadrilateral or rhombus forms are continually placed.
For sure, on this preferred embodiment, forming a reflection pattern is formed on the intaglio part and a irreflection pattern is formed on the relief part is illustrated, but conversely, a irreflection pattern can be formed on the relief part intaglio part and a reflection pattern can be formed on the relief part.
Also, on this preferred embodiment, forming the decoration patterns by an etching method is illustrated, but it isn't limited on this, if it is a method capable of forming an intaglio/relief structure, any of method of the grinding work, photo etching, laser machining and etc. can be used.
A front element ( 100 ) that a decoration part (D) is formed is placed with a method which is forcibly inserted on a install groove ( 92 ) of a door frame ( 72 ). Therefore, a front element is produced as a size that the forcible insertion on a install groove ( 92 ) is possible.
Also, a front element ( 100 ) is fixed on a by an adhesion element on a install groove ( 92 ) of a door front frame ( 72 ).
An adhesion element that an adhesion agent and a both-faced tape are typical is previously placed on the lower part of a install groove ( 92 ) before a front element is pressed in, and fixes a front element ( 100 ) which is inserted on a install groove ( 92 ).
A door ( 60 ) composed as afore-mentioned is reinforced of the strength by a metallic textured front element ( 100 ) as well as having a high classic textured sense by a decoration part (D) having lattice patterns on a front element ( 100 ) and prevented of glaring condition.
A door frame ( 72 ) is composed as being glided with a metallic texture inflict the same color with a front element to improve the external aspect of a door ( 60 ).
On the other hand, as a door ring ( 200 ) is formed as a rounded-ring constitution, placed as protruded not toward the front surface of a cabinet cover ( 62 ), but forward direction of a washing machine along the circumference of a door on a cabinet cover ( 62 ).
A cutting plane of a ring body ( 201 ) forming a door ring ( 200 ) has a semicircled shape to be bulgily protruded.
And on the cabinet cover ( 62 ), several install hole ( 63 ) are formed with a certain interval along the circumference of a door ( 60 ) that a door ring ( 200 ) can be installed, and on a door ring ( 200 ), several of hook structured union part ( 205 ) are formed each of a certain interval on the behind part of a ring body ( 201 ) to be united as being inserted on a install hole ( 63 ).
Accordingly, a door ring ( 200 ) is installed as a union part ( 205 ) is inserted on a install hole of a cabinet cover ( 62 ) and fixed on a cabinet cover ( 62 ).
It is suitable for a door ring ( 200 ) to be manufactured with an injection like synthetic resin etc. and a gliding layer ( 203 ) is formed on the surface.
On a door ring ( 200 ), manufacturing a ring body ( 201 ) and a union part ( 205 ) with same material is possible, and a mutual bonding or an assembling after manufacturing each in accordance with requirements.
Also, on a gliding layer, it is possible to compose with the same color or the contrasted color etc. as selecting variously with a decoration part (D) of a cabinet cover ( 62 ) or a door ( 60 ).
If a door ring ( 200 ) is installed around a door ( 60 ), with a decoration part (D), a door and a fine view of a door and the circumference, so it contributes to improve the entire external aspect of a washing machine.
Also, On a cabinet cover ( 62 ) formed with a usual iron plate material, as a door ring is additionally installed around a laundry entrance ( 64 ) supporting a quite weight of the load, the enough strength can be definite capable of supporting a door even if the capacity of a washing machine is enlarged.
The reference observing the manufacturing method will now be made in detail to the preferred embodiment No. 1.
FIG. 8 is a flow chart illustrating the manufacturing method of a front element used on a door of a drum washing machine according to the preferred embodiment No. 1 of the present invention, and FIG. 9 is a drawing illustrated orderly the manufacturing method of a front element used on a door of a drum washing.
First of all, cut out a ring-shaped front element ( 100 ) from a stainless steel plate body ( 102 ).
After that, to form a decoration part (D) on the surface of afore-mentioned front element, continually form the reflection/irreflection or intaglio/relief patterns through the etching process.
On a front element ( 100 ) formed the decoration part (D), install groove ( 92 ) of the front door frame ( 72 ) is dimensional processed to fit compulsorily, a both-faced adhesion tape ( 94 ) is arranged on the lower part of a install groove ( 92 ) of a door frame.
That is, as a front element ( 100 ) is inserted on a install groove ( 92 ), a front element ( 100 ) is fixed as pressed in on a install groove ( 92 ) as well as the rear surface of a front element ( 100 ) is adhesion fixed on the lower part of a install groove ( 92 ) by a both-faced adhesion tape, Therefore, a front element ( 100 ) is easily installed with a simple action like inserting on a install groove ( 92 ) of a door frame ( 70 ).
If a front element ( 100 ) is placed as inserted on a install groove of a door frame ( 70 ), the strength of a door frame is reinforced by a stainless steel textured front element ( 100 ).
Therefore, even if the load of a door glass ( 90 ) is increased as a size of a door ( 60 ) is enlarged according to the large-sized trend of washing machine, a door glass ( 90 ) is supported stably as the strength of a door frame is reinforced.
On the other hand, as illustrated on FIG. 8 to 9 , as observing more concretely the manufacturing method of a front element ( 100 ), several of front element piece( 100 A) are cut out from a stainless steel plate body ( 102 ) to manufacture front elements ( 100 ) on the cutting out procession. (S 1 )
A stainless steel plate body ( 102 ) is a plane plate member having a certain extent, and a front element piece ( 100 A) is cut out by press working.
And, the several front member pieces ( 100 A) are formed as a circular arc form of the same angles, a complete ring-shaped front element ( 100 ) is formed as a certain numbers of front element pieces ( 100 A) are united.
That is, a front element piece ( 70 A) is a divided form in the same angle along the column direction, the several pieces are identically formed as a circular arc of a certain angle.
On the welding process, a ring-shaped front element ( 100 ) is formed as joining a front element piece ( 100 A) which is cut out on the cutting process by welding. (S 2 )
At this time, the both ends of the several front element pieces ( 100 A) are connected each other by welding.
On the elaboration process, give the final polish as grinding the welded part of a front element ( 100 ) which is completed on the welding process. (S 3 )
Therefore, the front surface of a front element ( 100 ) is processed smoothly, so the discolored by the welding part is restored back as well.
On the texture forming process, on the front surface of a front element ( 100 ) which is smoothed on the final polish process, a decoration part (D) is formed having the lattice patterns by the method of etching processing afore-mentioned. (S 4 )
Therefore, the afore-mentioned manufacturing method of a front element ( 100 ), compare with the method that a front element ( 100 ) is cut as a ring shape directly from a stainless steel plate body ( 102 ) is prevented losing unnecessary material of a stainless steel plate body ( 102 ).
On the other hand, a front element ( 100 ) formed a decoration part (D) through the afore-mentioned process is united as adhere on a door frame ( 70 ) using a adhesion element ( 94 ) as shown on FIG. 7 .
FIG. 10 is a plane cross-sectional view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 2 of the present invention.
For reference, the same reference numbers are given for the same or similar composition elements with the composition of the preferred embodiment NO. 1 and the detailed descriptions are omitted.
On a washing machine according to the preferred embodiment No. 2 of the present invention, as illustrated on FIG. 10 , a door ring ( 210 ) is installed on the front surface of a cabinet cover ( 62 ), and other compositions are the same and similar with the compositions of the afore-mentioned preferred embodiment No. 1.
A door ring ( 210 ) is installed along the outside girth of a door as the afore-mentioned preferred embodiment No. 1, but on the present embodiment, installed as a form which is attached on a cabinet cover ( 62 ) by an adhesion element ( 215 ).
And a gliding layer that a metallic material is glided is formed on the surface of a ring body ( 211 ) of a door ring ( 210 ).
Because a door ring ( 210 ) afore-mentioned is installed as being attached on a cabinet cover ( 62 ) using an adhesion element ( 215 ), without separate processing of a cabinet cover ( 62 ) a dooring ( 210 ) is installed on a cabinet cover ( 62 ) easily, so the external fine view is improved as well as the strength of the structures around a door is reinforced.
FIG. 11 is a plane cross-sectional view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 3 of the present invention.
The same reference numbers are given for the same or similar composition elements with the composition of the preferred embodiment NO. 1 and the detailed descriptions are omitted.
As illustrated on FIG. 11 , a drum washing machine according to the preferred embodiment No. 3 of the present invention, a door ring ( 220 ) is formed as one body on a cabinet cover ( 62 ), and other compositions are the same and similar with the compositions of the afore-mentioned preferred embodiment No. 1.
That is, on a cabinet cover ( 62 ), a door ring ( 220 ) which is bulgily protruded as a rib or a bead shapes is formed as bended.
For sure, on the external surface of a door ring ( 220 ) a gliding layer ( 223 ) can be formed with the metallic material etc.
On a drum washing machine of the present preferred embodiment, as a door ring ( 220 ) is directly formed on a cabinet cover ( 62 ), improving the external aspect of a door and the circumference, and reinforcing the strength around a door without attaching any special structures.
FIG. 12 is a plane cross-sectional view illustrating a drum washing machine having a door ring according to the preferred embodiment No. 4 of the present invention, and FIG. 13 is a plane cross-sectional view according to the line C-C direction of FIG. 12 .
The same reference numbers are given for the same or similar composition elements with the composition of the preferred embodiment NO. 1 and the detailed descriptions are omitted.
As illustrated on FIG. 12 to 13 , a drum washing machine according to the preferred embodiment No. 4 of the present invention, a decoration part (D) isn't formed on a door frame ( 70 ) of a door ( 60 ), a door ring is installed on a cabinet cover ( 62 ) around a door ( 60 ), and other compositions are the same and similar with the compositions of the afore-mentioned preferred embodiment No. 1.
That is, a door is composed of: a front door frame ( 72 ); rear door frame ( 74 ); a door glass ( 90 ) constructed between the door frame ( 70 ); on a cabinet cover ( 62 ) formed a door ( 60 ), the door ring ( 200 ) with the afore-mentioned preferred embodiment No. 1.
A door ring ( 200 ), a ring body ( 201 ) and a union part ( 205 ) protruded to the behind direction, is placed as inserted on a install hole ( 63 ) of a cabinet cover ( 62 ).
For sure, it is possible for a door ring ( 200 ) to be attached using a adhesion element as the afore-mentioned preferred embodiment No. 2 and be composed as one body on a cabinet cover ( 62 ) as the afore-mentioned preferred embodiment No. 3.
The external fine view is improved as well as the strength of the structures around a door is reinforced as a door ring ( 200 ) is installed around a door on the present preferred embodiment.
C-C direction of FIG. 12 ;
FIG. 14 is a plane cross-sectional view illustrating a major part of a door of a drum washing machine according to the preferred embodiment No. 5 of the present invention, FIG. 15 is a disassembled perspective view of a door not showing some parts of a drum washing machine according to the preferred embodiment No. 5 of the present invention, and FIG. 16 and FIG. 17 are plane diagrams illustrating an afore state of a front element bended and a superior surface of a door that a front element is operated according to the preferred embodiment No. 5 of the present invention.
For reference, the same reference numbers are given for the same or similar composition elements with the composition of the preferred embodiment NO. 1 and the detailed descriptions are omitted.
As illustrated on FIG. 14 to 17 , a drum washing machine
according to the preferred embodiment No. 5 of the present invention is including: a door that a front element is fixed on a install groove ( 92 ) which is formed on a door frame ( 70 ) by a joint element as well as the patterns on the surface of a front element of a decoration part (D) are formed differently each other, and other compositions are the same and similar with the compositions of the afore-mentioned preferred embodiment No. 1.
The patterns of a decoration part (D) is a structure that several round-shaped patterns are continually formed. The patterns like this are possible as forming the round-shaped pattern to be intaglioed through the etching method.
For sure, rest of the parts which isn't formed as round-shaped, are formed as embossed, and formed smoother surface relatively than the intagioed part.
Next, a joint element ( 112 ) is comprising: a hitch projection ( 114 ) formed on a install groove ( 92 ), a hich hole ( 116 ) formed on a front element ( 110 ), that a hitch projection ( 114 ) is hitched as being inserted.
A hitch hole ( 116 ) is formed on each of the edge parts ( 100 a , 110 b ) of the external aspect and the inner aspect of a front element ( 110 ), and the external edge part ( 110 a ) and inner edge part ( 110 b ) of a front element ( 110 ) are bended toward the lower direction to be adhered on each of the inner aspect part and the external aspect part of a install groove ( 92 ).
Therefore, if a front element ( 110 ) is inserted on a install groove ( 92 ), a front element ( 110 ) is fixed as hitch projection ( 114 ) is fixed as inserted hitched on a hitch hole ( 116 ).
At this time, a front element ( 110 ) is formed as a “U” like section which opened toward the lower direction, a install groove ( 92 ) is formed on the inner side as a “U” like section that an unevenness is formed opposed with a front element. Therefore, a front element ( 110 ) is stably and safely reached on the inner part of a install groove ( 92 ).
On a hitch projection ( 114 ), as an inclination part is formed toward the inserting direction of a front element ( 110 ), a front element is easily inserted on a install groove ( 92 ), on the other side, an inclination part isn't formed toward to the removing direction of a front element, the breaking away of a front element ( 110 ) from a install groove ( 92 ) is prevented.
A hitch hole ( 116 ) and a hitch projection ( 114 ) formed as afore-mentioned are formed as confronted each other, and several pieces are formed as isolatedly with a certain interval along the column direction a front element ( 110 ) and a install groove ( 92 ).
Reference on the manufacturing method of a door of a drum washing machine will now be made in detail to the preferred embodiment No. 5 of the present invention.
Firstly, a ring-shaped front element ( 110 ) is cut as a fixed size from a stainless steel plate body ( 102 ), a decoration part (D) is formed as continually forming the round-shaped structure through the method of etching and etc. on the front surface.
In addition, a front element is formed as the inner aspect edge part ( 110 a ) and external aspect edge part ( 110 b ) are extended, several pieces of hitch hole ( 116 ) is formed toward the column direction as isolated with a certain interval on the inner aspect edge part ( 110 a ) and external aspect edge part ( 110 b ).
The edge parts ( 110 a , 110 b ) of a front element ( 110 ) formed a hitch hole ( 116 ) is bended toward the lower direction that a decoration part (D) isn't formed so as to be adhere closely on the inner aspect part and the external aspect part of a install groove ( 92 ) when a front element ( 110 ) is placed on a install groove ( 92 ) of a door frame.
That is, if a front element ( 110 ) is inserted on a install groove ( 92 ) of a door frame ( 70 ), the bended part of a front element ( 110 ) is adhere closely on the either aspect, a hitch projection ( 114 ) which is formed on a install groove ( 92 ) is hitched as being inserted on the hitch hole ( 116 ).
At this time, a hitch hole ( 116 ) and a hitch projection ( 114 ) formed as afore-mentioned are formed as confronted each other, and several pieces are formed as isolatedly with a certain interval along the column direction a front element ( 110 ) and a install groove ( 92 ).
Therefore, a front element ( 110 ) bends the edge parts ( 110 a , 110 b ) after forming a decoration part (D) and a hitch hole ( 116 ), after that, with a method fixing a door frame ( 70 ) into a install groove ( 92 ), simply installed.
On the other hand, As other manufacturing method of a door is the same as afore-mentioned preferred embodiment No. 1, the detailed explanations are omitted.
FIG. 18 is a plane cross-sectional view illustrating a door of a drum washing machine according to the preferred embodiment No. 6 of the present invention, and FIG. 19 is a plane diagram illustrating the inner side of a mold for molding a door frame according to the preferred embodiment No. 6 of the present invention.
For reference, the same reference numbers are given for the same or similar composition elements with the composition of the preferred embodiment No. 1 and the detailed descriptions are omitted.
As illustrated on FIG. 18 to 19 , a drum washing machine according to the preferred embodiment No. 6 of the present invention, on the front surface of a door frame ( 70 ) a decoration part (D) is directly formed, and including a door formed a metallic textured gliding layer ( 122 ) on the surface a decoration part (D), and other compositions are the same or similar with the afore-mentioned preferred embodiment No. 1.
A decoration part (D) is formed as one body at the same time on a rear door frame ( 72 ) during the injection molding of a front door frame ( 72 ), and a lattice form continued by relief and intaglio forms on the surface of a front door frame ( 72 ).
That is, on the injection molding ( 124 ) of a front door frame ( 72 ), as illustrated on FIG.19 , a decoration model (D′) is formed on a cavity ( 124 A) which is forming the front surface of a front door frame, as a front door frame ( 72 ) is injection molded with an injection mold ( 124 ), a decoration part is formed as a confronted form with the decoration model (D′) of an injection mold on the front part of a front door frame ( 72 ).
On a decoration model (D′), a cell unit form is a lattice structure having a trilatral shape as shown on FIG. 19 , and as the same shape as afore-mentioned, reflection/irreflection or relief/intaglio structures are continued.
Also, on a decoration model (D′): it is suitable that the parts irreflection or relief are formed as a trilatral lattice structure is rougher than the parts that reflection or intaglio are formed, and for sure, the opposite structure is possible.
On the surface of a front door frame ( 72 ) that a decoration part is formed, a metallic textured a chromium gliding layer ( 122 ) is formed.
And, a rounded plate form capable of covering the entire external surface is formed above the chromium gliding layer ( 122 ), and a transparent textured protective coating ( 125 ) can be worn.
Reference on the manufacturing method of a door of a drum washing machine will now be made in detail to the preferred embodiment No. 6 of the present invention.
FIG. 20 is a flow chart illustrating the manufacturing method of a door having a decoration part according to the preferred embodiment No. 6 of the present invention.
Firstly, on the texture forming process, a decoration model (D′) having a lattice structure is formed on an injection mold ( 124 ) of a front door frame so as a decoration part (D) to be formed on the front surface of an injection molded front door frame ( 72 ). (S 11 , S 12 )
That is, a decoration model (D′) is formed by an etching process on a cavity ( 124 A) one of the injection molds ( 124 ) of a door frame ( 72 ). Usually for a corrision management method, a photo etching technic is used to form a decoration model (D′), on a cavity ( 124 A) of a injection mold ( 124 ).
On the injection process, a front door frame ( 72 ) is injection molded as using an injection mold formed a decoration model on the texture forming process (S 13 ).
Therefore, a front door frame is injection molded from an injection mold ( 124 ) in a condition that a decoration part (D) having a latticed structure on the front surface is completed in one body. The major material of a door frame ( 70 ) is a plastic material that the special injection quality is excellent, the weight is low, and which is having a certain level of strength.
On the gliding process, a metallic gliding which inflicts the more of a high classic sense is completed on the external aspect of a door frame which is injected on the injection process. (S 14 , S 15 )
As the gliding material, chromium that a fine sense and inner abrasion quality are superior is broadly used. A luster of metallic quality is polished by the chromium gliding layer ( 122 ) as the front door frame ( 72 ), inflicts a high classic textured sense compared with a plastic surface.
Therefore, a door ( 60 ) of a drum washing machine forms a decoration part (D) on the surface of a door frame ( 70 ), and a chromium is glided on the decoration part (D), so the external aspect of a door ( 60 ) becomes high-classic.
After that, after coating the protection film ( 125 ) on a decoration part (D) of a door frame ( 72 ) which is manufactured as afore-mentioned, a door ( 60 ) is completed as assembling a door glass ( 90 ) on a center hole ( 70 A) of a door frame ( 72 ). (S 16 ) FIG. 21 is a plane cross-sectional view illustrating a door of a drum washing machine according to the preferred embodiment No. 7 of the present invention.
For reference, the same reference numbers are given for the same or similar composition elements with the composition of the preferred embodiment NO. 1 and the detailed descriptions are omitted.
As illustrated on FIG. 21 , a drum washing machine
according to the preferred embodiment No. 7 of the present invention including: a metallic gliding layer formed on the front surface of a door frame ( 70 ), a door directly formed a decoration part (D) on the metallic gliding layer ( 132 ), and other compositions are the same or similar with the afore-mentioned preferred embodiment No. 1.
A gliding layer ( 132 ) with metallic material like chromium is formed on a front door frame ( 72 ), and a decoration part is formed on the gliding layer ( 132 ).
A decoration part (D) is formed an intaglio/relief structure by the corrosion management method through the photo etching or a laser processing method on the chromium gliding layer ( 132 ), it is suitable for the relief part to have a irreflected surface.
If a door frame ( 72 ) is formed on the surface of a decoration part (D), a protection coating ( 136 ) is worn to protect a decoration part (D).
A protection film is formed as a transparent texture capable of showing a decoration part (D), the color and polish can be controlled according to a user's taste and trends.
Reference on the manufacturing method of a door of a drum washing machine will now be made in detail to the preferred embodiment No. 7 of the present invention.
FIG. 22 is a flow chart illustrating the manufacturing method of a door having a decoration part according to the preferred embodiment No. 7 of the present invention.
Firstly, as injection molded with a metallic texture on a door frame ( 70 ) which is injected with a plastic texture on the gliding process, raise the sense of quality of a door. (S 21 , S 22 ) That is, on the door ( 60 ), glide on a front door frame ( 72 ) among the door frames ( 90 ) with a metallic texture so as no to decrease the fine view by the plastic textured sense of a door frame ( 70 ).
For the. gliding material, chromium which gives the consumers the high classic textured sense, and that the abrasion quality is superior, chromium is used typically.
On the texture forming process, as forming a decoration part (D) continued with intaglio and relief structures by etching or I on the front part of a glided front door frame on the gliding process ( 72 ) (S 23 , S 24 ).
By the processed decoration part (D), the front external aspect of a door ( 60 ) capable of having a high classic texture and preventing the glaring, so the marketability of a drum washing machine is improved.
On the coating procession, a protecting coating ( 136 ) is worn on the front surface of the decoration part (D) of the front door frame ( 72 ) on the texture forming process to prevent etching and damages.
The natural gift sense and hardness of the chromium used for gliding of a front door frame ( 72 ) are excellent, but the adhesion property on the surface of plastic is low, usually, after gliding copper on the surface of the front door frame ( 72 ), glide chromium on the copper gliding layer ( 134 ).
That is, as gliding copper which is relatively glided well on the plastic texture of a front door frame ( 72 ), after forming a copper gliding layer ( 134 ), forming a chromium gliding layer as gliding chromium on the surface of a copper gliding layer ( 134 ).
At this time, if process to form a decoration part (D) on the texture forming process, as the chromium layer is worn off, a part of copper gliding layer ( 134 ) is bared out of exterior. As copper is different to chromium, a metal which is corroded well, the corrosion which is progressed on the bared copper gliding layer ( 134 ), on the contrary, decrease the external aspect of a door ( 60 ).
Therefore, to prevent the corrosion condition, the corrosion resistance protecting coating ( 136 ) is covered on the front surface of a front door frame ( 72 ) a decoration part is formed.
Also, the corrosion resistance protecting coating ( 136 ) prevents the situation that a decoration part (D) is injured or damaged by the exterior impact, make the surface of the continued by the intaglio and relief which could be rough smooth.
On the other hand, as a corrosion resistance protecting coating ( 136 ) is composed of a transparent texture, the high classic sense of a door ( 60 ) in order to the gliding of chromium and form of a decoration part (D) is visually transmitted to the consumers.
As the color and the luster of a corrosion resistance protecting coating ( 136 ) can be controlled according to the materials and the coating method, giving the proper texture quality on the front surface of a door frame ( 70 ) according to the necessity.
On the other hand, the manufacturing method of a washing machine and a door of a washing machine in accordance with the present invention are explained as referring to the illustrated figures, the present invention isn't limited to the preferred embodiment, the various transformation is surely possible on the extent of the technique abstraction of the invention.
That is, a composition of the external surface of a door ring of the present invention that a gliding layer is formed is illustrated, but according to the preferred condition, coating with a transparent material can be possible, and forming the various reflection/irrefletion or intaglio/relief patterns is possible.
Also, on the afore-mentioned preferred embodiment, the patterns on a decoration part isn't limited to trilateral shape, quadrilatral shape, lattice shape, round shape, reflection/irrefletion or intaglio/relief structures can be realized according to the preferred condition.
As afore-referenced, the manufacturing method of a washing machine and a door of a washing machine in accordance with the present invention is: as a front member is installed on the front surface of a door frame, without composing the entire door frame as metallic material or special material, reinforcing the entire strength is possible. Also, as the strength of a front member is reinforced as being installed on a door frame, a door glass having a heavy weight as enlarged is supported stably by a door frame.
Also, as a decoration part is formed on a front member of a door frame or directly formed on a door frame, a fine view of a door is improved.
Also, as a decoration part is formed of a reflection/ irrefletion or intaglio/relief structure, and as the glaring condition is prevented as the light is diffused reflected, a user's inconvenience is decreased.
Also, the fine view of a decoration part of a door is improved, and as the image of a product becomes high classic, the consumer's esthetical desire is satisfied, and the marketability of the washing machine is improved.
Also, a door ring is placed on a cabinet around a door of a washing machine of the present invention, reinforcing the strength of the structures around a door as well as improving the fine view of a front surface of a washing machine.
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A washing machine and a method of manufacturing a door thereof are provided. The washing machine may include a door rotatably coupled to a cabinet, and a door ring positioned on the cabinet at an external circumference of the door to reinforce a rigidity of the cabinet and to improve an external appearance of the washing machine.
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TECHNICAL FIELD
Embodiments of the present disclosure relate, in general, to aluminum coated articles and to a process for applying an aluminum coating to a substrate.
BACKGROUND
In the semiconductor industry, devices are fabricated by a number of manufacturing processes producing structures of an ever-decreasing size. Some manufacturing processes may generate particles, which frequently contaminate the substrate that is being processed, contributing to device defects. As device geometries shrink, susceptibility to defects increases, and particle contaminant requirements become more stringent. Accordingly, as device geometries shrink, allowable levels of particle contamination may be reduced.
SUMMARY
In one embodiment, an aluminum coating is formed on an article, and the aluminum coating is anodized to form an anodization layer. The anodization layer can have a thickness in a range between 40% to 60% of the thickness of the aluminum coating. The anodization layer can also have a thickness up to 2 to 3 times the thickness of the aluminum coating.
In one embodiment, the aluminum is a high purity aluminum. The aluminum coating may have a thickness in a range from about 0.8 mils to about 4 mils. The anodization layer may have a thickness in a range from about 0.4 to about 4 microns. In one embodiment, a surface roughness of the anodization layer is about 40 micro-inch.
In one embodiment, the article can include at least one of aluminum, copper, magnesium, an aluminum alloy (e.g., Al6061), or a ceramic material.
In one embodiment, the aluminum coating is formed by electroplating. About half of the anodization layer can be formed from conversion of the aluminum coating during anodization.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that different references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
FIG. 1 illustrates an exemplary architecture of a manufacturing system, in accordance with one embodiment of the present invention.
FIG. 2 illustrates a process for electroplating a conductive article with aluminum, in accordance with one embodiment of the present invention.
FIG. 3 illustrates a process for anodizing an aluminum coated conductive article, in accordance with one embodiment of the present invention.
FIG. 4 illustrates a process for manufacturing an aluminum coated conductive article, in accordance with one embodiment of the present invention.
FIG. 5 illustrates a cross-sectional view of one embodiment of an aluminum coating on a conductive article.
FIG. 6 illustrates a cross-sectional view of one embodiment of an aluminum coating and an anodization layer on a conductive article.
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiments of the disclosure are directed to a process for coating an article (e.g., for use in semiconductor manufacturing) with an aluminum coating, and to an article created using such a coating process. In one embodiment, the article is coated, and then at least a portion of the coating is anodized. For example, the article may be a showerhead, a cathode sleeve, a sleeve liner door, a cathode base, a chamber liner, an electrostatic chuck base, etc. of a chamber for processing equipment such as an etcher, a cleaner, a furnace, and so forth. In one embodiment, the chamber is for a plasma etcher or plasma cleaner. In one embodiment, these articles can be formed of an aluminum alloy (e.g., Al 6061), another alloy, a metal, a metal oxide, a ceramic, or any other suitable material. The article may be a conductive article (e.g., an aluminum alloy) or a non-conductive or insulating article (e.g., a ceramic).
Parameters for the anodization may be optimized to reduce particle contamination from the article. Performance properties of the aluminum coated article may include a relatively long lifespan, and a low on-wafer particle and metal contamination.
Embodiments described herein with reference to aluminum coated conductive articles may cause reduced particle contamination and on wafer metal contamination when used in a process chamber for plasma rich processes. However, it should be understood that the aluminum coated articles discussed herein may also provide reduced particle contamination when used in process chambers for other processes such as non-plasma etchers, non-plasma cleaners, chemical vapor deposition (CVD) chamber, physical vapor deposition (PVD) chamber, and so forth.
When the terms “about” and “approximately” are used herein, these are intended to mean that the nominal value presented is precise within ±10%. The articles described herein may be other structures that are exposed to plasma.
FIG. 1 illustrates an exemplary architecture of a manufacturing system 100 . The manufacturing system 100 may be a system for manufacturing an article for use in semiconductor manufacturing. In one embodiment, the manufacturing system 100 includes processing equipment 101 connected to an equipment automation layer 115 . The processing equipment 101 may include one or more wet cleaners 103 , an aluminum coater 104 and/or an anodizer 105 . The manufacturing system 100 may further include one or more computing device 120 connected to the equipment automation layer 115 . In alternative embodiments, the manufacturing system 100 may include more or fewer components. For example, the manufacturing system 100 may include manually operated (e.g., off-line) processing equipment 101 without the equipment automation layer 115 or the computing device 120 .
Wet cleaners 103 are cleaning apparatuses that clean articles (e.g., conductive articles) using a wet clean process. Wet cleaners 103 include wet baths filled with liquids, in which the substrate is immersed to clean the substrate. Wet cleaners 103 may agitate the wet bath using ultrasonic waves during cleaning to improve a cleaning efficacy. This is referred to herein as sonicating the wet bath.
In one embodiment, wet cleaners 103 include a first wet cleaner that cleans the articles using a bath of de-ionized (DI) water and a second wet cleaner that cleans the articles using a bath of acetone. Both wet cleaners 103 may sonicate the baths during cleaning processes. The wet cleaners 103 may clean the article at multiple stages during processing. For example, wet cleaners 103 may clean an article after a substrate has been roughened, after an aluminum coating has been applied to the substrate, after the article has been used in processing, and so forth.
In other embodiments, alternative types of cleaners such as dry cleaners may be used to clean the articles. Dry cleaners may clean articles by applying heat, by applying gas, by applying plasma, and so forth.
Aluminum coater 104 is a system configured to apply an aluminum coating to the surface of the article. In one embodiment, aluminum coater 104 is an electroplating system that plates the aluminum on the article (e.g., a conductive article) by applying an electrical current to the article when the article is immersed in an electroplating bath including aluminum, which will be described in more detail below. Here, surfaces of the article can be coated evenly because the conductive article is immersed in the bath. In alternative embodiments, the aluminum coater 104 may use other techniques to apply the aluminum coating such as physical vapor deposition (PVD), chemical vapor deposition (CVD), twin wire arc spray, ion vapor deposition, sputtering, and coldspray.
In one embodiment, anodizer 105 is a system configured to form an anodization layer on the aluminum coating. For example, the article (e.g., a conductive article) is immersed in an anodization bath, e.g., including sulfuric acid or oxalic acid, and an electrical current is applied to the article such that the article is an anode. The anodization layer then forms on the aluminum coating on the article, which will be discussed in more detail below.
The equipment automation layer 115 may interconnect some or all of the manufacturing machines 101 with computing devices 120 , with other manufacturing machines, with metrology tools and/or other devices. The equipment automation layer 115 may include a network (e.g., a location area network (LAN)), routers, gateways, servers, data stores, and so on. Manufacturing machines 101 may connect to the equipment automation layer 115 via a SEMI Equipment Communications Standard/Generic Equipment Model (SECS/GEM) interface, via an Ethernet interface, and/or via other interfaces. In one embodiment, the equipment automation layer 115 enables process data (e.g., data collected by manufacturing machines 101 during a process run) to be stored in a data store (not shown). In an alternative embodiment, the computing device 120 connects directly to one or more of the manufacturing machines 101 .
In one embodiment, some or all manufacturing machines 101 include a programmable controller that can load, store and execute process recipes. The programmable controller may control temperature settings, gas and/or vacuum settings, time settings, etc. of manufacturing machines 101 . The programmable controller may include a main memory (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM), static random access memory (SRAM), etc.), and/or a secondary memory (e.g., a data storage device such as a disk drive). The main memory and/or secondary memory may store instructions for performing heat treatment processes described herein.
The programmable controller may also include a processing device coupled to the main memory and/or secondary memory (e.g., via a bus) to execute the instructions. The processing device may be a general-purpose processing device such as a microprocessor, central processing unit, or the like. The processing device may also be a special-purpose processing device such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. In one embodiment, programmable controller is a programmable logic controller (PLC).
FIG. 2 illustrates a process for electroplating an article (e.g., a conductive article) with aluminum, in accordance with one embodiment of the present invention. Electroplating may produce an aluminum layer having a purity of 99.99. Electroplating is a process that uses electrical current to reduce dissolved metal cations to form a metal coating on an electrode, e.g, article 203 . The article 203 is the cathode, and an aluminum body 205 (e.g., high purity aluminum) is the anode. Both components are immersed in an aluminum plating bath 201 including an electrolyte solution containing one or more dissolved metal salts as well as other ions that permit the flow of electricity. A current supplier 207 (e.g., a battery or other power supply) supplies a direct current to the article 203 , oxidizing the metal atoms of the aluminum body 205 such that the metal atoms dissolve in the solution. The dissolved metal ions in the electrolyte solution are reduced at the interface between the solution and the article 203 to plate onto the article 203 and form an aluminum plating layer. The aluminum plating is typically smooth. For example, the aluminum plating may have a surface roughness (Ra) of about 20 micro-inch to about 200 micro-inch.
In one embodiment, the aluminum plating layer thickness is optimized for both cost savings and adequate thickness for anodization. Half of thickness of the anodization layer may be based on consumption of the thickness of the aluminum plating layer. In one embodiment, the anodization layer consumes all of the aluminum layer. Thus, the thickness of the aluminum layer may be half of the target thickness of the anodization layer. In another embodiment, the aluminum plating layer may be formed to have a thickness that is twice that of the desired thickness of the anodization layer. Other thicknesses of the aluminum plating layer may also be used. In one embodiment, the aluminum plating layer has a thickness of 5 mils. In one embodiment, the aluminum plating layer has a thickness in a range from about 0.8 mils to about 4 mils. Note that other aluminum coating processes other than electroplating may also be used in other embodiments.
FIG. 3 illustrates a process for anodizing an aluminum coated article 303 , according to one embodiment. Note that in some embodiments anodization is not performed. For example, the article 303 can be the article 203 of FIG. 2 . Anodization changes the microscopic texture of the surface of the article 303 . Preceding the anodization process, the article 303 can be cleaned in a nitric acid bath or brightened in a mix of acids, i.e., be subjected to a chemical treatment (e.g., deoxidation) prior to anodization.
The article 303 is immersed in an anodization bath 301 , including an acid solution, along with a cathode body 305 . Examples of cathode bodies that may be used include aluminum alloys such as Al6061 and Al3003 and carbon bodies. The anodization layer is grown on the article 303 by passing a current through an electrolytic solution via a current supplier 307 (e.g., a battery or other power supply), where the article is the anode (the positive electrode). The current releases hydrogen at the cathode body, e.g., the negative electrode, and oxygen at the surface of the article 303 to form aluminium oxide. In one embodiment, the voltage that enables anodization using various solutions may range from 1 to 300 V, in one embodiment, or from 15 to 21 V, in another embodiment. The anodizing current varies with the area of the aluminium body 305 anodized, and can range from 30 to 300 amperes/meter 2 (2.8 to 28 ampere/ft 2 ).
The acid solution dissolves (i.e., consumes or converts) a surface of the article (e.g., the aluminum coating) to form a coating of columnar nanopores, and the anodization layer continues growing from this coating of nanopores. The columnar nanopores may be 10 to 150 nm in diameter. The acid solution can be oxalic acid, sulfuric acid, or a combination of oxalic acid and sulfuric acid. For oxalic acid, the ratio of consumption of the article to anodization layer growth is about 1:1. For sulfuric acid, the ratio of consumption of the article to anodization layer growth is about 2:1. Electrolyte concentration, acidity, solution temperature, and current are controlled to forma consistent aluminum oxide anodization layer. In one embodiment, the anodization layer can have a thickness of up to 4 mils. In one embodiment, the anodization layer has a minimum thickness of 0.4 mils. In one embodiment, the anodization layer has a thickness in a range between 40% to 60% of the thickness of the aluminum coating. In one embodiment, the anodization layer has a thickness in a range between 30% to 70% of the thickness of the aluminum coating, though the anodization layer can have thicknesses that are other percentages of the aluminum coating. In one embodiment, all of the aluminum layer is anodized. Accordingly, the anodization layer may have a thickness that is twice the thickness of the aluminum coating (for anodization performed using oxalic acid) or that is approximately 1.5 times the thickness of the aluminum coating (for anodization performed using sulfuric acid).
In one example, if oxalic acid is used to perform the anodization, the aluminum coating is initially 4 mils thick, the resulting anodization layer may be 4 mils thick, and a resulting aluminum coating after the anodization may be 2 mils thick. In another example, if sulfuric acid is used to perform the anodization, the aluminum coating is initially 4 mils thick, the resulting anodization layer may be 3 mils thick, and a resulting aluminum coating after the anodization may be 2 mils thick. In one embodiment, a thicker aluminum coating is used if sulfuric acid is to be used for the anodization.
In one embodiment, the current density is initially high to grow a very dense barrier layer portion of the anodization layer, and then current density is reduced to grow a porous columnar layer portion of the anodization layer. In one embodiment where oxalic acid is used to form the anodization layer, the porosity is in a range from about 40% to about 50%, and the pores have a diameter in a range from about 20 nm to about 30 nm. In one embodiment where sulfuric acid is used to form the anodization layer, the porosity can be up to about 70%.
In one embodiment, the surface roughness (Ra) of the anodization layer is about 40 micro-inch, which is similar to the roughness of the article. In one embodiment, the surface roughness increases 20-30% after anodizing with sulfuric acid.
In one embodiment, the aluminum coating is about 100% anodized. In one embodiment, the aluminum coating is not anodized.
Table A shows the results of laser ablation inductively coupled plasma mass spectrometry (ICPMS) used to detect metallic impurities in an Al6061 article, an anodized Al6061 article, an aluminum coating including an aluminum plating layer on an Al6061 article, and an anodized aluminum coating including an aluminum plating layer on an Al6061 article. In this example, the aluminum plating layer is applied via electroplating, and the anodization occurs in an oxalic acid bath. The anodized aluminum plating layer on the Al6061 article shows the lowest levels of impurities.
TABLE A
RL
Al
Anodized Al
(detection
Anodized
Plating on
Plating on
Parameter
limit of test)
Units
Al 6061
Al 6061
Al6061
Al6061
Chromium
0.02
ppm
850
1600
1.7
(μg/g)
Copper
0.02
ppm
2500
2800
12
4
(μg/g)
Iron
0.05
ppm
1300
2700
140
26
(μg/g)
Magnesium
0.01
ppm
4200
9700
3.6
1.5
(μg/g)
Manganese
0.01
ppm
210
540
2.9
3.6
(μg/g)
Nickel
0.01
ppm
37
120
12
3
(μg/g)
Titanium
0.01
ppm
190
160
1.2
(μg/g)
Zinc
0.04
ppm
1000
1600
4.8
(μg/g)
FIG. 4 is a flow chart showing a method 400 for manufacturing an aluminum coated article, in accordance with embodiments of the present disclosure. The operations of process 400 may be performed by various manufacturing machines, as set forth in FIG. 1 . The process 400 may be applied to coat aluminum any article.
At block 401 , an article (e.g., an article having at least a conductive portion) is provided. For example, the article can be a conductive article formed of an aluminum alloy (e.g., Al 6061), another alloy, a metal, a metal oxide, or a ceramic. The article can be a shower head, a cathode sleeve, a sleeve liner door, a cathode base, a chamber liner, an electrostatic chuck base, etc., for use in a processing chamber.
At block 403 , the article is prepared for coating, according to one embodiment. The surface of the article may be altered by roughening, smoothing, or cleaning the surface.
At block 405 , the article is coated (e.g., plated) with aluminum. For example, the article can be electroplated with aluminum, as similarly described with respect to FIG. 2 . In other examples, the coating can be applied by physical vapor deposition (PVD), chemical vapor deposition (CVD), twin wire, arc spray, ion vapor deposition, sputtering, and coldspray.
At block 407 , the article with the aluminum coating is cleaned, according to one embodiment. For example, the article can be cleaned by immersing the article in nitric acid to remove surface oxidation.
At block 409 , the article with the aluminum coating is anodized, according to one embodiment. For example, the article can be anodized in a bath of oxalic acid or sulfuric acid, as similarly described with respect to FIG. 3 .
FIG. 5 illustrates a scanning electron micrograph 500 of a cross-sectional view of an Al6061 article 501 with an aluminum coating 503 , applied via electroplating at approximately 1000-fold magnification with a 50 micron scale shown. The thickness of the aluminum plating layer is about 70 microns.
FIG. 6 illustrates a scanning electron micrograph 600 of a cross-sectional view of an Al6061 article 601 with an aluminum coating 603 , applied via electroplating, and an anodization layer 605 , formed in an oxalic acid bath, at about 800-fold magnification with a 20 micron scale shown. The thickness of the aluminum plating layer is about 55 microns, and the thickness of the anodization layer is about 25 microns.
The preceding description sets forth numerous specific details such as examples of specific systems, components, methods, and so forth, in order to provide a good understanding of several embodiments of the present disclosure. It will be apparent to one skilled in the art, however, that at least some embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known components or methods are not described in detail or are presented in simple block diagram format in order to avoid unnecessarily obscuring the present disclosure. Thus, the specific details set forth are merely exemplary. Particular implementations may vary from these exemplary details and still be contemplated to be within the scope of the present disclosure.
Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrase “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. In addition, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.”
Although the operations of the methods herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operation may be performed, at least in part, concurrently with other operations. In another embodiment, instructions or sub-operations of distinct operations may be in an intermittent and/or alternating manner.
It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
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To manufacture a chamber component for a processing chamber, an aluminum coating is formed on an article comprising impurities, the aluminum coating being substantially free from impurities.
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BACKGROUND OF THE INVENTION
The invention relates to a system for deflecting through-the-flowline ("TFL") tools from a main flowline into a selected branch line.
Large multi-well subsea oil and gas production systems are generally associated with a subsea manifold at which their production is commingled in a common main flowline which delivers the accumulated oil and gas production to a surface process facility.
At times it is necessary to undertake downhole maintenance of the wells using TFL tool pumpdown techniques. In such operations a tool designed to perform a specific function, such as replacement of a downhole component, is assembled in an articulated TFL tool string at the surface facility. The tool string is then inserted into a special lubricator at the surface facility and pumped via the main flowline into a selected branch line and the associated well.
Numerous systems have been developed for deflecting TFL tools from a main flowline into a selected branch line. U.S. Pat. Nos. 3,545,489; 3,599,711; 3,664,376; 4,252,149; 4,224,986; 4,291,742 and 4,312,378 and U.K. Patent Nos. 1,321,684 and 2,170,579 disclose permanently installed diverters that are able to deflect a TFL tool into a selected branch line. The disadvantages of these diverters are that they require provisions to facilitate maintenance of the diverter and its actuator and that means for remotely switching the diverter must be provided.
An object of the present invention is to remedy these drawbacks and to provide a system for deflecting TFL tools without permanently installed deflector assemblies such that a simple and cheap flowline system is created which requires a minimum of maintenance.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention there is provided a system for deflecting TFL tools from a main flowline into a selected branch line, comprising a diverter tool which is movable through the flowline and which is equipped with:
a locking mechanism for positioning the diverter tool in the main flowline at a predetermined position near the selected branch line;
a wedge-shaped diverter head for guiding a TFL tool from the main flowline into the selected branch when the diverter tool is positioned at said location; and
means for orienting the diverter head in a predetermined orientation in the main flowline such that a smooth bore is formed from the main flowline into the branch line when the tool is positioned at said location.
In accordance with another aspect of the present invention the system includes a flowline circuit for use with the diverter tool, the circuit comprising:
a main flowline equipped with a lubricator for launching the diverter tool;
a plurality of branch lines that are connected to the main flowline such that at the point of connection each branch line has a predetermined orientation relative to the main flowline; and
a locking profile formed at the inner wall of the main flowline at a predetermined distance from each point of connection, said locking profile being shaped such that it is able to receive the locking mechanism of the diverter tool.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail with reference to the accompanying drawings, in which:
FIG. 1 is a partially sectioned view of a diverter tool and a section of a flowline circuit of a system for deflecting TFL tools according to the invention;
FIG. 2A is a longitudinally split sectional view of a locking mechanism of the diverter tool shown in FIGS. 1 and 2, the upper half of the mechanism being shown in an expanded position, the lower half being shown in a contracted position;
FIG. 2B is a cross-sectional view along line 2B--2B of FIG. 2A of the locking mechanism when seen in the direction of the arrows;
FIG. 2C is a top view of the locking mechanism of FIG. 2A;
FIG. 3 is a longitudinal sectional view of a self-orienting diverter head of the diverter tool shown in FIGS. 1 and 2; and
FIG. 4 is a schematic plan view of a flowline circuit in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is shown a diverter tool 1, which is locked to a locking profile 2 in the main flowline 3 at a location near a first branch line 4. The shown section of the circuit further includes a second branch line 5 and a second locking profile 6 which is arranged in the main flowline at a location near the second branch line 5.
The diverter tool 1 comprises a torpedo-shaped central body 8 to which a segmented locking ring 9 of the locking mechanism is secured. In the situation shown the locking ring 9 is expanded within the locking profile 2 near the first branch line 4 such that any movement of the tool 1 in downstream direction is prevented.
A bidirectional TFL piston assembly 10 is pivotally secured to one end of the central body 8 for enabling pumping the tool 1 up and down through the main flowline 3. A wedge-shaped diverter head 11 is rotatably secured by a ball joint 12 to another end of the central body 1 for creating a smooth bore from the main flowline 3 into one of the branch lines 4, 5 when the tool 1 is locked by the locking ring 9 to one of the locking profiles 2, 6.
In FIG. 1 the plane of the drawing is a vertical plane of cross-section. Thus, the main flowline 3 has at each branch line offtake a substantially horizontal orientation whereas each branch line is upwardly oriented at an acute angle of inclination of about 30 degrees relative to the main flowline 3.
In use the diverter tool 1 is inserted into a lubricator (not shown) at the upstream end of the main flowline 3. The tool 1 is then pumped through this flowline 3 in the direction of the arrow I. A counter mechanism that will be described in more detail with reference to FIGS. 3A-3C counts the amount of branch lines that are being passed by the tool and this mechanism has been programmed such that the locking ring 9 expands within a locking profile 2 adjacent to a selected branch line 4.
The wedge-shaped diverter head 11 has an eccentric center of gravity "G" and is freely rotatable relative to the central body 8 so that the longest side 12 of the wedge lies against the bottom of the main flowline 3 and a smoothly curved frontal surface 13 forms a deflection shoe which deviates subsequently inserted TFL tools that are pumped through the main flowline 3 into the branch line 4 in front of the diverter head 11.
FIGS. 2A-2C show the construction of a suitable counter mechanism for use in the diverter tool according to the invention.
FIG. 2A is a longitudinal sectional view of the central body 8 of the tool. In the upper half of this Figure the split locking ring 9 and one of the cams 22 are shown in an expanded position thereof while in the lower half of this Figure the locking ring 9 and one of the cams 22 are shown in their retracted position.
The central body 8 is equipped with a frusto-conical nose section 20 in which a ball joint (not shown) for connecting the body 8 to the TFL piston assembly is arranged.
The counter mechanism comprises four spring-loaded cams 22 that are connected via a linkage system 24 to a ratcher 25 on a central shaft 26.
Springs 27 push the cams 22 via the linkage system 24 towards an expanded position as shown in the upper half of FIG. 2A. The central shaft 26 is pulled by a tensioned spring 28 towards the nose section 20. The central shaft 26 is replacable and a kit of such shafts, each individually configured to a stop the diverter tool at the offtake of a specific branch line, will be required.
For example, if it required to stop the diverter tool at the seventh branch line a central shaft with a seven tooth ratcher 25 will be selected and mounted in the central body 8. On pumpdown through the main flowline the diverter tool will pass the offtake of the first six branch lines with one or two of the spring loaded cams being released at each offtake to move the central shaft 26 one tooth forward.
It is observed that the teeth of the linkage system 24 can slide over the ratcher in a direction away from the nose section 20 and that the depth of the locking profile 2 (see FIG. 1) near each branch line offtake is insufficient to fully release the cams 22 so that the ratcher is not activated when the cams 22 pass a locking profile. It is furthermore observed that it does not matter how many cams 22 are activated when the tool passes a branch line offtake as the ratcher will only advance by a single tooth in response to release of one or more cams 22 at the offtake.
On passing the seventh branch line offtake the teeth of the linkage system 24 have passed the seventh ratchet tooth of the ratcher 25 and the central shaft 26 is thus released to contract, i.e. to move towards the nose section 20 as shown in the upper half of FIG. 2A. This allows springs 30 to induce a set of four levers 31 to push the split locking ring 9 towards its expanded position. As soon as the locking ring 9 has reached a locking profile 2 it fully expands and blocks any further movement of the diverter tool in downstream direction.
The resulting rise in pumpdown pressure will indicate that the diverter tool has arrived its destination and is stalled inside the main flowline.
As shown in FIGS. 2 and 3 the diverter head 11 is connected to a ball joint 32 at the tail of the central body 8 via a set of connector rings 33, 34 and a connector pin 35. The connector rings 33 and 34 are screwed together such that they encase the ball joint 32 and thus form a universal joint. The connector pin 35 is at one end screwed to the diverter head 11 and passes at another end through a central bore in the connector ring 34.
Rings 37 of a low friction material ensure that the connector pin 35 and associated diverter head 11 can freely rotate relative to the connector rings 33, 34 and the central body 8. The tubular outer surface of the diverter head 11 may also be provided with a coating of a low friction material or with rollers (not shown) to ensure that the eccentric center of gravity G of the diverter head makes it self-orienting such that its longest side 12 always lies against the bottom of the main flowline 3 and its frontal surface 13 has an upward orientation.
FIG. 4 shows schematically a suitable flowline circuit for use with the diverter tool shown in FIGS. 1-3. The circuit comprises a main flowline 40 which is connected at its downstream end to a return flowline 41 by means of a subsea valve 42.
The main flowline 41 is at its upstream end equipped with a lubricator 43 for inserting TFL assemblies into the circuit. The motive power for the toolstring is provided by a pump P connected into the lubricator, and drawing suction from a tank T. The return flowline 41 discharges into the same tank or to a separator train via a back pressure controller C. Interconnecting spools and valves 44 allow the direction of pumping to be reversed.
Four branch lines 51, 52, 53 and 54 are connected to the main flowline 40 such that at the points of connection the main flowline 40 has a substantially horizontal orientation at the seabed whereas the branch lines have an upward inclination. The branch lines 51-54 are each connected to production tubings 61-64 of four oil and/or gas production wells via wellhead valves 65-68, respectively.
The production tubings 61-64 are each at a downhole location connected to a circulation conduit 71-74. These circulation conduits are connected to offtake lines 81-84 via valves 85-88, respectively.
The offtake lines 81-84 are each connected to the return flowline 41. The thus created flowline circuit can be used to produce oil and/or gas from a subsea reservoir via underwater wells. The produced oil or gas is commingled in the main production line 40 via which it is delivered to a surface process facility which is usually mounted on an offshore platform.
If it is required to effect downhole maintenance in the production tubing 63 of the third well then a diverter tool equipped with a three teeth ratcher is inserted into the circuit via the lubricator 43.
Then all the wellhead valves 65-68 and 85-88 are closed and the subsea valve 42 is opened whereupon the diverter tool is pumped through the main flowline 40 by actuating the pump P. Once the diverter tool has passed the third branch line 53 the counter mechanism will actuate the split locking ring to expand into the locking profile (as shown in FIGS. 1 and 3A) adjacent to this branch line and blocks any further movement of the diverter tool in downstream direction through the main flowline 40. The resulting rise in pumpdown pressure will indicate that the diverter tool has arrived its destination.
A TFL tool string is then inserted into the circuit via the lubricator 43 and pumped through the main flowline 40 after the valves 67 and 87 of the third wellhead have been opened and the other wellhead valves and the subsea valve 42 have been closed.
The direction of the arrows indicates the direction of circulation of fluid through the circuit in that situation and as a result of the presence of the diverter tool near the offtake of the third branch line 53 the TFL tool string will be deflected via this branch line 53 into the production tubing 63 of the third well. When the TFL tool has reached its destination inside said production tubing 63 the tool will stall which is monitored at the surface by a resultant rise in pumpdown pressure.
The pumping direction is then reversed by manipulating the valves 44 such that fluid is circulated in a direction opposite to the direction of the arrows as a result of which the TFL tool moves up through the production tubing 63 and returns back to the lubricator 43 via the branch line 53 and the main flowline 40. After retrieval of the TFL tool string from the lubricator 43 the TFL diverter tool is recovered by first closing all the wellhead valves 65-68 and 85-88 and opening the subsea valve 42 and then continuing pumping fluid through the main and return flowlines 40, 41 in a direction opposite to the direction of the arrows.
It is noted that the still expanded locking ring does not block movement of the diverter tool in this direction because, as illustrated in FIG. 2A, the locking ring has a sharp downstream edge 90 and a smooth upstream edge 91. The locking profiles consist of annular grooves which also have each a sharp downstream edge 92 and a smooth upstream edge 93. The smooth upstream edge 91 of the split locking ring 9 and the smooth upstream edges 93 of the locking profiles 2 enable the recovery of the diverter tool in upstream direction through the main flowline while the split locking ring expands in each locking profile and is subsequently pushed back again by the smooth upstream edge 93 of the profile.
After subsequent retrieval of the TFL diverter from the flowline circuit via the lubricator 43 the wellhead valves are opened again and production is resumed.
From the foregoing description it will be apparent that the flowline circuit and diverter tool according to the invention provide a system for deflecting TFL tools towards a desired well of a subsea production system without requiring permanently installed subsea diverter and actuator assemblies so that the amount of active subsea components is reduced to a minimum.
If desired a small diameter bypass conduit may be arranged between each branch line and a location of the main flowline downstream of the associated locking profile. These bypass conduits will induce the diverter tool to slow down at the location of each locking profile while it is pumped in a downstream direction through the main flowline so that a smooth landing of the split locking ring, if expanded, in the locking profile is accomplished.
Numerous other modifications of the diverter tool and flowline circuit shown in the drawing will become apparent to those skilled in the art upon reading of the foregoing description. Accordingly, it is to be clearly understood that the embodiments of the tool and circuit shown in the drawings are exemplary only.
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A system for deflecting through-the-flowline ("TFL") tools from a main flowline into a selected branch line comprises a diverter tool which is movable through the main flowline until it locks itself near a selected branch line. The tool is equipped with a diverter head which orients itself in the main flow line such that smooth bore is formed from the main flowline in the branch line.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/153,585 filed Feb. 18, 2009 (Feb. 18, 2009).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
THE NAMES OR PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
SEQUENCE LISTING
[0004] Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0005] Not applicable.
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] The present invention relates generally to hinge assemblies, and more particularly to hinges for closures, such as doors, windows, hatches, lids, ports, and the like, and also for panels or surface members that pivot in relation to another panel or surface member, such as shelves, awnings, ramps, gates, and the like.
[0008] 2. Discussion of Related Art Including Information Disclosed Under 37 CFR 1.97, 1.98
[0009] Locking hinges and hinge assemblies are known. Exemplary publications teaching such technology include:
[0010] U.S. Pat. No. 5,820,288 to Cole, which teaches an adjustable tool with a locking hinge mechanism. The tool may be moved between a number of selectable positions through the use of a hinge pin, which is splined along its length and holds the portions of the tool together. The hinge pin is movable between an unlocked position and a locked position. In the unlocked position, the tool is adjustable, and in the locked position the tool is fixed in position and ready for use.
[0011] U.S. Pat. No. 4,528,718 to Brockhaus shows a door hinge including a first and a second hinge member each having eyes with a hinge pin inserted through the eyes of the hinge members to connect them operatively together. The hinge pin is mounted so as to be freely rotatable relative to a first eye but secured against axial movement relative thereto. The hinge pin and a second eye are formed with axially extending splines engaged between them, and axially adjacent the splines, the hinge pin is formed with a cylindrical section which engages within a complementary cylindrical recess in the second eye, the cylindrical section having a diameter which is slightly greater than the addendum circle diameter of the splines.
[0012] U.S. Pat. No. 3,448,486 to Wright, teaches a locking hinge with a sliding adjustable pintle for locking cabinets, doors, lids, and the like. The pintle is formed with splines and is adjustable to a locked and unlocked position. In the locked position the splines engage hinge knuckles such that the hinge is prevented from turning. In the open position, the splines are disengaged from the knuckles and the hinge is free to turn.
[0013] The foregoing prior art reflects the current state of the art of which the present inventor is aware. Reference to, and discussion of, this prior art is intended to aid in discharging Applicant's acknowledged duty of candor in disclosing information that may be relevant to the examination of claims to the present invention. However, it is respectfully submitted that none of the above-indicated publications disclose, teach, suggest, show, or otherwise render obvious, either singly or when considered in combination, the invention described and claimed herein.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention is a novel hinge assembly that includes a first hinge member having a leaf and a lower sleeve. The lower sleeve includes an upper cylindrical passage with a first diameter and a lower cylindrical passage axially disposed immediately under the upper cylindrical passage and having a second diameter smaller than that of the upper cylindrical passage. The lower cylindrical passage has an interior wall with either a geometrical shape or surface topography. A second hinge member includes a leaf portion and an upper sleeve, the upper sleeve including an upper female portion and a lower male element extending axially downwardly from the female portion and has an outer diameter sized to fit tightly into the opening of the upper cylindrical passage of the lower sleeve so as to provide a smooth pivotal connection between the first and second hinge members. The male element further includes a lower portion with an interior wall configured substantially identically to that of the interior wall of the lower cylindrical passage of the lower sleeve. A through hole passes through the upper sleeve elements. When the male element of the upper sleeve is inserted into the lower sleeve, the through hole is axially aligned with the upper cylindrical passage and the lower cylindrical passage of the lower sleeve. A hinge pin is inserted into the upper cylindrical passage of the second hinge member and the lower cylindrical passage of the first hinge member. The hinge pin includes an outer surface configured or contoured in such a way to cooperate with the configuration of the interior wall of the lower sleeve. The hinge pin has an elevated unlocked position and a depressed locked position, such that when in the unlocked position no portion of the hinge pin outer surface engages the interior walls to prevent pivotal rotation of the hinge members in relation to one another, and when pushed into the down and locked position, the outer surface of the hinge pin engages the interior walls to prevent the hinge members from rotating in relation to one another.
[0015] The foregoing summary broadly sets out the more important features of the present invention so that the detailed description that follows may be better understood, and so that the present contributions to the art may be better appreciated. There are additional features of the invention that will be described in the detailed description of the preferred embodiments of the invention which will form the subject matter of the claims appended hereto.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] The invention will be better understood and its objects and advantages will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
[0017] FIG. 1 is an upper front perspective view showing the inventive hinge assembly in a fully open and unlocked position;
[0018] FIG. 1A is a top plan view thereof;
[0019] FIG. 2 is an upper front perspective view showing the possible hinge leaves rotation about the hinge pin when in an unlocked position so as to assume a partly closed position;
[0020] FIG. 2A is a top plan view thereof;
[0021] FIG. 3 shows the hinge assembly in a partly closed position and the hinge pin pushed into a locked position to prohibit all hinge leaf rotation;
[0022] FIG. 4 is an exploded upper front perspective view of the hinge of FIGS. 1-3 ;
[0023] FIG. 5 is an exploded front view in elevation showing the upper and lower hinge sleeves in cross section;
[0024] FIG. 6A is a partial cross-sectional front view in elevation taken along section lines 6 A- 6 A showing the hinge in a locked position;
[0025] FIG. 6B is a partial cross-sectional front view in elevation showing the hinge in an unlocked position;
[0026] FIG. 7 is a detailed view taken along section line 7 - 7 of FIG. 6B , showing the spring loaded ball bearing detent used to prevent unwanted migration of the hinge pintle from either the unlocked or locked position;
[0027] FIG. 8 is an upper cross-sectional view showing the splined interior of the lower hinge leaf taken along section line 8 - 8 of FIG. 5 ;
[0028] FIG. 9A shows an alternative configuration or shape for the exterior of the locking element of the hinge sleeve;
[0029] FIG. 9B shows yet another alternative configuration for the locking element of the hinge sleeve;
[0030] FIG. 10 is a cross-sectional side view in elevation showing the upper and lower sleeve portions and hinge pin of a second preferred embodiment of the inventive locking hinge;
[0031] FIG. 11 is a cross-sectional side view in elevation showing the upper and lower sleeve portions and hinge pint of a third preferred embodiment; and
[0032] FIG. 12 is a cross-sectional side view in elevation showing the upper and lower sleeve portions and hinge pint of a fourth preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Referring to FIGS. 1 through 12 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved locking hinge assembly, generally denominated 100 herein. These views collectively show that the inventive hinge assembly includes a first hinge member 110 having a leaf portion 120 and a lower cylindrical sleeve portion (a gudgeon or eye) 130 , which is roughly half the height of the leaf portion in dimension and extends along and is integral with the lower half of the interior edge 140 of the leaf portion. The lower sleeve 130 has an upper cylindrical passage 150 with a first diameter 160 and a lower cylindrical passage 170 axially disposed immediately under the upper cylindrical passage 150 and having a second diameter 180 smaller than that of the upper cylindrical passage. The lower cylindrical passage has an interior wall 190 that is splined ( FIG. 8 ) or otherwise provided with a surface topography, e.g., gear teeth 192 ( FIG. 9A ) or with a cross-sectional shape 194 ( FIG. 9B ) so as to function as a locking element in cooperation with the hinge pin (described fully below).
[0034] The hinge assembly next includes a second hinge member 200 having a leaf portion 210 and an upper sleeve (eye or gudgeon) 220 , the upper sleeve including an upper female portion 230 also comprising roughly half the height of the leaf portion and integral with the upper half of the inner edge 240 of the leaf portion. The upper sleeve further includes a lower male element 250 extending axially downwardly from the female portion and having an outer diameter 260 sized for a tight fit insertion into the opening of the upper cylindrical passage 150 of the lower sleeve 130 in a manner well known in the art so as to provide a smooth pivotal connection between the two hinge members. A lower portion 270 of the male element interior wall 280 is splined 290 or otherwise configured or shaped identically to that of the interior wall 190 of the lower cylindrical passage 170 of the lower sleeve 130 .
[0035] The upper sleeve includes a recess 300 (or countersink) at its upper end 310 and having a first diameter 320 and a cylindrical through hole 330 having a second diameter 340 . When the male element of the upper sleeve is inserted into the lower sleeve 130 , the through hole 330 is axially aligned with the upper cylindrical passage 150 and the lower cylindrical passage 170 of the lower sleeve 130 so as to accommodate insertion of a hinge pin 350 . The hinge pin includes an upper end 360 capped by an upper nut 370 threadably installed on the hinge pin. A helical compression spring 380 is disposed between the underside of the upper nut and the base 390 of the recess 300 in the upper sleeve. A lower nut 400 is threadably installed on the lower end 410 of the hinge pin. The helical compression spring is optional and is needed only when a single leaf hinge is employed, such as in a gate installation. While the spring may be employed to assist in keeping the hinge pin in an elevated (unlocked) position, the detent mechanism described below is sufficient for most applications.
[0036] Next, the outer surface 420 of a lower portion 430 of the hinge pin includes splines, gear teeth, or a shape or geometric cross-sectional configuration 440 that cooperates with the splined interior wall 190 of the lower sleeve 130 to prevent rotation of the hinge pin. It will be seen that when the hinge is pushed up into the unlocked position, no portion of the hinge pin splines engages the splines (or other topography or shape) to prevent pivotal rotation of the hinge.
[0037] The hinge pin further includes at least one, and preferably two, detent mechanisms, comprising first and second ball and spring combinations 450 , 460 , disposed in a through hole 470 drilled through the pin. A single spring may be employed with balls disposed at each end, and the balls are thus biased against the opposing sides of the interior portion of the female portion of the upper sleeve as the hinge pin travels through the upper sleeve. It will be seen that when the hinge pin is pushed down into the unlocked position ( FIG. 6A ) ball and spring combinations disposed in the through hole of the hinge pin cooperates with female portion of the upper sleeve prevent excursion of the hinge upwardly. When the hinge pin is pushed upwardly and out of the locked configuration ( FIG. 6B ), the helical compression spring 380 (if provided) and the ball and spring combinations 450 , 460 work to prevent unwanted drop of the hinge pin back into the locked position. When in the locked position, the splines on the hinge pin engage both the interior wall 190 of the lower cylindrical passage 170 of the lower sleeve 130 and the splines of the male element interior wall 290 such that the hinge members are prevented from pivoting relative to one another.
[0038] In the illustrated exemplary embodiment, the hinge members are shown as conventional butt/mortise door hinges, each having a plurality of holes 480 , 490 , for securing the hinge member to a door and/or door frame, though countless other hinge styles and configurations may incorporate the inventive system disclosed herein.
[0039] Referring next to FIGS. 10-12 , there is shown a second, a third, and a fourth preferred embodiments, respectively, 500 , 600 , 700 , of the novel locking hinge assembly, each providing a slightly different structural relationship of the operative elements of the invention. It will be appreciated that the changes relate principally to the relocation of the cooperative splined elements and the detent mechanism either upwardly or downwardly from the positions shown in the first preferred embodiment. In all other material respects, the inventive apparatus is essentially functionally identical to the above-described first preferred embodiment.
[0040] In each of the second, third, and fourth preferred embodiments, the apparatus includes an upper sleeve portion 510 , 610 , 710 , a lower sleeve portion 520 , 620 , 720 , having a male element 530 , 630 , 730 , and a hinge pin 540 , 640 , 740 with splines 550 , 650 , 750 , disposed around its exterior circumference that engage splines 560 , 660 , 760 disposed on the interior wall of some portion of the lower sleeve when the pin is in the locked position (shown in all three views). The spring detents 570 , 670 , 770 prevent the pin from moving from its locked position. When pushed into the unlocked position, splines 580 , 680 , 780 , at one end of the hinge pin engage splines 590 , 690 , 790 disposed in the upper sleeve portion.
[0041] In relation to known conventional door hinges, the most significant distinguishing features of the inventive locking hinge reside in the effect of removing the hinge pin. In the case of the prior art, the hinges essentially separate when the hinge pin is removed, much to the consternation of any handyman who has tried to remove or hang a door. By contrast, the inventive locking hinge includes a male element that slips into a female element so as to prevent such a separation. Indeed, the combined hinge members provide a fully functional hinge even without the hinge pin installed. The hinge pin provides further stability, but its essential function is not to hold the hinge members together, but to provide a rapid locking/unlocking mechanism.
[0042] The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.
[0043] Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims.
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A door hinge assembly with hinge members having axially aligned cylindrical passages with interior surface shape, and a selectively depressible hinge pin with an exterior shape that matches the interior hinge member passages so as to permit selective locking of the hinge members.
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BACKGROUND OF THE INVENTION
[0001] DE 44 36 397 B4 relates to a device for the aftertreatment of exhaust gases. The device comprises an exhaust gas collecting system, in which a reduction catalytic converter for reducing the levels of NO x constituents in the exhaust gas of the internal combustion engine is arranged. The device furthermore comprises a metering device, comprising an electrically controlled metering valve for the metered introduction of a reducing agent into the flow of exhaust gas supplied to the catalytic converter, depending on a value, which is stored in the map, for the NO x content in the exhaust gas at various operating parameters of the internal combustion engine and of the catalytic converter. The valve for controlling the supply of air is an electrically controlled control valve which is arranged downstream of the outlet opening of the metering valve and the outlet opening thereof leads directly into the exhaust gas flow of the internal combustion engine. The control valve is accommodated by a body through which a cooling medium can flow such that the control valve is cooled.
[0002] US 2008 0236147 A1 discloses an injection system which is used within the scope of selective catalytic reduction in a motor vehicle in order to reduce the levels of NO x portions in the exhaust gas. According to this solution, the injection system comprises an injector which is supplied with current via an electric terminal. The electric terminal contains an electric contact which is configured for receiving a plug of a connecting line.
[0003] US 2010 0108020 A1 relates to a connecting system for electric lines which are laid in hazardous areas, for example, an area in which there is a risk of explosion, such as, for example, the environment of an internal combustion engine. The disclosed connecting system is suitable for the electric connection of lines of various sensors and components. The connecting system comprises a rubber bush and a cap provided with an internal thread. The rubber bush here serves as an electric and thermal insulator and is compressed in the fitted state of the connecting system.
[0004] DE 10 2009 060 065 A1 discloses a fluid line for urea-water solutions in NO x reduction devices which operate in accordance with selective catalytic reduction (SCR). The fluid line is produced from a thermoplastic vulcanizate (TPV). The thermoplastic vulcanizate has rubber-like properties and is also known under the designation “thermoplastic elastomer”. The thermoplastic vulcanizate is distinguished in particular by high resistance to aggressive liquids and has a very high degree of flexibility and excellent pliability. According to DE 10 2009 060 065 A1, a fluid line manufactured from thermoplastic vulcanizate is used for connecting tanks, pumps, injection nozzles or for receiving couplings.
SUMMARY OF THE INVENTION
[0005] The invention is based on the object of providing a metering module for an exhaust gas aftertreatment system, said metering module withstanding high thermal loadings which occur during the operation of an internal combustion engine.
[0006] According to the invention, it is proposed, in a metering module, in order to protect the latter from overheating, to surround a wall of said component with an insulation shell and/or to implement water cooling. When an insulation shell is used, it is possible, for example to realize an air gap insulation which provides protection from overheating damage in particular in the plug region or in the region of the valve coil.
[0007] Following the solution proposed according to the invention, the metering element is enclosed by a heat sink which, comprising a plurality of parts, completely encloses the metering valve for introducing a fuel/additive, in particular a reducing agent, into the exhaust section of an internal combustion engine. According thereto, the heat sink constitutes a housing of the metering element. In a preferred variant embodiment of the solution proposed according to the invention, the heat sink constituting the housing of the metering valve is of multi-part design and comprises, for example, an upper shell, a central shell and a plug-in contact cover which is manufactured from a material having elastic properties, and is designed, for example, as a plastics bush or rubber bush. Furthermore, the housing of the metering module comprises a lower shell which is located below the central shell, wherein a cup-shaped insert is embedded in the lower shell of the heat sink constituting the housing of the metering module.
[0008] Whereas the upper shell of the heat sink, which is in particular of multi-part design, comprises a reducing agent inlet and also cavities through which a cooling fluid does not flow, but which constitute air gap insulation means, the central shell arranged below the upper shell comprises cavities through which the cooling fluid flows and cavities which are merely filled with air and therefore constitute air gap portions of an air gap insulation of an electric plug-in contact.
[0009] The lower shell, which accommodates the cup-shaped insert, is provided with a cavity through which cooling fluid flows. The circulation of the cooling fluid in the cup-shaped insert of the lower shell or through those parts of the central shell through which cooling liquid flows takes place through a cooling fluid inlet, which is accommodated on the lower shell, and via a cooling fluid return located on the circumferential surface of the central shell. Passage openings which permit cooling fluid to flow from the cavity of the lower shell into the cavity of the upper shell are located between the cup-shaped insert, which is accommodated in the lower shell, and the base of the central shell arranged above said lower shell.
[0010] Following the solution proposed according to the invention, the central shell constitutes to a certain extent a “hybrid component” which firstly permits air gap insulation with respect to the electric plug-in contact connection running through said central shell, but secondly has regions through which the cooling fluid flows. In the manner proposed according to the invention, the regions which conduct the cooling fluid are separated from the regions which constitute the air gap insulation of the electric content, wherein the number of required sealing points is reduced to a minimum. In order to separate the air gap portions constituting the air gap insulation in the central shell from the cavities which are formed in the central shell and conduct the cooling fluid, mention should advantageously be made of a separating rib which runs at an inclination through the central shell and separates the air gap portions of the air gap insulation from that cavity of the central shell which conducts the cooling fluid.
[0011] Following the solution proposed according to the invention, not only can the region of the metering module that lies in the region of an outlet opening of the fuel/additive, in particular of the reducing agent, be cooled with a cooling fluid, but further regions of the metering module can be cooled, this being achieved with the aid of the air gap insulation. In a particularly advantageous manner, the air gap insulation of the electric contact for activating the metering module can take place in the region, in particular in the central shell of the multi-part heat sink constituting a housing of the metering valve, since the electric contact connection is enclosed by a plastics cover which is manufactured from a material which has elastic properties. Owing to the elastic properties of the plastics cover, different coefficients of expansion of regions of the heat sink manufactured from metallic material and of parts of the heat sink manufactured from plastics material can be compensated for. The plug-in contact cover, which is designed, for example, as a plastics bush or rubber bush, can be fastened releasably to the upper shell by means of a latching closure and to the central shell in a latching means formed opposite on said component. By means of the plastics cover which can be fastened releasably to the upper shell and to the central shell of the multi-part heat sink constituting the housing, the air gap insulation can be effectively closed, but, at the same time, by omission of a welded joint, relative movements can be permitted without losses of sealing effect.
[0012] The solution proposed according to the invention takes simplifications in terms of assembly into consideration by virtue of the fact that the cooling is brought about in the upper region by convection, i.e. in the path of the air gap insulation, whereas liquid cooling can be implemented in the lower region of the metering module such that, following the solution proposed according to the invention, the entire cooling of the metering module can be achieved.
[0013] In addition, by the use of the water-cooled central shell, the thermal mass, this means the heat storage capacity, in the upper region of the metering module is increased. As a result, retarded heating of the valve can be achieved even if the cooling fluid circulation is interrupted. Therefore, even without active cooling fluid circulation, temporary temperature peaks do not result in damage of the metering module.
[0014] Furthermore, the metering module housing proposed according to the invention constitutes a means of protecting the metering valve from thermal shock in the event of abrupt cooling. Such cooling may occur, for example, when cleaning an engine when the engine is hot or when passing through water. A thermal shock is avoided since the heat sink with the large thermal mass thereof is cooled first. The metering valve enclosed by the heat sink is cooled more slowly as a result, and therefore stresses in the component due to different coefficients of thermal expansion are avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention is described in more detail below with reference to the drawing, in which:
[0016] FIG. 1 shows a perspective reproduction of the metering module, the metering valve of which is enclosed by a multi-part heat sink constituting a housing,
[0017] FIG. 2 shows a cross section through the metering module illustrated in FIG. 1 and through the multi-part heat sink thereof, and
[0018] FIGS. 3.1 and 3 . 2 show perspective views of the plug-in contact cover.
DETAILED DESCRIPTION
[0019] The metering module described below with reference to FIGS. 1 to 3 . 2 is a metering module for introducing a fuel/additive, in particular a reducing agent, such as, for example, urea or a urea-water solution, into the exhaust section of an internal combustion engine. Temperatures in the range between 100° C. and 160° C. prevail in the environment in which the metering module 10 proposed according to the invention is installed. Higher or lower temperature levels may also be present depending on the intended purpose and installation location. By means of the fuel/additive, in particular a reducing agent, such as, for example, urea or a urea-water solution, the NO x constituents which are present in the exhaust gas of internal combustion engines are reduced to H 2 O and N 2 . The apparatus proposed according to the invention for cooling a metering module 10 can also be used in other metering apparatuses, which are to be operated within a certain temperature range, as a cooling means therefor.
[0020] It can be gathered from the illustration according to FIG. 1 that a metering valve of a metering module 10 is enclosed by a complete housing 12 which to a certain extent constitutes a second housing. The complete housing 12 comprises an upper shell 20 , which can be designed, for example, in the form of a cap, and a plastics covering 17 which can be manufactured in particular from a material having elastic properties, such as, for example, a plastics material or a rubber. Furthermore, the housing 12 comprises a central shell 28 , and also a guide sleeve 32 arranged below the latter and a lower shell 29 which lies below said guide sleeve and into which a cup-shaped insert 24 —only partially illustrated in FIG. 1 —is embedded.
[0021] As emerges from the perspective illustration according to FIG. 1 , the metering valve of the metering module 10 is entirely enclosed by the components 17 , 20 , 28 , 29 listed above. Only a lower end of the cup-shaped insert 24 protrudes below the lower shell 29 of the complete housing 12 of the metering module 10 .
[0022] As furthermore emerges from the perspective illustration according to FIG. 1 , a cooling fluid inlet 22 is located in the circumferential surface of the lower shell 29 . By contrast, a cooling fluid return 26 is located in the circumferential surface of the central shell 28 .
[0023] A section through the multi-part embodiment of the heat sink of the metering module according to FIG. 1 can be gathered from the illustration according to FIG. 2 .
[0024] The cross section according to FIG. 2 shows that the entire metering valve 30 is surrounded by the complete housing 12 . The complete housing 12 here includes the upper shell 20 . The fuel/additive inlet 18 , via which in particular a reducing agent, such as, for example, urea or a urea-water solution, is supplied to the metering module 10 , extends through the upper shell 20 . FIG. 2 shows that said inlet 18 is of angled design and is encapsulated by the upper shell 20 by a flange covering an upper end side of the metering valve 30 . The upper shell 20 , for its part, comprises a cavity 42 which is separated from the cooling fluid by a separating rib 64 , which is denoted by reference number 64 , in relation to the central shell 28 , the cavity 44 of which has a cooling fluid flowing therethrough. As can furthermore be gathered from the sectional illustration according to FIG. 2 , the upper shell 20 in the region of a plug 16 or an electric plug-in contact 36 comprises an air gap portion 58 which is part of an air gap insulation 14 of the electric plug-in contact 16 or 36 of the metering module 10 .
[0025] A central shell which is identified by reference number 28 is located below the upper shell 20 , which is part of the complete housing 12 of the metering module. The central shell 28 comprises a receptacle 40 in which the upper shell 20 including the cavity 42 through which cooling fluid does not flow is embedded.
[0026] The central shell 28 likewise surrounds the metering valve 30 which is accommodated on the central shell 28 via a holding disk 34 . The central shell 28 sits on a guide sleeve 32 . The guide sleeve 32 , for its part, is accommodated on an insert 24 which is of substantially cup-shaped design.
[0027] It can be seen from the sectional illustration according to FIG. 2 that the central shell 28 comprises the cavity 44 through which the cooling fluid flows, and at the same time also contains a first air gap portion 54 and a second air gap portion 56 . The first air gap portion 54 and the second air gap portion 56 are separated from the cavity 44 by a separating rib 64 which is formed in the central shell 28 . In particular, the profile of the separating rib 64 in the central shell 28 is selected in such a manner that the first air gap portion 54 and the adjoining, second air gap portion 56 extend along the electric plug-in contact 36 in the direction of the plug-in contact cover 17 . The separating rib 64 which separates the first air gap portion 54 and the second air gap portion 56 from the cavity 44 through which the cooling fluid flows opens out at a wall end 52 of the central shell 28 . A latching connection 50 is also located there in the same manner as on the opposite side of the upper shell, compare position 48 in FIG. 2 . The plastics covering is latched releasably at the two latching points 48 and 50 which are formed on the upper shell 20 and on the central shell 28 . As already explained in conjunction with FIG. 1 , the plastics covering 17 is fastened by a latching means 58 to the upper shell 20 and by a latching means 50 opposite the first latching means to the outer side of the central shell 28 . Owing to the geometry of the plug covering 17 , the latching connections 50 and 52 bounding the opening 62 in the latter extend over the corresponding receiving regions of the upper shell 20 and of the central shell 28 in such a manner that extensions caused by temperature differences can be compensated for on account of the elastic properties of the material of the plug covering 17 . This makes it possible to avoid leakages which arise, for example, whenever materials which have different coefficients of thermal expansion, compensate for different extensions occurring during relative movements of the parts with respect to one another.
[0028] The solution proposed according to the invention firstly prevents leakage of cooling fluid to the outside and secondly ensures that the cooling fluid is kept away from the electric plug-in contact connection 36 such that no electric short circuit can occur in this region. In the region of the electric contact connection 36 , the cooling is realized in the manner proposed according to the invention by the air gap insulation 14 at the air gap portions 38 , 54 and 56 , as illustrated in FIG. 2 .
[0029] It emerges from the illustration according to FIG. 2 that the central shell 28 constitutes a “hybrid component” which realizes an air gap insulation in the region of the electric plug-in contact 36 and also has at least one cavity 44 through which cooling fluid flows.
[0030] As can be gathered from the lower region of the illustration according to FIG. 2 , the lower shell 29 is located below the guide sleeve 32 . The lower shell 29 , for its part, accommodates the cup-shaped insert denoted by reference number 24 .
[0031] At the lower end of the metering module 10 , temperatures of the order of magnitude of 120° C. and more can occur. For this reason, the cooling fluid inlet 22 into which the cooling fluid flows into the lower shell 29 and from there into a cavity 66 of the cup-shaped insert 24 is located in the region of the lower shell 29 . The lower region of the metering valve 30 also contains the injection nozzle via which a spray mist of fuel/additive and air is injected into the exhaust section of the internal combustion engine.
[0032] Since the highest temperatures are operationally induced here, in order to optimize the cooling effect the cooling fluid inlet 22 is located in this part of the metering module 10 proposed according to the invention so as to ensure an optimum removal of heat in the range of the high temperatures occurring there.
[0033] It furthermore emerges from the sectional illustration according to FIG. 2 that, after the cooling fluid enters through the cooling fluid inlet 22 after flowing through the cavity 66 of the cup-shaped insert 24 , the cooling fluid flows via passage openings 46 to the cavity 44 above the base of the central shell 28 . As FIG. 2 shows, passage openings 46 in the guide sleeve 32 and in the base of the central shell 28 are aligned with one another such that the cooling fluid, after flowing through the cup-shaped insert 24 , passes into the cavity 44 of the central shell 28 . After passage through the cavity 44 of the central shell 28 , which cavity is separated in a liquid-tight manner from the air gap portions 54 , 56 by the separating rib 64 , the cooling fluid heated by the waste heat in the metering module 10 after flowing around the latter leaves the cavity 44 of the central shell 28 at the cooling fluid return 26 , as illustrated in FIG. 2 .
[0034] The passage openings 46 ensure that the cooling fluid passes from the cavity 66 of the cup-shaped insert 24 into the at least one cavity 44 of the central shell 28 of the housing 2 . As can be gathered from the fitted state according to FIG. 2 , the plug cover 17 which is preferably manufactured from material having elastic properties permits the production of air gap insulation, i.e. cooling on account of convection in the region of the electric plug-in contact connection 36 in the upper part of the metering module 10 . There is also the possibility of providing water cooling at further components, in particular at the injection part of the metering valve 30 that is exposed to high thermal loadings, said water cooling making it possible for heat to be very reliably transported away. The solution proposed according to the invention realizes the cooling of all of the components of a metering module 10 . By means of the solution proposed according to the invention, materials optimized in each case with regard to the intended purpose thereof can in particular be used without the possibly different coefficients of thermal expansion thereof resulting in leakages or fatigue cracks.
[0035] Perspective views of the plug cover as illustrated in cross section in FIG. 1 and FIG. 2 can be gathered from FIGS. 3.1 and 3 . 2 .
[0036] FIG. 3.1 shows that the plug cover 17 encloses a cable outlet 60 and has an opening 62 . The opening 62 is bounded by latching means 48 , 50 which are formed opposite each other and can be formed as depressions or elevations, designed in a complementary manner with respect to the geometry thereof, on the upper shell 20 or in the plug region of the central shell 28 . FIG. 3.2 shows that the opening 62 in the plastics cover 17 can be, for example, of square or else rectangular design, which is favorable in respect of the formation of the latching connections 48 , 50 . If the latter are opposite each other, when the plug cover 17 is latched and a prestress is produced, a reliably sealing, but also re-releasable fastening of the plastics cover 17 to the upper shell 20 and central shell 28 of the heat sink which constitutes the housing 12 and is of multi-part design can be achieved.
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The invention relates to a device for cooling a metering module ( 10 ), in particular a module for metering an operating agent/auxiliary agent such as a reducing agent into the exhaust gas system of an internal combustion engine. A cooling device comprising a cooling member ( 17, 20, 24, 28, 29 ) through which a cooling liquid flows is associated with the metering module ( 10 ). The cooling member ( 17, 20, 24, 28, 29 ) acts as a housing ( 12 ) for the metering module ( 10 ). A first group of parts ( 17, 20, 28 ) forms an air gap insulation ( 38; 54, 56, 58 ) on an electric contact ( 16, 36 ), while cooling fluid flows through a second group of parts ( 28, 29, 40 ).
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FIELD OF THE INVENTION
This invention relates to a method for inhibiting external corrosion on an insulated pipeline by admixing an alkaline material with a coating material applied to the pipeline. A corrosion resistant coated pipeline is also disclosed.
BACKGROUND OF THE INVENTION
In many industrial applications wherein fluids are transported from one location to another pipelines are used. A continuing problem with such pipelines is that corrosion can occur in many forms and can weaken the pipeline to a point of failure. One of the most common types of corrosion is corrosion from the inside of the pipe as a result of corrosive materials which are transported in the pipe either as the primary material transported or as a contaminant material. This corrosion in many instances tends to form pits in the pipe and eventually may result in pinhole leaks or larger failures if the corrosion is particularly severe before discovery. Such failures typically result primarily in the loss of transported material with the resulting contamination of the environment and the like.
Frequently such pipelines are covered with coating materials, which may also function as an insulation material. Such coatings may be organic or inorganic fibrous materials, polymeric foams and the like. When such materials are used to cover the outside of the pipe, the potential exists for the accumulation of water in the coating material, particularly in pipelines which are insulated using insulating materials which are contained in an outer shell. Such materials are frequently used with an outer shell to protect the insulating material from the weather. When water collects in such insulating materials and comes in contact with the outer surface of the pipe, which is typically carbon steel, the water becomes corrosive to the pipe. Corrosion to the pipe in this fashion results in corrosion of the pipe from the outside over relatively large areas and may result in catastrophic pipe failures when periods of increased pressure occur and the like. Since many such insulating materials are closed cell or otherwise retain water, it is not feasible to remove this water by simply placing drains in the bottom of the outer shell. Further, the insulating material may be formed with an integral outer shell of sealing polymeric material or the like. Alternatively, the outer shell may be formed of a thin metallic material such as galvanized sheet steel. In any event, pipe failures for this reason are a significant problem in industry. Such pipes are frequently used in oil production operations, refinery operations, chemical operations, and a wide variety of other applications where it is desirable to transport fluids, especially if the fluids are at a temperature other than ambient.
As a result of the large number of pipe failures from external pipe corrosion as a result of water present in coating materials, methods have been sought to eliminate such failures.
SUMMARY OF THE INVENTION
According to the present invention, a method of inhibiting external corrosion on an insulated pipeline comprising a pipe and a coating material around the pipe is provided. The method consists essentially of mixing an alkaline material with the coating material around the pipe in an amount sufficient to provide a pH from about 8 to about 12 in water in the coating material.
The invention further comprises a corrosion inhibited pipeline comprising a pipe having an outside, a coating material containing an alkaline material in an amount sufficient to produce a pH from about 8 to about 12 in water in the coating materials and an outer shell having an inside, the coating material being positioned to substantially fill an annular space between the outside of the pipe and the inside of the outer shell.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a pipeline having a lower section; and,
FIG. 2 is a schematic diagram of a connection point of pipe sections.
DESCRIPTION OF PREFERRED EMBODIMENTS
In many instances polymeric foam materials, inorganic fibrous materials, organic fibrous materials, and the like are used to coat the exterior of pipelines to insulate or protect the pipelines which are used for the transportation of fluids. Such materials may be formed with a substantially waterproof exterior as a part of the coating material or they may be encased in a shell to cover the coating material to retard the entry of water, damage to the coating material and the like. In all such instances, the potential exists for the accumulation of water in the coating material in areas where the water is in contact with the exterior of the pipe. The contact of the water with the pipe over prolonged periods results in corrosion of the exterior of the pipe to the point that failures can occur over wide areas of the pipe. Since the pipes are typically made of carbon steel they are vulnerable to corrosion by water contact, especially contact with water at pH values below about 8.0.
According to the present invention, an alkaline material is admixed or formed as a part of or otherwise positioned in the coating material. The alkaline material is desirably present in a quantity sufficient to produce a pH from about 8.0 to about 12.0 in water in the coating material. Desirably the pH is about 9.5 when carbon steel is used as the pipe material.
Desirably the alkaline material is present in the coating material in an amount from about 0.001 molar to about 1.0 molar based upon the moles of the alkaline material in one liter of water-saturated coating material.
Any alkaline material which results in the desired pH in the water positioned in the coating material is suitable provided the alkaline material does not inhibit the application or formation of the coating material or result in degradation of the coating material or produce other undesirable effects in the coating material. Some suitable alkaline materials are sodium hydroxide, potassium hydroxide, sodium carbonate, ammonium hydroxide, lithium hydroxide, lithium hydroxide hydrates, sodium sulfide monohydrate, tribasic sodium orthophosphate, dibasic sodium phosphate, sodium meta-silicate, potassium orthophosphate, potassium sulfide mono-pentahydrate and mixtures thereof A preferred alkaline material is tribasic sodium orthophosphate.
The alkaline material can be incorporated into the coating material in a wide variety of ways. For instances, when polymeric foams are used the alkaline material may be mixed with one or all of the polymeric materials used to form the polymeric foam, the alkaline material may be formed in or otherwise associated with fibrous coating materials mixed with the coating prior to application to the pipe, and the like.
In one particularly preferred embodiment, the alkaline material is admixed with a polymeric foam used to coat pipelines.
A preferred polymeric foam is polyurethane foam. Polyurethane foams are well-known to the art as are a wide variety of other coating materials. Polyurethane foams are disclosed in McGraw - Hill Encyclopedia of science and Technology , 6th Ed., McGraw-Hill Book Co., 1987, pp. 168.
One illustration of a preferred embodiment of the present invention is shown in FIGS. 1 and 2. In FIG. 1, an insulated section of a pipeline 10 is shown. Pipeline 10 includes a pipe 12 , a shell 14 , insulation 16 positioned around pipe 12 with shell 14 being positioned to enclose insulation 16 with a low section 18 being shown in FIG. 1 . In pipelines of the type shown in FIG. 1, it is desired that shell 14 be substantially waterproof. Accordingly, pipeline 10 may be formed as shown in FIG. 2, where a second section 10 ′ is shown. Each section 10 and 10 ′ has a pipe end portion 20 or 20 ′, which extends beyond insulation 16 or 16 ′ in the respective pipe sections. These end portions have been joined at a weld 22 . A coupling 24 has then been placed to engage the outside of shell 14 and shell 14 ′. An insulating material, typically the same type material used to coat sections 10 and 10 ′, is then injected through a port 26 to insulate the weld area and a plug 28 is installed to close port 26 after injection of the insulation.
In the system shown, which is particularly adapted to the use of polyurethane or other polymeric foams as an insulating material, the components necessary to form the polyurethane form are injected into the annular space between an outside of pipe 12 and an inside of shell 14 to form the insulating foam in place. The alkaline materials are desirably added to one or all of the components used to form the polyurethane foam. Similarly, the alkaline materials are used in the components to form the polyurethane foam formed around the weld area as described above.
While the invention has been described in this preferred embodiment with particular reference to polyurethane foams, it should be understood that a wide variety of foams and other coating materials could be used to coat pipe 12 . These coatings can be used with or without shell 14 . Desirably the alkaline material is included in such coatings in the quantities discussed above to provide the desired pH in water in the coating material. The pH of water in the coating material is suitably from about 8 to about 12 and is desirably about 9.5. It is desirable that the pH be no higher than 12 because of concerns about damage to the pipe by reason of stress corrosion cracking. As a result, it is desirable when using highly basic materials, as the alkaline material that buffering compounds as known to the art be used to control the pH within the desired limits.
The quantity of alkaline material used is from about 0.001 to about 1.0 molar based upon the moles of the alkaline material in one liter of water saturated coating material. When tribasic sodium orthophosphate is used as the alkaline material, it is desirable that tribasic sodium orthophosphate be present in an amount from about 0.005 to about 0.10 molar.
Many of the polymeric foams, which are suitable for use in the present invention, are closed cell foams, which are generally considered to provide little or no fluid communication between the individual cells and to be relatively impervious to water. Nevertheless, it has been found that over extended periods of time either by vapor diffusion or other methods not clearly understood, water frequently becomes contained in such closed cell foams. When such water is contained in such closed cell foams, it is capable of contacting the pipe and corroding the pipe. It is not feasible, however, to drain the water from such coatings since the water does not flow freely from the coating. Penetration of the shell or the coating will result in the removal of only minor amounts of water from the immediate vicinity of the penetration. As a result, it is necessary that the water be treated to reduce its corrosiveness.
It is has been found that alkaline material can be incorporated into insulating and coating materials, without detriment to such materials, in sufficient quantities to result in the desired pH range in water in the coating materials. This has been found to greatly extend the useful life of pipe in such applications. In many such applications, the life of the pipe is sufficient if it lasts during the life of the operation contemplated. In other words, if the pipe is used to produce oil from an oil well, if the life of the pipe can be extended to last until production has been completed from the well, then the pipe will most likely be removed in any event. Similar considerations apply in other applications. By the use of the present invention, it is contemplated that the life of pipe may be extended by up to ten times the normal life when conventional coating materials are used.
EXAMPLE 1
A number of foam samples containing the alkaline materials shown in Table 1 below were prepared. These samples were then sectioned and carbon steel coupons were placed on each section. The samples were left in place in water for three months at ambient temperature and the resulting corrosion was observed. The foam samples were placed in volumes of water sufficient to provide the molarities shown in Table 1.
TABLE 1
ALKALINE
LIQUID
MATERIAL
MOLARITY
pH
RESULT
Water
0
0
7.46
Severe rust
Water
Na 3 PO 4
0.001
7.77
Rust
Water
Na 3 PO 4
0.005
8.32
Darkening
Water
Na 3 PO 4
0.01
8.71
Slight darkening
Water
Na 3 PO 4
0.05
9.24
Less darkening
Water
Na 3 PO 4
0.10
9.46
Negligible
darkening
Water
Na 3 PO 4
0.50
10.94
Neglible
darkening
Water
NaOH
0.01
8.96
Rust
Water
90% NaOH
0.01
9.2
Slight darkening
10% Na 3 PO 4
The test with sodium hydroxide was observed to result in rust very early in the test before the sodium hydroxide had leached from the foam to a sufficient extent to provide the desired pH. It is believed that in this test, corrosion was inhibited after the initial rust formation at the initial low pH.
EXAMPLE 2
A quantity of polyurethane foam containing a quantity of alkaline material was prepared and subsequently finely divided. This material was placed in water and the pH observed. The pH quickly increased to an elevated level indicating that the alkaline material is efficiently removed from the polyurethane foam material when water is present.
It is believed clear in view of the foregoing examples and discussion that the inclusion of alkaline material in coating material for pipes, especially polymeric foams and inorganic and organic fibrous materials is effective to prevent external corrosion of the pipe by water accumulation or presence in the coating material.
Having thus described the present invention by reference to certain of its preferred embodiments, it is pointed out that many variations and modifications are possible within the scope of the present invention. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments.
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A method for inhibiting external corrosion on an insulated pipeline including a pipe and a coating material around the pipe by positioning an alkaline material in the coating material.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of and claims priority to U.S. patent application Ser. No. 09/649,190, filed Aug. 28, 2000 by Paul V. Cooper.
FIELD OF THE INVENTION
[0002] The present invention relates to a device, called a scrap melter, for submerging scrap metal in a molten metal bath. The device preferably includes a drive source, an impeller and a drive shaft. The device preferably draws molten metal downward in order to submerge scrap placed on the surface of the bath.
BACKGROUND OF THE INVENTION
[0003] Scrap melter systems, such as the one shown schematically in FIGS. 1 and 2, generally use two devices, a circulation pump and a scrap melter. As shown in FIG. 1 the vessel V containing molten metal bath B is preferably divided into two compartments. Compartment 1 (called a pump well) houses circulation pump 2 . Compartment 3 (called a charge well) houses a scrap melter 10 . The circulating molten metal moves between compartment 1 and compartment 3 and is preferably circulated throughout vessel V. Scrap S is introduced into compartment 3 and is submerged by the downward draw created by the impeller of scrap melter 10 , which pulls the scrap downward into the molten metal bath. The molten metal bath is preferably maintained, at least partially, in a remelting furnace having a heating chamber interconnected to a melting chamber. Bath B is maintained at a temperature above the melting point of the scrap metal in order to melt the scrap metal.
[0004] A conventional scrap melter includes an impeller affixed to a drive shaft, and a drive source for rotating the shaft and the impeller. As stated above, the impeller draws molten metal and the scrap metal downward into the molten metal bath in order to melt the scrap. The circulation pump is preferably positioned in the pump well and circulates the molten metal between the chambers in order to maintain a relatively constant temperature within bath B. Such a system, including a circulation pump and a scrap melter, is disclosed in U.S. Pat. No. 4,598,899, issued Jul. 8, 1986 to Cooper, the disclosure of which that is not inconsistent with this disclosure is incorporated herein by reference. As defined herein, the terms auger, rotor and impeller refer to the same general structure, i.e., a device used in a scrap melter for displacing molten metal.
[0005] Scrap melter impellers generally move molten metal radially outward away from the impeller to create a downward draw above the impeller. However, such impellers can create turbulence or flow that may partially move into the path of the fluid entering the impeller from above, in which case some scrap may not be efficiently drawn into bath B where it can be melted and mixed, thus decreasing the fluid flow to the impeller and decreasing the efficiency of the scrap melting operation. In addition, the radial turbulence may cause some fluid that has been expelled from the impeller to be immediately recirculated through the impeller, thus decreasing the flow of virgin fluid through the impeller. That further decreases efficiency because it reduces the draw of molten metal from above the impeller. As a result, in order to maintain a desired volume of fluid flow through the impeller, the speed of the impeller may be increased to overcome these effects. Increasing the speed of the impeller, however, may cause excess vibration leading to part failure, downtime and maintenance expenses.
[0006] Scrap melters have been developed to restrict radial flow from the impeller to limit turbulence and produce more efficient flow. One such assembly, disclosed in U.S. Pat. No. 4,930,986, issued Jun. 5, 1990 to Cooper, the disclosure of which that is not inconsistent with this disclosure is incorporated herein by reference, includes an impeller positioned inside a drum, both of which rotate as a single unit. One disadvantage to this assembly is that pieces of scrap or dross can jam in it, which decreases its efficiency. Other prior art devices are disclosed in U.S. Pat. Nos. 4,286,985, 3,984,234, 4,128,415 and 4,322,245.
SUMMARY OF THE INVENTION
[0007] The preferred embodiment of the present invention is a scrap melter utilizing an open impeller to reduce jamming or clogging. Thus, the invention can function efficiently in virtually any scrap melting environment, handling particles of virtually any size that are likely to be encountered in any such environment. An impeller according to the invention functions by displacing molten metal to create a downward draw. It provides the benefit of reducing the problems associated with faster operating speeds (i.e., the possible creation of a vortex and turbulence, and/or part failure, greater downtime and higher maintenance costs). The way in which it achieves these results is by (a) displacing more molten metal while operating at the same speed as conventional impellers, and/or (b) moving at least some of the molten metal in a downward or partially downward direction.
[0008] An impeller according to the invention displaces more molten metal by the use of (1) a larger area on the blade surfaces that push against the molten metal as the impeller rotates, and/or (2) surfaces that push against the metal at angles that displace a relatively large amount of molten metal. One impeller according to the invention preferably moves molten metal at least partially in the downward direction, while another moves molten metal only in an outward direction.
[0009] In one preferred embodiment the impeller is preferably a four-bladed cross wherein each blade preferably includes an angled surface that directs molten metal at least partially in the downward direction. The impeller creates a draw that draws molten metal and any solid scrap metal contained therein downward into the molten metal bath. It also preferably provides at least some radial or partially radial flow, and may include a surface or structure specifically designed to generate radial or partially radial flow, to assist in circulating molten metal within the bath.
[0010] In another preferred embodiment, the impeller is preferably a four-bladed cross wherein each blade preferably includes a vertical surface that directs molten metal radially outward away from the impeller. The impeller creates a draw that draws molten metal and any solid scrap metal contained therein downward into the molten metal bath. It also assists in circulating molten metal within the bath.
[0011] A scrap melter according to the invention can be operated at lower speeds than conventional melters but still displace the same amount of molten metal per impeller revolution. Alternatively, it can be operated at the same speeds as, and displace more molten than conventional scrap melters. A benefit of the lower speed is that the scrap melter of the invention vibrates less and requires less maintenance and fewer replacement parts.
[0012] A preferred melter according to the invention includes a drive source, a drive shaft having a first end and a second end and an impeller. The first end of the drive shaft is connected to the drive source. An impeller according to the invention is connected to the second end of the drive shaft. The drive source is preferably a pneumatic or electric motor, but can be any device(s) capable of rotating the impeller.
[0013] A scrap melter according to the invention may be used in a scrap melter system comprising a scrap melter, a vessel containing a molten metal bath and a circulation pump. Conventional pumps for pumping molten metal that may be used as circulation pumps are generally disclosed in U.S. Pat. No. 2,948,524 to Sweeney et al., U.S. Pat. No. 5,203,681 to Cooper entitled “Submersible Molten Metal Pump,” pending U.S. application Ser. No. 08/759,780, filed Dec. 13, 1996, entitled Molten Metal Pump With a Flexible Coupling and Cement-Free Metal-Transfer Conduit Connection, U.S. Patent No. to Cooper entitled Impeller Bearing System for Molten Metal Pumps, U.S. application Ser. No. 09/152,168, filed Sep. 11, 1998, entitled Improved Gas Dispersion Device, U.S. Pat. No. 5,678,807 to Cooper and U.S. Pat. No. 5,662,725 to Cooper, the disclosures of which are incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments of the present invention will now be described with reference to the drawings, wherein like designations denote like elements, and:
[0015] [0015]FIG. 1 is a side view of a scrap melter system according to the invention comprising a scrap melter, a vessel and an impeller according to the invention.
[0016] [0016]FIG. 2 is a top view of the system shown in FIG. 1.
[0017] [0017]FIG. 3 is a perspective view of a preferred impeller according to the invention.
[0018] [0018]FIG. 4 is perspective view of an alternate preferred impeller according to the invention.
[0019] [0019]FIG. 5 shows an exploded, perspective view of an assembly according to the invention, including a drive shaft, the impeller of FIG. 3 and a nut.
[0020] [0020]FIG. 6 is a partial side view of the assembly shown in FIG. 5, showing the connected components.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Referring now to the figures, where the purpose is for describing a preferred embodiment of the invention and not for limiting same, FIG. 1 shows a scrap melter 10 submerged in a molten metal bath B. All of the components of scrap melter 10 exposed to molten metal bath B are preferably formed from oxidation-resistant graphite or other material suitable for use in molten metal.
[0022] A drive source 28 is connected to impeller 100 by any structure suitable to transfer driving force from source 28 to impeller 100 . Drive source 28 is preferably an electric, pneumatic or hydraulic motor although, as used herein, the term drive source refers to any device or devices capable of rotating impeller 100 .
[0023] A drive shaft 12 is preferably comprised of a motor drive shaft (not shown) connected to an impeller drive shaft 40 . The motor drive shaft has a first end and a second end, the first end being connected to motor 28 by any suitable means and which is effectively the first end of drive shaft 12 in the preferred embodiment. An impeller shaft 40 has a first end 42 (shown in FIG. 4) and a second end 44 . The preferred structure for connecting the motor drive shaft to impeller drive shaft 40 is a coupling (not shown). The coupling preferably has a first coupling member and a second coupling member. The first end 42 of impeller shaft 40 is connected to the second end of the motor shaft, preferably by the coupling, wherein the first end 42 of impeller shaft 40 is connected to the second coupling member and the second end of the motor drive shaft is connected to the first coupling member. The motor drive shaft drives the coupling, which, in turn, drives impeller drive shaft 40 . Preferably, the coupling and first end 42 of the impeller shaft 40 are connected without the use of connecting threads.
[0024] Impeller 100 is an open impeller. As used herein the term open refers to an impeller that allows dross and scrap to pass through it, as opposed to impellers such as the one shown in U.S. Pat. No. 4,930,986, which does not allow for the passage of much dross and scrap, because the particle size is often too great to pass through the impeller. Preferred impeller 100 is best seen in FIG. 3. Impeller 100 provides a greater surface area to move molten metal than conventional impellers. Impeller 100 is preferably imperforate, has two or more blades, is preferably formed of solid graphite, is attached to and driven by shaft 12 , by being attached to shaft 40 in the preferred embodiment, and is preferably positioned centrally about the axis of shaft 40 . Impeller 100 may, however, have a perforate structure (such as a bird-cage impeller, the structure of which is known to those skilled in the art) or partially perforate structure, and be formed of any material suitable for use in a molten metal environment.
[0025] Impeller 100 most preferably has four blades 102 and is shaped like a cross when viewed from the top. Impeller 100 includes a central section, or hub, 104 that is the area defined by the intersection between blades 102 , when impeller 100 has three or more blades. In the preferred embodiment, hub 104 is an approximately 8″ square. A connective portion 106 is preferably a nonthreaded, tapered bore extending through hub 104 , but can be any structure capable of connecting impeller 100 to drive shaft 12 . The preferred embodiment of impeller 100 also has a top surface 112 , a bottom surface 114 , and a trailing face 116 . The diameter of connective portion 106 is approximately 5″ at upper surface 112 and tapers to approximately 4″ at lower surface 114 to form a tapered bore as shown in FIGS. 3 and 5.
[0026] The height of surface 116 , measured vertically, is preferably between 6 and 7 inches. Each blade 102 preferably extends approximately 10″ outward from hub 104 , the overall preferred length and width of impeller 100 , including hub 104 , therefore being approximately 28″. A recess (not shown) may be formed from top surface 112 to trailing surface 116 .
[0027] Preferably, each blade 102 has the same configuration so only one blade 102 shall be described. In the preferred embodiment, blade 102 has a leading face 108 . Face 108 is on the leading side of blade 102 as it rotates (as shown impeller 100 is designed to rotate in a clockwise direction). Face 108 includes an angled portion 108 A and a vertical lip 108 B. Portion 108 A directs molten metal at least partly in the downward direction, toward the bottom of vessel V, as shown in FIG. 1. Surface 108 A may be substantially planar or curved, or multi-faceted, such that, as impeller 100 turns, surface 108 A directs molten metal partially in the downward direction. Any surface or structure that functions to direct molten metal downward or partially downward can be used, but it is preferred that surface 108 A is formed at a 30°-60°, and most preferably a 45° planar angle. Alternatively, leading face 108 may itself be, or include a surface that is, (1) vertical, (2) substantially vertical, or (3) angled to direct molten metal in a partially upward direction, because the radial displacement of molten metal alone will create a downward draw in the space above impeller 100 .
[0028] Impeller 300 , shown in FIG. 4, is also an open impeller. Preferred impeller 300 is best seen in FIG. 4. Impeller 300 also provides a greater surface area to move molten metal than conventional impellers. Impeller 300 is preferably imperforate, has two or more blades, is preferably formed of solid graphite, is attached to and driven by shaft 12 , by being attached to shaft 40 in the preferred embodiment, and is preferably positioned centrally about the axis of shaft 40 . Impeller 100 may, however, have a perforate structure (such as a bird-cage impeller, the structure of which is known to those skilled in the art) or partially perforate structure, and be formed of any material suitable for use in a molten metal environment.
[0029] Impeller 300 most preferably has four blades 302 . Impeller 300 includes a central section, or hub, 304 that is the area defined by the intersection between blades 302 , when impeller 300 has three or more blades. In the preferred embodiment, hub 304 is an approximately 8″ square. A connective portion 306 is preferably a nonthreaded, tapered bore extending through hub 304 , but can be any structure capable of connecting impeller 300 to drive shaft 12 . The preferred embodiment of impeller 300 also has a top surface 312 , a bottom surface 314 , and a trailing face 316 . The diameter of connective portion 306 is approximately 5″ at upper surface 312 and tapers to approximately 4″ at lower surface 314 to form a tapered bore as shown in FIG. 4.
[0030] The height of surfaces 308 , 316 , measured vertically, is preferably between 6 and 7 inches. Each blade 302 preferably extends approximately 10″ outward from hub 304 , the overall preferred length and width of impeller 300 , including hub 304 , therefore being approximately 28″. A recess (not shown) may be formed from top surface 312 to trailing surface 316 .
[0031] Preferably, each blade 302 has the same configuration so only one blade 302 shall be described. In the preferred embodiment, blade 102 has a leading face 308 . Face 308 is on the leading side of blade 302 as it rotates (as shown impeller 300 is designed to rotate in a clockwise direction). Face 308 is vertical (as used herein, the term vertical refers to any vertical or substantially vertical surface) and directs molten metal outward away from impeller 300 . Face 308 may be substantially planar or curved, or multi-faceted, such that, as impeller 300 turns, face 308 directs molten metal outward. Any surface or structure that functions to direct molten metal outward can be used, but it is preferred that surface 308 is vertical and extends the full height of blade 308 so that blade 308 has a square cross section. Alternatively, face 308 may itself be, or include a surface that is angled to direct molten metal in a partially upward direction, because the radial displacement of molten metal alone will create a downward draw in the space above impeller 300 .
[0032] As shown in FIGS. 5 and 6, second end 44 of impeller drive shaft 40 preferably has a tapered section 44 A that is received in the tapered bore of the preferred embodiment of connecting portion 106 . End 44 also preferably has a threaded section 44 B that extends below bottom surface 114 of impeller 100 when section 44 A is received in connecting portion 106 . In this preferred embodiment, a nut 200 , that has a threaded opening 202 , is screwed onto section 44 B to retain impeller 100 on end 44 of rotor drive shaft 40 . Nut 200 and section 44 B preferably have 4″- 4½ U.N.C. threads. Nut 200 is preferably a hex head nut having an overall diameter of approximately 7″.
[0033] The purpose of tapered bore 106 is easy removal of end 44 of shaft 40 from connective portion 106 . Some prior art devices utilize either a threaded bore and/or a right cylindrical bore, i.e., a bore having the same diameter at the top and bottom to connect the drive shaft to the impeller. The problem with such structures is that during operation of the scrap melter molten metal seeps between the end of the shaft and the bore in the impeller. This leads to difficulty in removing the shaft from the bore, and often the shaft must be chiseled out. The nonthreaded, tapered bore 106 of the invention alleviates this problem. Although only the preferred attachment of impeller 100 is shown, impeller 300 would preferably be attached to shaft 12 in the same manner as described for impeller 100 .
[0034] Preferred embodiments having now been described, variations that do not depart from the spirit of the invention will occur to others. The invention is thus not limited to the preferred embodiment but is instead set forth in the following claims and legal equivalents thereof, which are contemplated to cover any such variations. Unless specifically stated in the claims, any of the claimed inventions may include structures or devices other than those specifically set forth in the claims.
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A device for submerging scrap metal includes: (a) a drive source, (b) a drive shaft having a first end and a second end, the first end being connected to the drive source, and (d) an impeller connected to the second end of the drive shaft, the impeller preferably having two or more outwardly-extending blades. Preferably, each of the blades has a portion that directs molten metal at least partially downward. The impeller design leads to lower operating speeds, lower vibration, longer component life and less maintenance. Additionally, the impeller preferably has a connective portion. The connective portion is used to connect the impeller to the shaft and preferably comprises a nonthreaded, tapered bore extending through the impeller.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to 3'-demethoxy epipodophyllotoxin glucoside derivatives, to their therapeutic anti-tumor use, and to pharmaceutical dosage forms containing these new agents.
2. Description of the Related Art
Etoposide (VP-16, Ia) and teniposide (VM-26, Ib) are clinically useful anticancer agents derived from the naturally occurring lignan, podophyllotoxin (II). The numbering system used for nomenclature purposes is shown in Formula II. Etoposide and teniposide are 4'-demethyl epipodophyllotoxin derivatives; epipodophyllotoxin being ##STR1## the epimer of podophyllotoxin at the 4-position. Etoposide and teniposide are active in the treatment of a variety of cancers including small cell lung cancer, non-lymphocytic leukemia, and non-seminomatous testicular cancer (AMA Drug Evaluation, 5th Edition, American Medical Association, 1983, Chicago, Ill., p. 1554-5).
Etoposide and teniposide, and methods for producing them, are disclosed in U.S. Pat. No. 3,524,844 to Keller-Juslen et al. Etoposide 3', 4'-quinone (IIIa) has been generated from electrochemical oxidation of etoposide (Holthuis J. J. M., et al, J. Electroanal. Chem. Interfacial Electrochem., 1985, 184(2):317-29). The preparation of the quinone III by chemical oxidation is disclosed in US patent 4,609,644 to Josef Nemec. Epipodophyllotoxin 3', 4'-quinone derivatives III wherein R 1 and R 2 have the definition given hereinbelow for Formula IV serve as the starting material for 3'-demethoxy epipodophyllotoxin derivatives of the present invention. ##STR2##
SUMMARY OF THE INVENTION
The present invention provides 3'-demethoxy epipodophyllotoxin glucoside derivatives of Formula IV ##STR3## wherein R 2 is hydrogen and R 1 is selected from the group consisting of C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 3 -C 7 cycloalkyl, furyl, thienyl, pyridyl, pyrrolyl, C 6 -C 10 aryl and C 7 -C 14 aralkyl, said aryl and aralkyl rings optionally bearing one or more substituents selected from halo, C 1 -C 4 alkyl, nitro, hydroxy, C 1 -C 4 alkoxy, C 1 -C 4 alkanoyloxy, cyano, amino, C 1 -C 4 alkylamino, di(C 1 -C 4 alkyl)amino, carboxy, C 1 -C 4 alkylthio, mercapto, C 2 -C 4 alkenoylamino, C 2 -C 4 alkenyl and carbamoyl; or R 1 and R 2 are each C 1 -C 10 alkyl; or R 1 and R 2 and the carbon atom to which they are attached join to form a C 5 -C 6 cycloalkyl group. A preferred embodiment provides compounds of Formula IV wherein R 2 is H, and R 1 is selected from C 1 -C 10 alkyl and thienyl, with methyl being the most preferred.
Another aspect provides a method for inhibiting tumors in a mammalian host comprising administering to a tumor-bearing host a tumor-inhibiting amount of a compound of Formula IV.
A further aspect provides a pharmaceutical composition comprising a compound of Formula IV in a pharmaceutically acceptable carrier.
DETAILED DESCRIPTION OF THE INVENTION
Compounds of the present invention may be prepared by the reaction sequence shown in Scheme I wherein R 3 is C 1 -C 5 alkyl or aryl-C 1 -C 5 alkyl, and the term "EPIPODO" is used to represent the fragment. ##STR4##
The ortho-quinones III are, as previously mentioned, known compounds that may be prepared by oxidizing 4'-dimethylepipodophyllotoxin glucosides according to the procedure described in US 4,609,644 (J. Nemec, 1986). Reaction of the ortho-quinones III with an O-substituted hydroxylamine, or an acid addition salt thereof, in an inert organic solvent provides the corresponding 3'-oxime ether V. The reaction is preferably carried out at room temperature for a period sufficient to obtain the mono oxime ether, for example from about 30 minutes to about one hour. The products thus formed may be isolated and purified e.g. by flash chromatography; or alternatively, they may be reduced directly, without first being isolated, to the corresponding amine compound of Formula VI. Reduction of the oxime ether to the corresponding 3'-amino compound may be effected by conventional methodologies, e.g. a mild chemical reducing agent, or hydrogenation in the presence of a suitable catalyst such as Pt, Pd, Ni, Ru or Rh. Catalytic hydrogenation is preferably employed. Amine compounds of Formula VI may also be prepared directly from the ortho-quinone III by treatment with ammonia or an alkylamine at room temperature; reaction with the latter yields both the amine VI and the corresponding alkyl substituted amine. The preferred preparative method is the reduction of the oxime ether of Formula V. Diazotization of VI in an inert solvent at reduced temperature followed by aqueous work-up provides the diazonium salt VII. Reduction of the diazonium salt using reagents known in the art for this purpose, such as hypophosphorous acid, sodium borohydride, or an excess of thiophenol provides 3'-demethoxy-4' demethylepipodophyllotoxin of Formula IV.
BIOLOGICAL ACTIVITY
3'-Demethoxy etoposide was evaluated for its antitumor activity against transplantable murine P388 leukemia.
Female CDF 1 mice were implanted intraperitoneally with a tumor inoculum of 10 6 ascites cells of P388 murine leukemia and treated with various doses of a test compound; four mice were used for each dose level and ten were used as saline-treated control. The compounds were administered by intraperitoneal injection on days 5 and 8 (day 1 being the day of tumor implantation). Antitumor activity was expressed as % T/C which is the ratio of the median survial time (MST) of drug-treated group to the MST of saline-treated control group. A compound showing a % T/C value of 125 or greater is generally considred to have significant antitumor activity in the P388 test. The experiment lasted 31 days at the end of which time the number of survivors was noted. Table I presents the results of the above-described evaluation; only the maximum % T/C and the dose showing the maximum effect are reported.
TABLE 1______________________________________Antitumor activity against P388 Leukemia DoseCompound (mg/kg/inj.) Max. % T/C______________________________________3'-Demethoxy >40 245etoposideEtoposide 60 260______________________________________
It is apparent from the animal test results provided above that compounds of formula IV possess effective inhibitory action against mammalian tumors. Accordingly, this invention provides a method for inhibiting mammalian tumors which comprises administering an effective tumor-inhibiting dose of an antitumor compound of formula IV to a tumor bearing host.
Another aspect of this invention provides a pharmaceutical composition which comprises an effective tumor-inhibiting amount of an antitumor compound of formula IV and a pharmaceutically acceptable carrier. These compositions may be made up of any pharmaceutical form appropriate for the desired route of administration. Examples of such compositions include solid compositions for oral administration such as tablets, capsules, pills, powders and granules, liquid compositions for oral administration such as solutions, suspensions, syrups or elixirs and preprations for parenteral administration such as sterile solutions, suspensions or emulsions. They may also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, physiological saline or some other sterile injectable medium immediately before use.
Optimal dosages and regimens for a given mammalian host can be readily ascertained by those skilled in the art. It will, of course, be appreciated that the actual dose used will vary according to the particular composition formulated, the particular compound used, the mode of application and the particular situs, host and disease being treated. Many factors that modify the action of the drug will be taken into account including age, weight, sex, diet, time of administration, route of administration, rate of excretion, condition of the patient, drug combinations, reaction sensitivities and severity of the disease.
The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.
In the following examples, all temperatures are given in degrees Centigrade. Melting points were recorded on a Thomas-Hoover capillary melting point apparatus and are uncorrected. 1 H NMR spectra were recorded either on a Bruker WM 360 or a Varian VX2 200 spectrophotometer (using CDCl 3 as an internal reference). Chemical shifts are reported in δ units and coupling constants in Hertz. Splitting patterns are designated as follows: s, singlet; d, doublet; t, triplet; q, quartet; m, multiplet; bp, broad peak; and dd, doublet of doublet. Infrared spectra were determined either on a Beckman Model 4240 or a Perkin-Elmer 1800 Fourier Transform Infrared Spectrophotometer and are reported in a reciprocal centimeters (cm - 1). Thin-layer chromatography (TLC) was carried out on precoated silica gel plates (60F-254) using UV light and/or iodine vapors as visualizing agents. High and low resolution mass spectra were recorded on KRATOS MS 50 and KRATOS MS 25RFA Spectrophotometer, respectively. "Flash Chromatography" refers to the method described by Still (Still, W.C. et al, J. Org. Chem., 1978, 43:2923) and was carried out using either E. Merck silica gel (200-400 mesh) or Woelm silica gel (32-63 μm). All evaporations of solvents were performed under reduced pressure.
EXAMPLE 1
Etoposide-ortho-quinone-3'-O-methyloxime Va ##STR5##
A solution of etoposide ortho-quinone IIIa (350 mg, 0.611 mmol) in a pyridine (20 ml) was treated with a solution of methoxylamine hydrochloride (350 mg, 4.19 mmol) in pyridine (10 ml). The resultant orange solution was stirred for 30 minutes at room temperature and the pyridine was then removed in vacuo. The residue was dissolved in CH 2 Cl 2 (50 ml) and partitioned with H 2 O (20 ml) and 1N HCl (10 ml). The aqueous layer was further extracted with CH 2 Cl 2 (25 ml) and the combined organic extracts were dried over MgSO 4 . The solvent was evaporated in vacuo to give a dark orange oil. Flash chromatography on silica gel (14 g) with 5% CH 3 OH in CH 2 Cl 2 gave 243 mg (66%) of the title compound as an orange solid. Trituration with Et 2 O provided the analytical sample. On a larger scale, this enzyme is generally not purified but is directly hydrogenated to the amine VIa in an overall yield of ca 70%.
IR (KBr) 3480, 1775, 1670, 1625, 1488, 1237, 1040 cm -1 .
1 H NMR (CDCl 3 ) δ 6.82 (s,1H), 6.56 (s,1H), 6.48 (d,1H), 6.07 (d,1H), 6.01 (d,1H) 5.75 (d,1H), 4,92 (d,1H), 4.76 (q,1H), 4.66 (d,1H), 4.50 (dd,1H), 4.38 (dd,1H), 4.27 (d,1H), 4.22-4.17 (m,1H), 4.15 (s,3H), 3.79 (s,3H), 3.78-3.74 (m,1H), 3.63-3.58 (m,1H), 3.44 (dd,1H), 3.38-3.30 (m,3H), 2.95-2.87 (m,1H), 1.40 (d,3H).
Anal. Calcd for C 29 H 31 NO 13 : C,57.90; H,5.19; N,233. Found: C,56.01; H,5.04; N,2.41.
EXAMPLE 2
3-Amino-3'-demethoxy etoposide VIa ##STR6##
The crude oxime Va obtained from etoposide ortho-quinone IIIa (4.1 g, 7.2 mmol) and methoxylamine hydrochloride (4.1 g, 49 mmol) by the procedure described in Example 1 was dissolved in reagent alcohol (275 ml) and treated with 20% palladium hydroxide on carbon (290 mg) and 10% palladium on carbon (1.6 g). The mixture was hydrogenated at 40-50 psi H 2 . After 16 h, the mixture was filtered through Celite, washed with ethyl acetate, and the solvent was evaporated. The crude product was purified by flash chromatography on 300 g. E. Merck 230-400 mesh silica gel using 8:2 EtOAc/hexane as eluent to provide 2.89 g (70% overall) of the title compound as a white solid. Recrystallization from ethanol gave the analytical sample.
IR (KBr) 3455, 1775, 1615, 1490, 1235, 1070, 1030, 1000, 930 cm -1 .
1 H NMR (CDCl 3 ) δ 6.76 (s,1H0, 6.48 (s,1H), 6.37 (d,1H), 5.96 (ABq,2H), 5.65 (d,1H), 4.87 (d,1H), 4.73 (q,1H), 4.61 (d,1H), 4.47 (d,1H), 4.38 (dd,1H), 4.23-4.16 (m,2H), 3.78 (s,3H), 3.76-3.72 (m,1H), 3.60-3.55 (m,1H), 3.42 (dd,1H), 3.37-3.30 (m,2H), 3.21 (dd,1H), 2.97-2.88 (m,1H), 1.37 (d,3H).
Anal. Calcd for C 28 H 31 NO 12 : C,58.63; H,5.45; N,2.44. Found: C,57.85; H,5.76; N,2.35
EXAMPLE 3
Etoposide 3' 0diazonium hydroxide inner salt
VIIa ##STR7##
Glacial acetic acid (3.0 ml, 26.2 mmol) followed by NaNO 2 (0.15 g, 2.17 mmol) were added to a solution of 3'-aminoetoposide (product of Example 2, 0.22 g, 0.384 mmol) in dry THF (17 ml) stirring at 0° C. under N 2 . The reaction mixture was stirred for 3.4 hours at 0° C. and poured into 150 ml of CH 2 Cl 2 . The dark red organic layer was washed with 100 ml of aqueous NaHCO 3 . The combined organic extracts were washed with 100 ml of saturated NaHCO 3 , dried over MgSO 4 and concentrated in vacuo to provide 0.177 g (79%) of a reddish orange solid: mp. slow decomposition 150° C.
IR (KBr) 3440 (b), 2930, 2160, 2120, 1779 cm -1 .
1 H NMR (CDCl 3 ) δ 6.78 (s,1H), 6.73 (s,1H), 6.52 (s,1H), 5.97 (d,J=8.3Hz,2H), 5.82 (s,1H), 4.86 (d,J=2.2Hz, 1H), 4.72 (m,1H), 4.54 (d,J=7.6Hz,1H), 4.43 (t,J=9.0Hz,1H0, 4.35 (d,J=5.1Hz,1H), 4.26 (t,J=8.3Hz,1H), 4.14 (m,1H), 3.71 (s,3H), 3.55 (t,J=9.7Hz,1H), 3.40 (t,J=8.1Hz, 1H), 3.3 (bm,4H), 3.02 (m,1H), 1.35 (d,J=4.9Hz,3H).
EXAMPLE 4
3'-Demethoxy etoposide IV. ##STR8##
The crude etoposide diazonium salt of Example 3 (1.03 g, 1.76 mmol) was dissolved in absolute methanol (100 ml) and treated with sodium borohydride powder (400 mg) followed after 5 minutes by the addition of glacial acetic acid (5 ml). The mixture was stirred at room temperature for 2 hours, the solvent was evaporated in vacuo, and the residue was treated with H 2 O (100 ml) and extracted with CH 2 Cl 2 (100 ml then 2×50 ml). The combined extracts were washed with saturated aqueous sodium bicarbonate (25 ml) and brine (75 ml) and dried over MgSO 4 . Rotary evaporation followed by flash chromatography on silica gel (32 g) using 3-4% CH 3 OH in CH 2 CH 2 as eluant provided 400 mg (41%) of the title compound as a colorless solid, mp 190°-195° C.
IR (KBr) 3455, 1775, 1515, 1485, 1388, 1170, 1090, 1075, 1035, 1005, 933, 700 cm -1 .
1 H NMR (CDCl 3 ) δ 6.99 (d, 1H,J=1.7Hz), 6.79 (s, 1H), 6.65 (d,1H,J=8.2Hz), 6.51 (s, 1H), 6.01 (dd,1H,J=1.7 and 8.2Hz), 5.96 (d,2H), 5.50 (s, 1H), 4.87 (d,1H,J=3.4Hz), 4.73 (q,1H,J=5Hz), 4.64 (d,1H,J=7.6Hz), 4.57 (d,1H,J=5.2Hz), 4.39 (dd,1H), 4.21-4.13 (m,2H), 3.85 (s,3H), 3.71 (dd,1H), 3.56 (dd,1H), 3.43 (m,1H), 3.33-3.30 (m,2H), 3.23 (dd,1H,J=5.2 and 14.1Hz), 2.91-2.82 (m,1H), 2.66 (br s, 1H), 2.39 (br s, 1H), 1.37 (d,3H,J=5Hz). Anal. calcd for C 28 H 30 O 12 : C, 60.21; H, 5.41. Found: C, 59.45; H, 5.57.
EXAMPLE 5
The procedures described in Examples 1 to 4 are repeated with the exception that etoposide ortho-quinone is replaced with epipodophyllotoxin glucoside ortho-quinones having R 1 and R 2 as shown below to provide the corresponding 3'-demethoxy derivatives.
______________________________________ ##STR9## ##STR10##R.sup.1 R.sup.2______________________________________2-thienyl H2-furyl Hcyclohexyl Hphenyl Hbenzyl H4-methylphenyl H3-methoxyphenyl H4-hydroxyphenyl H4-(N,Ndimethylphenyl) H2-chlorophenyl Hmethyl methylethyl methylR.sup.1 + R.sup.2 = (CH.sub.2).sub.4= (CH.sub.2).sub.5______________________________________
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This invention relates to novel 3'-demethoxy epipodophyllotoxin glucosides, their use as anti-tumor agents, and pharmaceutical compositions thereof.
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FIELD OF THE INVENTION
[0001] This invention relates generally to frozen food products and, more particularly, to a method for producing a frozen fish product having a generally uniform thickness, and the frozen fish product produced thereby.
BACKGROUND
[0002] It is commonly understood that certain cuts of meat from various portions of an animal command a higher sale price than cuts from another portion of the same animal. For example, in the seafood industry, a “loin” portion of a fish generally refers to the locally thicker portion of a fillet, proximate the backbone or spine. Such cuts frequently have a higher value than other portions of the fish. To provide a loin portion of commercially viable size, however, the fish must be of a certain minimum size. Some prior art methods are known to adjust thickness.
[0003] See, for example, in U.S. Pat. No. 7,384,330 and German Patent Publication No. DE 19806003, the entire disclosures of which are hereby incorporated by reference herein. U.S. Pat. No. 7,384,330 discloses methods and apparatus for providing a fillet of generally uniform thickness, by cutting a thick loin portion of a fish fillet and folding the resulting butterflied portion over a thin belly portion of the fillet. German Patent Publication No. DE 19806003 discloses a method of providing a fish fillet of a relatively uniform thickness and an approximately standard width, by folding in the thin belly and tapered tail regions of a fish fillet; In addition or instead, tapered and thick regions of successive fillets are overlapped.
[0004] Methods for creating reconstituted meat products of preselected shapes from multiple trims of meat are also well known, such as the methods disclosed in U.S. Pat. No. 6,248,381 and International Patent Application No. PCT/US2004/005597, the entire disclosures of which are hereby incorporated by reference herein. These methods bind together trims of meat via the freezing of a “purge” formed by liquid emitted by the rupture of cells present in the meat. Such methods, however, involve additional equipment, materials, and processing steps, which increase cost, and are not as desirable to consumers, many of whom prefer minimally-processed food products.
[0005] Some types of frozen meat products can have sear and/or grill marks applied thereto, to increase flavor and appearance. For example, known processes of applying localized grill marks to a frozen fillet of fish can be done effectively using high temperature grill irons pressed into the frozen fish fillet momentarily. Only a small amount of thermal energy is transferred to the frozen fish and in localized areas, maintaining the bulk of the fish in the frozen state for further processing and packaging.
[0006] One challenge is to create a more uniform and extensive sear, reminiscent of char broiling, to an entire surface of a frozen fish fillet. However, the high temperature involved and the duration of exposure to achieve the desire surface effect causes an increase in bulk temperature of the frozen fillet. Partial thawing of the fillet results in: (1) loss of volume and weight (due to melting/dripping water); and (2) partial cooking of the entire fillet, especially at the edges, rather than only having the upper surface seared. These characteristics are compounded when surface searing technique is applied to fillets of a fish species that are relatively thin (e.g., Tilapia). These impact the cost of goods and complicate downstream processing (e.g., the addition of a flavor coating and refreezing of the entire fillet).
SUMMARY OF THE INVENTION
[0007] Examples of existing fish processing methods neither contemplate nor satisfy the combined needs of creating a fish portion with natural structure and texture in a size and configuration that transforms a relatively thin inexpensive starting fillet into a loin-type cut that is substantially thicker.
[0008] Accordingly, there is a need to transform thin flat fillets into more desirable, thicker loin-type cuts and optionally facilitate external surface processing to enhance consumer appeal.
[0009] In one aspect, the present invention is generally directed to a method for producing a minimally-processed frozen fish product from a whole fish fillet. The frozen fish product has many of the characteristics of a loin portion, including enhanced resistivity to partial thawing during the application of heat.
[0010] According to this aspect and related aspects, the invention relates to a method for processing a fish and a comestible fish product produced thereby, wherein the method includes the steps of providing a whole fish fillet having a lateral line generally disposed along a backbone of the fish, folding the whole fish fillet approximately in half, and freezing the folded fish fillet.
[0011] In various embodiments of the invention, the whole fish fillet may be skinned, deep skinned, or super deep skinned. Relatively flat whole fish fillets, such as Tilapia, may be used. In one embodiment, the whole fish fillet is folded along the lateral line; whereas, in another embodiment, the whole fish fillet is folded from head to tail. The fish fillet may be folded skin-side to-skin side. In one embodiment of the invention, the folded fish fillet has a minimum thickness of at least about 1.5 cm, whereas in another embodiment the folded fish fillet has a minimum thickness of about 1.9 cm.
[0012] The whole fish fillet may be trimmed after folding and prior to freezing, and may also be groomed for appearance prior to freezing. In one embodiment, a glaze (e.g., water with optional flavoring, tint, or other additive) is applied prior to or subsequent to freezing the folded fish fillet.
[0013] In various embodiments of the invention, the freezing step is accomplished by individual quick freezing, blast freezing, and/or tunnel freezing. In any of these embodiments, the folded fish fillet may be vacuum sealed prior to freezing. One embodiment of this aspect further includes providing, folding, and freezing a second whole fish fillet, wherein the folded fish fillets are frozen in a single layer, with spacing therebetween.
[0014] The invention further may include the step of processing at least a portion of an external surface of the frozen fish fillet. In various embodiments of this aspect, the processing may entail application of a marinade, searing, and/or char marking. As necessary, depending on the processing, the invention further includes the step of refreezing the processed fish fillet. The method may further include the step of cooking the processed frozen fish fillet.
[0015] In another aspect of the invention, the invention relates to a comestible fish product, wherein the comestible fish product is a whole fish fillet that has been folded approximately in half and frozen.
[0016] In one embodiment of the invention, the whole fish fillet is folded along a lateral line generally disposed along a backbone of the fish, whereas in another embodiment, the whole fish fillet is folded head to tail. The whole fish fillet is relatively flat prior to folding and may be Tilapia. The whole fish fillet may be skinned, deep skinned, or super deep skinned. In one embodiment of the invention, the folded fish fillet has been folded skin-side to skin-side. In various embodiments, the folded fish fillet has a minimum folded thickness of at least about 1.5 cm, or about 1.9 cm.
[0017] In one embodiment of the invention, the folded fish fillet has a groomed appearance, whereas in another embodiment, the folded fish fillet has a trimmed profile. In various embodiments of the invention, the folded fish fillet may be individually quick frozen, blast frozen, and/or and tunnel frozen. In any of these embodiments, the folded fish fillet may be vacuum sealed prior to freezing.
[0018] In one embodiment of this aspect, the fish fillet has a surface glaze and the surface glaze may be water with optional flavoring, tint, or other additive. In one embodiment of this aspect, the fish fillet has a processed external portion over at least a portion thereof. In various embodiments, the processed portion may be seared, marinated, and/or include char marking.
[0019] These and other objects, along with the advantages and features of the present invention herein disclosed, will become apparent through reference to the following description, the accompanying drawings, and the claims. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
[0021] FIG. 1A is a plan view of a whole fish fillet to be processed in accordance with various embodiments of the invention;
[0022] FIG. 1B is a plan view of another whole fish fillet to be processed in accordance with various embodiments of the invention;
[0023] FIG. 2A is a plan view of a folded fish fillet that is produced in accordance with one embodiment of the invention;
[0024] FIG. 2B is a plan view of a folded fish fillet that is produced in accordance with another embodiment of the invention;
[0025] FIG. 3 is a side view of a frozen fish fillet that is produced in accordance with one embodiment of the invention;
[0026] FIG. 4 is a plan view of multiple folded fish fillets that have been vacuum sealed in a single layer;
[0027] FIG. 5 is a plan view of a frozen fish fillet that has been further processed in accordance with one embodiment of the invention;
[0028] FIG. 6 is a schematic view of the further processing that is applied to a frozen fish fillet in accordance with one embodiment of the invention; and
[0029] FIG. 7 is a flow chart illustrating the processing method disclosed herein.
DETAILED DESCRIPTION
[0030] FIG. 1A is a plan view of a whole fish fillet 10 and FIG. 1B is a plan view of another whole fish fillet 10 . As used herein, a “whole fish fillet” may refer to either a trimmed fillet, as shown in FIG. 1A , or two separated sides of a trimmed fillet, as shown in FIG. 1B . The whole fish fillet 10 defines a lateral line 12 generally disposed along a backbone of the fish, and has a skin side 14 , a head end 16 , a tail end 18 , and an interior side 22 (best seen in FIG. 3 ). The whole fish fillet 10 may be skinned, deep skinned, or super deep skinned, and may be de-boned. Specifically, “deep skinned” fillets includes whole fillets 10 wherein some of the bloodline and fat flesh thereof have been removed, and “super deep skinned” includes whole fillets 10 wherein substantially all of the bloodline and fat flesh thereof has been removed. To prevent or reduce splitting of the tail end 18 , removal of the bloodline may be terminated at some distance (for example, about 4 cm) from the terminus of the tail end 18 . In one embodiment of the invention, the whole fish fillet 10 may be Tilapia or any other fish species producing a relatively thin or flat fillet.
[0031] In accordance with the invention, the whole fish fillet 10 is folded approximately in half, producing a folded fillet 20 . As discussed herein, “folding” includes both folding an intact fillet, such as that depicted in FIG. 1A , and stacking two separated sides of a fillet, such as that depicted in FIG. 1B , both producing a folded fillet 20 . The folding may be along the lateral line 12 , or may be from the head end 16 to the tail end 18 . FIG. 2A is a plan view of a whole fish fillet 10 that has been folded along the lateral line 12 , and FIG. 2B is a plan view of a whole fish fillet 10 that has been folded from the head end 16 to the tail end 18 , both providing an exposed, external surface 26 . In one embodiment of the invention, the folding is done such that the skin sides 14 of the two halves are in contact and the interior sides 22 form the exposed, external surface 26 , as shown in FIG. 3 .
[0032] The folded fillet 20 may have a minimum thickness “t” of at least about 1.5 cm at the thickest portion of the folded fillet 20 . In another embodiment of the invention, the folded fillet 20 has a minimum thickness “t” of about 1.9 cm. Additionally, prior to freezing, the whole fish fillet 10 or the folded fillet 20 may be trimmed and/or groomed for appearance. For example, the whole fish fillet 10 or the folded fillet 20 may have the tail cropped or undesirable portions thereof removed, and the folded fillet 20 may be manipulated to tuck in one or more portions thereof, such that a generally uniform shape is formed. Depending on the shape and profile of the whole fish fillet 10 and amount of trimming and/or grooming, the folded fillet 20 may have a substantially uniform thickness or may be tapered and somewhat thinner at the open edges and ends. In any event, the thinnest part of the folded fillet 20 will be thicker than the thinnest part of the whole fillet 10 , making the folded fillet 20 more suitable for subsequent processing.
[0033] In accordance with this aspect of the invention, the folded fillet 20 is then frozen. The freezing step may be accomplished by any method known in the art, including individual quick freezing (IQF), blast freezing, and tunnel freezing. Prior to freezing, multiple folded fillets 20 may be placed in a single layer, with spacing “s” between the fillets to avoid overlap, and are frozen at one time. The spacing “s” prevents the occurrence of two or more fillets becoming frozen to one another, which is undesirable for subsequent processing. In another embodiment of the invention, and as shown in FIG. 4 , prior to freezing, one or more folded fillets 20 are first placed in a single layer, with spacing “s” between the fillets to avoid overlap, and are subsequently vacuum sealed. Vacuum sealing facilitates consolidation and compaction of the two halves of the folded fillet 20 . It also removes air pockets, to reduce freezing time and allow for a more desirable and uniform appearance. Thus, the product of the freezing process is a frozen fillet 24 . Optionally, a glaze 30 is applied prior to or subsequent to freezing, to reduce or prevent dehydration. In one embodiment of the invention, the glaze 30 is water, though any of a variety of aqueous and/or non-aqueous glazes can be applied, including optionally flavors, colors, nutrients, and/or other additives.
[0034] FIG. 5 is a plan view of a frozen fillet 24 that has been further processed in accordance with one embodiment of the invention. Specifically, the frozen fillet 24 may have at least a portion of an external surface thereof 26 further processed. Specifically, at least a portion of the external surface 26 may have a marinade applied thereto 114 a , may have char marking applied thereto 114 c , or may seared 114 b , as depicted in FIG. 6 . FIG. 5 shows char marking 28 that has been applied. Subsequent to having at least a portion of the external surface thereof 26 further processed, the frozen fillet 24 may be refrozen, to minimize the effects of any thermal transfer that occurred as a result of the further processing. Subsequent to freezing or refreezing, the frozen fillet 24 may be packaged for distribution 118 , cooked, and eaten.
[0035] FIG. 6 is a schematic illustration of a process line for the further processing that the frozen fillet 24 may undergo. Specifically, after freezing 112 , a frozen fillet 24 may have a marinade applied to at least a portion of an external surface thereof 114 a . The marinade may be applied by any suitable method, such as dipping, spraying, etc. A crumb or breading coating may be applied, alternatively or additionally. The frozen fillet 24 may have a sear applied to at least a portion of an external surface thereof 114 b , for example by exposure to a broiler or high intensity flame for a short duration. Lastly, char marking may be applied to applied to at least a portion of an external surface thereof 114 c , for example with a high temperature platen or roller, or by flame impingement through a patterned mask. As will be readily understood any such external processing steps can occur solely or in combination and may occur in any order. The frozen fillet 24 may then be refrozen 116 . Subsequent to freezing or refreezing, the frozen fillet 24 may be packaged for distribution 118 .
[0036] FIG. 7 is a flow chart illustrating one embodiment of the method 100 described above. Specifically, the method 100 includes obtaining a whole fish fillet 102 , skinning the whole fish fillet 104 , and folding the whole fish fillet 106 . The process further includes any or all of optionally trimming 108 a , grooming for appearance 108 b , and/or 108 c glazing the whole fish fillet or the folded fillet. The process includes optionally vacuum sealing the folded fillet 110 , and freezing the folded fillet 112 . The resulting frozen fillet may have at least a portion of an external surface thereof further processed 114 , and may subsequently be refrozen 116 , packaged 118 , cooked, and eaten.
[0037] Accordingly, a relatively thin flat fish fillet, such as Tilapia, can be formed into a more substantial, thick loin-type portion. The increased thickness permits high temperature searing, char marking, and other processes to be performed effectively, without substantially increasing the bulk temperature (i.e., thawing) of the frozen fillet. Sole, flounder, and other thin flat fillets may be used, with similar advantageous results.
[0038] Having described certain embodiments of the invention, it will be apparent to those of ordinary skill in the art that other embodiments incorporating the concepts disclosed herein may be used without departing from the spirit and the scope of the inventions. The described embodiments are to be considered in all respects as only illustrative and not restrictive.
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The present invention is generally directed to a method for producing a frozen fish product from a whole fish fillet. The frozen fish product has many of the characteristics of a loin portion, including enhanced resistivity to partial thawing during the application of heat. The invention relates to a method for processing a fish and a comestible fish product produced thereby, wherein the method includes the steps of folding a whole fish fillet approximately in half and freezing the folded fish fillet, prior to subsequent external surface processing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to collapsible structures, and in particular, to collapsible frame assemblies that can be used in supporting collapsible structures. The collapsible frame assemblies may be twisted and folded to reduce the overall size of the resulting collapsible structures to facilitate convenient storage and use.
2. Description of the Prior Art
Collapsible structures have recently become popular with both adults and children alike. Examples of such structures are shown and described in U.S. Pat. No. 5,038,812 (Norman), U.S. Pat. No. 5,467,794 (Zheng) and U.S. Pat. No. 5,560,385 (Zheng). These structures have a plurality of panels that may be twisted and folded to reduce the overall size of the structures to facilitate convenient storage and use. As such, these structures are being enjoyed by many people in many different applications.
The wide-ranging uses for these collapsible structures can be attributed to the performace, convenience and variety that these structures provide. These collapsible structures are made up of a plurality of panels, each of which is supported by a coilable frame member. When fully expanded, these structures are stable and can be used as a true shelter without the fear of collapse. The coilable frame members allow these structures to be easily twisted and folded into a compact configuration to allow the user to conveniently store the structure. The light-weight nature of the materials used to make these structures makes it convenient for them to be moved from one location to another. These structures also provide much variety in use and enjoyment. For example, a child can use a structure both indoors and outdoors for different play purposes, and can use the same structure for camping.
The coilable frame members for these collapsible structures are often made from either a continuous frame member formed into a loop, or an elongated frame member having its opposite ends secured together to form a continuous loop. These frame members define the shape of the panels, and provide the requisite support to maintain the panels in their defined shape.
In this regard, many of the known coilable frame members are typically provided in a pre-formed configuration which cannot be changed. As a result, the variety of use and play for the resulting collapsible structures can be limited.
Thus, there still remains a need for coilable frame members that allow different collapsible structures to be assembled that provide increased variety of play, entertainment value, and utility.
SUMMARY OF THE DISCLOSURE
In order to accomplish the objects of the present invention, the present invention provides a collapsible frame assembly having a coilable frame member having a folded and an unfolded orientation, and a plurality of corner sleeves. Each corner sleeve has a lumen for retaining a selected portion of the frame member, with the plurality of corner sleeves positioned in spaced apart relation along the frame member to form a bend at each location of a corner sleeve.
Each collapsible frame assembly can be used to form a panel for a collapsible structure, with one side of each frame assembly hingedly coupled to another side of an adjacent frame assembly to form a series or ring of two or more frame assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective cut-away view of a frame assembly according to one embodiment of the present invention.
FIG. 2 is a perspective view of a corner sleeve of the frame assembly of FIG. 1 .
FIG. 3 is an exploded perspective view of a frame assembly according to another embodiment of the present invention.
FIG. 4A is a perspective view of a structure formed from a plurality of the frame assemblies of the present invention.
FIGS. 4B through 4F illustrate how the structure of FIG. 4A may be twisted and folded for compact storage.
FIG. 5 illustrates how a cover can be applied to the structure of FIG. 4 A.
FIGS. 6-8 are perspective views of different structures and frame assemblies formed from one of the frame assemblies of the present invention.
FIGS. 9-10 are perspective views of another structure formed from a plurality of the frame assemblies of the present invention.
FIG. 11 is a partial cut-away view of the section A of the structure of FIG. 4A illustrating a frame member retained within a sleeve.
FIG. 12 is a cross-sectional view of a connection between two adjacent panels of the structure of FIG. 10 taken along line 12 — 12 thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims.
The present invention provides coilable frame assemblies that can be formed of different shapes and sizes. These frame assemblies can be used to form and define panels that are assembled together to form collapsible structures. These structures can be folded and collapsed into a compact configuration for convenient storage and transportation.
FIGS. 1 and 2 illustrate a possible basic embodiment for a coilable frame assembly according to the present invention. The coilable frame assembly 20 has a frame member 22 and a plurality of corner sleeves 24 that receive selected portions of the frame member 22 . Each sleeve 24 is generally tubular and defines a lumen 26 for receiving a portion of the frame member 22 . FIG. 1 illustrates the frame assembly 20 in a cut-away view so that the frame member 22 can be shown lying inside the lumens 26 of the sleeves 24 . Each sleeve 24 should be made of a flexible material that allows it to be twisted and folded together with the frame member 22 . In particular, each sleeve 24 is made of a material that can be either flexible or stiff (depending on the application or intended use of the assembly 20 ), and the material can even have a memory. Examples of such materials can include plastic, PVC, rubber, and the like. Each sleeve 24 is also angled so as to define bends in the frame member 22 at the portions where the sleeve 24 is deployed.
In the embodiment of FIGS. 1 and 2, four sleeves 24 are provided to define a generally four-sided configuration for the frame assembly 20 . Therefore, each sleeve 24 in FIGS. 1 and 2 functions to cause a selected portion of the frame member 22 to be bent or angled, and in this case, by about ninety degrees, to form a corner. As illustrated in other embodiments herein, the number of sleeves 24 can be varied to provide frame assemblies having a different number of sides. In addition, the shapes (i.e., angles) of the sleeves 24 can be varied to provide different shapes for the resulting frame assembly 20 .
The frame member 22 may be provided as one continuous loop, or may comprise a strip of material connected at both ends to form a continuous loop. The frame member 22 is preferably formed of flexible coilable steel having a memory, although other materials such as plastics may also be used. The frame member 22 should be made of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, the frame member 22 is capable of assuming two positions or orientations, an open or expanded position such as shown in FIG. 1, or a folded position in which the frame member 22 is collapsed into a size which is much smaller than its open position (see FIG. 4 F).
FIG. 3 illustrates a modification to the frame assembly 20 . In frame assembly 20 a in FIG. 3, the sleeves 24 are still the same, but the singular frame member 22 has been replaced by a plurality of elongated frame members or sections 22 a . Each opposing end 28 a and 30 a of each elongated section 22 a is inserted into the lumen 26 of a different sleeve 24 and retained therein. The ends 28 a and 30 a can be secured inside the lumens 26 of the sleeves 24 by friction fit, glue, driving a nail or similar mechanism through the sleeve 24 and the end 28 a or 30 a , or similar methods. Thus, in addition to defining bends or corners, each sleeve 24 performs the additional function in the embodiment of FIG. 3 of connecting the ends 28 a and 30 a of two separate but adjacent elongated sections 22 a . The elongated sections 22 a can be made from the same material as the frame member 22 .
Notwithstanding the different structures for the frame members 22 and 22 a , each frame assembly 20 and 20 a can be used to form a panel that can be combined with other panels to form a collapsible structure. Therefore, even though the numeral designation 20 will be used to designate frame assemblies hereinbelow, it is intended that this numeral designation can be applicable to either of the frame assemblies 20 and 20 a.
One example of a collapsible structure 40 that utilizes a plurality of frame assemblies 20 is illustrated in FIG. 4 A. Structure 40 has four panels 42 , 44 , 46 , 48 that are coupled together to form an enclosed space 50 . Each of these panels 42 , 44 , 46 , 48 is defined by a frame assembly 20 , and each panel 42 , 44 , 46 , 48 has four sides 52 , 54 , 56 , 58 . The right side 56 of each panel (e.g., see panel 42 ) is hingedly connected to the left side 52 of an adjacent panel (e.g., see panel 44 ) by a retaining sleeve 60 , which has a lumen that retains the two adjacent frame members 22 of the adjacent panels (e.g., 42 and 44 ). As a result of this hinged connection, adjacent panels can be folded about the hinge formed by the retaining sleeve 60 . The retaining sleeve 60 can be made of a fabric or any of the materials used for the sleeves 24 .
Fabric or sheet material 62 can extend across any of the panels 42 , 44 , 46 , 48 . For illustrative purposes only, a portion of one of the panels 46 is shown with a fabric 62 , although it is possible to provide fabric material 62 to extend across any or all of the other panels 42 , 44 and 48 . The fabric 62 is held taut by the frame member 22 when in its open position. The fabric 62 can extend completely across the panel 46 to entirely cover the enclosed space defined by the frame member 22 , or can extend across selected portions of the enclosed space defined by the frame member 22 . The term fabric is to be given its broadest meaning and should be made from strong, lightweight materials and may include woven fabrics, sheet fabrics or even films. The fabric 62 should be water-resistant and durable to withstand wear and tear. The type of material used for the fabric 62 can be varied depending on the intended use. As one non-limiting example, a tough film-like material can be used if the panel 62 is intended for outdoor use or for use that may involve significant wear and tear. As another non-limiting example, a cloth-like material can be used if the structure 40 is intended primarily for indoor use.
Referring to FIG. 11, the fabric piece 62 is stitched at its edges by a stitching 64 to a peripheral sleeve 66 . The peripheral sleeve 66 may be formed by folding a piece of fabric, and then applying the stitching 64 to connect the peripheral sleeve 66 to the fabric. Alternatively, the peripheral sleeve 66 may be formed by merely folding over the fabric 62 and applying the stitching 64 . The frame member 22 and the sleeves 24 may be merely retained within the peripheral sleeve 66 without being connected thereto. Alternatively, the peripheral sleeve 66 may be mechanically fastened, stitched, fused, or glued to the frame member 22 and sleeves 24 to retain them in position.
FIGS. 4A-4F describe the various steps for folding and collapsing the structure 40 of FIG. 4A for storage. In FIG. 4A, the panels 42 and 44 are pushed in against panels 48 and 46 , respectively, about the hinges, in the direction of arrow A 1 . Then, the combined panels 44 and 46 are folded against the combined panels 42 and 48 about the hinges, in the direction of arrow A 2 (see FIG. 4B) to form one stack of panels 46 , 44 , 42 , 48 , in one possible order, as shown in FIG. 4 C. Thereafter, one opposing side or border of the combined panels 42 , 44 , 46 , 48 is folded in to collapse the frame members 22 with the panels 42 , 44 , 46 , 48 . As shown in FIGS. 4D-4F, the panels are twisted and folded to continue the collapsing so that the initial size of the panels is reduced. FIG. 4F shows the frame members 22 and panels collapsed on each other to provide for a small essentially compact configuration having a plurality of concentric frame members 22 and panels so that the collapsed structure 40 has a size which is a fraction of the size of the initial structure 40 in the expanded upstanding configuration.
To re-open the structure 40 to its expanded configuration, the panels 42 , 44 , 46 , 48 are unfolded. The memory (i.e., spring-load) of the frame members 22 will cause the frame members 22 to uncoil on their own and to quickly expand the panels 42 , 44 , 46 , 48 to their expanded configuration shown in FIG. 4 C. The respective panels 42 , 44 , 46 , 48 can then be folded about their hinged connections to be opened. The same principles can be applied to collapse, and to re-open, all the other embodiments of the present invention described above. In addition, the frame assemblies 20 , 20 a , 20 b , 80 , 90 of FIGS. 1, 3 , 6 , 7 and 8 , respectively, can be collapsed according to the steps shown in FIGS. 4D-4F.
FIG. 5 illustrates a structure 70 in which the frame assemblies in FIG. 4A are used as a support for a fabric covering 72 . The fabric covering 72 can be a four-sided enclosing fabric piece, with each side having generally the same shape and size as one of the frame assemblies 20 that make up the panels 42 , 44 , 46 , 48 . The covering 72 can then be slipped over the structure 40 to encircle or enclose the structure 40 , as shown in FIG. 5 .
FIG. 6 illustrates another application or use for the frame assembly 22 . The frame assembly 20 b in FIG. 6 can be used to support an item 76 (e.g., picture frame) or other exhibit or indicia. The frame assembly 20 b is the same as the frame assembly 22 or 22 a , except that connectors 78 (such as ties, straps, or the like) are coupled to the frame member 22 b and the item 76 . For example, each connector 78 can be a tie that has one end tied to the frame member 22 b and the opposing end tied to the item 76 . As another example, one end of the connector 78 can be nailed to the frame member 22 b , and the opposing end of the connector 78 tied to the item 76 .
The shape of the frame assembly 20 , 20 a can also be varied. An example of a frame assembly that has a different shape is shown in FIG. 7, where the frame assembly 80 is essentially the same in construction as either the frame assembly 20 or 20 a , except that frame assembly 80 has five sides. As a result, five sleeves 82 that are similar to sleeves 24 are provided to define the five-sided frame assembly 80 . Each sleeve 82 is the same as sleeve 24 , except that each is provided at a different angle to create the necessary configuration for the frame assembly 80 . For example, the sleeves 82 a and 82 b are provided to be generally right-angled at AN1 (i.e., ninety degrees), while sleeves 82 c and 82 d define an angle (e.g., AN2) greater than ninety degrees, and sleeve 82 e defines an angle (e.g., AN3) greater than angle AN2.
Another example of a frame assembly that has another different shape is shown in FIG. 8, where the frame assembly 90 is essentially the same in construction as either the frame assembly 20 or 20 a , except that frame assembly 90 has three sides. As a result, three sleeves 92 that are similar to sleeves 24 are provided to define the three-sided frame assembly 90 . Each sleeve 92 is the same as sleeve 24 , except that each is provided at a different angle to create the necessary configuration for the frame assembly 90 . For example, the sleeves 92 a and 92 b are provided at a first angle AN4, while sleeve 92 c defines an angle (e.g., AN5) greater than angle AN4.
FIG. 9 illustrates the use of four of the three-sided frame assemblies 90 to form a four-sided collapsible structure 100 . The principles illustrated in connection with the structure 40 of FIG. 4A are applicable to the structure 100 of FIG. 9, the only difference being that the frame assemblies 90 in FIG. 9 have a different shape from the frame assemblies 20 in FIG. 4 A. As with FIG. 4A, each frame assembly 90 defines a panel 102 , 104 , 106 , 108 , and fabric pieces 62 can be stitched to cover one or more of the panels 102 , 104 , 106 , 108 defined by the frame assemblies 90 . In addition, retaining sleeves 110 (which can be the same as retaining sleeves 60 ) can be used to hingedly couple adjacent frame assemblies 90 . The structure 100 can be folded and collapsed using the same method illustrated above for structure 40 .
FIG. 10 illustrates the structure 100 of FIG. 9 with each panel 102 , 104 , 106 , 108 partially or completely covered by fabric 62 . For example, the fabric 62 that extends across panel 108 can have a meshed portion 112 , while the fabric 62 that extends across panel 102 can have slits 114 that are used to define a door. Therefore, the structure 100 as illustrated in FIG. 10 can be used as a tent or shelter. The fabric 62 can be attached to the frame members of the frame assemblies 90 using the principles illustrated in FIG. 11 .
In addition, the retaining sleeves 110 can be omitted in FIG. 10 . Instead of providing the retaining sleeves 110 to couple and hinge the sides of adjacent panels, it is possible to stitch the sides of adjacent panels to form a hinged connection. In particular, the right side 122 of each panel can be stitched to the left side 120 of each panel. For example, FIG. 12 illustrates one method for hingedly connecting the right side 122 of panel 108 and the left side 120 of panel 102 . The fabric pieces 62 for each panel 102 and 108 are folded over at their edges along the bottom side 124 to define the respective peripheral sleeves 66 in the manner described in connection with FIG. 11 . The fabric pieces 62 are stitched at their edges by a stitching 126 to the respective peripheral sleeves 66 . The stitching 126 also acts as a hinge for the panels 102 and 108 to be folded upon each other. The same hinge structure can be used for hingedly connecting the right sides 122 and the left side 120 of the other adjacent panels.
The structures 40 and 100 can be used in the same applications as those similar structures described in U.S. Pat. Nos. 5,301,705 and 5,560,385. Thus, the frame assemblies of the present invention provide the flexibility of forming panels and structures having a variety of different shapes, thereby increasing the applications and use of the resulting collapsible structures to provide the user with an unlimited source and variety of fun and entertainment.
While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.
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A collapsible frame assembly has a coilable frame member having a folded and an unfolded orientation, and a plurality of corner sleeves. Each corner sleeve has a lumen for retaining a selected portion of the frame member, with the plurality of corner sleeves positioned in spaced apart relation along the frame member to form a bend at each location of a corner sleeve. Each collapsible frame assembly can be used to form a panel for a collapsible structure, with one side of each frame assembly hingedly coupled to another side of an adjacent frame assembly to form a series or ring of two or more frame assemblies.
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REFERENCE TO A RELATED APPLICATION AND PRIORITY CLAIM
[0001] This application claims the priority of Provisional Application No. US60/658,617, filed on 4 Mar. 2005 naming Richard D. Fortino as inventor.
FIELD OF THE INVENTION
[0002] This invention relates to a valve closure system comprising an electric motor for turning a rotary actuator of a valve to operate the valve from open to closed. Such valve closure systems allow valves of vessels, such as cylinders and containers, that hold fluids, such as industrial gases for example, to be quickly operated from a remote location.
[0003] Various types of transportable vessels are used for packaging various commercial and industrial gases at superatmospheric pressure. One type of vessel is a gas cylinder, an example of which is an elongate metal tank adapted to contain gas at relatively high pressure. An upper axial end of the cylinder has a neck containing an opening to the interior. A shut-off valve is mounted in closure of the neck opening. Another type is a container, a vessel that may have substantially larger volume than a cylinder. A container may have several such shut-off valves each mounted in closure of a respective opening in the container wall.
[0004] A representative shut-off valve comprises a first port fitted in sealed relation to an opening in a vessel wall, a second port, and a valve mechanism that is operable via an external actuator, handle, or tool, to allow and disallow fluid communication between the two ports. The second port is externally available for connection to a gas supply source when the cylinder is to be filled and for connection to a gas utilization system at a facility that uses gas stored in the cylinder. The valve mechanism comprises a stem that is rotated by the external actuator, handle, or tool to open and close the valve. An external actuator may be either manual or powered. An electric- or pneumatic-powered prime mover is an example of a power actuator. A wrench is an example of a hand tool for turning the valve stem.
[0005] The representative valve may be a globe style valve whose stem is rotatable more than one full turn between closed and full open positions. Opening the valve allows contained gas to pass from the vessel by entering the first port, flowing through the valve, and exiting via the second port. In such case, the first port forms a gas inlet connected to the vessel, and the second port a gas outlet. The gas outlet may be connected via a conduit to a point of use of the gas.
[0006] Such vessels can hold gases that may be considered hazardous, examples of such gases including chlorine and sulfur dioxide. A facility that utilizes one or more of such gases in a process, or processes, conducted at the facility may, for example, have any number of such vessels containing the same or different gases on the premises. When connected to a gas handling system at the facility, such vessels are able to deliver gas, or gases, into the system once their shut-off valves have been opened.
[0007] Because of inherent characteristics of certain gases, vessels that contain them may be housed in locations that are remote from attending personnel, and/or the vessels may be in use at times when personnel are absent.
[0008] When a vessel, or vessels, is, or are, in use at a facility, and gas leakage is detected, it may be appropriate to shut off all vessels in an attempt to minimize further gas leakage.
[0009] Accordingly, an automatic gas leak detection and valve shut-off system may be employed at a facility to address such a situation. Such a system may include a power actuator associated with the shut-off valve of each vessel. Examples of known valve closure systems include electromechanical actuators and pneumatic actuators.
[0010] Commonly owned U.S. Pat. Nos. 6,170,801 and 6,840,503 disclose valve closure systems for gas-containing vessels. When mounted on a vessel, a valve closure system associates with a valve having a rotatable stem that opens and closes the valve. The closure systems described in those patents comprise mounting brackets and air motors. With the valve open, the bracket is fit to the valve and a coupling on an external end of the air motor shaft is fit to the valve stem. The long axis of the air motor is coincident with the axis of the stem, or at a right angle to the valve stem. When pressurized air is delivered to the air motor, the motor shaft rotates the stem in a sense that closes the valve.
[0011] In certain facilities that use those types of valve closure systems, compressed air either may not be readily available or else may not be a preferred power source for operating the valve closure systems. In such instances, an electromechanical operator like an electric motor may be preferred.
[0012] Because a valve closure system must be removed when a gas cylinder is empty and thereafter installed on a fresh replacement cylinder, it is believed important for an electric-motor-operated valve closure system for such gas cylinders to be relatively light in weight and convenient to remove and install. Because space considerations may also be important in such facilities, minimizing the overall dimensions of a valve closure system is believed conducive to customer acceptance of a particular design. For example, the long axis of an electric motor affects the overall length of a valve closure system, and keeping that dimension as small as possible is apt to be desired by certain users.
[0013] When an electric motor is direct coupled in-line with a valve stem, the motor shaft will turn the valve stem in one-to-one correspondence (i.e. a 1:1 ratio) unless there is an intervening gear reduction mechanism. By providing a gear reduction mechanism, a smaller motor can be used to meet the valve torque requirements.
[0014] Parts for mounting valve closure systems on gas cylinders may, but do not necessarily, include a standard part commonly called a yoke that is clamped to the valve body and typically serves to embrace a fitting that connects a hose to a port of the valve. After having been fitted onto a valve body, the yoke is fastened in place by tightening a screw in a threaded hole in one side of the yoke to clamp the yoke to the valve body. Additional mounting parts serve to locate and support the valve closure system on the valve body and provide for the shaft of the operator to assume operative coupling with the valve stem.
[0015] The in-line coupling of the operator shaft to the valve stem typically has a non-circular transverse cross section that fits to a similarly shaped stem to provide for torque transmission to the stem. When the valve closure system is being installed, an installer may have an obstructed view of the coupling and stem and therefore an inability to easily judge when proper circumferential registration between the stem and coupling is attained so that the coupling can come into driving engagement with the valve stem. If the coupling is out of registration with the stem, the installer must perform some sort of manipulation in order to secure registration, and that may be an inconvenient task whose avoidance would be desirable.
[0016] Also, a valve closure system should be sufficiently rugged and durable for the environmental and operating conditions that it is expected to encounter when placed in use.
SUMMARY OF THE INVENTION
[0017] The present invention relates to further improvements in valve closure systems for fluid-containing vessels, the term “fluid” including both liquids and gases.
[0018] Briefly, and without limiting the scope that is defined by the claims, the invention comprises, in a disclosed presently preferred embodiment: a novel organization and arrangement of mounting parts, that may include a standard yoke, for enabling personnel to conveniently install and remove a valve closure system on and from a gas cylinder; and an electric motor that not only can turn the valve stem of a gas cylinder shut-off valve for opening and closing the valve, but also can be conveniently jogged to allow a coupling on the end of the motor shaft to readily attain proper circumferential registration with the valve stem during installation of the valve closure assembly on a gas cylinder.
[0019] The inventive valve closure system is also relatively compact, light-weight, and durable. It can be used on a gas cylinder whose valve turns about a vertical axis and also on a gas cylinder whose valve turns about a horizontal axis.
[0020] The preferred embodiment of the inventive closure system is well suited for use with known, and commonly used, gas shut-off valves, although certain principles are generic to use of the inventive system with different forms of shut-off valves. Certain principles of the invention may also extend to valve closure systems in which the fluid storage medium is a form of storage vessel other than the particular container and cylinder vessels mentioned above.
[0021] One generic aspect of the invention relate to a valve closure system for operating a valve of a fluid-containing vessel between an open and a closed position to allow and disallow communication of the interior of the vessel through the valve. The valve closure system comprises: an operating part shaped to engage and rotate a rotary actuator protruding from a valve body to operate the valve from one position to another when the valve closure system is associated with the valve; a motor for rotating the operating part; a walled located part disposed on a housing of the motor; and a walled locating part shaped for mounting on the valve body, the walled parts respectively comprising respective walls shaped to mutually telescopically engage when, with the locating part mounted on the valve, the motor housing has been properly circumferentially and axially aligned with the locating part and then advanced to move the operating part toward engagement with the rotary actuator of the valve.
[0022] Another generic aspect relates to a valve closure system for operating a valve of a fluid-containing vessel between an open and a closed position to allow and disallow fluid flow with respect to the interior of the vessel. The valve closure system comprises: an electric motor for rotating an operating part that is shaped to engage a rotary actuator of a valve for operating the valve from one position to another when rotated by the motor; a mounting via which a housing of the motor is constrained against rotation relative to a body of the valve when the motor rotates the operating part while the latter is engaged with the rotary actuator; and a jogging switch disposed on the motor housing for jogging the motor to turn the operating part to a proper position for engagement with the rotary actuator of the valve when the motor is being operatively associated with the valve.
[0023] Still another generic aspect of the invention relates to a method of associating a motor-operated valve closure system with a valve of a fluid-containing vessel for operating the valve, via a rotary actuator of the valve, between an open and a closed position to allow and disallow communication of the interior of the vessel through the valve. The method comprises: circumferentially and axially aligning a located part on the motor with a locating part on the valve and advancing the motor toward the valve to mutually telescopically engage respective walls of the located and locating parts and couple an operating part coupled to the motor to the rotary actuator to couple the rotary actuator to the motor.
[0024] The accompanying drawings, which are incorporated herein and constitute part of this disclosure, illustrate a presently preferred embodiment of the invention, and together with the written description given herein disclose principles of the invention in accordance with a best mode contemplated at this time for carrying out the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0025] FIG. 1 is a perspective view showing a presently preferred embodiment of the inventive valve closure system mounted on a gas cylinder valve.
[0026] FIG. 2 is another perspective view looking in a different direction.
[0027] FIG. 3 is an elevation view in the direction of arrows 3 in FIG. 1 .
[0028] FIG. 4 is a cross section view in the direction of arrows 4 - 4 in FIG. 3 .
[0029] FIG. 5 is an exploded perspective view of the valve closure system and the valve.
[0030] FIG. 6 is a perspective view useful in understanding the installation and removal sequences for installing and removing the valve closure assembly on and from the valve.
[0031] FIG. 7 is a perspective view of a multi-piece part corresponding to, but different from, one of the parts previously described.
[0032] FIG. 8 is a top view in the direction of arrow 8 in FIG. 7 .
[0033] FIG. 9 is a perspective view of one of the pieces of the part shown in FIGS. 7 and 8 .
[0034] FIG. 10 is a front elevation view of another multi-piece part corresponding to, but different from, another of the parts previously described.
[0035] FIG. 11 is a view of one of the pieces of the part of FIG. 10 , as taken in the direction of arrows 11 - 11 in FIG. 10 .
[0036] FIG. 12 is a perspective view of another of the pieces of the part shown in FIG. 10 .
[0037] FIG. 13 is a side elevation view of the parts of FIGS. 7 and 10 in mutual association mounting a motor of the valve closure system on a valve.
DETAILED DESCRIPTION
[0038] The drawing FIGS. 1-6 illustrate one presently preferred embodiment of cylinder valve closure system 30 according to principles of the invention intended for association with a cylinder valve 32 . Those drawings show a vertical installation, but the closure system can also be installed horizontally when the valve axis is horizontal.
[0039] Valve 32 is a commercially available cylinder tank shut-off valve that comprises a body 34 having a first port 36 at the bottom and a second port 38 at a side. Port 36 is adapted to fit in sealed closure of an opening in a neck at the top of a gas cylinder CYL (not shown in FIGS. 1-6 , but shown in phantom in FIG. 13 ). Port 38 is adapted for connection to a gas supply source when the cylinder is to be filled with gas. When the cylinder is in use at a facility, port 38 is connected to a gas handling system through which gas can flow from the cylinder to a point of use at the facility.
[0040] Valve 32 further includes an operating mechanism comprising a valve element within body 34 that is operated to open and close an internal gas flow path between ports 36 and 38 . The valve element is operated by turning an actuator, which for the illustrated valve, is a stem 40 on the exterior of body 34 . The turning of stem 40 occurs as rotation about an axis 42 . Stem 40 has a polygonally-shaped transverse cross section (a square shape for example) that can be engaged by a complementary shaped tool or socket for turning the stem. At the location where stem 40 protrudes from valve body 34 is a hexagonal-shaped head 44 that is concentric with axis 42 . Immediately below, and concentric with head 44 , body 34 has a cylindrical wall 46 of smaller diameter that allows portions of head 44 to protrude radially outwardly and overhang wall 46 .
[0041] FIG. 6 shows a motor assembly 48 , a bracket 50 , a yoke 52 , and a hitch pin 54 . Yoke 52 is shown in engagement with a fitting 56 on one end of a hose of conduit 58 forming a portion of the gas handling system to which port 38 of valve 32 is connected when in use at a typical facility that uses valve closure systems. Yoke 52 is a standard part for that may be used on gas cylinder valves at such facilities and comprises what is essentially a four-sided rectangular frame having two longer sides 60 , 62 and two shorter sides 64 , 66 . Side 64 has a discontinuity at its center that allows that side to embrace fitting 56 . Side 66 has a threaded hole at its center into which a screw 68 is threaded. Turning of screw 68 via a wrench surface 70 at one end in opposite directions advances and retracts a clamp 72 at the other end for clamping and unclamping yoke 52 to and from valve body 34 . In this way, yoke 52 accomplishes its usual purpose of holding fitting 56 on valve 32 after the fitting has been threaded and properly tightened to port 38 typically with a suitable sealing gasket between the port and the fitting. In certain valves, port 38 is externally threaded.
[0042] As will become apparent from following description, yoke 52 may be considered part of the valve closure system shown in FIGS. 1-6 because in so holding fitting 56 to valve body 34 , the yoke constrains movement of the bracket 50 on the valve body while also preventing removal of the bracket from the valve body. General principles of the invention however do not require that such a standard yoke be present.
[0043] Bracket 50 comprises a length of three-sided channel stock having side walls 74 , 76 , and 78 . A metal piece 80 is formed to have a right-angle bend 81 in FIG. 4 . To one side of bend 81 , piece 80 has a collar 83 containing a circular through-hole 82 . To the other side of bend 81 , piece 80 is notched to provide clearance for valve 32 while endowing the piece with two legs 85 that join respectively with side walls 74 , 78 to secure piece 80 to the channel stock. Through-hole 82 is large enough to fit over port 38 while side walls 74 , 76 , and 78 bound the valve on three sides. Aligned through-holes 84 , 86 at the upper corners of side walls 78 , 74 opposite piece 80 are clear of the valve body when bracket 50 is installed on the valve.
[0044] Motor assembly 48 comprises a multiple part housing 90 that provides an enclosure for an electric motor 92 and a casing 93 that contains a planetary gear drive. Housing 90 comprises a cylindrical side wall 94 having an open upper end closed by a removable cap 96 and a lower end to which a bracket 98 is fastened. FIG. 5 shows bracket 98 to comprise a flat circular ring 100 and a length of square tube stock 102 joined to and extending downward from and coaxial with ring 100 . Tube stock 102 comprises four apertured side walls dimensioned to provide the tube stock with a telescopic fit to bracket 50 .
[0045] FIG. 5 also shows an end plate 104 that has four locator tabs 106 protruding radially beyond the nominal inside diameter of side wall 94 at 90° intervals about a main longitudinal axis 108 of motor assembly 48 . End plate 104 is one end part of casing 93 . Motor 92 is secured to another end part of the gear drive casing opposite end plate 104 . Motor 92 and casing 93 are secured in proper position in motor assembly 48 by assembling them into the housing through the open lower end of side wall 94 to lodge tabs 106 in mating notches 110 arranged at 90° intervals about axis 108 in the end margin of side wall 94 . Bracket 98 is then placed axially of the lower end of side wall 94 and advanced toward the side wall to capture tabs 106 . Four screws 112 pass through aligned clearance holes 114 in ring 100 and in the four tabs 106 and are tightened in tapped holes 116 in side wall 94 .
[0046] A coupler 118 is assembled to an output shaft 120 of motor 92 in a manner that allows the coupler to move axially on the shaft without falling off. A spring 122 is disposed between end plate 104 and an inner end of coupler 118 effectively resiliently biasing the coupler in the direction away from the interior of housing 90 while allowing the coupler to move axially toward the interior against the spring bias force. Coupler 118 has a circumferentially keyed connection to shaft 120 and provides a socket having a shape for fitting to stem 40 so that motor torque can be transmitted through the coupler to turn stem 40 . The end portion of shaft 120 has an elongate slot 124 parallel to the shaft length. A spring pin (not shown) passes through a circular radial hole in the coupler wall, through slot 124 , and a circular radial hole in the opposite portion of the coupler wall causing the coupler to be kept on the shaft end, but allowing the coupler to position itself axially along the shaft end. The lost motion allows for some tolerance in length of the valve stem and the extent of stem displacement while turning. The limited displacement travel serves to accommodate axial travel of the valve stem as the stem is being rotated, but it does not allow coupler 118 to lose driving engagement with the valve stem while the system remains installed.
[0047] The planetary gear drive provides a gear reduction between the motor and the valve stem to amplify the motor torque to proper level for turning the valve stem. The use of a planetary gear drive also contributes to robustness of the motor assembly.
[0048] Cap 96 has a dome 126 surrounding a circular walled cavity 128 . A push-button switch 130 is mounted on a bottom wall of the cavity. The button actuator 132 is on the outside of the housing interior where it can be depressed by thumb or finger. It does not however protrude above the rim of dome 126 , thereby requiring a person's thumb or finger to enter the open top of the cavity in order to actuate switch 130 . The mounting is made weather-tight by an O-ring gasket 133 sealing the switch housing to the cap.
[0049] Electric wires inside a conduit 134 provide power to switch 130 and motor 92 . Switch 130 and motor 92 are arranged in circuit with power supplied by the electric wires such that pressing button 132 to actuate switch 130 causes motor shaft 120 to turn only in a direction that will act to open valve 32 . This assures that the installer will not inadvertently close an otherwise open valve, an important consideration at certain facilities such as water treatment plants. The circuit arrangement provides for the actuation of switch 130 to energize a solenoid that operates contactors through which current is carried to the motor. In that way, the switch carries only a small current because the larger motor current doesn't pass through the switch. And as mentioned before the actuation of switch 130 causes the motor to operate only in a direction that will open a valve so that an already open valve will not be inadvertently closed by jogging the motor when the coupler is engaged with the valve stem. The solenoid is located in a control panel that is remote from the motor assembly.
[0050] Conduit 134 is secured in a weather-tight manner to motor assembly 48 via a fitting 136 that tightened in a threaded hole in side wall 94 . In addition, there are electric wires from a remote control panel that will operate the valve closure system to close an open valve in situations where valve closing is called for.
[0051] Cap 96 has a series of six through-holes 138 in its outer margin. Six screws 140 pass through the six holes 138 and are tightened in tapped holes in the upper end of side wall 94 to fasten cap 96 to the side wall thereby enclosing motor 92 at that end of the motor assembly. An O-ring gasket 142 is received in a circular groove in the radially outer surface of a short cylindrical wall 144 that fits closely to the inside of side wall 94 to make the cap-to-side wall joint weather-tight.
[0052] An O-ring gasket 146 seals the motor housing to side wall 94 in a similar way at the lower end of the motor assembly.
[0053] The foregoing description now allows the installation and removal of the valve closure system to be explained. First, with screw 68 backed off, the distance between clamp 72 and side 64 of yoke 52 allows the yoke to be placed over valve 32 until it rests on the gas cylinder (not shown). Then bracket 50 is placed on the valve by aligning hole 82 with port 38 and moving the bracket radially to insert the port into the hole. Although collar 83 has a slightly loose fit around the outside of port 38 , bracket 50 can turn only a very limited amount about the axis of port 38 due to sides 60 and 62 of the yoke presenting interference to the vertical sides of the collar. Once the collar has been placed over and around outlet port 38 , fitting 56 can then be connected.
[0054] Next yoke 52 is raised off the gas cylinder to the position shown by FIG. 4 , and screw 68 is tightened to clamp the yoke to the valve body and engage fitting 56 as shown. This also prevents bracket 50 from falling off the valve. Motor assembly 48 is then placed over the valve with its axis generally aligned with valve axis 42 and lowered to telescope tube 102 inside the channel of bracket 50 . In this way, bracket 50 forms a locating part for locating tube 102 , the latter part being the located part.
[0055] Operative engagement of coupler 118 with stem 40 can be attained only when they have proper circumferential registration. If circumferential registration exists as the motor assembly is being placed on the valve, coupler 118 will attain rotatable coupling with stem 40 . If the coupler and stem are out of registration, the coupler will contact the stem 40 , but without attaining rotatable coupling, in which event button 132 can be depressed to jog motor 92 until registration occurs at which time the motor assembly may drop down slightly in a vertical installation as shown. The weight of the motor assembly will be borne by abutment of end plate 104 with the upper ends of the bracket channel side walls, and resulting transmission of that weight through bracket 50 to port 38 by virtue of collar 83 resting on the port. Weight is not borne through coupler 118 although the coupler's engagement with the valve stem stabilizes the mounting.
[0056] For keeping the motor assembly in place on the valve, hitch pin 54 is inserted through hole 84 to pass through aligned holes 148 in opposite sides of tube 102 and then hole 86 . The placement of holes 84 , 148 , and 86 provides for hitch pin 54 to clear valve 32 . With the hitch pin in place, the motor assembly cannot be removed unless the hitch pin is first extracted. Removal of the valve closure system from the valve can be easily accomplished by lifting the motor assembly off the valve after the hitch pin has been extracted.
[0057] The telescopic engagement between the channel of bracket 50 and tube 102 keeps substantial axial alignment of the motor assembly to the valve stem as the motor assembly is being placed. Once the motor assembly has been placed, none of its weight is transmitted to yoke 52 , and bracket 50 is free of contact with the yoke.
[0058] FIGS. 7-13 illustrate brackets 150 , 198 representing modified forms of brackets 50 and 98 .
[0059] Bracket 150 , like bracket 50 , comprises three side walls 174 , 176 , and 178 . It is a formed sheet metal part of suitable thickness. A piece 180 that is shown by itself in FIG. 9 is welded to bracket 150 to provide a collar 183 containing a circular through-hole 182 . Piece 180 is a machined metal piece. Aligned through-holes 184 , 186 are present at the upper corners of side walls 178 , 174 but those two side walls unlike side walls 78 , 74 are not rectangular in shape because the lower corners have been cut away.
[0060] Piece 180 differs from piece 80 by having full side walls 185 rather than merely two legs 85 . Certain features of piece 180 have significance in relation to bracket 150 and to valve 32 . The upper portions 185 A of walls 185 have reduced thickness that provides horizontal dimensional clearance to the nuts of certain valves from which the valve stems emerge. Notches 185 B and chamfers 185 C provide clearance and facilitate installation for certain valves.
[0061] For controlling the horizontal dimension between the inner face of collar 183 and the centerline of through-holes 184 , 186 so that the inner collar face can be disposed against the portion of the valve body adjoining port 36 and the hitch pin can pass through the telescoped brackets with a desired closeness to the valve body on the side opposite port 36 , a ridge 183 A is present at the top of the side wall containing the collar. A rectangular opening 183 B is also present in that same side wall above through-hole 182 to provide for clearance to the valve. For controlling the vertical dimension between the centerline of through-hole 182 and the centerline of through-holes 184 , 186 , the height of ridge 183 A is chosen such that the lower surface of the ridge and the lower surface of side wall 176 will be located against a common horizontal surface in a welding jig before the machined and formed pieces are welded together around the outside of the overlapping margins of three side walls.
[0062] Bracket 198 , like bracket 98 , has a flat circular ring 200 , corresponding to ring 100 , and a square tube 202 , corresponding to tube 102 , joined to and extending downward from, and coaxial with, ring 200 . A face of ring 200 has a shallow recess 201 for locating tube 202 to it prior to the two pieces being welded together. Tube 202 comprises four apertured side walls dimensioned to provide the lower end portion of the tube below a shoulder 203 with a telescopic fit to bracket 150 . One of the apertures 205 allow installer viewing of coupler 118 through the telescoped brackets. Shoulder 203 rests on the upper edge of bracket 150 when the motor is mounted on the valve. Through-holes 248 in opposite side walls align with through-holes 184 , 186 to provide for passage of the hitch pin through both brackets to pin them together when the motor is in place on the valve.
[0063] A bent tab 207 containing a threaded through-hole 209 forms a continuation of the one side wall of tube 202 that is opposite collar 183 . A thumbscrew 211 is threaded into hole 209 and can be tightened to cause its tip to bear against the backside of the valve body. In doing so the thumbscrew provides an adjustment for minimizing non-parallelism of the motor axis to the valve stem axis while relieving some of the weight being applied to the valve port on which collar 183 bears. Although it was mentioned in connection with FIGS. 1-6 that the valve stem doesn't bear any of the weight of the valve closure system, certain valve stems can bear some or all of the weight.
[0064] While a presently preferred embodiment of the invention has been illustrated and described, it should be appreciated that principles of the invention apply to all embodiments falling within the scope of the following claims.
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A valve closure system ( 30 ) for operating a valve ( 32 ) of a fluid-holding cylinder (CYL) between an open and a closed position to allow and disallow communication of the interior of the cylinder through the valve. A coupler ( 118 ) engages and rotates a stem ( 40 ) of the valve. An electric motor ( 92 ) rotates the coupler. A square tube ( 102 ) on the motor housing surrounds the coupler. A bracket ( 50 ) mounts on the valve body. The parts ( 50, 102 ) have respective walls shaped to mutually telescopically engage when, with bracket ( 50 ) mounted on the valve, the motor housing has been properly circumferentially and axially aligned with the bracket and then advanced to move the coupler toward engagement with the valve stem. The parts ( 50, 102 ) may be pinned together by a hitch pin ( 54 ).
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FIELD OF THE EMBODIMENTS
[0001] Embodiments relate to thermoplastic polymer compositions that include nucleating agents whereby the compositions have improved properties for use in carpet backing applications. Non-limiting examples of nucleating agents include silica-containing nucleating agents such as sand, glass, and specifically, ground, powdered, or crushed glass. The polymer compositions provide improved properties relating to processing, dimensional and thermal stability, improved crystalline structure, and flame retardant properties. The polymer compositions are useful, for example, for carpet backing applications.
DESCRIPTION OF RELATED ART
[0002] It has long been recognized that filling polymers with inorganic materials can modify the polymer properties. There are a large number of such filled polymers that are used commercially. In many instances, fillers are utilized as much for economics as they are for performance. In some instances, however, fillers can result in improved properties for the underlying composition to which they are added.
[0003] Fiberglass reinforced resins have been commercially used for some time.
[0004] These are generally thermosetting resins with polyester backbones dissolved or dispersed into a reactive diluent such as styrene that can be cross-linked into rigid or semi-rigid networks. These resins also can be set off with peroxide accelerators. Other resins used in similar applications include acrylics or epoxy polymers, or combinations of the two. Fiberglass reinforced resins typically are used in fabricating bathtubs, shower stalls, boats, boat hulls, and automotive parts.
[0005] Other water-soluble or emulsion polymers have been filled with various ingredients to provide a more economical product. In some cases glass has been added to form a roughened surface after the polymer has been dried on the surface. Glass also has been added to provide a decorative finish to wall and floor coverings.
[0006] It is important for the polymer or resin to have properties that allow it to “wet” out or bind with the filler. If this “wetting out” property is not achieved, then delamination or failure of the polymer/filler bond can occur. In many instances the polymer can only be loaded with a limited amount of filler before the wetting ability becomes consumed. It then becomes important to add wetting or coupling agents to boost the amount of filler the polymer composition may accept.
[0007] The description herein of problems or disadvantages associated with known compositions, compounds, apparatus, and methods is not intended to limit the embodiments to their exclusion. Indeed, various embodiments may include one or more known compositions, compounds, apparatus, and methods without suffering from the previously known problems or disadvantages.
SUMMARY
[0008] It is a feature of the embodiments to provide polymer compositions having improved physical properties, and improved processability. It is an additional feature of the embodiments to provide a polymer composition and method of making the polymer composition that has improved properties suitable in carpet backing applications. It is a further feature of the embodiments to provide carpet backing compositions and carpet tiles prepared using the compositions, as well as methods of making the carpet tiles.
[0009] In accordance with these and other features of the embodiments, there is provided: a thermoplastic polymer composition comprising a thermoplastic polymer and at least one nucleating agent, whereby the polymer composition may have one or more properties selected from:
an MT4 value of less than about 0.125 and a CT4 value of less than about 0.1, when measured according to the AACHEN Test; a surface tackiness disappearance time of less than about 1 hour; a sufficient rigidity time of less than about 75 hours; a time to ignition of greater than about 13 seconds; and a time to self-extinguish of less than about 60 seconds.
[0015] In accordance with an additional feature of an embodiment, there is provided a thermoplastic polymer composition comprising a thermoplastic polymer and at least finely ground glass powder. Suitable thermoplastic polymers include those that are capable of wetting out large amounts of the ground glass filler. Dispersing agents may be added in some embodiments to allow greater amounts of ground glass fillers to be added to the composition.
[0016] Another feature of an embodiment includes a method of making a thermoplastic polymer composition: having one or more of the properties described above, whereby a thermoplastic polymer is admixed with a nucleating agent filler material, the nucleating agent filler material being in an amount of from about 10 to about 70 percent by weights based on the total weight of the thermoplastic polymer composition.
[0017] Another feature of an embodiment includes a carpet backing composition comprising the thermoplastic polymer composition described above. An additional feature of an embodiment includes a method of making a carpet backing comprising heating the carpet backing composition, and applying the carpet backing composition to a plurality of carpet backing yarns, carpet cloths, or non-woven fabrics, to form a carpet backing. Suitable methods of making carpet tile backings are disclosed in U.S. Pat. No. 5,834,087, the disclosures of which is incorporated by reference herein in its entirety. The thermoplastic polymer compositions of the invention are suitable in any method of forming a carpet backing for conventional carpet materials, or for carpet tiles.
[0018] An additional feature of an embodiment includes a carpet tile comprising the thermoplastic polymer composition described above. These and other features of the embodiments will be readily apparent to those skilled in the art upon review of the detailed description that follows.
DETAILED DESCRIPTION
[0019] The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. As used throughout this disclosure the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “a polymer composition” is a reference to one or more compositions and equivalents thereof known to those skilled in the art, and so forth.
[0020] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which these embodiments belong. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the embodiments, the methods, devices, and materials are now described. All publications mentioned herein are cited for the purpose of describing and disclosing the various components that are reported in the publications and that might be used in connection with the embodiments. Nothing herein is to be construed as an admission that the embodiments are not entitled to antedate such disclosures by virtue of prior invention.
[0021] The polymer compositions described herein possess unexpected but highly beneficial increases in dimensional stability that may be achieved by using relatively large amounts of nucleating agents. In one embodiment, these beneficial increases are achieved by utilizing a finely ground glass filler in thermoplastic adhesive and/or layering compositions. This dimensional stability is believed to be important for applications such as backing of carpet tiles where the current art relies primarily on a fiberglass matt to achieve the needed dimensional stability.
[0022] While not intending on being bound by any theory of operation, the inventor believes that the finely ground glass filler materials act as a surprising source of nucleation sites in the thermoplastic polymers that are crystalline or semi-crystalline nature. The inventor further believes that smaller particle sizes of the ground glass filler material or other nucleating agent(s), or combinations thereof, contributes to an increased number of nucleation sites. The use of nucleating agents is well documented in industry and typically is described as controlling crystallinity during the application of certain polymers. Controlling the rate and degree of crystallinity is believed to be important in obtaining certain properties in certain applications, such as, for example, where the thermoplastic composition is being used for adhesive purposes.
[0023] The nucleating agents described herein also may provide an added benefit to the polymer composition in terms of fire retardancy. Fire retardancy is a desirable property for many polymer applications. Many of the fire retardants used with thermoplastics have the effect of ceramitizing the surface and thus preventing oxygen from getting to the fuel source. Finely ground glass powder has this effect either alone in high concentrations or to augment other flame retardant systems.
[0024] The thermoplastic polymer composition includes a nucleating agent and may have one or more properties selected from:
an MT4 value of less than about 0.125 and a CT4 value of less than about 0.1, when measured according to the AACHEN Test; a surface tackiness disappearance time of less than about 1 hour; a sufficient rigidity time of less than about 75 hours; a time to ignition of greater than about 13 seconds; and a time to self-extinguish of less than about 60 seconds.
[0030] The thermoplastic composition may have two or more of the properties listed above, and may have three or more, and may even possess all of the aforementioned properties.
[0031] Applications of thermoplastics are too numerous to specifically mention in this disclosure. Generally thermoplastics can be used to coat other substrates, as film formers either alone or applied to substrates, as adhesives or adhesive layers, and in forming articles by various molding concepts. The thermoplastic compositions described herein are suitable for use in any or all of these applications.
[0032] Fillers typically are added to compositions tot decrease the cost of the composition (e.g., use less polymer by adding fillers that typically are inert). Some filler materials may provide beneficial properties, such as imparting impact resistance, altering the texture or feel of a finished object, etc. Generally, fillers are added to the molten polymer in a number of ways but most frequently they are added into an extruder as a mixture along with pellets of the thermoplastic or downstream in the extruder in a side stuffer. It may be beneficial to add these fillers in a very carefully controlled environment and at a higher level than the end product requires, pelletize, and then mix the pellets with non-filled thermoplastic in an extruder again to produce a final product composition. In this regard, the filled resin could be called a “Masterbatch.”
[0033] Additional methods of providing fillers to thermoplastic polymers involve a batch process further upstream in the vessel in which the polymer itself is made. In these cases, the filler can be added to a vessel or reactor directly into the molten polymer. The composition may be agitated until the composition in thoroughly mixed and then the mixture is either applied directly or extruded into pellets, pillows, bricks, etc. for further processing.
[0034] Suitable thermoplastics for use in the embodiments include, for example, any known thermoplastic polymer material. Suitable thermoplastics include esters of polyethylene terephthalate (PET), optionally with a modifying polymer, esters of polyethylene naphthalate (PEN), optionally with a modifying polymer other polyester materials, polyesters (all copolymers), polyamides (all copolymers), ethylene vinyl acetates and polyethylene copolymers, polyolefins, polystyrenes, polystyrene butadienes, acrylonitrile butadiene styrene and copolymers, polyvinyl chloride, acrylics, styrene maleic acrylics, acetal, fluoropolymers and copolymers, polybutylene, polycarbonate, polyimides and polyetherimides, polysulfones, and polyethersulfones, polyvinylindene chlorides, silicones, and mixtures and combinations thereof. The optional modifying polymer, for example, may be one or more of polyethylene glycol, diethylene glycol, trimethylol propane, phthalic anhydride, adipic acid, and combinations or mixtures thereof. Additionally, esterification catalysts may be added to the mixture in order to promote esterification of the modifying polymers and trans-esterification with PET and PEN.
[0035] The thermoplastic polymer may be mixed with additives to impart additional beneficial qualities to the finished carpet. Applicable additives include, but are not limited to, fire retardants, fillers, weighters, oxidization stabilizers, antibacterial agents, antimicrobial agents, antifungal agents, UV stabilizers, and combinations or mixtures thereof. One skilled in the art will recognize other applicable additives that may optionally be added to the hot melt adhesive, in accordance with the guidelines provided herein.
[0036] One filler suitable for use in the embodiments is a nucleating agent that is capable of imparting one or more of the properties described above to the polymer composition. For example, a finely ground glass material or other silica-containing nucleating agent may be added to the thermoplastic polymer composition. These fillers include powdered glass, powdered sand, powdered quartz, powdered silica-containing ceramics, and the like. The filler can be added in an amount of from about 10 to about 70 weight percent, based on the total weight of the polymer composition, or it may be added in an amount of from about 40 to about 60 weight percent. The filler may have a mesh size of about 40 to about 250 mesh, or from about 50 to about 70 mesh.
[0037] The thermoplastic polymer compositions described herein may be used in carpet tile backing applications, where a meltable composition is desirable. The composition can be applied to any known carpet backing material to provide a carpet backing having improved dimensional stability, improved fire retardance, and other desirable properties described herein. For example, the thermoplastic polymer composition can have a relatively lower viscosity when melted so that it may more fully penetrate the fiber tufts of the greige carpet typically used for carpet backings. The thermoplastic polymer compositions described herein may have a viscosity of less than 300,000 centipoise at 325° F., or the composition could have a viscosity of less 75,000 centipoise at 325° F.
[0038] The thermoplastic composition described herein may be applied to the secondary backing material or primary backing material to form the carpet backing. Applying the thermoplastic composition to the carpet backing material may take place in any applicable manner. For example, the thermoplastic composition may be sprayed or rolled on the carpet backing material, or it may be applied in one application, or multiple applications to provide a multi-coated carpet backing material.
EXAMPLES
Example 1
[0039] In the carpet industry, thermoplastic materials have been and are being used as a suitable adhesive layer for adhering tufts into a backing material. In this regard, they are applied to the back of the carpet onto the tufts protruding through the primary backing. Various materials have been used to achieve this, but more recently polyesters have been used. The polyester materials have the ability to wet out and adhere to the tufts providing both internal and external binding. To provide increased weight and improved economics, various fillers have been tried, some with marginal success.
[0040] In the batch process using thermoplastic polyester, finely ground glass powder of 60 mesh size or less was added to the finished polymer at levels of 10 to 70 percent, or from 40 to 60 percent prior to application on the carpet back. It was found to provide properties that none of the other previously tried fillers had, and even more so the resulting composition had a combination of properties not believed to have been previously achieved using conventional fillers and polymers. These properties provide the following added benefits.
[0041] Improved processing due to the flow properties of the thermoplastic composition allows for slight changes in running conditions without affecting the final product. Some of these flow properties can be attributed to the internal heat sinking effect of the composition containing the glass. The specific heat of the polymer/glass composition is believed to be considerably more than that of the polymer alone.
Example 2
Dimensional Stability
[0042] This property was measured using a test for carpet tile dimensional stability called the AACHEN test. In this method the carpet is subjected to a series of conditions that mimic the action of steam, moisture, and heat on the carpet tile. The results are provided in table 1 below:
TABLE 1 AACHEN TEST DESCRIPTION VALUES-Average Control = 50% Polyester/50% Magnetite filler MT4 = .127 CT4 = .052 with Fiberglass Matt 50% Polyester MHF/50% Magnetite filler with MT4 = .295 CT4 = .102 no Fiberglass Matt 50% Polyester MHF/50% Barium Sulfate filler MT4 = .262 CT4 = .181 with no Fiberglass Matt 50% Polyester MHF/50% Ground Glass MT4 = .123 CT4 = .071 Powder with no Fiberglass Matt
[0043] The results in the table above reveal that the polymer compositions of the embodiments provide a carpet back with improved dimensional stability, and in fact can provide the same or better dimensional stability as carpet backings that utilize a fiberglass matt. Thus, embodiments of the carpet backing may not include a fiberglass matt, yet still possess the requisite dimensional stability, thereby reducing carpet backing costs and processing time.
Example 3
Controlled Nucleation of Polyester Formula
[0044] It was found on during the processing of the polyester carpet backing that the crystallinity of the polyester may have had a significant influence on the properties of the finished carpet. If the crystallinity was too high initially then the desirable properties of tuft bond strength and Velcro fiber stability may have suffered. If the crystallinity was not high enough, then the carpet backed surface may have become too tacky resulting in numerous processing problems including, but not limited to blocking, fiber transfer, excessive drape, and dimensional stability as in above example. Using the guidelines provided herein, those skilled in the art will be capable of modifying the thermoplastic polymer composition to have the requisite crystallinity, depending on the particular application of the polymer composition.
[0045] Two test parameters were used in the following table 2. These parameters were surface tackiness after application and backing rigidity, both of which are believed to be directly related to polymer crystallinity. The addition of the ground glass powder resulted in the ability to control these parameters more sufficiently.
TABLE 2 Time to Time to Running disappearance of sufficient Formulation Temperature surface tackiness rigidity Polyester 330° F. ˜30 hours ˜168 hours MDF/Magnetite 50/50 Polyester MHF/ 330° F. ˜24 hours ˜120 hours Magnetite 50/50 Polyester MHF/ 350° F. ˜12 hours ˜120 hours Magnetite 50/50 Polyester MHF/Barium 330° F. ˜12 hours ˜96 hours Sulfate 50/50 Polyester MHF/Calcium 330° F. ˜5 hours ˜96 hours Carbonate 50/50 Polyester MHF/Ground 330° F. ˜3 minutes ˜60 hours Glass 50/50 Polyester MHF/Ground 350° F. ˜5 minutes ˜48 hours Glass 50/50
[0046] In this example the ground glass is apparently offering numerous sites for crystallinity to initiate, and consequently, is behaving as a nucleating agent.
Example 4
[0047] It was also found that glass filled compositions offered flame retardant properties greater than the thermoplastic polyester formulation alone or thermoplastic polyester formulations filled with other known fillers. Two properties were tested. These properties were time to initial ignition when exposed to a torch flame and time for the ignition to self-extinguish once the torch flame was removed. It was determined that these two properties related well to the Radiant Panel Carpet Test that is used to standardize flame retardancy in the carpet industry. The results are listed in table 3 below:
TABLE 3 Time to Time to Self- Formulation Ignition Extinguish Polyester Polymer MDF-100% 10 seconds <1 minute Polyester Polymer MHF-100% 15 seconds <1 minute Polyester Polymer MHF/Calcium 15 seconds <1 minute Carbonate 50/50 Polyester Polymer MHF/Ground 15 seconds <1 minute Glass 90/10 Polyester Polymer MHF/Ground 15 seconds <1 minute Glass 80/20 Polyester Polymer MHF/Ground 22 seconds 30 seconds Glass 70/30 Polyester Polymer MHF/Ground 33 seconds 10 seconds Glass 60/40 Polyester Polymer MHF/Ground 40 seconds 2 seconds Glass 50/50
[0048] From these data it is clear to see that the effect of ground glass, especially in the higher loading levels, sufficiently increases the flame retardancy of the thermoplastic polymer. It was especially interesting that the char formation on the surface seemed to be much harder indicating that a least some melting and subsequent ceramitizing of the surface was occurring.
[0049] Other embodiments, uses, and advantages of the embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. The specification should be considered exemplary only, and the scope of the embodiments is accordingly not intended to be limited thereby.
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The embodiments disclosed herein relate to thermoplastic polymer compositions that comprise a thermoplastic and nucleating agents, such as silica-containing nucleating agents. The polymer compositions provide improved properties relating to processing, dimensional and thermal stability, improved crystalline structure, and flame retardant properties. The thermoplastic polymer compositions are useful, for example, for carpet backing applications. It is a further feature of the embodiments to provide carpet backing compositions and carpet tiles prepared using the thermoplastic polymer composition, as well as methods of making the carpet tiles.
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BACKGROUND OF INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a microscope apparatus for viewing microscopic features. More specifically, the present invention relates to an optical microscope which provides high contrast and sharp images, providing for higher detail.
[0003] 2. Background Art
[0004] Microscopes have assisted scientists and researchers for hundreds of years. From chemistry to the construction of computer chips to genetics to medical research, nearly every imaginable discipline has benefited from the ability to magnify the very small.
[0005] The oldest of microscopes were optical in nature, and were comprised of little more than a few lenses and a light source. These microscopes use the visible wavelengths of light to observe the microscopic. Over time, such optical microscopes have become more and more complex using dozens of lenses and reflecting/refracting elements. Medical researchers often use optical microscopes, as they allow living specimens to be observed without causing harm to the specimens. Today, such optical microscopes are considered to have a “theoretical limit” of resolution of about 200 nanometers—more precisely, 187 nanometers—because of the resolution limitations of lenses, the limited wavelengths of visible light, and limitations on the angular apertures of lenses. Thus, things smaller than approximately 0.2 microns are not readily viewable through standard optical microscopes. Even when viewing features at this lower resolution limit, some contrasts and color are often lost.
[0006] More recent developments in microscopy have resulted in electron microscopes, which use beams of electrons instead of beams of light. As electrons can be accelerated to produce a much smaller wavelength than visible light, electron microscopes allow much higher resolution than standard optical microscopes.
[0007] However, while electron microscopes can resolve features less than 0.2 microns, they typically cannot be used on living specimens. Electron microscopes use very high energy electron beams which can be harmful to living specimens. Also, to be viewed by an electron microscope, each specimen must be placed in a vacuum for viewing, as a gas would improperly scatter the electron beam, which vacuum would cause the death of a living specimen. Further, electron microscopes are often quite expensive to purchase and maintain, and require special power sources and a stable building.
[0008] Therefore, it would be preferable to combine the higher resolution qualities of an electron microscope with the lower expense and the ability to view living specimens of an optical microscope. It would further be preferable to view true color and high contrast images through an optical microscope.
BRIEF SUMMARY OF THE INVENTION
[0009] One or more of the embodiments of the present invention provide for an optical microscope apparatus including a light source, a base unit, a rotary monochromatic dispersion unit, a condenser, a stage, an objective, a tubular assembly and an ocular assembly. In a preferred embodiment, light travels from the light source sequentially through each of these seven components, producing an image of the contents of a slide on the stage to a user looking through the ocular assembly.
[0010] In the base unit, in place of a standard mirror which would direct the light vertically up into the scope along the z-axis, a right angle piece of single crystal Calcite, known as Iceland Spar is used, which has a birefringent affect. The double refracted light then passes up through the rotary monochromatic dispersion unit, which contains at least one Risley Prism, and then up through a standard condenser, stage (with slide) and objective. The light then travels through the tubular assembly which includes an Abbe Koenig prism, and then up through the ocular assembly.
[0011] Another embodiment provides for an optical microscopy method including the steps of directing light from a light source through a birefringent material, directing said light from said birefringent material through a standard microscope condenser, stage and objective, directing light from said objective through a tubular assembly containing an Abbe Koenig prism, and directing light from said tubular assembly through an ocular assembly for viewing by a user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a better understanding of the present invention, reference may be made to the accompanying drawings in which:
[0013] FIG. 1 is a photograph of a microscope according to one embodiment of the present invention.
[0014] FIG. 2A is a perspective view of a base unit.
[0015] FIG. 2B is a bottom view of a base unit having an Iceland Spar prism.
[0016] FIGS. 3A-3C are diagrams of light paths through a right angle Iceland Spar prism from various angles.
[0017] FIG. 4 is a diagram of the light path through a plano-convex lens made of Iceland Spar.
[0018] FIG. 5 is a top view of a base unit.
[0019] FIGS. 6A and 6B are top and side views of a Risley Prism.
[0020] FIG. 7A-7C are perspective, side and top views of a rotary monochromatic dispersion unit.
[0021] FIG. 8 a perspective view of a condenser and stage.
[0022] FIGS. 9A and 9B are top and side views of a condenser.
[0023] FIG. 10 is a top view of a stage.
[0024] FIG. 11A is a side view of a tubular assembly.
[0025] FIG. 11B is top view into a tubular assembly having an Abbe Koenig prism.
[0026] FIGS. 12A and 12B are side and top views diagramming the light path through the objective and lower prism assembly.
[0027] FIGS. 13A and 13B are perspective and side views of a lower prism assembly.
[0028] FIG. 14 is a top view of the inside of a tubular assembly wing.
[0029] FIG. 15A is a diagram of the light path through a tubular assembly wing.
[0030] FIG. 15B is a top view of a wing relative to the tubular assembly.
[0031] FIGS. 16A and 16B are front perspective and side views of an Abbe Koenig prism.
[0032] FIG. 17A is a side view diagram of a tubular assembly.
[0033] FIG. 17B is a top view of the inside of a tubular assembly.
[0034] FIGS. 18A and 18B are perspective and top views of the upper prism assembly.
[0035] FIG. 18C is an exploded view of the upper prism assembly.
[0036] FIG. 18D is an exploded view of a dual prism holder.
[0037] FIGS. 19A and 19B are top and side views diagramming the light path through the upper prism assembly and ocular assembly.
[0038] FIG. 20 is a side view diagram of the light path from the objective through the tubular assembly through the ocular assembly.
[0039] FIG. 21 is an exemplary out of focus image taken through a microscope according to one embodiment of the present invention.
[0040] FIG. 22 is an exemplary focused imaged taken through a microscope according to one embodiment of the present invention.
[0041] FIG. 23 is a side view diagram of the light path from the objective through the tubular assembly through the ocular assembly with additional lenses.
[0042] FIG. 24 is an exemplary out of focus image taken through a microscope according to one embodiment of the present invention.
[0043] FIG. 25 is an exemplary focused imaged taken through a microscope according to one embodiment of the present invention.
[0044] FIG. 26 is an exemplary image of 0.11 micron poly latex microspheres, taken with a 40× objective according to one embodiment of the present invention.
[0045] FIG. 27 is an exemplary image of 0.11 micron poly latex microspheres, taken with a 40× objective according to one embodiment of the present invention.
[0046] FIG. 28 is an exemplary image of 0.11 micron poly latex microspheres, taken with a 40× objective according to one embodiment of the present invention.
[0047] FIG. 29 is an exemplary image of 0.05 micron gold particles, taken with a 40× objective according to one embodiment of the present invention.
[0048] FIG. 30 is an exemplary image of 0.05 micron gold particles, taken with a 100× objective according to one embodiment of the present invention.
[0049] FIG. 31 is a top view diagram of an alternative arrangement of the components of the tubular assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0050] In one embodiment of the present invention, the microscope is an optical microscope that may be capable of resolving details smaller than 50 nanometers. As can be seen in FIG. 1 , which is an image of the full microscope, the scope is comprised of eight main sections. See FIGS. 20 and 23 for exploded views of the optical components of the scope.
[0051] I. & II. Light Source ( 1 ) and Base Unit ( 2 )
[0052] Light source ( 1 ) of the Truman Nanoscope is preferably a MicroLite FL2000 light source, though most any light source could be used. Light source ( 1 ) outputs light to the base unit ( 2 ) of the scope through the light input path ( 4 ), shown in FIG. 2A . Base unit ( 2 ) is that of a Zeiss Microscope, model 4290785, though, again, nearly any base could be acceptably substituted. However, in the Zeiss base unit ( 2 ), in place of a standard mirror which would direct the light vertically up into the scope along the z-axis, a right angle piece of single crystal Calcite, known as Iceland Spar ( 6 ) and measuring 22 mm×22 mm×22 mm with an angle of 45°30′ (±40″), is present. See FIG. 2B . The Iceland Spar ( 6 ) has: a linear tolerance of +0, −0.1 mm; an angular tolerance of +/−40 arc sec; three rectangular surfaces polished 60/40 scratch/dig and ¼ wave at 520 nm flat and two triangular surfaces fine ground; and bevel of 0.3 mm nom.×45 deg. Additional specifications of the right angle piece of Iceland Spar ( 6 ) are given in FIGS. 3A-3C .
[0053] Iceland Spar, formerly known as Iceland Crystal, is a transparent form of calcite or crystallized calcium carbonate. It is a birefringent material, and thus has two difference refractive indices. Iceland Spar therefore splits light into an ordinary wave (“o-wave”) and an extraordinary wave (“e-wave”) as shown in FIG. 3C . If a material has a single axis of anisotropy (directional dependence) or optical axis (i.e. it is uniaxial), birefringence can be formalized by assigning two different refractive indices to the material for different polarizations. The birefringent magnitude is then defined by the formula Δn=ne−no, where for calcite the refractive indices are: Δn=−0.172; ne=1.486; and no=1.658. A plano-convex lens made of Iceland Spar could also be used. See FIG. 4 .
[0054] Once the light has passed through the Iceland Spar ( 6 ) and has been directed upward, it travels approximately 10-mm and leaves the base unit through a first glass-protected iris ( 8 ) with a diameter of between 22-mm and 1-mm. See FIG. 5 . It is noted that all distances between optical components discussed hereinafter are approximate. This iris ( 8 ) is original to the Zeiss base unit ( 2 ) described above, and controls the amount of light which passes through. After the light has passed through the iris ( 8 ), it leaves base unit ( 2 ) and travels 7-mm to the Rotary Monochromatic Dispersion Unit ( 10 ) where it encounters the Risley Prism ( 12 ).
[0055] III. The Rotary Monochromatic Dispersion Unit ( 10 )
[0056] The light then travels vertically along the z-axis through a 15°, 1.25 inch diameter Risley Prism 12 , which consists of two 15° prisms mounted such that rotating one of the prisms in one direction causes the other to be rotated an equal amount in the opposite direction and vice versa. See FIGS. 6A , 6 B. The Risley Prism ( 12 ) is mounted inside a housing ( 14 ), which housing ( 14 ) is moveably connected to a threaded rod ( 16 ) allowing the Risley Prism ( 12 ) and housing ( 14 ) to move frontward and rearward (on the y-axis) by several decimeters. The Risley housing ( 14 ) and the threaded rod ( 16 ) are mounted to a Risley Mounting Bracket ( 18 ). See FIG. 7A (Rotary Monochromatic Dispersion Unit 10 inverted for ease of viewing).
[0057] The Risley mounting bracket ( 18 ) is also mounted to an x-axis adjustment assembly ( 20 ) which was cannibalized from a standard square stage ( 20 ) such as Cynmar part number 101-01347, and is shown in FIGS. 7B and 7C . This x-axis adjustment assembly ( 20 ) includes an adjustment knob ( 22 ) which allows the table to be adjusted along the x-axis of the scope independently of the Risley Prism ( 12 ) and the Risley mounting bracket ( 18 ). A second iris ( 24 ) having an adjustment lever ( 26 ) is mounted to the x-axis adjustment assembly ( 20 ) with an iris mounting bracket ( 21 ), allowing the iris ( 24 ) to be moved along the x-axis. This iris ( 24 ) is a 22-mm to 1-mm iris, as was iris ( 8 ) above. See FIG. 7C . The distance from the topmost portion of Risley prism ( 12 ) and iris ( 24 ) is 28-mm Thus, the Risley prism ( 12 ) can be moved along the y-axis while the iris ( 22 ) can be independently moved along the x-axis. After the light travels from the Risley prism ( 12 ) through the iris ( 22 ), it leaves the Rotary Monochromatic Dispersion Unit (“RMD”) ( 10 ) and travels to the Condenser ( 28 ).
[0058] IV & V Condenser ( 28 ) and Stage ( 34 )
[0059] After the light has passed through the second iris ( 24 ), it proceeds 6-mm up to a standard 1.4 N.A. Zeiss condenser ( 28 ), numbered achr. apl. 1.4 (achromatic-aplanatic 1.4). See FIG. 8 . As is seen in FIG. 8 , the dovetail of the RMD Unit ( 10 ) connects to the bracket of the condenser ( 28 ) such that raising and lowering the condenser ( 28 ) also raises and lowers the RMD Unit ( 10 ). This condenser ( 28 ) can be substituted with other condensers, with little to no effect on the magnification or resolution of the Nanoscope. Using oil with the condenser is preferable. The condenser ( 28 ) has a third iris ( 30 ), similar to the first two and being adjustable from 22-mm to 1-mm via an adjustment lever ( 32 ). See FIGS. 9A and 9B .
[0060] After passing through the condenser ( 28 ), the light passes up through a Zeiss 473357-9901 Zeiss rotary microscope stage ( 34 ), in between which is oil when used. See FIG. 10 .
[0061] VI & VII Objective ( 36 ) and Tubular Assembly ( 38 )
[0062] After passing the stage ( 34 ), the light travels up through the objective ( 36 ) an adjustable distance. Objectives ( 36 ) of power 5 to power 100 have been successfully used. Depending on the length of the objective, the entire assembly from the objective to the oculars can be raised and lowered with standard the course and fine adjustment knobs. After passing through the objective ( 36 ), the light travels along the z-axis into the tubular assembly ( 38 ). The tubular assembly ( 38 ) itself has five main components: the lower prism assembly ( 40 ), the right wing ( 48 ), Abbe Koenig prism ( 60 ), the left wing ( 62 ), and the upper prism assembly ( 68 ). See FIGS. 11A and 11B .
[0063] The light travels from the objective ( 36 ) approximately 32-mm vertically (z-axis) up into the lower prism assembly ( 40 ), where it encounters a right angle glass prism (“RAP”) ( 42 ) which directs the light from the z-axis to the y-axis toward the back of the scope where it immediately encounters another right angle glass prism ( 44 ). All RAP prisms are 22-mm wide, 21-mm deep and tall, and each are made of BK7 with a dimensional tolerance of ±0.1-mm, a surface quality of 60-40, a surface accuracy of ½λ, and angle tolerance of ±5 arc min., and have an aluminized hypotenuse, overcoated with inconel and black paint. This right angle prism ( 44 ) directs the light from the y-axis (toward the back of the scope) to the x-axis (toward the right of the scope). See FIGS. 12A and 12B . These two right angle prisms are housed in a dual prism holder ( 46 ) shown below in FIGS. 13A and 13B . See FIGS. 18C and 18D below for exploded views of the Upper prism holder ( 66 ) (which is substantially a mirror image of the lower prism holder ( 40 )).
[0064] The light then travels from the lower prism assembly ( 40 ) (which is connected to the bottom of the tubular assembly 38 ) toward the right of the scope along the x-axis approximately 35-mm where it enters the right wing ( 48 ) and encounters a third glass right angle prism ( 50 ). This right angle prism ( 50 ) directs the light from the x-axis toward the right of the scope to the z-axis toward the top of the scope. See FIG. 14 , looking down into the right wing ( 48 ) with right angle prism ( 56 ) removed such that only right angle prism ( 50 ) is visible.
[0065] Mounted on top of the right angle prism ( 50 ) may be several lenses ( 52 , 54 ) of varying magnification, though preferably lens ( 52 ) is a 36-mm focal length, 12-mm diameter biconvex (or double-convex) lens, and lens ( 54 ) is a 17-mm focal length, 17-mm diameter biconvex (or double-convex) lens. Whether the light travels through these lenses or not, it travels 35-mm vertically from the third right angle prism ( 50 ) and enters a fourth right angle glass prism ( 56 ) which directs the light from the z-axis back to the x-axis, toward the left of the scope. See FIGS. 15A , 15 B. Again, an additional 60-mm focal length, 17-mm diameter biconvex (or double-convex) lens ( 58 ) is optional after the right angle prism ( 56 ). These lenses tend to increase magnification but reduce resolution.
[0066] In any case, after traveling approximately 13-mm from right angle prism ( 56 ) toward the left of the scope along the x-axis, the light travels through an Abbe Koenig prism ( 60 ), which may or may not be of the type which has an air gap between the roof prism and the primary prism, and which inverts the image both horizontally and vertically. The Abbe Koenig prism is 54-mm long, 22-mm wide and 17-mm high, and is shown in FIGS. 16A and 16B below.
[0067] The light then exits the Abbe Koenig prism ( 60 ), travels approximately 13-mm to the left wing ( 62 ) and encounters a fifth right angle prism ( 64 ) which redirects the light from the x-axis vertically upward along to the z-axis. The light again travels approximately 35-mm to a sixth right angle prism ( 66 ) which redirects the light from the z-axis to the x-axis toward the right of the scope. The left wing ( 62 ) is substantially a mirror image of the right wing ( 48 ) shown in FIGS. 14 and 15A above, in which the fourth right angle prism ( 56 ) of the right wing ( 48 ) is at approximately the same height as the Abbe Koenig prism ( 60 ) and the fifth right angle prism ( 64 ) of the left wing ( 62 ), as shown in the diagram and photo of the tube of tubular assembly ( 38 ) in FIGS. 17A and 17B . This tubular assembly is composed machined aluminum, though it could be composed of brass or another suitable material.
[0068] The light then enters the Upper Prism Assembly ( 68 ) and encounters a seventh glass right angle prism ( 70 ) which redirects the light from the x-axis to the y-axis toward the front of the scope where it immediately encounters an eighth right angle glass prism ( 72 ) which redirects the light vertically toward the top of the scope. The seventh and eighth right angle prisms are housed in a dual prism holder ( 74 ) as above with the lower prism assembly ( 40 ). See FIGS. 18A through 18D .
[0069] VIII. Oculars ( 76 )
[0070] The light then exits the Upper Prism Assembly ( 68 ), and thereby exits the tubular assembly ( 38 ). It travels 19-mm until it encounters the oculars ( 76 ), as seen below in FIGS. 19A and 19B . The oculars ( 76 ) are mounted to the Upper Prism Assembly ( 68 ) as shown in FIG. 1 , and are 10× each. The exact oculars used are a Carlsan CS700, though it is envisioned that nearly any oculars would suffice. The image may be viewed through the oculars or may be recorded by a camera attached to the ocular assembly.
Example
[0071] What follows are two examples of the Truman Nanoscope in use. The same sample of blood was viewed in both examples, and the objective in both is a 40× objective. In the first example, the optional lenses ( 52 , 54 , 58 ) were not used, such that the optical components in the tubular assembly 38 are as shown in FIG. 20 .
[0072] Prior to conducting the example procedure, all of the adjustable components of the scope were zeroed out: the irises ( 8 , 24 , 30 ) were opened fully to their 22-mm positions; the Risley prism ( 12 ) was centered over the Iceland Spar ( 6 ) and set to zero degrees; and the tubular assembly ( 38 ) was raised such that the objective ( 36 ) was 15-mm above the stage ( 34 ). There was effectively no image visible.
[0073] The Risley prism ( 12 ) was then rotated from zero to 25 diopters (75 degrees), the first iris ( 8 ) was set to a diameter of 6-mm, the second iris ( 24 ) was set to a diameter of 7-mm, and the third iris ( 30 ) was set to a diameter of 3-mm. The tubular assembly ( 38 ) was lowered such that the height of the objective ( 36 ) off of the stage ( 34 ) was approximately 2-mm. This height resulted in an image that was slightly out of focus, as seen in FIG. 21 .
[0074] From this position, the tubular assembly ( 38 ) was lowered by another 30 graduations of the fine adjustment knob, which equals approximately 0.0033 inches. This adjustment resulted in the focused image as seen in FIG. 22 .
[0075] In the second example, the optional lenses ( 52 , 54 , 58 ) were used, such that the optical components in the tubular assembly 38 are as shown in FIG. 23 .
[0076] Prior to conducting the example procedure, all of the adjustable components of the scope were again zeroed out: the irises ( 8 , 24 , 30 ) were opened fully to their 22-mm positions; the Risley prism ( 12 ) was centered over the Iceland Spar ( 6 ) and set to zero degrees; and the tubular assembly ( 38 ) was fully raised such that the objective ( 36 ) was 15-mm above the stage ( 34 ). There was effectively no image visible.
[0077] The Risley prism ( 12 ) was then rotated from zero to 25 diopters (75 degrees), the first iris ( 8 ) was set to a diameter of 6-mm, the second iris ( 24 ) was set to a diameter of 7-mm, and the third iris ( 30 ) was set to a diameter of 3-mm. The tubular assembly ( 38 ) was lowered such that the height of the objective ( 36 ) off of the stage ( 34 ) was approximately 2-mm. This height resulted in an image that was slightly out of focus, as seen in FIG. 24 .
[0078] From this position, the tubular assembly ( 38 ) was lowered by another 30 graduations of the fine adjustment knob, which equals approximately 0.0033 inches. This adjustment resulted in the focused image as seen in FIG. 25 .
[0079] FIGS. 26 through 28 are additional examples of images taken of 0.11 micron poly latex microspheres through an optical microscope with a 40× objective according to an embodiment of the present invention. FIGS. 29 and 30 are additional examples of images taken of 0.050 micron gold particles through an optical microscope with 40× and 100× objectives, respectively, according to an embodiment of the present invention.
[0080] Alternatives
[0081] The tubular assembly ( 38 ), as opposed to being oriented vertically, could be oriented substantially horizontally as shown in the FIG. 31 .
[0082] While particular elements, embodiments, and applications of the present invention have been shown and described, it is understood that the invention is not limited thereto because modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is therefore contemplated by the appended claims to cover such modifications and incorporate those features which come within the spirit and scope of the invention.
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An embodiment of the present invention provide for an optical microscope apparatus including a light source, a base unit, a rotary monochromatic dispersion unit, a condenser, a stage, an objective, a tubular assembly and an ocular assembly. In a preferred embodiment, light travels from the light source sequentially through each of these seven components, producing an image of the contents of a slide on the stage to a user looking through the ocular assembly. In the base unit, in place of a standard mirror which would direct the light vertically up into the scope along the z-axis, a right angle piece of single crystal Calcite, known as Iceland Spar is used, which has a birefringent affect upon the light as it passes up through the scope.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for drying a wet cake of aminoguanidine bicarbonate under a CO 2 -containing atmosphere at selected temperatures.
2. Brief Description of the Prior Art
Aminoguanidine bicarbonate (AGB) is a known chemical intermediate for many useful chemical products. For example, it may be converted into 3-amino-1,2,4-triazole, a known herbicide. AGB is a stable compound at ambient conditions whereas aminoguanidine is not stable under those conditions. Furthermore, AGB has advantageous properties as compared to other aminoguanidine salts. For example, it is insoluble in H 2 O, which makes it easy to prepare in aqueous media.
Generally, AGB is made by reacting hydrazine or hydrazine hydrate with cyanamide or its salts (e.g. sodium or calcium) in the presence of an acid such as HCl, followed by adding a bicarbonate salt to the reaction mixture to precipitate out the AGB. The precipitated AGB is removed as a wet cake from the reaction mixture by filtration or centrifugation or the like. However, AGB is extremely heat sensitive when wet and discolors at temperatures as low as 35° C. under normal drying conditions such as drying under air or nitrogen. Furthermore, drying AGB at temperatures below about 35° C. results in long drying times and, in some cases, still results in undesirable amounts of residual moisture.
Accordingly, there is a need for an improved method of drying AGB whereby higher drying temperatures may be utilized without the undesirable discoloration.
It is an object of this invention to provide such an improved method for drying AGB.
BRIEF SUMMARY OF THE INVENTION
The present invention is, therefore, directed to a process for drying a wet cake of aminoguanidine bicarbonate (AGB), which comprises subjecting the wet cake of aminoguanidine bicarbonate to drying temperatures from about 35° C. to about 95° C. under a carbon dioxide-containing atmosphere for a sufficient amount of time to form a dried aminoguanidine bicarbonate product which is substantially free of moisture.
DETAILED DESCRIPTION
When aminoguanidine bicarbonate (AGB) is prepared by reacting hydrazine with cyanamide in the presence of HCl, followed by conversion to the bicarbonate salt with sodium bicarbonate, the following reactions (A) and (B) are thought to occur: ##STR1## However, aminoguanidine bicarbonate is known to decompose to aminoguanidine, water and CO 2 according to the following reaction (C) in the presence of excessive heat: ##STR2##
Also, aminoguanidine is reported to degrade to 3,6-diamino-1,2-dihydrotetrazine and ammonia according to reaction (D) as follows: ##STR3## 3,6-Diamino-1,2-dihydrotetrazine has a red color. It is thought that above reactions (C) and (D) describe the discoloration (and degradation) that occurs in the normal course of drying AGB as employed in the past.
Of course, AGB may be prepared by other synthesis methods, such as from sodium and calcium cyanamide. Also, other degradation products of AGB may be made which may cause the formation of an undesirable color in the product. Accordingly, the present invention encompasses all methods of making AGB where the product is recovered as a water-containing cake ready to be dried. Furthermore, the present invention is not to be limited as to avoiding any particular color-containing degradation product.
The term "wet cake" of AGB as employed in the present specification and claims refer to any water-containing AGB product which contains at least 5% by weight water. In most conventional processes, wet cakes of AGB from a filter press or centrifuge will contain from 15% to about 50% by weight water.
The wet cake of AGB may be dried at temperatures from about 35° C. to about 95° C. with any conventional drying means such as a shelf-type drying oven, a rotary drying oven or the like, as long as a CO 2 -containing atmosphere is provided above the wet cake. It is believed that the CO 2 -containing atmosphere suppresses degradation reactions such as shown in reactions (C) and (D), above. The term "CO 2 -containing atmosphere" refers to any gaseous atmosphere which contains a sufficient amount of CO 2 to substantially retard or prevent the discoloration of aminoguanidine bicarbonate. A substantially pure (i.e. above 95% by volume) CO 2 atmosphere is preferred.
Preferably, the drying temperatures are from about 50° C. to about 90° C. The most preferable drying temperatures are from about 75° C. to about 85° C. At temperatures below about 35° C., even with a CO 2 -containing atmosphere, the drying times are relatively long and uneconomical. At temperatures above about 95° C., small amounts of discoloration do occur even with a CO 2 -containing atmosphere. It has been found that drying temperatures of about 75° C. to about 85° C. under a CO 2 atmosphere give relatively fast drying times without excessive heating costs and without degradation of the product.
The phrase "a dried aminoguanidine bicarbonate product which is substantially free of moisture" as employed herein refers to a dried AGB product which contains less than about 3% by weight H 2 O. For most operations, it is preferred that the dried product contains less than about 2.5% by weight H 2 O, more preferably, less than about 1% by weight water. The drying times will depend upon the moisture content in the wet cake, the drying temperature and the drying apparatus employed. Usually drying times will range from about 15 minutes to about 150 minutes or more.
The following example and comparison further illustrates the present invention. All parts and percentages are by weight unless explicitly stated otherwise.
EXAMPLE 1
A. Synthesis of Aminoguanidine Bicarbonate (AGB)
Hydrazine hydrate (64% hydrazine, 20 lbs, 0.4-mole) was charged to a 30-gal glass-lined reactor and hydrochloric acid (32.1%, 45.4 lbs, 0.4 lb-mole) was added to it with stirring and cooling over 30 min. The resulting hydrazine hydrochloride solution was heated to 80° C. and cyanamide (50%, 36 lbs, 0.43 lb-mole) was metered in over ˜30 min in 5-lb increments while maintaining the reaction temperature at ˜85° C. Reaction is exothermic; introduction of an initial 7-lb charge of H 2 NCN caused a temperature excursion from 80° to 103° C. during the first minute. Thereafter, with full reactor cooling, the temperature was maintained at 80°-85° C. range during remainder of addition. The mixture was stirred at 85° C. for 2 hrs, then cooled to 25° C. and the pH measured, which showed a value of 7.6. A slurry of sodium bicarbonate (35 lbs, 0.42 lb-mole) in 65 lbs of water was added all at once and the reaction was stirred overnight. The white solid product was isolated by centrifugation, washed with water (4 gal), then returned to the reactor and resuspended with 150 lbs fresh water. A final centrifugation gave 82 lbs of wet-cake which was dried in a vacuum oven at ˜35° C. and 29 in Hg. Assay of the dried material showed 99% AGB, for an overall yield of 96% based on hydrazine charged.
B. Drying of Wet Centrifuge Cake Under CO 2 at 75° C.
A sample of AGB wet centrifuge cake (100 grams), 23.5% water, was placed on a watch glass in a 75° C. oven which was constantly purged with CO 2 . After 2 hours, the sample was pure white and the moisture content was <0.5% by weight.
COMPARISON 1
Drying under Air at 75° C.
Another 100-g sample of AGB centrifuge cake was placed on a watch glass in a 75° C. oven, which was not purged of air. After 1 hour, the majority of the surface of the sample was a reddish color which indicated that surface portions of AGB decomposed.
COMPARISON 2
Drying under Nitrogen Atmosphere
Another 100-g sample of centrifuge cake was placed on a watch glass in a 75° C. oven, which was purged with nitrogen instead of CO 2 . After 1 hour in the oven, the sample was observed to have reddish color on a majority of its surface. This again indicated that surface portions decomposed.
COMPARISON 3
Drying at Higher Temperature (100° C.)
A 100-g sample of centrifuge cake was placed on a watch glass in a 100° C. oven which was purged with CO 2 . After 1 hour, the sample was dry but had a slight pink tinge indicating minor degradation.
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A process for drying a wet cake of aminoguanidine bicarbonate (AGB), which comprises subjecting the wet cake of aminoguanidine bicarbonate to drying temperatures from about 35° C. to about 95° C. under a carbon dioxide-containing atmosphere for a sufficient amount of time to form a dried aminoguanidine bicarbonate product which is substantially free of moisture.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a focusing arrangement for a video camera, and especially to an arrangement for aiding manual focusing through an electronic viewfinder. More specifically, the invention pertains to a signal processing circuit of the type that isolates a focus-related characteristic of a video signal and uses the isolated characteristic to accentuate the display of a well-focused image in the viewfinder.
2. Description Relative to the Prior Art
In a manually focussed video camera, an electronic viewfinder is not only used to compose a scene as recorded by the camera but also to determine when the scene image is properly focused. As is the case with many optical systems, the proper focus is not a discrete distance but a range of distances through which the image is acceptably defined, i.e., a range indicated by the depth of field for a particular optical (lens) aperture and subject distance. An electronic viewfinder repeats images of the scene at the television frame rate, i.e., 1/30 second. This "exposure interval" dictates a particular lens aperture for the existing light condition and, therefore, establishes a particular depth of field for each subject distance. A special problem emerges when the viewfinder is used with a video still camera, which provides several exposure interval and aperture combinations for each light condition. The light condition that dictates a certain aperture . . . and thus a certain depth of field . . . for the electronic viewfinder may require an entirely different aperture for the still exposure (because the exposure interval may not be 1/30 second). Thus the depth of field for viewing may be an artificial indication of the actual picture-taking condition. The "real" depth of field may be considerably compressed from that observed in the viewfinder with the attendant possibility that a properly-focused viewfinder display may be unfocused with respect to the recorded picture.
If one could reliably locate the central focus position for the displayed depth of field, the picture would be in focus for any aperture (that is, for any depth of field). Owing, however, to the small size of the display screen in the viewfinder and the limited bandwidth available for the display, differences between details shown on the viewfinder screen are not very sharp or clear. Searching for optimum focus, necessary in view of the depth of field considerations heretofore mentioned, is a procedure marked by uncertainty. U.S. Pat. No. 4,481,540 suggests one arrangement for dealing with such focus problems. Two versions of the video signal, one unmodified and the other blurred by a low pass filter, are applied to the viewfinder via a switching device controlled by the high frequency content of the video signal. The unmodified part of the image is switched to the display during the presence of high frequency content while the blurred part of the image is displayed otherwise. As the image is brought into focus, more unmodified image, and less of the intentionally blurred image, appears in the viewfinder.
The focusing arrangement in U.S. Pat. No. 4,481,540, however, requires a special viewing mode that detracts from the other purpose of the viewfinder . . . to observe the scene as recorded by the camera. Secondly, the focused image, which is scattered throughout the field of view, requires the viewer to key upon the whole picture rather than to concentrate attention upon some unshifting area. But most importantly, the relatively low bandwidth of the electronic viewfinder ordinarily limits the rendition of high frequency, well-focused picture information. The difference between the blurred and the unmodified but focused image is ordinarily not great enough to be eye-catching.
SUMMARY OF THE INVENTION
Instead of using a focus-related characteristic, such as high frequency content, to switch the video signal to the electronic viewfinder, the isolated characteristic can be used directly to modify the display signal. The trick, however, is to modify the signal in a way that is not defeated by the limited bandwidth of the system. To this end the focus-related characteristic of the video signal, e.g., the high frequency content, is used according to the invention to vary the gain applied to the video signal within a selected area of the viewfinder display. This ties picture contrast, a readily observable quality, to focus. Furthermore, having the focusing information confinded to a selected area of the field of view results in a less intrusive display and permits one display to serve both purposes . . . composition and focusing.
A special display that accentuates the focused part of the image is provided as follows. A high pass filter isolates the high frequency content of the video signal. The average amplitude of the high pass signal is converted into a control signal that couples with a voltage controlled amplifier to regulate its gain according to the average amplitude of the high frequencies in the video signal. The voltage controlled amplifier is switched into the path of the video signal whenever the selected area is being traced in the viewfinder display. In this way, a partial area of the display, ordinarily the center, will show a level of contrast that varies with the degree of focus--the more contrast, the greater the focus.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the drawings, wherein:
FIG. 1 is a diagram of portions of a video camera, including circuit components for an electronic viewfinder in accordance with the invention;
FIG. 2 is a raster diagram of the central part of the viewfinder display as provided by the circuit components of FIG. 1; and
FIG. 3 is a set of timing diagrams relating to the operation of the circuit components of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 stresses those elements of a video still camera 2 that are useful in generating a focusing aid within a central area 4 of the display screen of a monochrome electronic viewfinder 6. Other elements of the camera, either omitted or not shown in detail, may be readily selected from like elements known in the art. For example, the entire record section 8 of the camera, which is unessential to an understanding of the invention, may be provided by ordinary components well known in this art.
FIG. 1 will be described, as necessary, with reference to the raster diagram in FIG. 2 and to the timing diagrams in FIG. 3. Referring to FIG. 1, a subject 10 is imaged upon an image sensor 12 by an imaging assembly 14. Within the imaging assembly 14 is a diaphragm 16 for controlling the optical aperture of the assembly, i.e., for determining the amount of imaging light to reach the sensor 12. Also included in the assembly 14 is a lens system 18 that is manually movable according to an arrow 20 in order to focus an image of the subject 10 upon the sensor 12. (The imaging assembly 14 is typically a barrel-like structure having a knurled exterior ring connected by conventional gearing to the lens system 18 for adjusting the focus setting.) A light shutter 22 is interposed between the lens assembly 14 and the sensor 12 for controlling the exposure interval. The sensor 12 is, for example, an interline transfer device having a horizontal register 24 from which a video signal is removed line-by-line in a known fashion.
The video signal obtained from the sensor 12 is applied to a video signal processing and timing circuit 26, which includes the necessary matrices for generating luminance and color difference signals. The luminance and color difference signals are directed to the record section 8. The luminance signal is also separately directed to the viewfinder 6 via a pair of alternative circuit paths. In one path, the luminance signal is provided directly to the viewfinder 6; in the other path, it is first branched through a voltage-controlled amplifier 28. Which circuit path is connected to the viewfinder 6 is determined by the condition of a switch 30. The voltage-controlled amplifier 28 controls the gain applied to the luminance signal according to a control voltage representing a focus-related characteristic of the luminance signal. Since high frequency content is associated with the sharpness, or focus, of the image, a high pass filter 32 is used to isolate the focus-related characteristic, i.e. the high frequency component, of the luminance signal.
The isolated high requency component is applied to a peak-to-peak detector 34 via a switch 36. When the switch 36 is closed the detector 34 converts the average amplitude of the high frequency component to a dc control voltage (the sharper the focus, the greater the dc voltage). Within the detector 34 the positive- and negative-going extremes of the high frequency component are separated by a peak detector 36a and a valley detector 36b and applied to the inputs of a differential amplifier 38 operated as an integrator. The decay times of the peak and valley detectors 36a and 36b are equivalent to about one video field (16 ms.) so that the peak detector 34 smoothly follows changes in the high frequency component. The output dc voltage from the detector 34 is used to control the gain of the voltage-controlled amplifier 28 (the sharper the focus, the greater the gain). As the gain of the amplifier 28 is increased, the contrast of the picture produced by the video signal is increased (the sharper the focus, the greater the contrast). The picture generated by the signal from the amplifier 28, therefore, will pass from average contrast to high contrast and back again as the lens system 18 is manually adjusted through the range of sharpest focus.
The position of the switch 30 determines whether the unmodified video signal or the contrast-adjusted video signal will be displayed in the viewfinder 6. The switch 30 is activated to pass the contrast-adjusted video signal only during the time the display in the viewfinder 6 corresponds to the central area 4. The video signal processing and timing circuit 26 produces a horizontal drive signal HD (see also FIG. 3) at the beginning of the retrace of each video line. The drive signal HD initiates a series of events that controls the switch 30. A one-shot multivibrator 40 triggers on the rising edge of the horizontal drive signal HD and provides an output signal OS1 to a second one-shot multivibrator 42. The pulse width of the signal OS1 is set to 30 μseconds, which corresponds spatially up to the beginning of the central area 4 (see FIG. 2). A second pulse signal OS2 from the one-shot multivibrator 42 originates on the falling edge of the first signal OS1 and has a width (13 μseconds) corresponding to the width of the central area 4 (see FIG. 2). Meanwhile a line counter 44 is triggered at the beginning of each field to count the display lines produced in the viewfinder 6. When the counter 44 is between lines 100 and 165 (considering consecutive lines in one field), its output signal CTR is set high (see FIG. 3). This period corresponds to the height of the central area 4 (see FIG. 2).
The signals CTR and OS2 are applied to an AND gate 46; when both signals are high the output of the gate 46 becomes high (see FIG. 3) and causes a switch driver 48 to throw each of the switches 30 and 36 from respective contacts A to contacts B. This provides the contrast-adjusted signal from the voltage controlled amplifier 28 to the viewfinder 6 during the time the central area 4 is being generated. The switch 36 is also closed but only during this time, to ensure that the integrated output signal of the peak detector 34 only represents the high frequency component seen in the central area 4. Otherwise, due to signal retention in the integration process, the output signal from the detector 34 would represent focused image parts from other areas within the display.
The video camera 2 normally employs a control system, represented by a system controller 50, to manage the operation of the overall system. In FIG. 1, the controller 50 has only been shown connected to the line counter 44 and the record section 8 but, as is well known, the controller 50 would be connected to various other components as necessary in a particular application. An exposure controller 52 is shown separate from the system controller 50 to emphasize exposure-related functions that affect the viewed picture, namely the sampling of imaging light by a photodiode 54 and the operation of the diaphragm 16 and the shutter 22.
The circuit as described in connection with FIG. 1 feeds enhanced information into the viewfinder pertaining to the best focus position for the subject of interest. The portion of the image in the central area 4 will tend to "snap" in and out of focus as the lens system 18 is adjusted through the best focus position. The "snappiness" of the picture, however, is not so much a function of the perceived sharpness . . . which tends to be dulled in the band-limited field of view . . . but moreso a function of the abruptly changing contrast within the central area 4. The point of highest contrast is more easily perceived under these conditions than the point of sharpest focus, which is especially important if the lens system 18 is to be adjusted to the approximate center of the depth of field for a given aperture.
The invention has been described in detail with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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A focusing aid for a video camera alleviates manual focusing uncertainty due to difficulty in rendering sharply defined features in an electronic viewfinder. The focusing aid impacts a central viewing area by modifying the picture contrast, a visual substitute for a bandwidth-limited rendition of picture sharpness. A high frequency component of a luminance signal generated by the camera is converted into a dc control signal having an amplitude that varies with high frequency content. By using the control signal to adjust the gain applied to the luminance signal, the contrast of the picture formed in the central area is accentuated according to the degree of focus.
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TECHNICAL FIELD
[0001] The present invention relates generally to methods of making nonwoven fabrics, and more particularly, to a method of manufacturing a two-sided nonwoven fabric exhibiting a three-dimensional image, permitting use of the fabric in a wide variety of consumer applications.
BACKGROUND OF THE INVENTION
[0002] The production of conventional textile fabrics is known to be a complex, multi-step process. The production of fabrics from staple fibers begins with the carding process whereby the fibers are opened and aligned into a feedstock referred to in the art as “sliver”. Several strands of sliver are then drawn multiple times on a drawing frames to further align the fibers, blend, improve uniformity and reduce the sliver's diameter. The drawn sliver is then fed into a roving frame to produce roving by further reducing its diameter as well as imparting a slight false twist. The roving is then fed into the spinning frame where it is spun into yarn. The yarns are next placed onto a winder where they are transferred into larger packages. The yarn is then ready to be used to create a fabric.
[0003] For a woven fabric, the yarns are designated for specific use as warp or fill yarns. The fill yarns (which run on the y-axis and are known as picks) are taken straight to the loom for weaving. The warp yarns (which run on the x-axis and are known as ends) must be further processed. The large packages of yarns are placed onto a warper frame and are wound onto a section beam were they are aligned parallel to each other. The section beam is then fed into a slasher where a size is applied to the yarns to make them stiffer and more abrasion resistant, which is required to withstand the weaving process. The yarns are wound onto a loom beam as they exit the slasher, which is then mounted onto the back of the loom. The warp yarns are threaded through the needles of the loom, which raises and lowers the individual yarns as the filling yarns are interested perpendicular in an interlacing pattern thus weaving the yarns into a fabric. Once the fabric has been woven, it is necessary for it to go through a scouring process to remove the size from the warp yarns before it can be dyed or finished. Currently, commercial high-speed looms operate at a speed of 1000 to 1500 picks per minute, where a pick is the insertion of the filling yarn across the entire width of the fabric. Sheeting and bedding fabrics are typically counts of 80×80 to 200×200, being the ends per inch and picks per inch, respectively. The speed of weaving is determined by how quickly the filling yarns are interlaced into the warp yarns, therefore looms creating bedding fabrics are generally capable of production speeds of 5 inches to 18.75 inches per minute.
[0004] In contrast, the production of nonwoven fabrics from staple fibers is known to be more efficient than traditional textile processes, as the fabrics are produced directly from the carding process.
[0005] Nonwoven fabrics are suitable for use in a wide variety of applications where the efficiency with which the fabrics can be manufactured provides a significant economic advantage for these fabrics versus traditional textiles. However, nonwoven fabrics have commonly been disadvantaged when fabric properties are compared to conventional textiles, particularly in terms of resistance to elongation, in applications where both transverse and co-linear stresses are encountered. Hydroentangled fabrics have been developed with improved properties, by the formation of complex composite structures in order to provide a necessary level of fabric integrity. Subsequent to entanglement, fabric durability has been further enhanced by the application of binder compositions and/or by thermal stabilization of the entangled fibrous matrix.
[0006] Nonwoven composite structures typically improve physical properties, such as elongation, by way of incorporation of a support layer or scrim. The support layer material can comprise an array of polymers, such as polyolefins, polyesters, polyurethanes, polyamides, and combinations thereof, and take the form of a film, fibrous sheeting, or grid-like meshes. Metal screens, fiberglass, and vegetable fibers are also utilized as support layers. The support layer is commonly incorporated either by mechanical or chemical means to provide reinforcement to the composite fabric. Reinforcement layers, also referred to as a “scrim” material, are described in detail in U.S. Pat. No. 4,636,419, which is hereby incorporated by reference. The use of scrim material, more particularly, a spunbond scrim material is known to those skilled in the art.
[0007] Spunbond material comprises continuous filaments typically formed by extrusion of thermoplastic resins through a spinneret assembly, creating a plurality of continuous thermoplastic filaments. The filaments are then quenched and drawn, and collected to form a nonwoven web. Spunbond materials have relatively high resistance to elongation and perform well as a reinforcing layer or scrim. U.S. Pat. No. 3,485,706 to Evans, et al., which is hereby incorporated by reference, discloses a continuous filament web with an initial random staple fiber batt mechanically attached via hydroentanglement, with a second random staple fiber batt then attached to the continuous filament web, again, by hydroentanglement. A continuous filament web is also utilized in U.S. Pat. Nos. 5,144,729; 5, No. 187,005; and No. 4,190,695. These patents include a continuous filament web for reinforcement purposes or to reduce elongation properties of the composite.
[0008] More recently, hydroentanglement techniques have been developed which impart images or patterns to the entangled fabric by effecting hydroentanglement on three-dimensional image transfer devices. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, which is hereby incorporated by reference; with the use of such image transfer devices being desirable for providing a fabric with enhanced physical properties as well as an aesthetically pleasing appearance.
[0009] For specific applications, a two-sided, three-dimensionally imaged nonwoven fabric must exhibit a combination of specific physical characteristics. U.S. Pat. No. 5,302,446 discloses a two-sided nonwoven fabric, however the fabric is ultrasonically bonded and both sides of the fabric are treated with a surfactant so as to render it hydrophilic. The two-sided hydroentangled fabric of the present invention is comprised of at least three layers. The second layer acts as a fiber distribution control layer between the first and third layers wherein the fibrous matrix of the two outer layers may be of the same or different compositions. This construct specifically lends itself useful as a wipe. For example, when the fabric of the present invention is employed in the formation of cleansing wipes, the fabric construct can exhibit sufficient softness for intimate contact with the skin, but also can be capable of exfoliating the skin. Further, the two-sided, three-dimensionally imaged nonwoven fabric is reinforced with a support layer or scrim that is water pervious to ensure effective integration of the construct during hydroentanglement, but able deter the fibers from the first side and from second side of the fabric from becoming extensively intermingled in the production process and yet retain sufficient resistance to delamination.
[0010] Notwithstanding various attempts in the prior art to develop a three-dimensionally imaged nonwoven fabric acceptable for home, medical and hygiene applications, a need continues to exist for a nonwoven fabric which provides a pronounced image, as well as the requisite mechanical characteristics.
SUMMARY OF THE INVENTION
[0011] The present invention is directed to a method of forming a two-sided nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a first precursor web comprising a first fibrous matrix and a second precursor web comprising a second fibrous matrix. Between the first and second precursor web, a fluid-pervious support layer or scrim, is interposed and subjected to hydroentanglement on a moveable imaging surface having a three-dimensional image transfer device. By formation of a nonwoven fabric in this fashion, a three-dimensional image that is durable to abrasion and distortion due to elongation is imparted and a product formed which exhibits on its opposite surfaces the unique properties of the respective fibrous matrix used.
[0012] In accordance with the present invention, a method of making a nonwoven fabric embodying the present invention includes the steps of providing a first precursor web comprising a fibrous matrix and a second precursor web comprising a second matrix. While use of staple length fibers is typical, the first and/or second fibrous matrices may comprise substantially continuous filaments. In a particularly preferred form, the first and second fibrous matrices comprise staple length fibers, which are carded and cross-lapped to form precursor webs. In one embodiment of the present invention, the precursor webs are subjected to pre-entangling on a foraminous-forming surface prior to juxtaposition of a support layer or scrim and subsequent three-dimensional imaging. Alternately, one or more layers of fibrous matrix are juxtaposed with one or more support layers or scrims, then the layered construct is pre-entangled to form a precursor web which is imaged directly, or subjected to further fiber, filament, support layers, or scrim layers prior to imaging.
[0013] In a first embodiment, the fabric has a first side or surface comprised of a first fibrous matrix and a second side or surface comprised of a second fibrous matrix, wherein said first and second fibrous matrix are dissimilar. Further, the first and second sides are separated by an intermediate water pervious, fiber distribution control layer, which acts to deter the excessive intermingling of the first fibrous matrix and second fibrous matrix.
[0014] In a second embodiment, the fabric further includes apertures wherein the apertures may extend partially or entirely through one or more of the component layers.
[0015] In a third embodiment, the fibrous constituent of the first fibrous matrix and the second fibrous matrix exhibit a by fiber modulus difference of at least 10%, wherein the fibrous matrix with the lower fiber modulus comes in contact with the three-dimensional imaging transfer device. For example, if the first side is comprised of a first fibrous matrix comprising a 1.2 dpf fiber and the second side is comprised of a second fibrous matrix comprising a 15 dpf fiber, then the first side would become the side that comes in contact with the three-dimensional imaging transfer device.
[0016] The first and second precursor webs, with an interposed fiber distribution control layer, are advanced onto the imaging surface of the image transfer device. Hydroentanglement of the precursor web is affected to form a three-dimensionally imaged fabric. Significantly, the incorporation of a fiber distribution control layer acts to limit the ability of the fibrous constituent of the first precursor web and the second precursor web from becoming extensively intermixed, and yet results in a nonwoven fabric that exhibits sufficient resistance to delamination.
[0017] Subsequent to hydroentanglement, the three-dimensionally imaged fabric may be subjected to one or more variety of post-entanglement treatments. Such treatments may include application of a polymeric binder composition, mechanical compacting, application of surfactant or electrostatic compositions, and like processes.
[0018] In the preferred form, the precursor webs are hydroentangled on a foraminous surface prior to hydroentangling on the image transfer device. This pre-entangling of the precursor web acts to integrate the fibrous components of the web, but does not impart a three-dimensional image as can be achieved through the use of the three-dimensional image transfer device.
[0019] Optionally, subsequent to three-dimensional imaging, the imaged nonwoven fabric can be treated with a performance or aesthetic modifying composition to further alter the fabric structure or to meet end-use article requirements. A polymeric binder composition can be selected to enhance durability characteristics of the fabric, while maintaining the desired softness and drapeability of the three-dimensionally imaged fabric. A surfactant can be applied so as to impart hydrophilic properties. In addition, electrostatic modifying compound can be used to aid in cleaning or dusting applications.
[0020] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a diagrammatic view of an apparatus for manufacturing a durable nonwoven fabric, embodying the principles of the present invention.
DETAILED DESCRIPTION
[0022] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0023] The present invention is directed to a method of forming two-sided nonwoven fabrics by hydroentanglement, wherein three-dimensional imaging of the fabrics is enhanced and a fiber distribution control layer put into place between the two sides by the incorporation of at least one fluid-pervious support layer or scrim. Enhanced imaging can be achieved utilizing various techniques, one such technique involves minimizing and eliminating tension in the overall precursor web as the web is advanced onto a moveable imaging surface of the image transfer device, as represented by co-pending U.S. patent application Serial No. 60/344,259, to Putnam et al, entitled Nonwoven Fabrics Having a Durable Three-Dimensional Image, and filed on Dec. 28, 2001, which is hereby incorporated by reference. The use of a support layer or scrim benefits the fabric of the present invention providing a median fiber distribution control layer wherein the support layer deters the fibrous constituents of the two outer layers from becoming excessively intermingled with one another. The incorporation of a support layer improves the overall performance of the two-sided fabric by providing a three-dimensionally imaged nonwoven fabric that exhibits a pronounced difference in surface performance properties inherent to the fibrous matrix used.
[0024] A method of making the present two-sided, three-dimensionally imaged nonwoven fabric comprises the steps of providing at least a first precursor web comprised of a first fibrous matrix and a second precursor web comprising a second fibrous matrix and a median support layer or scrim to act as the fiber distribution control layer, which is subjected to hydroentangling. The precursor webs are formed into a three-dimensionally imaged nonwoven fabric by hydroentanglement on a three-dimensional image transfer device. The image transfer device defines three-dimensional elements against the precursor web whereby the first fibrous matrix is displaced into the three-dimensional topography while the second fibrous matrix is significantly retained on the side away from the three-dimensional topography forced during hydroentanglement.
[0025] With reference to FIG. 1, therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous matrix, which typically comprises staple length fibers, but may comprise substantially continuous filaments. The fibrous matrix is preferably carded and cross-lapped to form a fibrous batt, designated F. In a current embodiment, the fibrous batt comprises 100% cross-lap fibers, that is, all of the fibers of the web have been formed by cross-lapping a carded web so that the fibers are oriented at an angle relative to the machine direction of the resultant web. U.S. Pat. No. 5,475,903, hereby incorporated by reference, illustrates a web drafting apparatus.
[0026] A support layer or scrim is then placed in face to face to face juxtaposition with a first fibrous web and hydroentangled to form precursor web P. Alternately, the fibrous web can be hydroentangled first to form precursor web P, and subsequently, at least one support layer or scrim is applied to the precursor web, and the composite construct optionally further entangled with non-imaging hydraulic manifolds, then imparted with a three-dimensional image on an image transfer device.
[0027] [0027]FIG. 1 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous-forming surface in the form of belt 10 upon which the precursor web P is positioned for pre-entangling by entangling manifold 12 . Pre-entangling of the precursor web, prior to three-dimensional imaging, is subsequently effected by movement of the web P sequentially over a drum 14 having a foraminous-forming surface, with entangling manifold 16 effecting entanglement of the web. Further entanglement of the web is effected on the foraminous forming surface of a drum 18 by entanglement manifold 20 , with the web subsequently passed over successive foraminous drums 20 , for successive entangling treatment by entangling manifolds 24 ′, 24 ′.
[0028] The entangling apparatus of FIG. 1 further includes a three-dimensional imaging transfer device 24 comprising a three-dimensional image transfer device for effecting imaging of the now-entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 26 which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed.
[0029] The present invention contemplates that the fluid-pervious support layer or scrim be any such suitable material, including, but not limited to, wovens, knits, open mesh scrims, and/or nonwoven fabrics, which exhibit low elongation performance. Two particular nonwoven fabrics of particular benefit are spunbond fabrics, as represented by U.S. Pat. No. 3,338,992, No. 3,341,394. No. 3,276,944, No. 3,502,538, No. 3,502,763, No. 3,509,009; No. 3,542,615; and Canadian Patent No. 803,714, these patents are incorporated by reference, and nanofiber fabrics as represented by U.S. Pat. No. 5,678,379 and No. 6,114,017, both incorporated herein by reference. A particularly preferred embodiment of support layer or scrim is a thermoplastic spunbond nonwoven fabric. The support layer may be maintained in a wound roll form, which is then continuously fed into the formation of the precursor web, and/or supplied by a direct spinning beam located in advance of the three-dimensional imaging drum 24 .
[0030] Manufacture of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the fibrous matrix, which can include the use of staple length fibers, continuous filaments, and the blends of fibers and/or filaments having the same or different composition. Fibers and/or filaments are selected from natural or synthetic composition, of homogeneous or mixed fiber length. Suitable natural fibers include, but are not limited to, cotton, wood pulp and viscose rayon. Synthetic fibers, which may be blended in whole or part, include thermoplastic and thermoset polymers. Thermoplastic polymers suitable for blending with dispersant thermoplastic resins include polyolefins, polyamides and polyesters. The thermoplastic polymers may be further selected from homopolymers; copolymers, conjugates and other derivatives including those thermoplastic polymers having incorporated melt additives or surface-active agents. Staple lengths are selected in the range of 0.25 inch to 10 inches, the range of 1 to 3 inches being preferred and the fiber denier selected in the range of 1 to 22, the range of 2.0 to 20 denier being preferred for general applications. The profile of the fiber and/or filament is not a limitation to the applicability of the present invention.
[0031] Using a forming apparatus as illustrated in FIG. 1, a nonwoven fabric was made in accordance with the present invention by providing a layered precursor web comprised of differing fiber compositions. In a preferred embodiment, a layered precursor web comprising a first side comprising layers including a first fibrous matrix blend of 85%, 1.2 dpf polyester, made commercially available as Wellman Type 472, and 15%, 2.0 dpf low melt bicomponent fiber, commercially available as Stein Type 131-00251S, and a second layer blend of 90%, 1.2 dpf polyester fiber and 10% rayon fiber, made commercially available as Lenzing 8192. The precursor web included a median layer of 0.50 os/y 2 of polypropylene spunbond, and a second side comprising a second fibrous matrix blend of 50%, 3 dpf polyester and 50% 15 dpf polyester. The first side, comprised of the first fibrous matrix comprising 1.2 dpf fibers was placed in contact with the three-dimensional imaging transfer device. The image transfer device defines three-dimensional elements against the precursor web whereby the first fibrous matrix is displaced into the three-dimensional topography while the second fibrous matrix is significantly retained on the side away from the three-dimensional topography forced during hydroentanglement. Such a construct, allows for a soft side comprised of fine denier fibers wherein upon imaging, the fine fibers perform so as to provide a pronounced imaged. The spunbond layer incorporated therein acts to separate the aforementioned three-dimensionally imaged side from the courser side, which is comprised of a larger fiber.
[0032] Optionally, the fabric of the present invention may comprise apertures. The apertures may be of various shapes and sizes while spaces equal distances from one another or randomly distributed throughout the resultant fabric. Further, the apertures may extend through one or more layers of the fabric.
[0033] The material of the present invention may be utilized in the construction of a numerous home cleaning, personal hygiene, medical, and other end use products where a three-dimensionally imaged nonwoven fabric can be employed. Disposable absorbent hygiene articles, such as a sanitary napkins, incontinence pads, diapers, and the like, wherein the term “diaper” refers to an absorbent article generally worn by infants and incontinent persons that is worn about the lower torso of the wearer can benefit from the improved resiliency of the imaged nonwoven in the absorbent layer construction. An imaged nonwoven fabric may also be utilized as a landing zone affixed to the disposable absorbent article whereby the distal end of a fastening strip may attach; the imaged nonwoven fabric exhibiting improved “loop” durability and fuzz resistance to repeated, or finite, “hook” attachment cycles. In addition, the material may be utilized as medical gauze, or similar absorbent surgical materials, for absorbing wound exudates and assisting in the removal of seepage from surgical sites. Other end uses include; fabrication into wet or dry facial or hard surface wipes, which can be readily hand-held for cleaning and the like, protective wear for medical and industrial uses, such as gowns, shirts, bottom weights, lab coats, face masks, and the like, and protective covers, including covers for vehicles such as cars, trucks, boats, airplanes, motorcycles, bicycles, golf carts, as well as covers for equipment often left outdoors like grills, yard and garden equipment, such as mowers and roto-tillers, lawn furniture, floor coverings, table cloths and picnic area covers. The material may also be used in apparel construction, such as for bottom weights of every day wear, which includes pants and shorts.
[0034] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
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The present invention is directed to a method of forming a two-sided nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a first precursor web comprising a first fibrous matrix and a second precursor web comprising a second fibrous matrix. Between the first and second precursor web, a fluid-pervious support layer or scrim, is interposed and subjected to hydroentanglement on a moveable imaging surface having a three-dimensional image transfer device. By formation of a nonwoven fabric in this fashion, a three-dimensional image that is durable to abrasion and distortion due to elongation is imparted and a product formed which exhibits on its opposite surfaces the unique properties of the respective fibrous matrix used.
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BACKGROUND OF THE INVENTION
[0001] The present invention is directed to a system and method for processing an image. More specifically, the present invention is directed to a method of generating additive primary colors from PostScript code to drive a visual display.
[0002] A primary application of the PostScript language is to describe the appearance of text, graphical shapes, and sampled images on printed or displayed pages according to the Adobe imaging model. More specifically, a program in the PostScript language communicates a description of an image or document from a composition system to a printing system or control the appearance of text and graphics on a display. Within the PostScript language, colors are suitably specified in a variety of ways including: grayscale, red, green, and blue (RGB), cyan, magenta, yellow, and black (CMYK), and Commission Internationale de l'Eclairage-based (CIELab).
[0003] Furthermore, a duotone is the result of a method to colorize a grayscale image or to create a visual special effect. The term “duotone” refers to an image reproduced with two colorants. A duotone differs from a spot color. A spot color is defined by coordinates in a color space. In contrast, a duotone is defined by either a vector from a white point to the maximum saturation value defined by the spot color coordinates in that color space, a plane defined by the vector of two colors, or, in the case of three or more spot colors, a three dimensional gamut defined by the vector of the three spot colors from white to each saturation value.
[0004] Duotone use represents one of the more difficult color reproductions in image generation, particularly in the values of each colorant used. In addition to duoton, monotones, one color, tritons, three colors, and quadtones, four colors, are also known for image generation. The term quadtone is often times confusing. In some instances, a quadtone refers to an image reproduced with four spot colorants. In other instances, a quadtone is used by photographers to describe images produced in 4, 6, and 7 shades of black and gray colorants on an inkjet printer or offset press. As used herein, the term duotone will be used to refer to an image produced with any number of colorants. Susan: Photoshop users can use primary colors.
[0005] As mentioned, an original intent of the PostScript language, and of a duotone, is to prepare data contained in a grayscale image for reproduction with user selected colorants, such as a number of black and spot or match colorants. However, it is also useful to prepare these images for reproduction on printers having cyan, magenta, yellow, and black (CMYK) colorants and for display on red, green, and blue (RGB) monitors. Therefore, a conversion from named colorants to device colorants is desirous. Moreover, there is a need for a system and method for generating additive primaries for visual display, such as in a monitor with red, green, and blue (RGB) data being generated from PostScript code.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, there is provided a system and method for processing an image. Further, in accordance with the present invention, there is provided a system and method that generates monitor red, green, and blue (RGB) data from PostScript code.
[0007] Still further, in accordance with the present invention, there is provided a system for processing an image. The system includes means adapted for receiving an image having image values and described in a first color space, means adapted for determining the image color space from a received image, means adapted for associating the image values in the first color space to values in a second color space so as to generate associated image values, and means adapted for converting the associated values in the second color space to a third color space for display, the third color space differing from the second color space by including additive primary colors.
[0008] In a preferred embodiment of the preset invention, the image is described in the PostScript language and the third color space is the red, green, and blue (RGB) color space.
[0009] In another embodiment of the present invention, a three-dimensional look up table (LUT) created in CIELab color space is used for looking up, referencing, and/or converting colorant values.
[0010] Still further, in accordance with the present invention, there is provided a method for processing an image. The method comprises the steps of receiving an image having image values and described in a first color space and determining the image color space from a received image. The method further includes associating the image values in the first color space to values in a second color space so as to generate associated image values and converting the associated values in the second color space to a third color space for display, the third color space differing from the second color space by including additive primary colors.
[0011] In a preferred embodiment of the present invention, if the image is determined to be a grayscale image, the method further includes the steps of requesting linearization curves, requesting colorants, obtaining CIELab values, and associating gray levels with steps in CIELab. If the image is determined not to be a grayscale image, the method further includes the steps of converting the image to a grayscale image, requesting linearization curves, requesting colorants, obtaining CIELab values, and associating gray levels with steps in CIELab. Similarly, if the image is determined to be a duotone, the method further includes the steps of reading colorants, converting the image values to CIELab values, and associating gray levels with steps in CIELab.
[0012] These and other aspects, advantages, and features of the present invention will be understood by one of ordinary skill in the art upon reading and understanding the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The subject invention is described with reference to certain parts, and arrangements to parts, which are evidenced in conjunction with the associated drawings, which form a part hereof and not, for the purposes of limiting the same in which:
[0014] FIG. 1 is a block diagram illustrative of the system of the present invention; and
[0015] FIG. 2 is a flowchart illustrating a method for processing an image in accordance with principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The present invention is direct to a system and method for processing an image. In a preferred embodiment, the present invention is directed to a method of generating monitor red, green, and blue (RGB) data from PostScript code. FIG. 1 is a block diagram illustrating an exemplary environment for practicing the present invention. System 100 comprises an image generating device 102 and a hardware platform 104 . The image generating device 104 is placed in data communication with the user interface 102 as generally indicated at reference numeral 106 . More specifically, and in some embodiments of the present invention, the image generating device 102 is placed in data communication with the hardware platform 104 through electrical coupling provided by a cable 106 . In other embodiments of the present invention, the image generating device 102 is placed in data communication with the hardware platform 104 using a network (not shown).
[0017] Image generating device 102 is any device capable of generating image outputs in a tangible medium, such as, for example, a printer, a facsimile machine, a scanning device, a copier, a multifunctional peripheral device, or other like peripheral devices. Image generating device 102 generally comprises a processor 108 , a memory 110 , and a tangible medium generating mechanism 112 . Processor 108 and memory 110 store and execute program code to control tangible medium generating mechanism 112 such that image generating device 102 has one or more functions including, but not necessarily to limited to, printing, faxing, scanning, and copying.
[0018] In some embodiments of the present invention, processor 108 and/or memory 110 are suitably referred to as a raster image processor (RIP). In a preferred embodiment of the present invention, processor 108 and memory 110 store and execute program code written in the PostScript language.
[0019] Tangible medium generating mechanism 112 includes hardware that allows the mechanism 112 to produce images and/or documents in a tangible medium in one of a number of different color spaces. For example, in some embodiments of the present invention, mechanism 112 includes hardware that produces grayscale images. In other embodiments of the present invention, mechanism 112 includes hardware that produces duotone images. Typically, the term “duotone” refers to an image reproduced with two colorants. As used herein, the term “duotone” refers to an image produced with any number of combinations of non-primary colorants. Thus, the term “duotone” includes monotones, tritones, quadtones, etc. In yet other embodiments of the present invention, mechanism 112 includes hardware that produces images in color spaces other than grayscale and duotone images.
[0020] Hardware platform 104 suitably comprises a central processing unit 114 , a display screen or monitor 116 , a keyboard 118 , and a mouse 120 . Central processing unit 114 includes a processor 122 and a memory 124 for storing and executing program code. Keyboard 118 and mouse 120 are used to input data, while monitor 116 is used to view or display data, such as images and/or documents.
[0021] In various embodiments of the present invention, monitor 116 includes hardware that uses a number of primary colorants. For example, in a preferred embodiment of the present invention, monitor 116 includes hardware that produces red, green, and blue (RGB) primary colorants. In numerous other embodiments of the present invention, a suitable user interface 102 is a personal computer, a laptop computer, a mainframe computer, a computer terminal, or the like. Standing alone, or in combination, image generating device 102 and hardware platform 104 provide a system 100 for processing an image.
[0022] In view of the foregoing structural and functional features described above, methodologies in accordance with various aspects of the present invention will be better appreciated with reference to FIG. 2 . FIG. 2 is a flowchart illustrating a method 200 for processing an image according to the present invention. More specifically, FIG. 2 shows an exemplary method of processing a grayscale or duotone image for display. For example, such an image is suitably generated on image generating device 102 and displayed on monitor 116 , both of which are shown in FIG. 1 .
[0023] While, for purposes of simplicity of explanation, the methodology of FIG. 2 is shown and described as executing serially, it is to be understood and appreciated that the present invention is not limited by the illustrated order, as some aspects suitably, in accordance with the present invention, occur in different orders and/or concurrently with other aspects from that shown and described herein. Moreover, not all illustrated features may be required to implement a methodology in accordance with an aspect of the present invention.
[0024] In addition, methodologies of the present invention are suitably implemented in software, hardware, or a combination of software and hardware. In one embodiment, for example, method 200 is stored as a computer-readable medium in memory 110 and executed by processor 108 of image generating device 102 , shown in FIG. 1 .
[0025] Referring now to FIG. 2 at 202 , the image generating device 102 receives image data representing a source image. In one embodiment, the processor 108 of the image generating device 102 generates a three-dimensional look up table (LUT) is created in the CIELab color space as defined by the Commission Internationale de l'Eclairage (CIE). The look up table is characterized by an ability to calculate 256 steps from any coordinate position in the look up table (LUT) to white. The look up table (LUT) is used to look up, reference and/or convert colorants as will be described hereinafter.
[0026] In other embodiments of the present invention, one or more formulas are suitably used to define a CIELab color space. However, those of ordinary skill in the art will appreciate that a look up table (LUT) is used to ease processing and/or improve processing speed. In yet other embodiments, a look up table or formulas suitably similarly define other color spaces.
[0027] At 204 an image, such as a PostScript image, having values and described in a color space is analyzed and the color space of the image is determined. If the image is determined to be a grayscale image, processing proceeds to 206 , and if the image is determined to be a duotone, processing proceeds to 224 . Again, the term “duotone” refers to an image produced with any number of non-primary colorants. Similarly, if the image is determined to be other than a grayscale or duotone image, processing proceeds to 220 .
[0028] If the image is determined to be a grayscale image, a request is made for linearization curves at 208 . In a preferred embodiment, such a request is made using a curves interface. At 210 , a request is made for colorants. In a preferred embodiment, the request is made using a list of colorants, e.g., Pantone, interface, and the like. Moreover, the listing includes the colorant name and the colorant CIELab value. At 212 , CIELab values are obtained from the list of colorants.
[0029] At 214 , each gray level in the image data is associated with a corresponding step in CIELab. At 216 , each image data point defined in CIELab is converted to the red, green, and blue (RGB) color space. In one embodiment, the conversion is performed using a preselected formula. In another embodiment, the conversion is preformed using a look up table, such as an International Color Consortium (ICC) profile. At 218 , the image is displayed.
[0030] In other embodiments of the present invention, each image data point defined in CIELab is converted to the primary colors of other color spaces. Thus, the present invention is not limited to particular primary colors in particular color spaces. Rather, the red, green, and blue (RGB) color space is merely used for purposes of illustration since monitors typically include hardware that produces red, green, and blue (RGB) primary colorants.
[0031] If the image is determined not to be a grayscale image, as indicated at 220 , the image is converted to a grayscale image at 222 . The conversion is performed using any suitable method known to those skilled in the art. For example, in one embodiment, the conversion is performed using a formula. In another embodiment, the conversion is performed using a look up table (LUT), e.g. an International Color Consortium (ICC) profile. Processing then continues as before beginning at 206 .
[0032] If the image is determined to be a duotone, e.g., a PostScript duotone, as indicated at 224 , the colorants list is read from the header of the image data at 226 . Processing then continues to 212 and proceeds as discussed above.
[0033] Thus, system 100 and method 200 , shown and described in conjunction with FIGS. 1 and 2 , respectively, generates monitor red, green, and blue (RGB) data from PostScript code.
[0034] The invention extends to computer programs in the form of source code, object code, code intermediate sources and object code (such as in a partially compiled form), or in any other form suitable for use in the implementation of the invention. Computer programs are suitably standalone applications, software components, scripts or plug-ins to other applications. Computer programs embedding the invention are advantageously embodied on a carrier, being any entity or device capable of carrying the computer program: for example, a storage medium such as ROM or RAM, optical recording media such as CD-ROM or magnetic recording media such as floppy discs. The carrier is any transmissible carrier such as an electrical or optical signal conveyed by electrical or optical cable, or by radio or other means. Computer programs are suitably downloaded across the Internet from a server. Computer programs are also capable of being embedded in an integrated circuit. Any and all such embodiments containing code that will cause a computer to perform substantially the invention principles as described, will fall within the scope of the invention.
[0035] The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to use the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
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A method for processing an image. The method includes receiving an image having image values and described in a first color space and determining the image color space from a received image. Image values in the first color space are associated with values in a second color space so as to generate associated image values. Values in the second color space are converted to a third color space for display, wherein the third color space differs from the second color space by including additive primary colors.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of International application PCT/DE02/00668, filed Feb. 22, 2002, which designated the United States, and which was not published in English.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a circuit configuration for demodulating a voltage that is ASK (amplitude-shift keying) modulated by altering the amplitudes between a low level and a high level.
When using contactless chip cards and the like, such as “contactless tags”, “ASK modulation” is often used. This is understood to mean a high-frequency signal that alternates between a first level and a second level using data available in digital form, and thus modulates the high-frequency signal.
In the same way as a distinction is drawn between “yes” and “no” or “1” and “0” or “high” and “low” for digital data, a distinction is drawn between a high amplitude and a low amplitude. In this context, two modulation types ASK 100 and ASK 10 are currently the norm. Modulation type ASK 100 signifies a level difference of 100% and ASK 10 signifies a level difference of 10%. Other differences are also possible, however, and the invention described below is not restricted to these two customary modulation types.
The problem with ASK modulation is that when the distance between the sender and the receiver of a signal being modulated in this way changes while the amplitude of the transmitted signal is constant, the received amplitude at the receiver changes. The same applies if differences arise in the intervening space between the sender and the receiver.
To make matters worse, when using signals which always return to “zero” (i.e. the signal returns to “zero” between two binary “ones”), and signals which do not always return to zero, the “0” and “1” sequences that are modulated and transferred are of different lengths.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a circuit configuration for demodulating a modulated voltage having an amplitude alternating between a low level and a high level, which overcomes the above-mentioned disadvantages of the prior art apparatus of this general type.
In particular, the object of the invention is to provide a demodulator circuit, which reliably identifies the level change between two states during ASK modulation operations, and which has as little complexity as possible.
With the foregoing and other objects in view there is provided, in accordance with the invention, a circuit configuration for demodulating a modulated voltage having an amplitude alternating between a low level and a high level. The circuit configuration includes a high-frequency input, and a rectifier circuit connected downstream of the high-frequency input. The rectifier circuit has an output and an input for obtaining an input voltage. The circuit configuration also includes a first charging circuit for producing a charging voltage and a second charging circuit for producing a charging voltage. The first charging circuit and the second charging circuit are connected in parallel to the output of the rectifier circuit. The circuit configuration also includes a decoupling device for decoupling the charging voltage of the first charging circuit and the charging voltage of the second charging circuit when there is a prescribed ratio between the respective charging voltage and the input voltage for the rectifier circuit. The circuit configuration also includes an evaluation circuit for ascertaining a modulation level from the ratio of the charging voltages.
The specified circuit has the advantage that it is a simple matter to identify the change in the modulation level when comparing the two charging voltages.
In accordance with an added feature of the invention, there is provided a floating current-mirror circuit for the first charging circuit and the second charging circuit.
In accordance with an additional feature of the invention, there is provided a voltage transformer for changing the charging voltage of the first charging circuit and/or the is charging voltage of the second charging circuit.
In accordance with another feature of the invention, there is provided a diode for coupling the first charging circuit and the second charging circuit when there is a predetermined ratio between the charging voltage of the first charging circuit and the charging voltage of the second charging circuit.
In accordance with a further feature of the invention, a voltage on the second charging circuit is converted into two different voltages.
In accordance with a further added feature of the invention, the first charging circuit and the second charging circuit have different discharge times.
In accordance with a further additional feature of the invention, there is provided a charging-current amplification circuit and a changeover apparatus for turning on the charging-current amplification circuit from a prescribed degree of modulation onwards.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in circuit configuration for demodulating a voltage which is ASK modulated by altering the amplitude between a low level and a high level, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a first exemplary embodiment of an inventive circuit configuration;
FIG. 2 is a graph of the envelope for an ASK modulated signal;
FIG. 3 is a graph of illustrative curves for the first and second charging voltages;
FIG. 4 is a diagram of a second exemplary embodiment of the circuit configuration;
FIG. 5 is a diagram of an example of an evaluation circuit;
FIG. 6 is a graph of a characteristic discharge curve for Vref;
FIG. 7 is a diagram of a circuit that implements the invention; and
FIG. 8 is a graph of a characteristic charging curve for Vref.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a first inventive exemplary embodiment of the invention, specifically a demodulator circuit, in which a high-frequency input voltage U HF is applied to the input of the demodulator circuit. The input is denoted by the two input connections LA and LB. FIG. 2 shows the envelope for the amplitude value of the high-frequency input voltage over time. As can be seen, it alternates between a high amplitude level, denoted by “high” and a low amplitude level, denoted by “low”. This rectified high-frequency input voltage U HF is thus present in rectified form on the node Y shown in FIG. 1 . The node Y has two charging circuits connected to it in parallel, which are is charged by the rectified high-frequency voltage.
The first charging circuit includes the capacitor C 1 and a current source i 1 , which are connected in parallel from the voltage node V 1 . Correspondingly, the second charging circuit includes the capacitor C 2 and the current source i 2 , which are connected in parallel from the current node V 2 . The second charging circuit is connected to the node Y via a charging switch S 1 . This switch S 1 is actuated with the low-frequency voltage U NF used to modulate the high-frequency AC voltage U HF . This is made possible in an extremely simple manner using a diode (not shown).
The way in which this circuit works is explained below. While the rectified high-frequency voltage U HF on the node Y is greater than the voltage on the input nodes V 1 and V 2 of the charging circuits, and the switch S 1 is on, the capacitors C 1 and C 2 are charged to the value of the rectified high-frequency AC voltage U HF .
At the same time, the capacitors C 1 and C 2 are discharged by the current sources i 1 and i 2 , the time constant of the two charging circuits can be chosen such that it is high with respect to half the period of the high-frequency input voltage U HF 80 that the two input nodes V 1 and V 2 of the charging circuits experience no substantial voltage fluctuation (hum) caused by the zero crossings of the high-frequency AC voltage.
As FIG. 2 shows, the amplitude of the high-frequency input voltage U HF is now intended to be at the “high” level up until the time before t 1 . At the time t 1 , it changes over to the “low” level. The result of this change is that the switch S 1 turns off and the second charging circuit, and hence the input node V 2 , is decoupled from the rest of the circuit. If the time constants of the first and second charging circuits are chosen to be different, the two capacitors C 1 and C 2 discharge differently. This is possible, by way of example, by choosing the two capacitors C 1 and C 2 to be of the same size, whereas the current sources i 1 and i 2 are chosen to have different strengths. The resultant discharge behavior is shown in FIG. 3 .
As can be seen in FIG. 3, the voltage on the node V 2 drops much more sharply than the voltage on the node V 1 . As can be seen in FIG. 1, the voltage V 1 is again converted to a voltage at V 1 ′ by using a voltage divider X%. As can be seen in FIG. 3, this causes the discharge curves V 2 and V 1 ′ to intersect. The point of intersection S is now suitable for identifying the passage from the “high” level to the “low” level. An evaluation circuit {described later} can be used to detect such a point of intersection.
FIG. 4 shows another form of the inventive demodulator circuit. In this case, reference will first be made to the two voltage dividers Y% and Z% which convert the voltage on the node V 2 into two different voltages V 2 ′ (also referred to as “V siglow ”) and V 2 ″ (also referred to as “V sighigh ”).
The circuit shown in FIG. 4 works, in principle, in exactly the same way as the circuit described with reference to FIG. 1 . In this case, the time constant of the second charging circuit needs to be much lower than that of the first charging circuit, i.e. the current source i 2 discharges the capacitor C 2 much faster than the current source i 1 on the capacitor C 1 .
This can be seen clearly in FIG. 6 . The signals V sighigh and V siglow thus follow the level change in the high-frequency input voltage from “high” to “low” fairly accurately. As has also already been described in FIG. 3 with reference to FIG. 1, the point of intersection S is produced between the signal V ref and a signal that corresponds to the voltage signal V sighigh .
As soon as the discharge by way of the current source i 2 has caused the voltage on the voltage node V 2 to fall to the extent that the voltage is below the high-frequency input voltage U HF , the switch S 1 turns on again. This means that the current source i 2 now additionally discharges the capacitor C 1 via the resistor R 1 . This can be identified from the fact that the discharge curve for V ref in FIG. 6 becomes steeper is from the time t 2 onwards. If the high-frequency voltage U HF now changes level from “low” to “high”, the capacitors C 1 and C 2 in the charging circuits are charged again and, as shown in FIG. 8, a point of intersection S′ is produced between the curve V ref and V siglow .
The diode D 3 ensures that in each case there is only a voltage difference corresponding to the voltage drop across this diode D 3 between V 1 and V 2 . Hence, the voltage is carried in parallel on the two node points, even with large modulation swings, such as ASK 100 , where the amplitude of the high-frequency input voltage comes close to 0 volts for the “low” level. This ensures, even with these large modulation swings, that it is always possible to ascertain an accurate point of intersection between V sighigh and V ref .
FIG. 5 shows one possible evaluation circuit for the signals V ref corresponding to V 1 ′, V 2 ′ corresponding to V sighigh , and V 2 ′ corresponding to V siglow . In this context, V 1 ′ is respectively applied to the negative input of two differential amplifiers, and V sighigh and V siglow are respectively applied to the positive input. The outputs of the differential amplifiers, in turn, are connected to an RS flipflop, as shown. The output of the RS flipflop then outputs a signal corresponding to a “high” level or to a “low” level. Other evaluation circuits are also conceivable, however.
FIG. 7 shows the implementation of the invention in circuitry using customary CMOS technology. In this case, the input AC voltage is also applied to the input connections LO and LD. In this technology, the diodes D 1 to D 2 in the preceding exemplary embodiments are formed using transistors N 4 and N 5 .
There is a low-pass input filter (R 6 , C 4 ) for suppressing the carrier frequency, which is connected to the rectifier circuit.
In contrast to the charging circuit in the preceding exemplary embodiments, a floating current-mirror circuit including the p-channel transistors P 1 and P 0 is provided. This current-mirror circuit charges the capacitors C 1 and C 2 , to which the current sinks including the n-channel transistors N 8 and N 10 are connected. The ratio of the charging current delivered by the current-mirror circuit to the discharge current determines the respective charging time constant of the capacitors C 1 and C 2 . The resistors R 4 , R 5 and R 7 realize the voltage dividers already explained in connection with the preceding exemplary embodiments. These voltage dividers deliver the signals V ref — dem , V sighigh and V siglow supplied to the window circuit.
The diodes N 24 and N 25 decouple the voltages V 1 and V 2 as soon as the input voltage drops below the voltage level of V 1 or V 2 .
The diode N 11 has the same function as the diode D 3 explained previously.
As an addition to the earlier exemplary embodiments, when a high degree of modulation is identified on the output signal pausex, a corresponding control signal demodenx is supplied on the gate NA 6 . This control signal operates the two parallel current sinks N 1 and N 0 connected in series with the current mirror P 4 . The current mirror P 4 is in turn connected in parallel with the current-mirror circuits P 1 and P 0 , as a result of which the charging current of the capacitors is increased by a multiple. This ensures an unreduced detection bandwidth, since the steady state is restored in accelerated fashion even in the case of modulation with a large swing.
The signals V refdem , V sigigh and V siglow are otherwise evaluated in a similar manner to that in the preceding exemplary embodiments.
The design variables for the circuit can be taken directly from the circuit.
In general, the invention is not restricted to the exemplary design, however.
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The invention provides a circuit configuration for demodulating a voltage that is ASK modulated by altering the amplitude between a low level and a high level. In this case, a first and a second charging circuit each produce a charging voltage and decoupling device decouples the first charging circuit when there is a prescribed ratio between the charging voltage of the second charging circuit and an input voltage for the rectifier circuit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims the benefit of Chinese Patent Application No. 201410499470.7, filed Sep. 25, 2014, which is incorporated herein by reference in its entirety, for all purposes.
BACKGROUND OF THE INVENTION
The present invention relates to a mobile communications device and methods of operation. More specifically, embodiments of the present invention relate to a mobile communications device, such as a smart phone, including an ultraviolet light source, and methods of controlling the ultraviolet light source using the smart phone.
The inventor of the present invention is aware of the use of ultraviolet light for disinfectant purposes. Currently, there are few stand-alone products on the market that provide ultraviolet light for cleaning surfaces or purifying water. One such product is a hand held UV wand that is plugged into a wall socket, and waved over surfaces; and another such product is a hand-held unit that runs on batteries, and is inserted to sanitize a bottle of water.
Some drawbacks contemplated by the inventor, to such devices include the high power consumption of such devices limit utility of such devices. For example, surface sanitizers are typically bulky and need to be powered by plugging them into a wall socket; and portable water sanitizers use batteries, but drain them quickly. Additional drawbacks are when the user travels, the user must remember to bring along. Because of gadget overload, such dedicated ultraviolet light (UV) sources are not believed to be widely adopted.
It is desired to have an ultraviolet light source without the drawbacks described above.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a mobile communications device and methods of operation. More specifically, embodiments of the present invention relate to a mobile communications device, such as a smart phone, including an ultraviolet light source, and methods of controlling the ultraviolet light source using the smart phone.
In some embodiments, a case or dongle for a smart phone is contemplated having an integrated ultraviolet (UV) light source and a power source, e.g. batteries. In such embodiments the UV light source may be located near one or more holes of the case, or anywhere else, where the camera of a smart phone is located. In some embodiments, power for the UV light may be drawn from the smart phone or from the case or dongle.
In some embodiments, a smart phone is contemplated having an integrated UV light located near the camera of a smart phone is located, or anywhere else. In some embodiments, power for the UV light may be drawn from the smart phone.
In some embodiments, application software is installed upon the smart phone, and programs the processor of the smart phone to perform one or more operations. Some operations may include monitoring a camera image or accelerometers, directing the UV light to turn on and off, and the like. In some examples, the camera image may be monitored to determine where the UV light is directed towards, may be monitored to determine whether the UV light is pointed upwards or downwards, etc. In other examples, the camera image may be used to determine if the UV light is close enough to a surface for disinfectant purposes, or the like.
In some embodiments, accelerometers, gyroscopes, etc. may also be used to determine orientation of the smart phone. In particular, if the UV light of the smart phone is directed upwards, the power may be shut-off from the UV light; while the UV light of the smart phone is directed, e.g. within 45 degrees of downwards, the UV light may be turned on, or the like.
In various embodiments, using data from one or more of these sensors, the smart phone may be programmed to indicate to the user how long to hold the UV light source of the smart phone over a particular surface; when a particular surface is sanitized and when to move the UV light source of the smart phone to a new location; or the like. In addition, the smart phone may be programmed to turn off the UV light upon unsafe usage conditions.
According to one aspect of the invention, a device for providing ultraviolet light is disclosed. One device includes a shell for a portable device, wherein the shell includes an interior region and an exterior region, wherein the interior region is adapted to be disposed adjacent to the portable device. An apparatus includes a power source configured to provide electrical power, and an ultraviolet light source coupled to the power source and embedded into the exterior region of the shell, wherein the ultraviolet light source is configured to output the ultraviolet light in response to the electrical power.
According to another aspect of the invention, a method for providing ultraviolet light includes providing a shell having an interior region and an exterior region, wherein the shell comprises an ultraviolet light source embedded into the exterior region of the shell, wherein the ultraviolet light source is configured to output ultraviolet light. A technique may include disposing a portable device adjacent to the interior region within the shell, and powering the ultraviolet light source to cause the ultraviolet light source to output the ultraviolet light to a plurality of surfaces. In other aspects, a method includes coupling a UV source dongle to the portable device, e.g. plugging into an interface/power port of the portable device.
Additional objects, features and advantages of the present invention can be more fully appreciated with reference to the detailed description and accompanying drawings that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to more fully understand the present invention, reference is made to the accompanying drawings. They are not to be considered limitations in the scope of the invention, the presently described embodiments and the presently understood best mode of the invention are described with additional detail through use of the accompanying drawings in which:
FIG. 1 illustrates an example of various embodiments of the present invention;
FIG. 2 illustrates a functional block diagram of embodiments of the present invention;
FIG. 3 illustrate block diagrams of flow processes of various embodiments; and
FIGS. 4A-B illustrate examples of various embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates various embodiments of the present invention. More specifically, FIG. 1 illustrates a hand-held computing device (e.g. smart phone, tablet) 100 . In various embodiments, as illustrated, the back casing 110 of device 100 , may include a camera 120 , a LED light source (e.g. flash) 130 , and a UV light source 140 . In FIG. 1 , UV light source 140 may be positioned such that light 150 from the UV light source 140 is within a field of view 160 of camera 120 . In other embodiments, light 150 may not be within field of view 160 . UV light source 140 may be positioned on the side, top, bottom, or the like of smart device 100 .
FIG. 2 illustrates a functional block diagram of various embodiments of the present invention (smart device), e.g. iPad, iPhone, Nexus, etc. In FIG. 2 , a computing device 200 typically includes an applications processor 210 (e.g. A7 Core, Tegra), memory (including controllers) 220 (e.g. DRAM, Flash), a touch screen display 230 (e.g. OLED, IPS) and driver 240 , a camera 250 (e.g. CMOS, CCD), audio input/output devices 260 (speakers/microphone), and the like. Communications from and to computing device are typically provided by via a wired interface 270 , a GPS/Wi-Fi/Bluetooth interface 280 , RF interfaces 290 (e.g. CDMA, GSM, HSUPA) and processor 300 , and the like. Also included in various embodiments are physical sensors 310 , e.g. multi-axis Micro-Electro-Mechanical Systems (MEMS) including accelerometers, gyroscopes, magnetometers, pressure sensors, or the like. In various embodiments, operating systems may include iOS, Windows Mobile, Android, or the like.
In some embodiments, computing device may include an integrated UV light source 330 . The UV light source 330 may be embodied as a UV light source being developed by the assignee of the present patent application, RayVio, although other sources may also be used. In some embodiments, UV light source 330 may include a UV LED that outputs light within the UV-A range, the UV-B range, and/or the UV-C range.
FIG. 2 is representative of one computing device 200 capable of embodying the present invention. It will be readily apparent to one of ordinary skill in the art that many other hardware and software configurations are suitable for use with the present invention. Embodiments of the present invention may include at least some but need not include all of the functional blocks illustrated in FIG. 2 . For example, in some embodiments, the hand-held computing device need not be a multi-purpose smart-device, but may be a dedicated device. Further, it should be understood that multiple functional blocks may be embodied into a single physical package or device, and various functional blocks may be divided and be performed among separate physical packages or devices.
In some embodiments, as illustrated in FIGS. 4A-B , the UV light source may be embodied in a protective case for a smart device ( FIG. 4A ), and/or a device that can be attached and detached from a smart device ( FIG. 4B ). As will be discussed below, such devices may include a UV light source, power source, UV controller, physical sensors (MEMS), wired or wireless communications capability, or the like. It should be understood that the processes described herein may be applied to the integrated smart device embodiments discussed in conjunction with FIG. 1 , as well as the peripheral embodiments discussed in conjunction with FIGS. 4A and 4B , below.
FIG. 3 illustrates block diagrams of flow processes according to some embodiments. More specifically, FIG. 3 describes a disinfection or sanitization process. Initially, the user initiates an application (software) upon the smart device to start a UV sanitation process, step 400 . This may include the user tapping upon an application icon of a display of the smart device, the user hitting a physical button on the smart device, a software timer going off, or the like.
In some embodiments, the smart device determines whether it is safe to turn on or keep on the UV light, step 410 . In some embodiments, this may include the smart device monitoring the MEMS sensors and/or cameras, discussed above, to ensure that the UV light of the smart phone is directed towards a “safe” direction, e.g. the ground, e.g. not upwards towards the face of the user. In some embodiments, this may include the smart device monitoring the amount of light reaching the camera. For example, if there is little light reaching a downwards facing camera, but a lot of light reaching an upwards facing camera, it might be assumed that the UV light faces a surface being sanitized and can be considered safe to be turned on. In another example, if the tilt angle of the downwards orientation is within +/−10 degrees, +/−45 degrees, or the like from downwards, as sensed by the MEMS, the UV light may still be considered safe to be turned on. In some embodiments, based upon the tilt angle, the amount of UV may be varied, for example, at 0 degrees, the UV light may be 100%, at 10 degrees, the UV light may be 50%, etc. In other embodiments, combinations of MEMS sensors and optical detection may be used for this step.
In some embodiments, images from the cameras may be processed by pattern recognition software to provide additional capabilities. In some examples, images from a downwards facing camera (UV assuming the light is also directed downwards) can be used to help determine if the UV light is directed towards a safe surface for sanitization. In some examples, if the downwards facing camera captures an image of a face, animal, skin, or the like, the UV light may be inhibited; if neither the upwards facing camera nor the downwards facing camera recognizes a face, only then can the UV light may be allowed; or the like. In some embodiments, only groups of specific surfaces can be sanitized, after these surfaces are visually identified. As examples, when surfaces with printed letters, e.g. keyboards, magazines, airplane emergency cards are identified by character recognition software, the UV light source may be enabled. In other examples, surfaces to be sanitized may be enabled and/or identified by bar-code, QR code, image, target, or the other such identifier. In such examples, only surfaces bearing such identifiers can be sanitized. One of ordinary skill in the art will recognize many other examples of image recognition that may be used in various embodiments of the present invention.
In some embodiments, a focus distance of the camera may be used to determine whether the UV light source is inhibited or not. For example, in some embodiments, when camera determines that the surface is within about 6 inches away from the camera/UV light source, the UV light may be activated; and for safety sake, when the distance is further than 6 inches, the UV light source may be deactivated. In various embodiments, the safety measures may be implemented as a combination of hardware and software. In some cases, the user may be able to override safety measure in certain circumstances and turn on the UV light, e.g. with a click-through agreement, age verification, password verification, fingerprint recognition, biometric recognition, or the like. In other cases, certain safety measures may not be overridden, e.g. UV light is turned off if the UV light is pointed upwards and a face is detected in the field of view of the camera.
In various embodiments, if safe, power may be applied to the UV light and one or more timers may be initiated, step 420 . When the UV light is turned on, the user may be notified, for example, an auxiliary visible light source may turn on, the display of the smart device may turn blue, a sound may be emitted, a vibration may be produced, etc.
In various embodiments, while the UV light is positioned over a particular surface, the cameras and/or the MEMS sensors may be used to determine whether the smart phone has moved, step 430 . In some embodiments, to sanitize a surface, the surface should be exposed to UV light for a certain amount of time. However, if the user moves the UV light around, a keyboard, for example, regions of the keyboard may not be sufficiently exposed to the UV light. Accordingly, based upon optical tracking (from camera images), and/or MEMS sensors, the smart device can recognize what surface the UV light is illuminated.
In various embodiments, based upon pattern recognition and/or image stitching functions, software can determine how long different parts of surface, e.g. a keyboard, have been exposed to UV light. In such an example, the application software can determine that the asdf keys were exposed to UV light for 15 seconds, and thus sanitized, but the jkl; keys were exposed to UV light for only 5 seconds, thus further exposure is necessary. In some embodiments, as the user scans across a surface, multiple images of the surface may be captured and stitched together automatically, and as the UV light is swept across the surface, approximate exposure times for different portions of the surface are associated with portions of the stitched image. In various embodiments, movement sensors may provide feedback regarding an optimal scanning rate of the UV light over the surface.
In some embodiments, the timers may be used to determine whether the UV light has exposed a surface a sufficient period of time, step 440 , and/or to determine whether the UV light has been powered on for too long, step 450 . In the latter case, the UV light may be automatically switched off, step 460 . In other embodiments, many other such timers may be used for similar purposes. The amount of time may vary upon the type of surface to be disinfected, for example, fruit, water, and plastic surfaces may require different exposure times.
In various embodiments, after a particular surface has been exposed to UV light for a sufficient period of time, the smart device may notify the user, e.g. sound, image, vibration. In some embodiments, the user may terminate the above process at any time.
FIG. 4A illustrates another embodiment, a protective housing 500 for a smart device.
As illustrated, protective housing 500 may include an opening 510 where the camera of the smart device is positioned. Additionally, housing may include a UV light source 520 , typically near opening 510 , and a region 530 for a power source, e.g. battery. In other words, in some embodiments, UV light source 520 receives power from a smart device that is nestled within protective housing 500 . For example, a plug, or the like may be provided that physically plugs into a port of the smart device and draws power therefrom. In some embodiments, the port may be an I/O port, power port, peripheral port, USB, Firewire or other ports. In such embodiments, the smart device may control light from UV light source 520 by selectively applying power over the port, as was discussed. In particular, under control of one or more software applications running upon the smart device, the UV light may be turned on or off, and the UV light intensity may be adjusted. In some embodiments, housing 500 communicates with smart device via a wireless communication mechanism, e.g. Bluetooth, NFC, or the like, or a wired connection, e.g. a tether.
In other embodiments, protective housing 500 may include an internal battery, e.g. an external battery pack for the smart device, from which to draw power. In such embodiments, the UV light upon housing 500 may still be under the control of the smart device, as discussed above, and/or under the control of housing 500 . For example, housing 500 may have a physical enable button or switch for the UV light, and if enabled, the smart device can power on the UV light source. In another example, housing 500 may have a MEMS device that senses when the UV light is pointed upwards, and disables the UV light from being powered-on, even though the smart phone tries to power-on the UV light. In other embodiments, power may be drawn from the smart device via a USB port, Firewire port, headphone port, or the like.
In various embodiments of housing 500 , exposure of UV light source 520 may be within a field of view of a smart device camera. In other embodiments, e.g. relying upon MEMS devices, exposure and field of view for the camera may not overlap. MEMS accelerometers, or the like may be integrated into protective housing 500 in some embodiments, for the purposes previously discussed above.
FIG. 4B illustrates another embodiment of the present invention, a dongle (peripheral) or device 540 for a smart device. In this embodiment, dongle 540 typically includes a physical and/or mechanical interface 550 for attachment onto and detachment from a smart device. In various embodiments, device 540 includes one or more UV light sources 560 . Dongle 540 may be self-powered (e.g. via battery) or may be powered by the smart device.
In some embodiments, device 540 may be physically attached to a smart device in operation. The UV light sources 560 may operate with and/or be controlled by smart device, similar to the embodiments described above. Additionally, UV light sources 560 may receive power from smart device or an internal battery.
In other embodiments, device 540 may be physically detached from a smart device in operation. Once detached, the user may point UV light sources 560 towards a surface to sanitize, and active UV light sources 560 through software operating upon the smart device. In some embodiments, device 540 may include a proximity sensor, image sensor, or the like. The sensor may be used by device 540 to determine whether the surface is within a distance, e.g. within 6 inches, of UV light sources 560 . If so, device 540 may allow the smart device to activate UV light sources. In some embodiments, device 540 may include position sensors, e.g. MEMS accelerometers, or the like. Such position sensors may also be used by device 540 to determine whether UV light sources 560 are pointed downwards. If so, device 540 may allow the smart device to activate UV light sources.
In some embodiments, device 540 may be relatively water-proof. In some examples, device 540 is separated from the smart device and then immersed in water to disinfect or sanitize the water. As described above, device 540 may be partially controlled by smart device during the sanitization process.
In the various embodiments described above, for sanitization or disinfection purposes, the UV LED light sources are typically within the UV-C band, although UV-A band and UV-B band also provides some degree of sanitization. In such embodiments, a blue-colored LED (and/or a UV-A LED) may also be used. Since UV-C is typically not visible to the human eye, the blue-colored LED is a visual indicator for a user that shows whether the UV-C light is active. Additionally, in some embodiments, the blue LED illuminates the same area as the UV-C LED. Accordingly the user will sanitize a surface by directing the blue light towards that surface. The supplemental blue LED may be used in any of the above-described embodiments.
FIG. 6 illustrates block diagrams of flow processes according to some embodiments. More specifically, FIG. 6 describes a UV inspection process. Initially, the user initiates an application (software) upon the smart device to start a UV inspection process, step 600 . This may include the user tapping upon an application icon of a display of the smart device, the user hitting a physical button on the smart device, a software timer going off, or the like.
In some embodiments, the smart device determines whether it is safe to turn on or keep on the UV-A light, step 610 . Similar to the embodiments described above, the process may include the smart device monitoring the MEMS sensors and/or cameras for unsafe situations. For example, pattern recognition software can be used to ensure the UV-A light is not pointed to a person's face, an animal, or the like; and/or pointed to an appropriate surface, e.g. computer keyboard, printed media, cloth faces, etc. As merely another example, a camera focal distance, a reflected UV light detector, a proximity sensor, or the like may be used to limit the distance between the UV light and the surface.
In various embodiments, if safe, power may be applied to the UV-A wavelength LED and one or more timers may be initiated, step 620 . When the UV light is turned on, the user may be notified, for example, an auxiliary visible light source may turn on, the display of the smart device may turn blue, a sound may be emitted, a vibration may be produced, etc.
In various embodiments, in step 630 , the safety metrics determined in step 610 are monitored. While still safe, in some embodiments, a software application running on the smart device may allow the user to capture a photograph of the surface, step 640 . In some embodiments, no visible-light flash is used when capturing the image, so that the natural fluorescence of the surface in response to the UV-A light is captured, step 670 . In some examples, driver's licenses, passports, currency, quality labels, and the like may include UV-A responsive ink as a fluorescence source. Accordingly, in this step, an image of the fluorescence can be used for bookkeeping, evidentiary purposes, or the like. As merely an example, the image may show the fluorescence of bed-bugs on a bed, the fluorescence of pathogens on a surface, or the like.
In some embodiments, a visible-light flash may be used during image capture. For example, it is contemplated that the UV-A light source may be used by a user to physically inspect a surface, e.g. passport, for authentication purposes. Subsequently, when the user wants to take a picture of the surface, the flash is activated so a visible light image of the surface may be captured, step 670 . Again, the visible light image may be used for bookkeeping, evidentiary purposes, or the like. As merely an example, the image may be a driver's license of a person going through airport security.
Next, in various embodiments, a determination is made whether the UV light has been powered on for too long, step 650 . In the latter case, the UV light may be automatically switched off, step 660 . In other embodiments, many other such timers may be used for similar purposes. The amount of time may vary upon the intensity of the UV light, the temperature, and the like.
Further embodiments can be envisioned to one of ordinary skill in the art after reading this disclosure. For example, in some embodiments, a UV light sensor may be included on the smart device, protective case, dongle, or the like. The UV light sensor may be positioned proximate to the one or more UV light sources. In operation, the UV sensor may be used to determine if UV light is reflected from a surface, and/or an intensity of reflected UV light. In one embodiment, when reflected UV light is not detected, the UV light source may not be pointed at a surface, for example, the UV light source may be pointed into space. In such an embodiment, the amount of UV light output from the UV light sources may be decreased or pulsed for safety's sake. When reflected UV light is subsequently detected by a UV light sensor, it may be assumed that UV light is reflecting off of a relatively close surface. Accordingly, the UV light source output may be increased to the desired UV light intensity. In some embodiments, if too much reflected UV light is detected, the UV light intensity may be decreased.
In other embodiments, combinations or sub-combinations of the above disclosed invention can be advantageously made. For example, in some embodiments, the UV light peripheral may be stored separate from the smart device. In operation, the user would plug-in the UV peripheral into the smart device, and the UV peripheral would draw power and/or receive instructions from the smart device. Software applications running on the smart device would then selectively activate and deactivate the UV light source on the UV peripheral. When disinfecting, the user would then move their smart device (and the attached UV light source) over the treatment surface. After satisfactory completion, the user may detach the UV light peripheral from the smart device, and physically store the peripheral separate from the smart device. In other embodiments, the UV light peripheral may be stored adjacent to the smart device. The block diagrams of the architecture and flow charts are grouped for ease of understanding. However it should be understood that combinations of blocks, additions of new blocks, re-arrangement of blocks, and the like are contemplated in alternative embodiments of the present invention.
The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims.
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A UV device includes a housing having a portion configured to be removably attached to a smart device, a UV light source disposed within the housing, wherein the UV light source is configured to provide output of UV light in response to an operating powered, a communication mechanism disposed within the housing, wherein the communication mechanism is configured to receive instructions from the smart device, a control mechanism disposed within the housing, wherein the control mechanism is coupled to the UV light source, and to the communication mechanism, wherein the control mechanism is configured to provide the operating power to the UV light source, in response to the instructions received from the smart device.
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TECHNICAL FIELD
[0001] This invention relates to the method of shearing drill pipe for drilling oil or gas wells, especially in deep water.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0004] Not applicable
BACKGROUND OF THE INVENTION
[0005] The drill bit for drilling oil and gas wells is facilitated by having a heavy load applied to assist in crushing and pulverizing the formation being drilled. The formation material must be reduced to particles small enough that the flow of drilling mud up to the surface will carry it to the surface. Drill collars are connected to the drill bit to provide the heavy load for this purpose.
[0006] The drill bit and drill collars are part of a drill string which also includes drill pipe which extends to the drilling rig at the surface.
[0007] The drill pipe which extends to the surface is thin walled. Its primary design requirement is to support the weight of the drill string including the drill collars during running and retrieving of the drill string.
[0008] Conversely, the drill collars are at the bottom of the drill string and they only support themselves. The drill pipe can be 20,000 feet long or longer and drill collars seldom exceed 1,000 feet in length. Although the drill collars are heavier, there is much more length in drill pipe, and the drill pipe must support the drill collars and the drill pipe.
[0009] Drill collars have as small a bore as practical and as large an outer diameter as is practical so that they will be heavy. The drill collars have metal sealing threaded connections on each end. These threaded connections are benefited by being made of high strength steel. As a result the entire drill collar is made of high strength steel. They are extremely strong as a result, but do not have a requirement for being extremely strong. They are characteristically so strong that the average person presumes they need to be strong, because they always are.
[0010] A problem resulting from this is that the thick cross section of high strength steel cannot be sheared by the blind shear rams in the primary well control device, the blowout preventer stack. The blind shear rams are to cut the pipe in the bore and seal across the bore to keep a well from blowing out. When as much as 1000 feet of drill collars pass in front of the blind shear rams, the well bore literally cannot be closed.
[0011] On land or platform wells this is not a major concern as in unexpected pressure situations there is always a closable valve on the top of the drill string except for the short time for making connections at the surface. For the annular area between the outside diameter of the drill string in the well and the bore of the blowout preventer stack, there are annular and ram type blowout preventers which are well known in the art and can be closed to seal this annular area.
[0012] In deepwater drilling situations from a floating vessel the situation is different. In the worst case scenario the vessel can be blown off location or can have a steering computer accidental drive off when you are in an unexpected pressure situation. If this happens when the drill collars are in the bore in front of the blind shear rams, you cannot close the blowout preventers and you cannot let go of the pipe string. In other words you have a blowout.
BRIEF SUMMARY OF THE INVENTION
[0013] The object of this invention is to provide a drill collar which can be sheared with conventional blowout preventer shear rams.
[0014] A second object of this invention is to provide drill collars of a higher unit weight such that the length of the drill collars to provide a desired weight on the bit will be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a view of a deepwater drilling system using the drill collars of this invention
[0016] FIG. 2 is a half section of a drill collar of conventional design.
[0017] FIG. 3 is a cross section of the drill collar of FIG. 2 taken along lines “ 3 - 3 ”.
[0018] FIG. 4 is a half section of a drill collar of this invention.
[0019] FIG. 5 is a cross section of the drill collar of FIG. 4 taken along lines “ 5 - 5 ”.
[0020] FIG. 6 is a half section of one and one half drill collars of this invention
[0021] FIG. 7 is a half section of a cylindrical tube which might be used to manufacture the drill collar of this invention.
[0022] FIG. 8 is a half section of the tube of FIG. 7 which is rolled and forged to an appropriate shape.
[0023] FIG. 9 is a half section of the tube of FIG. 8 machined.
[0024] FIG. 10 is a half section of the tube of FIG. 9 with a spacer ring added to the bottom and an internal tube added.
[0025] FIG. 11 is a half section of weight material added to the components of FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to FIG. 1 , a view of a complete system for drilling subsea wells 20 is shown in order to illustrate the utility of the present invention. The drilling riser 22 is shown with a central pipe 24 , outside fluid lines 26 , and control lines 28 .
[0027] Below the drilling riser 22 is a flex joint 30 , lower marine riser package 32 , lower blowout preventer stack 34 and wellhead 36 landed on the seafloor 38 .
[0028] Below the wellhead 36 , it can be seen that a hole was drilled for a first casing string, that string 40 was landed and cemented in place, a hole drilled thru the first string for a second string, the second string 42 cemented in place, and a hole is being drilled for a third casing string by drill string 44 which includes drill bit 45 , heavy weight drill collars 46 , and lighter weight drill pipe 47 .
[0029] The lower Blowout Preventer stack 34 generally comprises a lower hydraulic connector for connecting to the subsea wellhead system 36 , usually 4 or 5 ram style Blowout Preventers, an annular preventer, and an upper mandrel for connection by the connector on the lower marine riser package 32 .
[0030] Below outside fluid line 26 is a choke and kill (C&K) connector 50 and a pipe 52 which is generally illustrative of a choke or kill line. Pipe 52 goes down to valves 54 and 56 which provide flow to or from the central bore of the blowout preventer stack as may be appropriate from time to time. Typically a kill line will enter the bore of the Blowout Preventers below the lowest ram and has the general function of pumping heavy fluid to the well to overburden the pressure in the bore or to “kill” the pressure. The general implication of this is that the heavier mud will not be circulated, but rather forced into the formations. A choke line will typically enter the well bore above the lowest ram and is generally intended to allow circulation to circulate heavier mud into the well to regain pressure control of the well.
[0031] Normal drilling circulation is the mud pumps 60 taking drilling mud 62 from tank 64 . The drilling mud will be pumped up a standpipe 66 and down the upper end 68 of the drill pipe 47 . It will be pumped down the drill pipe 47 , out the drill bit 45 , and return up the annular area 70 between the outside of the drill pipe 47 and the bore of the hole being drilled, up the bore of the casing 42 , through the subsea wellhead system 36 , the lower blowout preventer stack 34 , the lower marine riser package 32 , up the drilling riser 24 , out a bell nipple 72 and back into the mud tank 64 .
[0032] During situations in which an abnormally high pressure from the formation has entered the well bore, the thin walled central pipe 24 is typically not able to withstand the pressures involved. Rather than making the wall thickness of the relatively large bore drilling riser thick enough to withstand the pressure, the flow is diverted to a choke line 26 . It is more economic to have a relatively thick wall in a small pipe to withstand the higher pressures than to have the proportionately thick wall in the larger riser pipe.
[0033] When higher pressures are to be contained, one of the annular or ram Blowout Preventers are closed around the drill pipe and the flow coming up the annular area around the drill pipe is diverted out through choke valve 54 into the pipe 52 . The flow passes up through C&K connector 50 , up pipe 26 which is attached to the outer diameter of the riser 24 , through choking means illustrated at 74 , and back into the mud tanks 64 .
[0034] On the opposite side of the drilling riser 24 is shown a cable or hose 28 coming across a sheave 80 from a reel 82 on the vessel 84 . The cable 28 is shown characteristically entering the top of the lower marine riser package 32 . These cables typically carry hydraulic, electrical, multiplex electrical, or fiber optic signals. Typically there are at least two of these systems, which are characteristically painted yellow and blue. As the cables or hoses 28 enter the top of the lower marine riser package 32 , they typically enter the top of the control pod to deliver their supply or signals. When hydraulic supply is delivered, a series of accumulators are located on the lower marine riser package 32 or the lower Blowout Preventer stack 34 to store hydraulic fluid under pressure until needed.
[0035] Referring now to FIG. 2 , conventional drill collar 100 comprises a central thick wall section 102 , an upper female thread 104 , a lower male thread 106 , an upper sealing shoulder 108 and a lower sealing shoulder 110 .
[0036] Referring now to FIG. 3 , a cross section of FIG. 2 is shown along lines “ 3 - 3 ” showing the thick cross section required to be sheared.
[0037] Referring now to FIG. 4 , a half section of the drill collar 120 of the present invention is shown being made of a thin wall formed tube 122 with an upper thread 124 , a lower thread 126 , upper sealing shoulder 128 and lower sealing shoulder 130 . Ring 132 lands on shoulder 134 and supports thin walled tube 136 . Heavy weight material such as lead 138 is melted and poured into the area between tube 122 and thin walled tube 136 .
[0038] Referring now to FIG. 5 , a cross section of FIG. 4 is shown along lines “ 5 - 5 ” showing the majority of the section required to be sheared is of the lower shear strength material such as lead. As the density of steel is 0.283 lbs. per cubic inch and the density of lead is 0.410 lbs. per cubic inch, lead is approximately 45% heavier than steel. This means that the length of the drill collars of this invention could be up to 45% shorter than conventional drill collars.
[0039] Referring now to FIG. 6 , a drill collar 140 of this invention is shown with a portion of a second drill collar 142 attached at thread 144 . This illustrates that even the connection of the drill collar of this invention has a smaller cross section of steel than that of a conventional drill collar such as is shown in FIG. 2 .
[0040] Referring now to FIG. 7 , a simple thin wall tube 150 is shown which can be used as material for a portion of the drill collar of the present invention.
[0041] Referring now to FIG. 8 , tube 150 of FIG. 7 is rolled tube 160 to a suitable profile, with some forging upset occurring at locations 162 and 164 where thicker cross sections will be beneficial for machining. This is especially important when the connections are tapered threads.
[0042] Referring now to FIG. 9 , is shown with the rolled tube 160 of FIG. 8 is a machined tube 170 with a lower thread 172 , an upper thread 174 , a lower sealing shoulder 176 , an upper sealing shoulder 178 , and an internal shoulder 180 .
[0043] Referring now to FIG. 10 , machined tube 170 has ring 132 and thin walled tube 136 installed.
[0044] Referring now to FIG. 11 , lead 190 is poured into the assembly of FIG. 10 and allowed to solidify. As lead tends to shrink when solidifying, percentages of bismuth, antimony, and tin can be added to eliminate the shrinkage or to cause a slight expansion if desired. Alternately, a temporary tube can be placed in the bore for molding and then be removed.
[0045] 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. Accordingly, the protection sought herein is as set forth in the claims below.
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The method of shearing drill collars used in the drilling of oil and gas wells, comprising providing an outer sleeve of a first material for carrying structural loads, providing a second material within the outer sleeve which is lower in shear strength and is greater in unit weight than the first material, and providing a hole in the second material for the circulation of fluids.
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FIELD OF THE INVENTION
This invention relates generally to the manufacturing of structural members for use in automobiles and, more particularly, to a process for roll-forming sheet metal into a structural beam having an internal web to increase strength of the beam.
BACKGROUND OF THE INVENTION
Manufacturing processes for automobiles have evolved from one that utilized primarily stamped and bent sheet metal pieces that were welded together through a MIG welding processes, i.e. a welding process in which a line of molten material is deposited by the welder in joining two pieces of metal together. Now, conventional automobile manufacturing processes incorporate in a greater degree hydroformed tubular members that are shaped to fit into the chassis of an automobile in a desired manner. The hydroformed members are particularly conducive to being welded through a spot-welding process, which involves the passage of electrical current between two electrodes to melt and join two pieces of metal placed between the electrodes. Spot-welding requires a frame design having appropriate access holes that is conducive to being manufactured using the spot-welding process. For example, if two tubular members are being spot-welded together, access to the adjoining walls of the two tubular members by the spot-welder electrodes must be provided. Other welding techniques, such as gas metal arc welding (GMAW), are also be utilized for welding tubular designs.
Roll-forming is a process for forming a structural tubular member involving the transformation of a piece of flat sheet metal into the structural beam by passing the sheet metal through a series of rollers arranged to bend the sheet metal into the structural beam. Generally, tubular members are formed through the roll-forming process. These tubular members can be used directly in the manufacture of an apparatus, such as an automobile, or be used in a subsequent manufacturing process called hydroforming to create a specially shaped and bent structural member that roll-forming cannot by itself create.
Hydroforming is a process by which a standard tubular stock member is placed into a form shaped to correspond to the particular member to be formed. A liquid is then introduced into the interior of the tubular stock and pressurized until the tubular stock expands to assume the shape defined by the configured form. The expanded and re-shaped tubular stock now has a substantially different shape. By forming cutouts and other access openings into the re-shaped tubular member, spot-welding electrodes can gain access to opposing adjacent sides to create a weld bond between juxtaposed members. In this manner, a frame, as an example, for an automobile can be created using in large part hydroformed tubular members. Once the hydroformed part is formed, attachment brackets are attached to the part to permit other components of the automobile to be mounted. Typically, these attachment brackets are welded to the hydroformed part by either a MIG or spot-welding process, whereupon the other components can then be bolted or welded to the attachment brackets.
Whether hydroformed or merely roll-formed, the structural tubular member is not conventionally formed with any internal reinforcement and, thus, the walls of the tubular member must carry the entire load placed on the structural member and provide the requisite stiffness needed for the structural member to perform its operative function. The load carrying ability of the tubular member is a limiting factor in the design of hydroformed or roll-formed structural members and can result in a non-optimized beam design having increased material thickness in the walls of the beam or increased tube diameter. Either of these enhanced load carrying characteristics leads to an expensive overweight design. Furthermore, the increasing of the tube diameter causes problems in the packaging of the enhanced design, making automotive design more difficult.
Accordingly, it would be desirable to provide a manufacturing process by which the structural beam can be formed with multiple tubular cells that provide a single structural member having an integral internal reinforcement to increase structural strength for a roll-formed beam of a given size and shape.
SUMMARY OF THE INVENTION
It is an object of this invention to overcome the aforementioned disadvantages of the known prior art by providing a roll-forming process to create a tubular structural member that has an internal web reinforcement.
It is another object of this invention to provide a roll-forming process for manufacturing a structural tubular member having multiple cells.
It is still another object of this invention to roll-form a flat sheet of metal into a shaped tubular beam by rolling the sheet metal on top of itself to form an internal reinforcement web between two structural cells.
It is an advantage of this invention that a roll-formed structural member can have increased strength for a given size and shape due to an integral internal reinforcement separating the cells of the structural member.
It is another advantage of this invention that the cost of manufacturing automobiles can be reduced.
It is a feature of this invention that the roll-formed structural beam is manufactured with an internal rib forming a reinforcement along the entire length of the beam.
It is another feature of this invention that the roll-formed structural beam is formed in a fashion that creates two cells with a rib member separating the two cells.
It is still another advantage of this invention that the roll-formed component, manufactured into multiple cells with an internal rib separating the cells to reinforce the component, increases strength, rigidity and stiffness of the structural component, while maintaining a predetermined size and shape.
It is another advantage of this invention that the improved roll-forming process enhances the structural properties of the component without adding additional parts or external reinforcements to the component.
It is a further object of this invention to provide a roll-forming process that creates an automotive component with multiple cells having an integral internal rib reinforcement that is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use.
These and other objects, features and advantages are accomplished according to the instant invention by providing a roll-forming process for the manufacture of a structural member that can be used in the manufacture of an automotive vehicle. The roll-forming process creates a component that has multiple cells with an integral internal web separating the cells, enhancing the strength, rigidity and stiffness of the component for any given size and shape. The roll-forming process starts with a piece of sheet metal and rolls the sheet metal into a desired shape and then rolls the tube back over on itself to create a second cell with the internal reinforcing web positioned between two structural cells of the beam. The rolled form is then welded into the formed shape to create the structural beam. The two cells of the beam can be the same general size or be formed as completely disparate sizes, depending on the design requirements of the structural member.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will become apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a representative cross sectional view of a pillar forming part of an automotive frame manufactured from a piece of sheet metal using a roll-forming process according to the principles of the instant invention;
FIG. 2 is a perspective view of a piece of sheet metal from which the pillar of FIG. 1 is formed according to the principles of the instant invention;
FIG. 3 is an end view of the structural member following a first formation stage of the roll-forming process to create the pillar of FIG. 1 ;
FIG. 4 is an end view of the structural member following a second formation stage and welding overlapping portions to form the pillar depicted FIG. 1 ;
FIG. 5A is an end view of a second embodiment of the roll-formed beam having an internal web showing a first stage of formation according to the principles of the instant invention;
FIG. 5B is an end view of a second embodiment of the roll-formed beam having an internal web after the final stage of formation, this second embodiment being particularly adapted for further formation through a subsequent hydroforming process;
FIG. 6A is an end view of a third embodiment of the roll-formed beam having an internal web showing a first stage of formation according to the principles of the instant invention;
FIG. 6B is an end view of a third embodiment of the roll-formed beam having an internal web after the final stage of formation, this third embodiment also being particularly adapted for further formation through a subsequent hydroforming process;
FIG. 7 is a partial perspective view of the A-pillar beam to depict the formation of optional slots formed in the outer in the outer wall of the first cell to permit certain welding techniques, such as laser edge welding;
FIG. 8 is a partial perspective view of the opposing side of the A-pillar shown in FIG. 7 to depict an optional opening in the second cell for internal access for welding purposes; and
FIG. 9 is a partial perspective view of the A-pillar to show an optional weld access opening.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-4 , a structural beam formed according to the principles of the instant invention can best be seen. The structural member 10 can be used in a variety of devices in known manners, such as is depicted in FIG. 1 , which is the A-pillar 10 of an automobile. Generally, automotive frame design requires structural components with this particular shape, size and configuration, which when assembled together form the chassis of an automotive vehicle. The A-pillars 10 are generally vertical frame members located at the front corners of the automobile to support the front part of the roof (not shown), the windshield W, side glass (not shown), and the front doors (not shown). The envelope 11 in which the A-pillar is positioned has a limited size and certain characteristics relating to the strength, rigidity and stiffness for the component 10 have to be maintained. To increase the strength or other properties of this particular structural component 10 , external reinforcements (not shown) or additional parts (not shown) could be added strategically to the structural member 10 as needed. Such additional parts or reinforcements add manufacturing steps, and additional materials to attain the requisite structural properties, and thus, increase the cost of manufacturing the component and the automotive vehicle into which this component 10 is assembled.
As is reflected in FIGS. 2-4 , the A-pillar 10 is manufactured through a roll-forming process during which a flat piece of sheet metal 20 is passed through a series of properly arranged rollers (not shown), as is known in the art, to bend the sheet metal 20 into a first cell 12 during a first stage of formation of the structural member 10 . The first cell 12 has an outer wall 13 , a side wall 14 and an inner wall 15 . Because of the particular utilization of this structural member 10 as an A-pillar, the first cell is also formed with a first mounting flange 18 and a second cell flange 19 .
The first cell 12 and the second cell flange 19 are then passed through a second stage of rollers (not shown) to effect a bending of the second cell flange into a second cell 22 that folds back over the first cell 12 such that the second cell 22 is formed with a first end wall 23 that is positioned against the first mounting flange 18 , and a second end wall 24 that overlaps the side wall 14 of the first cell 12 and terminates in a second mounting flange 28 . Because of the particular application of this structural beam 10 as an A-pillar the mounting flange 18 bends around a portion of the outer wall 13 of the first cell before extending outwardly therefrom for connection to supporting structure of the vehicle chassis. The first and second end walls 23 , 24 are separated by an exterior wall 25 . In this particular configuration, the A-pillar is formed in a generally trapezoidal shape such that the first and second cells 12 , 22 are also shaped generally as trapezoids with the outer wall 13 and the exterior wall 25 being the primary external walls of the A-pillar with the inner wall 15 defining a reinforcing web extending generally parallel midway between the two primary external walls 13 , 25 .
Welding the first end wall 23 to the first mounting flange 18 against which the first end wall 23 rests, as well as welding the overlapping areas of the second end wall 24 of the second cell 22 and the side wall 14 of the first cell 12 , and optionally the overlapping areas of the second mounting flange 28 and the outer wall 13 of the first cell 12 , as is represented by the “x” designators in FIG. 4 , secures the beam 10 in the two cell configuration with an internal reinforcement web 15 and provides a structural member that can be used in the design of an automotive frame. One skilled in the art will readily recognize that the specific shape of the structural beam 10 can be designed to fit the strength and stiffness parameters associated with the utilization of the beam 10 . The principles of the instant invention would have the structural beam 10 formed with a first cell and then with a second cell that folds back onto the first cell to provide a two cell structural beam with one of the walls of the first cell 12 becoming the internal reinforcement web 15 for the beam 10 .
Welding can be accomplished through many known procedures, including MIG welding, spot welding, and other welding techniques, such as gas metal arc welding (GMAW). As can best be seen in FIGS. 7-9 , these certain welding techniques can best be utilized if slots 42 or openings 40 are pre-punched into the sheet metal blank 20 to be properly positioned upon formation of the beam 10 to permit access into the interior of the cells 12 , 22 . For example, as depicted in FIG. 7 , the slots 42 formed into the outermost thickness of sheet metal at the overlap area on the first cell 12 allow the use of laser edge welding or GMAW welding techniques to join the layers of overlapping sheet metal. The access opening 40 in the exterior wall 25 of the second cell 22 would need to be aligned with a correspondingly located opening (not shown) in the internal reinforcing web 15 to permit access into the first cell for spot-welding the overlapping areas of the first cell 12 . Similarly, the weld access opening 40 in the end wall 24 , shown in FIG. 9 would allow spot-welding techniques to be utilized at the end wall 23 . Accordingly, appropriately positioned openings 40 , 42 will facilitate the welding of the cells 12 , 22 to form the integral beam 10 . Preferably, the slots 40 are placed in the single thickness walls of the cells 12 , 22 ; however, the slots can also be formed in the overlapping sections, though alignment of the slots 40 in one wall with the slots in the overlapping wall can be problematic.
Referring now to FIGS. 5A-6B , additional configurations of the two cell roll-formed structural member 30 can be seen. In FIGS. 5A and 5B , the structural member 30 starts with a flat piece of sheet metal parent material, as depicted in FIG. 2 , and rolls the sheet metal parent material into a cellular configuration that forms the first cell 36 from a portion of the sheet metal and then rolls the remaining parent sheet metal back against the first cell 36 to form the second cell 37 . While the two cells 36 , 37 can be formed in a generally circular configuration or in a box-like configuration, as depicted in the drawings, the structural member 30 is formed so that the second end 32 mates against the side of the upper cell 36 with the second end 32 being welded to the outside of the second cell 36 . The first end 31 of the parent sheet metal is then welded to the outside of the lower cell 37 at a position that is spaced from the second end 32 with an intermediate strip 35 of the parent material extending between the first and second ends 31 , 32 . Since the structural member 30 is formed from a continuous piece of sheet metal parent material extending from the first end 31 to the second end 32 , the strip 35 is an integral part of the blank 30 . Furthermore, the strip 35 forms the barrier between the upper and lower cells 36 , 37 and creates an internal reinforcement web.
An alternative configuration for the dual cell structural member 30 can be seen in FIGS. 6A-6B in which the first end 31 is rolled into the first cell 36 and then into the second cell 37 . The first end 31 is welded to a point on the sheet metal to define the first cell 36 , while the second end 32 is welded along the first cell 36 at a distance spaced from the first end 31 such that the strip of sheet metal becoming the barrier 35 between the first and second cells 36 , 37 extends from the first end 31 , rather than along an intermediate strip of the sheet metal per the configuration of FIG. 5A-5B . Either configuration of the dual cell structural member 30 works satisfactorily in a subsequent hydroforming process, particularly if the first and second cells 36 , 37 are formed in a generally circular configuration; however, certain characteristics of one configuration may be desired over the other, as can be recognized below.
Although the first and second cells 36 , 37 of the structural member are depicted as being substantially the same size, the roll-forming process through which the structural members 30 are manufactured does not require that the cells 36 , 37 be the same size or even the same shape. If the envelope in which the beam 30 is to be placed, or the operational characteristics desired for the beam, requires different sizes or shapes of the respective cells 36 , 37 , such a configuration can be easily arranged.
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.
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A roll-forming process for the manufacture of a structural member can be used in the manufacture of an automotive vehicle. The roll-forming process creates a component that has multiple cells with an integral internal web separating the cells, enhancing the strength, rigidity and stiffness of the component for any given size and shape. The roll-forming process starts with a piece of sheet metal and rolls the sheet metal into a desired shape and then rolls the tube back over on itself to create a second cell with the internal reinforcing web positioned between two structural cells of the beam. The rolled form is then welded into the formed shape to create the structural beam. The two cells of the beam can be the same general size or be formed as completely disparate sizes, depending on the design requirements of the structural member.
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TECHNICAL FIELD
This invention relates to the field of crop harvesting and, more particularly, to harvesting headers of the type which are operable to sever standing crops as the header is advanced through a field, to gather the crops thus severed along the leading edge of the header, and to subsequently discharge such gathered crops back onto the ground in a properly formed windrow.
BACKGROUND ART
Windrowing headers having the capability of selective positioning of their draper or conveyor sections for either left, right or center crop delivery and discharge are not per se new. However, the various means for effecting such shifting movement and for reversely or forwardly driving the sections when at their various right or left positions not heretofore been unduly costly, complex, and slow-operating.
SUMMARY OF THE PRESENT INVENTION
Accordingly, an important object of the present invention is to retain the three-way selective delivery feature of prior machines but to avoid in the present invention the complexities, costs and performance disadvantages inherent in prior arrangements for driving and adjustably shifting the conveyor sections of such headers. Pursuant to this objective, the present invention contemplates using a single hydraulic piston and cylinder assembly and related components as a shifter for one of the two conveyor sections of the header and then relying upon a selectively operable latching and unlatching arrangement for connecting the two sections together at those times when movement or shifting thereof to a different operational position is desired, at which time movement of the hydraulically shifted section is utilized to supply the movant force for the other section of the conveyor. By having the latching, unlatching and shifting functions controllable by the operator from a cab of the vehicle to which the header is attached, the adjustment procedure can be readily carried out on-the-go without requiring that the operator step down from the operator's position and assemble or disassemble and reorganize any components for adjustment purposes. Insofar as drive line aspects of the invention are concerned, an arrangement is provided whereby two oppositely rotating drive shafts are located generally in opposite end portions of the header for supplying driving power in their respective directions of drive to one or more of the conveyor sections depending upon the positions to which the sections have been placed by the shifting mechanism therefor. When the sections are shifted to the right end of the header in side-by-side relationship for lefthand delivery toward the opposite end of the header, the drive shaft at the right end if the header becomes matingly coupled with a driven shaft of the right conveyor section. The right conveyor section in turn has its driven shaft matingly coupled with the driven shaft of the left conveyor section. On the other hand, when the sections are located at the opposite left end of the header for crop delivery in a rightward direction, the drive shaft at the left end of the header matingly engages a driven shaft on the left conveyor section which in turn matingly engages a driven shaft of the right conveyor section such that all three of such shafts rotate in the same direction. In the third alternative, when the left and right sections are separated and disposed at opposite right and left ends of the header to present a central discharge opening therebetween, the left drive shaft mates with the driven shaft of the left section to drive the same rightwardly toward the center opening, while the right drive shaft mates with the driven shaft of the right conveyor section to drive the latter leftwardly toward the center opening. Mating engagement and disengagement of the various shafts of the drive line occur through the simple expedient of axial movement of the drive line components during shifting of the conveyor sections, totally without the need for manual intervention to insert or remove various connecting devices or pins and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top plan view of a harvesting header according to the principles of the present invention connected to the front of a self-propelled vehicle with the conveyor sections of the header situated for rightward crop delivery and discharge as viewed from the rear of the machine;
FIG. 2 is a schematic view of the header and vehicle of FIG. 1 but with the conveyor sections shifted to opposite ends of the header and driven in directions for center delivery and discharge of the crop material;
FIG. 3 is a schematic view similar to FIGS. 1 and 2 but with the conveyor sections shifted toward the right end of the header and driven in a direction for leftward delivery and discharge of the crop materials;
FIG. 4 is an enlarged, fragmentary, left elevational view of the header and propelling vehicle with the left end wall of the header removed to reveal details of construction;
FIG. 5 is a fragmentary, rear elevational view of the header with certain parts broken away to reveal details of construction and with the conveyor section positioned for rightward delivery;
FIG. 6 is an enlarged, fragmentary view of a portion of the drive line for the conveyor sections with parts being shown in cross section and elevation for clarity;
FIG. 7 is a fragmentary, transverse cross sectional view through the rear frame of the header;
FIG. 8 is a fragmentary, rear elevational view of the header similar to FIG. 5 but with the conveyor sections separated and driven for center delivery and discharge of crop materials;
FIG. 9 is a fragmentary, rear elevational view of the header as in FIGS. 5 and 8, but with the conveyor sections situated at the right end of the header for left crop delivery and discharge;
FIG. 10 is a fragmentary, top plan view of the left end of the header when the conveyor sections are positioned and driven for rightward crop delivery and discharge;
FIG. 11 is a fragmentary, schematic, front elevational view of the header with components removed for clarity and with the conveyor sections positioned and driven for rightward crop delivery and discharge;
FIG. 12 is a similar fragmentary, schematic, front elevational view of the header but with the conveyor sections thereof situated and driven for leftward crop delivery and discharge; and
FIG. 13 is a fragmentary, schematic, front elevational view of the header similar to FIGS. 11 and 12 but with the conveyor sections positioned and driven for center crop delivery and discharge.
DETAILED DESCRIPTION
The harvester 10 as shown in FIGS. 1-4 includes as its most fundamental elements a propelling vehicle 12 and a header 14 attached to the front of the vehicle 12 for movement with the latter across and through a field. Lower links 16 (FIG. 4) and upper links 18 effect the attachment of header 14 to the vehicle 12 and may be raised and lowered so as to likewise raise and lower the header 14 by suitable hydraulic piston and cylinder means such as the unit 20 shown in FIG. 4. Suitable spring mechanism such as that illustrated by the spring 22 in FIG. 4 may be utilized to assist in proper flotation of the header 14. It is to be appreciated, of course, that although the present invention has been illustrated for use in connection with a self-propelled machine, such is by way of example only and is not intended to be in any way limiting to the scope of the present invention.
The header 14 includes a main frame broadly denoted by the numeral 24 which supports across the leading front edge thereof a reciprocatory sickle assembly 26 for severing crops from the ground as the harvester 12 is advanced. A reel 28 (FIG. 4) is also supported by the frame 24 and is located generally above and slightly forwardly of the sickle assembly 26 for the purpose of sweeping standing crops into the sickle assembly 26 and propelling the severed materials rearwardly into the header 14 as the harvesting operation progresses. A conveyor broadly denoted by the numeral 30 is situated within the confines of the frame 24 and is supported thereby in upwardly and rearwardly inclined disposition behind the reel 28 for receiving the materials as they are severed by the sickle assembly 26 and propelled rearwardly by reel 28. The conveyor 30 has a broad, flat upper surface and is commonly referred to as a "draper" by those skilled in this art.
The conveyor 30 includes two primary and somewhat independently operable conveyor sections 32 and 34 respectively. Each of the sections 32, 34 includes a pair of generally fore and aft extending rolls 36 (FIGS. 4, 10, and 11-13) at opposite ends of the sections 32 or 34 which are supported by elongated, front and rear, transversely extending support members 38 and 40 respectively. The front member 38 has a series of rollers 42 associated therewith which bear against the proximal face of a lower front beam 44 of the frame 24 so as to render the section 32 or 34 shiftable in a lateral sense relative to the frame 24. The upright, planar rear member 40 is likewise provided with supporting and guiding rollers 46 as shown in FIGS. 4 and 7 which ride within a track 48 secured to a transverse, upper rear beam 50 of the frame 24 along the length thereof. Each pair of rollers 36 is enveloped by an endless fabric or rubberized material 52 to be driven by the rollers 36 in order to present a moving, flat conveying surface for the crop materials.
As shown in FIGS. 11, 12 and 13, the conveyor sections 32 and 34 are shiftable between a fully leftward position as shown in FIG. 11 (as viewed from the rear of the machine) for right end delivery of crop materials, a fully rightward position as shown in FIG. 12 and driven for lefthand delivery, and a separated position as shown in FIG. 13 and driven for center delivery. A shifter broadly denoted by the numeral 54 for effecting such positioning of the sections 32, 34 includes a single, fluid pressure, piston and cylinder assembly 56 having one end 58 thereof pivotally anchored to the upper rear beam 50 of the frame 24 by a pair of mounting lugs 60 situated substantially midlength of the beam 50. The rod 62 of assembly 56 has a clevis 64 at its outer end which carries a double sheave assembly 66 having an upper sheave 68 and a lower sheave 70 that are independently rotatable about a common substantially vertical axis. A first cable 72 has one end thereof securely fastened by an anchor 74 to the top surface of the beam 50 somewhat adjacent the left end thereof and is trained around the top sheave 68 and thence back to a vertically disposed sheave 76 rotatable about a horizontal axis and positioned on the front face of the beam 50 adjacent the left end thereof. From the sheave 76, the cable 72 returns rightwardly until reaching an anchor 78 secured to the upper portion of support member 40 of left conveyor section 32. A second cable 80 is secured at one end thereof to the anchor 78 on conveyor section 32 and extends along the front face of the beam 50 until looping around a sheave 82 rotatable about a substantially horizontal, fore and aft axis. From the sheave 82, the cable 80 returns to and is looped around the lower sheave 70 of double sheave assembly 54, and from sheave 70 the cable 80 extends to an anchor 84 on the top face of beam 50 at a location spaced rightwardly from the anchor 74 for the cable 72. In this manner, extension and retraction of the rod 62 of hydraulic cylinder assembly 56 transmits pulling power to the left conveyor section 32 via the cables 72 or 80 to effect shifting of the left section 32 in the desired direction along the trackway defined in the frame 24 by upper track 48 and the lower front beam 44.
As shown perhaps best in FIGS. 10-13, the left conveyor section 32 is provided with a latch 86 pivotally mounted on the support member 40 of conveyor section 32 by a mounting lug 88 that is located adjacent the right end of section 32. The latch 86 is free to swing by gravity about a pivot pin 90 associated with the mounting lug 88 in a generally vertical sense between latching positions as shown in FIGS. 11 and 13 and an unlatched position as shown in FIG. 12. An upstanding projection 92 on the left end of the support member 40 of conveyor section 34 is so disposed that it may be received within a downwardly opening notch 94 in the lower linear edge of the latch 86 when the latter is in its lowered position of FIGS. 11 and 13. Thus, the two sections 32 and 34 may be securely joined together by the latch 86 for shifting as a unit along the frame 24 under the action of the hydraulic cylinder assembly 56.
In order that the latch 86 may be remotely controlled such that the section 32 and 34 can be selectively interconnected or disconnected, a latch operating device 96 is provided on the frame beam 50 at a location substantially adjacent the right end of travel of the left section 32. The device 96 basically comprises a lever 98 that is vertically swingable about a horizontal pivot 100 that attaches the lever 98 to the front face of the beam 50. The left end of the lever 98 on one side of the pivot 100 is inclined generally upwardly and leftwardly to present a latch releasing component 102. On the other hand, on the opposite end of the lever 98 is disposed a downwardly projecting tang 104 which may be matingly received within an opening 106 in the top surface of the support member 40 of right section 34 when the latter is in its full rightward disposition of FIGS. 12 and 13. An upstanding crank 107 is secured to the lever 98 on the same side of pin 100 as the tang 104 and has its upper end coupled with an operating cable 108 which extends to the operator's station such as in the cab of the vehicle 12. The cable 108 is of the type which will exert a push-pull force depending upon the direction of actuation by the operator such that the device 96 may be operably rocked about the pivot 100 in either of its two opposite directions by the operator upon manipulation of the cable 108. As illustrated in FIG. 12, when the device 96 is pushed by the cable 108 to its counterclockwisemost position or is substantially adjacent such position as in FIG. 11, the component 102 is disposed within the path of travel of an inclined leading edge 110 of the latch 86 as it travels with the left section 32 along the frame 24, and the distance between the pivot 90 of the latch 86 and the pivot 100 of the device 96 is such that component 102 will engage the inclined surface 110 and lift the latch 86 until projection 92 has been cleared from the notch 94. On the other hand, if the device 96 is rocked clockwise from its positions of FIGS. 11, 12 and 13 so that the component 102 is substantially level rather than inclined, the component 102 will be out of the path of travel of the inclined edge or surface 100 so as to leave the latch 86 in its latching position to either remain engaged with the projection 92 or to become engaged therewith for purposes of retrieving the right section 34, depending upon the stage of operation of the conveyor section 32, 34.
Driving power for the various components of the header 14 is supplied via a diagonally extending U-joint drive shaft 112 as shown in FIG. 4 which obtains driving power from mechanism within the vehicle 12. As shown in FIGS. 5, 6, 8, 9 and 10, the diagonal drive shaft 112 has a U-joint connection 114 with a relatively short jack shaft 116 journaled for rotation by suitable supporting structure along the back side of the header frame 24. The jack shaft 116 has a sprocket 118 at its left end (FIG. 4) about which its entrained a drive chain 120 that is also entrained about a pair of idler sprockets 122 and 124, as well as about a fourth sprocket (not shown) which is fixed to a long shaft 126 extending along the central portion of the rear beam 50. Adjacent the middle of the shaft 126, a pair of spaced apart sheaves 128 and 130 are located as shown for example in FIGS. 5, 8 and 9. The sheaves 128 and 130 receive opposite ends of an endless drive belt 132 which is also drivingly looped around a pair of double sheaves 134 and 136 shown only in FIG. 4, such sheaves 134 and 136 being generally rotatable about a fore and aft axis and respectively associated with a pair of circular, pitman mounting plates 138 and 140. The plate 138 is mechanically connected to the sheave 134 in order to be driven thereby, while the plate 140 is mechanically connected to the sheave 136 in order to be driven by that structure. A pitman 142 is eccentrically connected to the mounting plate 138 and extends toward the right end of the header 14 for ultimate driving connection with a sway bar (not shown) which in turn supplies driving power to one-half of the sickle assembly 26 which is split in a known manner and driven by two separate sources of drive at opposite ends thereof. Likewise, a second pitman 144 is eccentrically connected to the plate 140 and extends leftwardly therefrom to the left end of the header 14 for ultimate connection with a second sway bar (not shown) which in turn is utilized to drive the other half of the split sickle assembly 44 in the known manner. At the right end of the shaft 126 as shown in FIG. 5 is located a chain and sprocket assembly 146 which is ultimately connected with the reel 28 for rotating the latter in a counterclockwise direction viewing FIG. 4.
The left end of the shaft 126 projects outwardly beyond the drive chain 120 and carries a sprocket 148 (FIG. 4) that is backwrapped by a drive chain 150 which in turn is entrained around a pair of idler sprockets 152 and 154. The drive chain 150 is also entrained around a fourth sprocket 156 fixed to a drive shaft 158, details of which are shown in FIG. 6 and on a reduced scale in FIGS. 4, 5, 8 and 9. The drive shaft 158 extends rightwardly from the sprocket 156 for a relatively short distance along the back of the header frame 24 and terminates in a splined end 160 having a cup-shaped, frictional coupler component 162 retained thereon for rotation therewith. The coupler component 162 is reciprocable axially of the shaft 158 on a limited basis as defined by a lock ring 164 on the one hand and a compression spring 166 on the other hand that is trapped between and engages the back side of the cuplike component 162 and a spaced collar 168 on the shaft 158.
The coupler component 162 is selectively engageable and disengageable with a truncated, conelike coupler component 170 fixedly secured to one end of a driven shaft 172 that is attached to the back side of the left conveyor section 32 for shifting movement with the latter. The shaft 172 is in axial alignment with the shaft 158 and the coupler components 162 and 170 are so sized that the component 170 is matingly received within the component 162 in frictional, drive transmitting engagement therewith when the left conveyor section 32 is in its leftwardmost position. The driven shaft 172 is bearing mounted in a suitable manner and has a sheave 174 fixed thereto between its opposite ends for rotation with the shaft 72. Sheave 174 is entrained by an endless belt 176 that is twisted 90° and looped at its lower end about a sheave 178 (FIGS. 4, 5, 8 and 9) rotatable about a generally fore and aft axis and fixed to a shaft 180 that supplies driving power to the proximal conveyor roll 36 of the left conveyor section 32. At its opposite, inner end the driven shaft 172 is provided with a coupler plate 182 having a series of circumferentially spaced projections 184 on the inboard face thereof, such projections 184 having rotatably oppositely facing surfaces 186 and 188 which are normal to the proximal plane or face of the plate 182 and inclined in the direction of rotation with respect to the plane of the plate 182 respectively.
The right conveyor section 34 has structure corresponding to the components 170-188 of the left section 32 but disposed in the opposite orientation. In this regard, at the left end of the right section 34 is located a second driven shaft 190 (FIGS. 5, 8 and 9) that is mounted for rotation in axial alignment with the driven shaft 172 of left conveyor section 32. The driven shaft 190 has a truncated conelike coupler component 192 at its outboard end, a sheave 194 intermediate its opposite ends and entrained by a twisted, endless belt 196 that is also looped around a lower sheave 198 which supplies driving power to a fore and aft shaft 200 coupled with the roll 36 of the right conveyor section 34, and an inboard located coupler plate 202 having projections 204 oriented to matingly engage the corresponding projections 184 of coupler plate 182 when the plates 202 and 182 are in face-to-face engagement as shown in FIGS. 5 and 9.
Fixed to the header frame 24 rightwardly of the central portion thereof and along the back of the header 14 is a second drive shaft arrangement corresponding to the components 158 through 168 previously described but oriented in the opposite direction. In this regard, a drive shaft 204 is suitably bearing supported for rotation in axial alignment with the shafts 190, 172 and 158 and has a cuplike friction coupler 206 spline-mounted on the inboard end thereof in the same manner that the component 162 is mounted on the shaft 158. Spring 208 cushions limited axial displacement of the coupler component 206 in the same manner that the spring 166 cushions the limited axial shifting of the coupler component 162. At the opposite, outboard end of the shaft 204, a chain and sprocket assembly 210 couples the shaft 204 with the long shaft 126 so as to receive driving power therefrom. It is important to note that because of the way in which the chain 150 at the left end of the shaft 126 is backwrapped around the sprocket 148 relative to the way in which it is wrapped around the sprocket 156 associated with shaft 158, the shafts 126 and 158 rotate in opposite directions. As a result of the chain and sprocket assembly 210, the drive shaft 204 is caused to rotate in the same direction as the long shaft 126, and thus the two drive shafts 158 and 204 are caused to rotate in relatively opposite directions at all times that the main U-joint drive line 112 from the vehicle 12 is in operation.
OPERATION
The header 14 is adjusted for righthand delivery as shown in FIGS. 1, 5 and 11, for center delivery as shown in FIGS. 2, 8 and 13, and for lefthand delivery as shown in FIGS. 3, 9 and 12. The combined length of the conveyor sections 32 and 34 is less than the length of the header 14 so that a discharge opening for crop material moved by the section 32, 34 is always presented regardless of the particular positions thereof. For example, when the sections 32, 34 are disposed for righthand delivery and are shifted to their leftwardmost positions, the discharge opening 212 is defined at the right end of the header 14 in the bottom of the latter. When the conveyor sections 32 and 34 are disposed for center delivery and are thus located at opposite ends of their path of travel, a discharge opening 214 is disposed centrally of the header 14 in the bottom thereof. And, when the conveyor sections 32, 34 are disposed for lefthand delivery and are located at the rightwardmost end of their path of travel, a discharge opening 216 is presented at the left end of the header 14 in the bottom thereof. Such positioning of the discharge point for crop materials with respect to the header 14 can be especially beneficial with respect to the practice of forming double windrows, for example, in which the discharging material is laid down in a windrow beside one previously formed in order that the harvesting machine subsequently processing the crop materials will have a larger volume of material to pickup along each pass across the field.
Assuming that the header 14 is initially disposed for righthand delivery as shown in FIG. 1, the conveyor sections 32, 34 are maintained in a latched together condition by the latch 86 as shown in FIG. 11, and the piston and cylinder assembly 56 remains fully retracted so that the cables 72 and 80 associated therewith maintain the left conveyor section 32 in its full leftward condition to keep the conical friction coupler 170 of shaft 172 matingly received within the cuplike coupler 162 of drive shaft 158. Inasmuch as the drive shaft 158 is constantly rotating in a clockwise direction viewing FIG. 4, clockwise rotation is likewise transmitted to the sheave 174 by the driven shaft 172 to in turn drive the lower sheave 178 in a clockwise direction as shown in FIG. 5. This, therefore, has the result of driving the left conveyor section 32 in a rightward direction. In view of the fact that the latch 86 holds the sections 32 and 34 in side-by-side relationship at this time, the coupler plates 182 and 202 of sections 32 and 34 respectively are held in face-to-face engagement with one another so as to drivingly interengage their respective projections 184 and 204 whereby driven shaft 190 of right conveyor section 34 is also driven in a clockwise direction viewing FIG. 4 to in turn drive the lower sheave 198 in a clockwise direction as shown in FIG. 5 such that conveyor section 34 is also rightwardly driven.
If it is then desired to adapt the header 14 for lefthand delivery as shown in FIG. 3, the hydraulic cylinder assembly 56 is then actuated to extend the rod 62 thereof such that the cable 80 pulls the left section 32, and hence also the right section 34, rightwardly as the cable 72 pays out from double sheave assembly 66. As the conveyor sections 32, 34 move toward the right end of their path of travel, the tang 104 of latch operating device 96 bears against the under moving support member 40 of right conveyor section 34 until such time as opening 106 comes into alignment with the tang 104, whereupon, if the device 96 is springloaded as it preferably is, the tang 104 will be pushed down into the receiving opening 106 so as to releasably lock the right conveyor section 34 in its full rightward position. The left conveyor section 32 is held in side-by-side relationship to the right section 34 by the extended hydraulic cylinder assembly 56 and the tension in cable 80.
During the time that the sections 32 and 34 are shifting as a unit to their rightward positions, the conical coupler 170 of driven shaft 172 is withdrawn from the receiving coupler component 162 of shaft 158 such that driving power to the driven shaft 172 and 190 is temporarily halted, even though the shafts 172 and 190 remain operably interengaged via the coupler plates 182 and 202. As the conveyor sections 32, 34 then reach their rightward positions, the conical coupler 192 of driven shaft 190 enters into the rotating cuplike coupler 206 of drive shaft 204 which, it will be recalled, is rotating in a counterclockwise direction viewing FIG. 4. Thus, as the couplers 192 and 206 come into frictional interengagement, the driven shafts 190 and 172 commence rotating in a counterclockwise direction viewing FIG. 4 to in turn rotate the sheaves 198 and 178 in a counterclockwise direction as shown in FIG. 9. This causes the rolls 36 of the conveyor sections 32 and 34 to likewise be driven in a counterclockwise direction viewing FIG. 9, whereby the upper surfaces of the sections 32, 34 are driven leftwardly toward the discharge opening 216.
Adapting the header 14 for center delivery simply requires that the left section 32 be separated from the right section 34 and returned to its full leftward position. This is accomplished by merely actuating the hydraulic cylinder assembly 56 in such a way that the rod 62 thereof is retracted so that the cable 72 pulls on the left section 32 as the cable 80 pays out of the sheave assembly 66. It is to be noted that with the actuator device 96 disposed in a position to maintain the tang 104 thereof inserted into the opening 106, the latch releasing component 102 is in such a position as to engage the inclined surface 110 of latch 86 and hold the latter up out of latching engagement with the projection 92 whenever the left conveyor section 32 is in or adjacent to its rightmost position. Thus, as left section 34 is shifted leftwardly by the hydraulic shifter assembly 56, the latch 86 remains unlatched from the projection 92 until leaving engagement with the component 102 as a result of departing movement of the conveyor section 32, whereupon the latch 86 simply falls by gravity to its lowered position as illustrated in FIG. 13. Left conveyor section 32, therefore, leaves the right conveyor section 34 behind as section 32 moves leftwardly toward its FIG. 13 position.
As conveyor section 32 departs leftwardly from conveyor section 34, the coupler plates 182 and 202 become disengaged such that driving power to the driven shaft 172 of conveyor section 32 is temporarily halted. Driven shaft 190 of right conveyor section 34 continues to rotate in a counterclockwise direction viewing FIG. 4, however, such that the top surface of conveyor section 34 continues to move leftwardly.
As the left conveyor section 32 arrives at its leftward position as in FIGS. 2, 8 and 13, the cone coupler 170 of driven shaft 172 becomes received within the rotating cuplike coupler 162 of drive shaft 158. Consequently, clockwise rotation of the driven shaft 172 (as viewed in FIG. 4) is once again established so that the upper surface of the left section 32 moves rightwardly toward the central discharge opening 214. Thus, both upper surfaces of the conveyor sections 32, 34 are driven toward the central opening 214 for centrally disposed crop discharge therethrough.
With the two sections 32 and 34 separated as shown in FIG. 2, it is a simple matter to retrieve the section 34 if desired in order to reestablish rightward crop delivery. This is accomplished by shifting the left section 32 over into side-by-side relationship with the right section 34 and then locking the two sections together through the latch 86 before returning the two sections 32, 34 to the left end of their path of travel as a unit. It is to be noted that as the left section 32 approaches the right section 34, the inclined surface 110 of the lowered latch 86 makes engagement with the projection 94 on top of the right section 34. As rightward shifting of the left section 34 continues, such interengagement has the effect of camming the latch 86 slightly upwardly so that the latter rides up and over the projection 92 against the force of gravity until such time as the notch 94 comes into alignment with the projection 92, whereupon the latch 86 drops back down and the projection 92 becomes received within the notch 94. In order to effect such engagement of the latch 86 with the projection 92, it is necessary that the operator pull on the cable 108 so as to rock the device 96 sufficiently clockwise viewing FIGS. 11, 12 or 13 that the component 102 will be rocked below the path of travel of the inclined surface 110 of latch 86 to avoid raising the same to its unlatched position as shown in FIG. 12. Thus, with the latch 86 relatched and the device 96 appropriately rocked to maintain the component 102 lowered and the tang 104 lifted out of the opening 106, the hydraulic shifter assembly 56 may then be retracted so as to cause the conveyor sections 32, 34 to shift leftwardly as a unit.
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The header has generally transversely disposed, flat, apron-like conveyor mechanism for receiving the stalks of grain or other crop materials severed along the leading edge of the header and for gathering such materials so that they might be discharged in a continuous stream for producing a windrow. The conveyor mechanism comprises a pair of largely self-contained sections which may be latched together and shifted to one end of the header with their upper surfaces driven in a common leftward direction for left delivery and discharge, or shifted to the opposite end of the header and driven with their upper surfaces in a righthand direction for right end delivery of the materials, or they may be unlatched and separated while their upper surfaces are driven in opposite directions centrally toward one another for centered delivery of the materials. By virtue of a latch for releasably connecting the sections together and a cooperating, selectively operable latch releasing device, the necessary shifting adjustment of the sections between their various positions may be accomplished through the medium of only a single shifting assembly coupled with one of the sections. A special selectively engageable and disengageable drive line arrangement for the conveying surfaces of the conveyor sections includes components which are matingly engaged or disengaged and driven in one or the other of two opposite directions depending upon the shifted position of the sections by the shifter assembly.
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CLAIM OF PRIORITY
[0001] This patent application claims priority to U.S. Provisional Patent Application No. 61/135,322, entitled “LINEAR REVOLVING DOOR FOR SECURE ACCESS”, by Robert Osann, Jr., filed on Jul. 18, 2008.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0003] The current invention relates generally to secure entry points and access control devices that control the passage of pedestrians or vehicles in such a way as to provide a more secure access path to a building, premises, or secured area.
BACKGROUND
[0004] A wide variety of security access control devices exist today which attempt to control access to secure areas. Security checkpoints at airports include metal detection and various forms of x-ray and scanning capability, however if a person carrying a weapon was determined to pass through such a security checkpoint while knowing they would be instantly detected, they could do so, and until they were apprehended they could use their weapon within the airport. Metal detectors at the entrance to banks will warn if someone carries a gun into a bank, however it will not stop them from doing so.
[0005] Many security systems combine identification mechanisms such as cards, fingerprints, or optical scan in order to identify an individual and allow them access. Unfortunately, the perpetrator of the crime is sometimes one normally allowed access to a facility or area, and use of an identification card will not hinder them. In the case of large gatherings such as lecture halls at universities, schools in general, sporting events, and large business facilities, if a person with suicidal tendencies is determined to wreak havoc and destruction upon a large number of people, today's security access devices will not prevent them from entering if they are carrying a weapon and intend to use it.
[0006] Therefore, a new security access control device is needed that will not only detect a person carrying a weapon and attempting to pass through an access point, but will absolutely prevent that person from passing if a decision is made to prevent them—that decision often being made automatically. Also, and given the fact that many of the institutions mentioned above normally allow unhindered access into areas where large gatherings occur, it is important that any new security access device allow high traffic flow at peak times while still being capable of stopping a person carrying a weapon.
[0007] A form of access mechanism still popular today is that of a revolving door. It provides continuous flow in both directions, and in spite of the fact that entry into a revolving door can be a little intimidating for some people, revolving doors are deemed to be safe, people understand how to use them, and they continue to be designed into new buildings including hotels, banks and airports. As a side benefit, a revolving door minimizes energy loss due to the manner in which air passes through the door.
[0008] There are negatives relative to using a conventional revolving door in a security application, and especially in applications where the amount of traffic is substantial. Conventional revolving doors provide a fixed amount of traffic flow, and the level of flow is always equal in both directions. Thus at a time of day when most people will be exiting a facility, a revolving door will have one half of its capacity unutilized, and therefore a conventional revolving door is space-inefficient. In other words, given an entry passageway to a facility or area of a certain width, a conventional revolving door would be wasting half of that width at times of peak flow in primarily one direction.
[0009] If a person in a revolving door was detected to be suspect of carrying a weapon, the revolving door would be stopped and possibly reversed, however if another person was simultaneously exiting in the opposite direction within the same revolving door, they would be stuck in the door, or forced to back up.
[0010] Full height turnstiles with multiple crossbars can be useful but have similar problems. Only half the width of a conventional turnstile unit is used for passage and the other half is not usable because of the style of construction of these units. Also, because a conventional turnstile is stationary, placing two of them in series in order to stop a detected perpetrator between them creates the requirement for both of them to be closed at the same time, and also that they both should never be open simultaneously. As a result, a person cannot enter such a turnstile complex while the person ahead of them is simultaneously leaving. Thus the use of a conventional turnstile tends to impede the flow of traffic and is space-inefficient in a manner similar to a revolving door.
[0011] What is needed is a security access control device that is space efficient, extremely high throughput, and offers great flexibility in directional control, while at the same time will absolutely prevent a person carrying a weapon from entering a secured area. Applicant has identified these, as well as other shortcomings and needs in the current state of the art in coming to conceive the subject matter described and claimed throughout in this patent application.
SUMMARY OF THE INVENTION
[0012] The embodiments of the invention described herein are electromechanical and electronically controlled access devices for controlling access to a building, premises or area in a secure manner such that a person who is deemed ineligible for access will be barred entry and may be optionally retained. One or more access control devices according to this invention would be deployed such that only way to enter a secured area would be through an access control device. A subject wishing to enter a secured area protected by such devices would find the spaces adjacent to and above the access control device sealed allowing the only route of passage to be through an access control device. The direction of flow through a device according to these embodiments is electronically controlled and may be changed at any point in time. At any instant in time, the flow through the device is unidirectional. The terms “access control device” and “security portal” and “portal” are herein used synonymously.
[0013] One object of the various embodiments of this invention is to provide a security access control device that is space (width) efficient while offering extremely high throughput, such that subjects attempting to walk through the security access control device may do so while walking continuously through the security access control device. The security access control device should be suitable for operation at the entrance to different forms of facilities where people may gather, including the following:
[0014] Airport main entrances
[0015] Train and Bus stations
[0016] Hotels
[0017] Banks
[0018] Churches, Synagogues, and Mosques
[0019] Marketplaces and Malls
[0020] Stadiums and conference halls
[0021] Government and office buildings
[0022] Factories
[0023] High schools, colleges, and universities
[0024] One object of the various embodiments is that multiple access control devices such as those described herein may be stacked side by side to allow further increased traffic flow, and that the width is as small as possible to allow a large number of such access devices to be stacked side-by-side thereby further increasing traffic flow when the space available for such access devices is limited. When multiple access control devices are used, the number of devices allowing flow in one direction relative to the opposite direction may be varied according to time of day and according to demand. For instance if used at the entrance to a building at a time when individuals are expected to be mostly entering the secure area, the majority of the access controlling devices would be controlled to allow flow in the direction consistent with entering. Control of which portals within a stack or gang are in “enter” mode and which are in “exit” mode may be optionally performed automatically by a central control system that controls multiple portals. Such a central control system may make decisions on the directional flow of individual portals within a gang based on information describing the aggregate directional flow of a crowd of subjects as determined by sensor(s) that observe the areas on the exit and entrance sides of a stack or gang of multiple portals. Such sensor(s) may use visual, sonic, IR, or RF imaging to observe aggregate traffic flow to determine the overall magnitude of flow and the aggregate magnitudes of flow in each of entrance and exit directions. As part of this control, a particular portal may need to change direction from time to time. When a portal is about to change direction, a message can be displayed on that particular portal that in a specific time period, it will change direction and cease to allow passage for those currently in line should a queue exist. Such a message can also count down the tine remaining so that individuals who will need to move to a different portal are properly and fairly notified in plenty of time to make the move. Upon an emergency such as a fire or earthquake, all devices could be set to a mode consistent with exiting the secured premises. Alternately, the device is capable of being electronically controlled to be placed in a mode where all doors contained therein are fully open and individuals have unimpeded capability to exit a premises in the emergency.
[0025] In various embodiments, a variety of sensor technologies may be incorporated into the device, such that as an individual is entering and is subsequently contained within the doors of the device, the individual and their belongings are scrutinized to determine if a weapon is present. Such technologies may include but are not limited to metal detectors, chemical, explosive, biological, and radiological sensors, and different scanning technologies including x-ray imaging and penetrating RF imaging such as (UWB) radar imaging or millimeter wave imaging. Such sensors and associated sensor-related components may be incorporated into any components of the structure comprising the linear revolving door mechanism, including the side walls, floor, ceiling, and any surfaces of the moving door panels. Video imaging may also be included such that a subject's face may be observed as they walk through the access control device. Observing and analyzing the expressions on a subject's face have been shown to offer clues as to a subject's state of mind—especially when they are contemplating a violent act and/or self-destruction.
[0026] Another object of the various embodiments is that each door panel should move automatically without requiring or allowing any contact with subjects passing through the access control device, and by sensing the proximity and movement of subjects passing through, will automatically adjust the rate of movement of the different door panels within the access control device to match the speed of movement of a subject, thus maximizing the throughput rate of the access control device by adapting to the rate of movement of each subject passing through. In order to do this, door panels are driven by electromechanical means controlled by a computer/processor. In addition, proximity sensors in the door panels and/or the side panels sense the location of individuals approaching the access control device and passing through it, and the rate of movement and position of the door panels is controlled such that panels never touch individuals passing through. The movement of the door panels can be controlled to track the pace of the subject walking through and match their pace to allow maximum throughput, as long as there is still enough time while both door panels are “closed” to form a detection chamber and take a reading of included threat sensors. Various types of proximity sensors are known in the art and may be used including sound, IR, and RF based sensors. Additionally, emitters and receivers for position and/or proximity sensing may be placed in the top cover and/or the floor of the portal.
[0027] Another object of the various embodiments is that weapon passing from one perpetrator to another through the access control device is not possible. To fulfill this objective, any gaps that exist between a door panel and a side panel at any point during the motion of that door panel may be optionally filled by additional sliding panels which move adjacent to a side panel in the vicinity of a door panel and are electro-mechanically controlled such that any gap that may emerge is filled, these additional sliding “filler panels” being controlled such that their motion does not interfere with the movement of any door panel. Alternately, each of the moving door panels may contain a telescopic extension that extends to fill the gap between that panel and a side panel of the access control device. To further prevent passing of weapons through the portal, and also to enable temporary sealing of a “detection chamber” that is briefly formed when the moving door panels of a portal are parallel, additional gap filling and sealing embodiments are included between the moving door panels and the top cover of the portal to temporarily block air movement in and out of the “detection chamber” and also to prevent the passing of weapons through the portal.
[0028] Another object of the various embodiments is that it be constructed with door panels and side panels fabricated from bulletproof material such that a perpetrator who becomes trapped within the device cannot shoot their way out, or if they are carrying an explosive device, the blast will be at least partially contained if the explosive device is activated from within the access control device. A clear bulletproof material such as polycarbonate may be suitable, as well as certain composite materials such as Kevlar.
[0029] Another object of the various embodiments is to provide a provision for disabled individuals in wheelchairs to pass through. In order to do this it may be appropriate to utilize a security verification mechanism such as a card reader, fingerprint reader, or retina scan mechanism used in conjunction with the access control device—such security verification mechanisms authenticating that the individual is in fact disabled and has the right to pass through the access control device in a wheelchair.
[0030] Another object of the various embodiments is to allow a parent with child to pass together through the security access control device. A similar capability will allow a second person to accompany a disabled person through the portal. If that person is a guard carrying a weapon, a biometric device can be available to allow the guard to be properly identified and allowed to pass through along with a disabled person or child that has also been properly identified. Sensors in the portal can validate that only the persons being biometrically identified are in the portal.
[0031] Another object of the various embodiments is that the access control device can be optionally programmed so that when an alarm is set off, the door panel behind the individual opens thereby allowing the person to exit in the reverse direction. To avoid false alarms when large numbers of individuals are passing through the security access control devices during peak traffic times, the access control device may be used in conjunction with a pre-chamber where individuals who believe they might set off an alarm, possibly due to equipment they are carrying or embedded metallic medical devices in their body, can determine if they will pass successfully before attempting to pass through the access device whereby they gain entry to the building, premises, or secured area. Objects that set off the alarm can be separately screened in a security screening conveyer similar to those found at airports.
[0032] Another object of the various embodiments is that the access control device may be used in conjunction with a crowd motion sensing means, such that the directionality of individual devices within a cluster of access control devices according to this invention may be controlled from moment to moment in such a way as to match directional throughput capability of the cluster with the requirements indicated by crowd movement.
[0033] Another object of the various embodiments is that the access control device is capable of operating unattended for extended periods of time. A stack or gang of access control devices according to this invention may also operate unattended, or alternately may require only minimal attendance, for instance a single security guard who presides over a stack or gang of multiple access control devices.
[0034] Another object of the various embodiments is that the access control device may include ducting for controlled air flow such that air in the vicinity of the subject entering and within the device may be moved and passed through sensor devices which may detect chemical, biological, and/or radiological hazards.
[0035] Another object of the various embodiments is that the access control device may include ducting for controlled air flow such that air moving from within a building into the access control device is at least partially re-circulated back into the building rather than released to the outdoors, in order to conserve energy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is an illustration of a security access control device, in accordance with various embodiments of the invention.
[0037] FIG. 2 is an illustration of the preferred embodiment of the security access control device functionality, in accordance with various embodiments of the invention.
[0038] FIG. 3 is an illustration of the preferred embodiment of the security access control device, in accordance with various embodiments of the invention.
[0039] FIG. 4 is a flow chart diagram of the process for operating the security access control device, in accordance with the embodiment illustrated in FIG. 1 .
[0040] FIG. 5 is a flow chart diagram of the process for operating the security access control device, in accordance with the embodiment illustrated in FIG. 2 .
DETAILED DESCRIPTION
[0041] The invention is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. References to embodiments in this disclosure are not necessarily to the same embodiment, and such references mean at least one. While specific implementations are discussed, it is understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the scope and spirit of the invention.
[0042] In the following description, numerous specific details are set forth to provide a thorough description of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as not to obscure the invention.
[0043] In accordance with the embodiments of the invention, there are described devices and methods for controlling secure passage between two or more locations. Each of these devices can contain multiple rotatable door panels that can be positioned behind one another. In various embodiments, the door panels can be controlled by mechanized arms or other control devices in order to perform the functionality described herein.
[0044] FIG. 1 is an illustration of a security access control device, in accordance with various embodiments of the invention. Although this diagram depicts components as logically separate, such depiction is merely for illustrative purposes. It will be apparent to those skilled in the art that the components portrayed in this figure, or in any other figure of this specification, can be combined, or divided into separate parts. Furthermore, it will also be apparent to those skilled in the art that such components, regardless of how they are combined or divided, can be distributed among multiple devices and can function in conjunction with one another.
[0045] According to the embodiment illustrated in FIG. 1 , there are two door panels within the device, each capable of controlled rotation and lateral movement perpendicular to the direction of flow. The sequence begins with timeframe T 1 where a subject is about to enter the access control device. In T 2 , door 1 rotates and moves laterally and by T 3 the subject has entered the device. In T 4 , door 1 now rotates and moves laterally in a motion emulating a revolving door, eventually closing behind the subject in timeframe T 5 . In T 5 the chamber within the access control device is essentially sealed, thus forming a detection chamber, and sensors will determine the presence of any weapons and whether or not the individual will be allowed to pass. The amount of time the moving door panels remain parallel is programmable. In T 6 , door 2 starts to rotate and move laterally thereby opening an exit for the subject and by T 7 , door 2 has now completely opened allowing an individual to exit. In T 8 as door 2 has almost closed, door 1 is beginning to open to allow the next individual to enter, and in T 9 the next individual is in the process of entering the access control device. The invention embodiment according to FIG. 1 requires that door 2 be closed or almost closed before door 1 can open to allow the next person to enter. This constraint reduces throughput to some degree relative to the next embodiment shown in FIG. 2 .
[0046] It is noted that the term “perpendicular,” as used throughout the various embodiments of this disclosure, is not necessarily limited to the precise geometrical perpendicularity of ninety degrees. Rather this term should be construed as substantially perpendicular with respect to the sidewalls and/or direction of traffic flow, so as to cause a closed position of the door panel(s) in order to block the passage of an individual or object through the security portal.
[0047] The preferred embodiment for the invention is shown in FIG. 2 and FIG. 3 . FIG. 2 is shows the sequence of events whereby one individual may be entering the access control device simultaneously with another individual leaving the device, thereby enhancing throughput. In the embodiment shown in FIGS. 2 and 3 , each door panel is electronically controlled to rotate and move both laterally and longitudinally relative to the direction of flow. In timeframe T 1 an individual is within the access control device while another is entering, and both door 1 and door 2 are instantaneously parallel to one another and preferably moving forward simultaneously, thus for that instant forming a detection chamber. When the moving door panels are parallel, they may move together in the direction of flow for a programmable amount of time to control the duration of time for which the detection chamber exists. In T 2 , door 2 is moving forward and rotating in a manner emulating a revolving door allowing the individual within the access control device to begin to exit. Simultaneously in T 2 , door 1 is moving forward allowing the next individual to enter. In T 3 , the individual just entering continues to move forward behind door 1 while door 2 moves to become adjacent to the side panel and then slides along the side panel at a faster rate until it is behind the person currently entering as shown in T 4 . In T 5 , door 2 now begins to rotate and move laterally in a manner emulating a revolving door, eventually assuming a position behind the person who has just entered as shown in T 6 where the two moving door panels are instantaneously parallel to one another and thus for that instant form a detection chamber. During T 5 and T 6 , both door 1 and door 2 are also moving forward in the direction of flow, thus always allowing persons entering the access control device to be continually moving. Subsequent to timeframe T 6 , the sequence of T 1 through T 6 essentially repeats, however this time door 2 is in front of the person about to enter the access control device and door 1 is in front of the person who is currently within the access control device.
[0048] Note that at certain points in the sequence of operation, there appear to be gaps between a door panel and the side panel opposite that where that door panel's control arm attaches. To prevent these gaps being used by a perpetrator for passing weapons to another perpetrator, any gaps that exist between a door panel and a side panel at any point during the motion of the door panel may be optionally filled by additional sliding panels which move adjacent to a side panel in the vicinity of a door panel and are electro-mechanically controlled such that any gap that may emerge is filled, these additional sliding “filler panels” being controlled such that their motion does not interfere with the movement of any door panel.
[0049] FIG. 3 shows both a top view and cross-section view of an access control device according to the preferred embodiment of this invention. Each of the panels represented as door 1 and door 2 is suspended from control arms shown as arm 1 and arm 2 . These control arms contain electromechanical mechanisms which cause the attached door panel to rotate, and also move the door panel attachment point laterally relative to the direction of flow. In addition, each control arm is capable of moving longitudinally, the arm being driven by an electromechanical mechanism, thereby allowing the attached door panel to be moved longitudinally as the control arm it is suspended from moves longitudinally. The control arm moves longitudinally along a track which is mounted at the top of the side panel.
[0050] FIG. 4 is a flow chart diagram of the process for operating the security access control device, in accordance with the embodiment illustrated in FIG. 1 . Although this figure depicts functional steps in a particular sequence for purposes of illustration, the process is not necessarily limited to this particular order or steps. One skilled in the art will appreciate that the various steps portrayed in this figure can be changed, rearranged, performed in parallel or adapted in various ways. Furthermore, it is to be understood that certain steps or sequences of steps can be added to or omitted from this process, without departing from the spirit and scope of the invention.
[0051] As shown in step 400 , the device can comprise an entryway can be deployed between two or more locations. This entryway can include two sidewalls with a first door panel adjacent to the first sidewall and a second door panel adjacent to the second sidewall. The second door panel is located behind the first door panel with respect to the direction of flow through the entryway.
[0052] Step 402 illustrates a possible starting position for the security access device. A shown in step 402 , the first panel is in a position perpendicular to the first sidewall and the second panel is in a position perpendicular to the second sidewall. This effectively blocks passage through the entryway at each door panel. While both door panels are positioned perpendicular to the sidewalls and parallel to each other, a subject enclosed between the first and second panels may be scanned with one or more threat sensors to determine if they represent a threat. Should a threat be detected, the sequence of door panel movements may be subsequently altered to be different from that shown in FIG. 4 and may open the door behind the subject and allow them to exit the portal in reverse. It should be noted, however, that step 402 only shows the starting position for purposes of illustration, and that the device can actually start with the door panels being in any position shown throughout the figure.
[0053] In step 404 , the first panel is rotated to a position parallel to the first sidewall, thereby allowing passage through the first door panel for an individual (or other subject). At the same time, the second door panel continues to be in the perpendicular position, blocking the remaining passage through the entryway.
[0054] Once the individual has passed the first panel, the first door panel rotates once again into the position perpendicular to the first sidewall, thereby effectively closing the chamber between the two panels (step 406 ). At this time, the subject can be scanned or otherwise inspected in the chamber.
[0055] In step 408 , the second door panel then rotates to a position parallel to the first sidewall, allowing passage through the entryway for the individual. Once the individual passes through the opening, the second door panel can rotate back into the perpendicular (closed) position, as shown in step 410 .
[0056] At this point in the flow chart, the process loops back to step 404 , where the first door panel begins opening again to allow entrance to the next subject in line. In one embodiment, the first door panel can begin opening as soon as the second door panel has finished closing. In alternative embodiments, the first door panel can begin opening before the second door panel has finished closing, so long as the first panel is not completely open before the second panel has finished closing. With the embodiments described in FIGS. 1 and 4 , it is generally undesirable to have both door panels open simultaneously (except in emergency situations, such as earthquakes or fires) due to the possibility of object/subject passing through the entryway.
[0057] FIG. 5 is a flow chart diagram of the process for operating the security access control device, in accordance with the embodiment illustrated in FIG. 2 . Although this figure depicts functional steps in a particular sequence for purposes of illustration, the process is not necessarily limited to this particular order or steps. One skilled in the art will appreciate that the various steps portrayed in this figure can be changed, rearranged, performed in parallel or adapted in various ways. Furthermore, it is to be understood that certain steps or sequences of steps can be added to or omitted from this process, without departing from the spirit and scope of the invention.
[0058] As shown in step 500 , the device includes two sidewalls, a first panel and a second panel, as previously described. In contrast to the embodiment shown in FIG. 1 with operational steps shown per FIG. 4 , the embodiment of FIG. 2 and operational steps per FIG. 5 add a degree of freedom for the moving door panels. Whereas FIG. 1 and FIG. 4 describe door panels which may rotate 360° and move in a direction perpendicular to the direction of flow of subject movement, FIGS. 2 and 5 also allow the moving door panels to move independently in the direction of flow of subject movement. Moreover, for ease of understanding, the process illustration begins with both door panels in the closed position, as shown in step 502 . While both moving door panels are positioned perpendicular to the sidewalls and parallel to each other as shown in step 502 , a subject enclosed between the first and second moving door panels may be scanned with one or more threat sensors to determine if they represent a threat. Should a threat be detected, the sequence of door panel movements may be subsequently altered to be different from that shown in FIG. 5 and may open the door behind the subject and allow them to exit the portal in reverse.
[0059] In step 504 , the first door panel is moved in the direction of flow, while the second door panel is simultaneously rotated into a position parallel to the sidewall, allowing passage through the second door. Once the second panel is in the open position, it begins to slide in the direction opposite from the direction of flow until it passes the first door panel (step 506 ). At this point, the second door panel is now in front of the first door panel.
[0060] In step 508 , once the second door panel is in front of the first, it rotates into a closed position (perpendicular to the sidewalls). At this point, the second door panel begins to move in the direction of flow, while being maintained in the closed position.
[0061] After the second panel has been closed and is moving along the direction of flow, the first panel is rotated into an open (parallel) position, allowing passage therethrough, as shown in step 510 .
[0062] In step 512 , the first panel is slid opposite to the direction of flow until it passes the second panel. In the meanwhile, the second door panel continues to move in the direction of flow.
[0063] In step 514 , once the first panel is in front of the second panel, it is rotated back into the closed position and begins to move once again in the direction of flow. At this point, the process can loop back to step 504 , where the second panel is rotated to the open position.
[0064] The processes shown in FIGS. 4 and 5 can continue indefinitely, or can be stopped and (re)started automatically or as needed. It should also be noted that the unidirectional traffic flow through the entryway can be reversed, as will be clearly evident to one of ordinary skill in the art in light of this disclosure.
[0065] As mentioned earlier, it is highly preferable that there not be a moment in time where a gap exists that would allow passage of even a small weapon (for instance a small gun or grenade) through the portal. As shown in FIGS. 6 and 7 it is desirable to have means for filling the gap between a moving door panel and a sidewall. Thus, the scenario may be prevented where two or more subjects work together such that a first subject who does not carry a weapon may pass through the portal first, and subsequently a second subject might toss a weapon through the gap in the portal to the first subject who is already on the inside of the facility being protected by the portal. For the embodiment of FIG. 2 where each moving door panel must occasionally pass alongside the other moving door panel during operation of the portal, there must be a gap available for this passage to occur. As shown in FIG. 6 a , this gap is filled by telescoping extensions 601 and 602 that project from door panels 603 and 604 respectively under control of the portal's control system. In FIG. 6 b , as door panel 603 moves closer to a position parallel with the sidewall, telescoping extension 602 starts to withdraw into door panel 604 to create a gap for panel 603 to pass. In FIG. 6 c , door panel 603 is now parallel and adjacent to the sidewall and is passing alongside door panel 604 , telescoping extension 602 having now been completely withdrawn into door panel 604 .
[0066] A similar scenario exists in FIG. 7 where sliding filler panels 701 and 702 performing similar tasks to the telescoping extensions of FIG. 6 . In FIG. 7 a , sliding filler panels 701 and 702 fill the gaps adjacent to door panels 703 and 704 respectively. In FIG. 7 b , door panel 703 is moving towards the sidewall and starting to pass through the gap adjacent to door panel 704 , while sliding filler panel 702 is beginning to withdraw from the gap which door panel 703 will shortly occupy. In FIG. 7 c , door panel 703 is now fully adjacent to the sidewall and is in the gap adjacent to door panel 704 , filler panel 702 having withdrawn to allow the passage of door panel 703 . At another point in the sequence of operation, sliding filler panel 701 performs a similar function to filler panel 702 , moving aside to allow door panel 702 to pass through a gap between door panel 703 and the opposite sidewall.
[0067] It may be desirable to include chemical sensors within the portal for the detection of explosive devices, CWAs (chemical warfare agents), or bio-pathogens being carried by a subject passing through the portal. It may also be desirable to include sensors to detect chemical vapors emitted by a subject that may be useful as part of a biometric sensing strategy to determine the subject's state of mind. For any of these vapor sensing applications, it is useful to have the detection chamber defined by the two moving door panels and the two side walls be sealed to the movement of air for that brief moment when the moving door panels are fully parallel to one another. During that brief moment, such sealing of the detection chamber may allow a forced movement or “puff” of air to mobilize some particles that may be clinging to the subject or the subjects clothing or emanating from the subject or an explosive device, and move any suspect particles or vapors into one or more threat detection devices. Such threat detection devices may include without limitation MS, MS-MS, IMS, GC, GCMS, SAW array sensors, or various forms of polymer coated sensing devices including microcantilevers and capacitive or resistive sensing devices. As shown in FIG. 8 a , seals 801 and 802 may be attached to the top of a moving door panel while seal 803 may be attached to the side of a moving door panel (or to the edge of a telescoping gap filler device such as 602 ). To create an effective seal at the top of the portal, top cover 804 is included as shown in FIG. 8 b , this cover running for the length of the portal. The presence of cover 804 also prevents a weapon from being tossed over the portal.
[0068] FIG. 9 shows further possibilities for temporarily sealing the detection chamber formed when the moving door panels 910 are parallel to each other. In FIG. 9 a , seals 901 , 902 and 903 appear similar to seals 801 , 802 and 803 of FIG. 8 . However, as shown in FIG. 9 b , gap filler extension 904 is attached to seal 902 in order to allow seal 902 to be raised and contact top cover 906 when the moving door panels are parallel to one another. Additionally, seal 903 is attached to telescoping gap filler extension 905 in order to form a seal with the sidewall.
[0069] Notice that in FIG. 9B , there is still a gap 907 in the upper right-hand corner of the detection chamber which is not sealed by gap filler extensions 904 and 905 . One solution to this problem is described in FIG. 9 c . One embodiment for filling gap 907 when the moving door panels are parallel or near parallel is accomplished by gap filler extension 908 that telescopes sideways and emerges from gap filler extension 904 . Attached to gap filler extension 908 is seal 909 that is normally stored within seal 902 and emerges from within seal 902 in a sideways telescoping manner when gap filler extension 908 also moves sideways. The amount of sideways movement of extension 908 and seal 909 can be controlled according to the angle of moving door panel 910 so that gap 907 is filled even when door panel 910 is not parallel to the other door panel and perpendicular to the sidewall. This enables extension 908 and seal 909 to prevent passing of a weapon through gap 907 both before and after a detection chamber is formed between the door panels and the sealing to limit air movement becomes critical for CBE detection (Chemical, Explosive, and Bio).
[0070] Another solution for filling gap 907 is shown in FIG. 10 . FIG. 10 a shows the point in time where the two moving door panels are perpendicular to each other, and seals 101 , 102 and 103 are effective because of the alignment of the door panels. However, the point in time corresponding to FIG. 10 a is not when the detection chamber is formed. FIG. 10 b shows the point time when the two door panels are parallel to one another and gap 907 in the upper right-hand corner of FIG. 9 b would be formed were object 1004 not available to fill this gap. Object 1004 is an extra moving arm similar to the arms that support the moving door panels, except that object 1004 has no moving door panel attached, instead having seal 1005 attached to it. Therefore when the two moving door panels are parallel, and extra moving arm such as 104 will slide into position over each moving door panel thereby filling gap 907 .
[0071] FIG. 11 shows a top view of the access control device or portal according to this invention where extra moving arms are included that may slide into position to fill gaps at the top corners of the detection chamber formed when the moving door panels are parallel to each other. FIG. 11 a shows extra moving arms of 1101 , 1103 , 1104 , and 1105 , none of which are attached to moving door panels, and all of which contain a seal such as seal 1102 attached to extra moving arm 1101 . In the scenario of FIG. 11 a , the moving door panels are not parallel to each other and thus none of the extra moving arms are positioned to complete a seal of the detection chamber. In the scenario of FIG. 11 b , the moving door panels are positioned parallel to each other and thus extra moving arm 1101 is positioned to complete a seal above one of the moving door panels while extra moving arm 1105 is positioned to complete a seal above the other moving door panel, thus completing sealing of the detection chamber. Extra moving arms 1103 and 1104 are not utilized in the scenario of FIG. 11 b . In FIG. 11 c , the moving door panels are also parallel to one another forming a detection chamber, but their relative positions are reversed. Thus in FIG. 11 c , extra moving arms 1103 and 1104 are positioned to perform seals above the moving door panels while extra moving arms 1101 and 1105 are not utilized.
[0072] As shown in FIG. 12 , when moving door panels 1207 and 1208 are parallel, a detection chamber is formed with side walls 1203 and 1204 forming the other two walls of the chamber. In addition to conventional metal detection technologies, and various chemical, explosive, and Bio-detection technologies, there are imaging technologies which may be employed to observe the subject, the subject's clothing, and objects that the subject may be carrying whether concealed or visible. Various RF imaging technologies exist such as UWB radar, that enable a view of the subject that penetrates any clothing to reveal shapes that may correspond to the shape of various weapons. Emitters and/or detectors for these RF imaging technologies may be located in both the moving door panels and the side panels, and the paths of RF radiation within the detection chamber may be represented by arrows 1201 and 1202 when emitters and/or detectors are mounted in the side walls, and by arrows 1205 and 1206 when emitters and/or detectors are mounted in the moving door panels. Note that the moving door panels may be continuously rotated 360° in either direction, and that depending upon their position in the operational sequence when a detection chamber is created, either side of a moving door panel may in fact be facing the detection chamber. Thus, any imaging emitters and/or detectors mounted on a moving door panel should be mounted redundantly on both sides of the door panel.
[0073] Similarly, video cameras for optical imaging of a subject may be mounted both sides of the moving door panels and optionally on the side walls as well. Video imaging may be included such that a subject's face may be observed as they walk through the access control device. Observing and analyzing the expressions on a subject's face have been shown to offer clues as to a subject's state of mind—especially when they are contemplating a violent act and/or self-destruction. To ensure that the subject's face is properly viewed such that the image can be properly analyzed by computer, the system can prompt a subject—by voice or signage or both—to look straight ahead for consistent and proper video capture. When thus prompted, if the subject does not comply, the system may optionally stop allowing forward progress of the subject until they comply, or alternately may deny passage and back them out of the portal.
[0074] As a further aid to monitoring the position of a subject passing through the portal and further to ensure the number of subjects within the portal, position detection may also be performed by mounting emitters and/or sensors in either the floor or top cover of the portal or both. These positions sensors may be of IR, sonic, or some other technology.
[0075] At times, it may be useful to identify a subject who is within the detection chamber of an access control device according to this invention. This circumstance may occur if a security guard wishes to pass through the portal and is carrying a weapon. As shown in FIG. 13 , to allow this person to pass, the operational sequence of the portal may pause at the point where the moving door panels 1307 and 1308 are parallel forming a detection chamber. The subject may then interact with a biometric detection device such as 1305 and 1306 located in a moving door panel, or 1301 and 1302 located in sidewalls 1303 and 1304 respectively. A common way to perform this biometric validation would be a fingerprint identification mechanism. Alternately, or in combination, a device capable of performing a retinal scan may also be included. Thus, if the system confirms that there is only one person in the detection chamber and that person is positively identified as being allowed to pass while caring a weapon, the sequence of operation of the portal will continue and allow the person to enter the secured area. Another circumstance where biometric specification is useful is to identify disabled persons that may need to pass through the portal along with various metallic devices such as a wheelchair, crutches, or cane. Again, if this person is certified to be safe to pass and the detection mechanisms in the detection chamber within the portal determine that only this person is present and they are validated, then the operation of the portal may proceed further and allow them to pass. Yet another circumstance may arise where a security guard may assist a disabled person or child in passing through the portal. Again, the security guard can identify themselves to the biometric sensing system and be allowed to pass along with the person they are escorting.
[0076] FIG. 14 a shows cross sections of an embodiment of the portal where moving arms 1401 and 1402 are attached to tracks on the inside of the sidewalls as opposed to the top or outside of the sidewalls as shown in previous figures. This allows the top cover 1403 of the portal to be lowered somewhat, and reduces the amount of space/gap such as gap 907 in FIG. 9 b to be filled in order to seal the detection chamber and/or thwart weapon passing over the moving door panels. In FIG. 14 b , this gap is filled by corner gap filler panel and seal 1405 which may be moved into position by telescoping vertically from within horizontal telescoping extension 1406 attached to seal 1407 . Alternately, gap filler panel 1405 could be implemented to telescope horizontally from extension 1408 attached to seal 1409 .
[0077] To simplify the deployment of a filler panel for gap 907 or the gap filled by gap filler panel 1405 , a filler panel may be implemented as shown in FIG. 15 where gap filler panel 1501 slides diagonally into position when needed (when the moving door panels are essentially parallel to each other or whenever gap 907 might allow a weapon to be passed over a moving door panel). FIG. 15 a shows gap filler panel 1501 and arm 1502 attached to it in a retracted position. In FIG. 15 b , gap filler panel 1501 and arm 1502 slide diagonally, with arm 1502 sliding in channel 1503 , until filler panel 1501 arrives fully in position in gap 907 to effect a full seal of the detection chamber formed when the two moving door panels are essentially parallel.
[0078] The various embodiments described throughout this specification also include the software and object code used to control the access control device according to various embodiments of this invention. These embodiments include a computer program product which is a storage medium (media) having instructions stored thereon/in, which can be used to program a general purpose or specialized computing processor(s)/device(s) to perform any of the features presented herein. As a non-limiting illustration, the instructions stored on the computer readable storage medium can cause a processor to rotate and move the panels of the security door in a particular sequence/manner. Similarly, the instructions can cause the processor to start, stop and resume the rotation of the door according to signals received from a set of sensors embedded in the security door. Additionally, the instructions can cause the processor to reverse the sequence of movement of the door panels after a suspected threat is detected such that the subject is compelled to back out of the access control device, or optionally be restrained within the access control device.
[0079] The storage medium can include, but is not limited to, one or more of the following: any type of physical media including floppy disks, optical discs, DVDs, CD-ROMs, microdrives, magneto-optical disks, holographic storage, ROMs, RAMs, PRAMS, EPROMs, EEPROMs, DRAMs, VRAMs, flash memory devices, magnetic or optical cards, nanosystems (including molecular memory ICs); paper or paper-based media; and any type of media or device suitable for storing instructions and/or information.
[0080] Stored one or more of the computer readable medium (media), the present disclosure includes software for controlling both the hardware of general purpose/specialized computer(s) and/or processor(s), and for enabling the computer(s) and/or processor(s) to interact with a human user or other mechanism utilizing the results of the present invention. Such software may include, but is not limited to, device drivers, operating systems, execution environments/containers, user interfaces and applications.
[0081] The foregoing description of the preferred embodiments of the present invention has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations can be apparent to the practitioner skilled in the art. Embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the relevant art to understand the invention. It is intended that the scope of the invention be defined by the following claims and their equivalents.
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Electro-mechanical and electronically controlled access devices are described for controlling access to a building, premises or area in a secure manner such that a subject who is deemed ineligible for access will be barred entry and may be optionally retained. The devices can contain multiple rotatable door panels, which can be positioned behind one another. The door panels can be controlled by mechanized arms or other control devices in order to control the passage through the device. The direction of flow through a device according to these embodiments is electronically controlled and may be changed at any point in time. At any instant in time, the flow through the device is unidirectional. Multiple devices can be stacked together to form clusters, which can be controlled according to traffic, time of day, or other factors.
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Genus and species of plant claimed: Hydrangea paniculata.
Variety denomination: ‘PIIHP-I’.
BACKGROUND OF THE INVENTION
The present invention relates to a new and distinct cultivar of Hydrangea paniculata , a member of the Hydrangeaceae family, hereinafter referred to by its cultivar name ‘PIIHP-I’. ‘PIIHP-I’ is grown primarily as an ornamental for landscape use and for use as a potted plant.
‘PIIHP-I’ originated as an open-pollinated seedling from seed collected from Hydrangea paniculata ‘HYPMAD I’ (U.S. Plant Pat. No. 19,082) growing in Watkinsville, Ga. ‘PIIHP-I’ was selected in the summer of 2006 by the inventor in a cultivated environment in Dearing, Ga. from the progeny of this open-pollination by continued evaluation for growth habit and foliage and flower characteristics.
Asexual reproduction of ‘PIIHP-I’ by softwood cuttings since 2006 in Watkinsville, Ga. has shown that all the unique features of ‘PIIHP-I’, as herein described, are stable and reproduced true-to-type through successive generations of such asexual propagation.
SUMMARY OF THE INVENTION
Plants of the new cultivar ‘PIIHP-I’ have not been observed under all possible environmental conditions. The phenotype may vary somewhat with changes in light, temperature, soil and rainfall without, however, any variance in genotype.
The following traits have been repeatedly observed and are determined to be unique characteristics of ‘PIIHP-I’. These characteristics in combination distinguish ‘PIIHP-I’ as a new and distinct cultivar: 1) Compact rounded growth habit. 2) Strong stems that hold the inflorescences upright and do not splay. 3) Thick, dark green foliage. 4) Solid inflorescences in which the showy white sepals cover the fertile flowers.
Plants of the new cultivar ‘PIIHP-I’ differ from plants of its female parent ‘HYPMAD I’ primarily in growth habit, stem strength, and foliage and flower characteristics, as plants of ‘PIIHP-I’ have a smaller, more compact growth habit, stronger stems, thicker, darker green foliage, and more dense inflorescences, whereas plants of the ‘HYPMAD I’ have a larger, less compact growth habit, weaker stems, lighter green foliage, and less dense inflorescences.
‘PIIHP-I’ can be compared to ‘ILVOBO’ (U.S. Plant Pat. No. 22,782) but differs in that ‘PIIHP-I’ has a rounded growth habit, begins flowering in late July, sepals age to green with reddish tinges, and inflorescences are smaller 13 cm×13 cm panicles. ‘ILVOBO’ has an upright and mounded growth habit, begins flowering in early July, sepals age to red-purple, and inflorescences are larger 27 cm×16 cm panicles.
‘PIIHP-I’ can also be compared to ‘Jane’ (U.S. Plant Pat. No. 22,330) but differs in that ‘PIIHP-I’ has a rounded growth habit, sepals begin white and age to green with reddish tinges, and inflorescences are true panicles. ‘Jane’ has an upright and mounded growth habit, sepals begin green and age to greyed purple, and inflorescences are rounded, mophead shaped panicles.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying color photographs illustrate the flower and foliage characteristics and the overall appearance of ‘PIIHP-I’, showing the color as true as it is reasonably possible to obtain in color reproductions of this type. The photographs are of plants that are approximately 3 years old. Colors in the photographs may differ slightly from the color values cited in the detailed botanical description which accurately describe the colors of ‘PIIHP-I’.
FIG. 1 illustrates the overall appearance and growth habit of ‘PIIHP-I’.
FIG. 2 illustrates a close-up view of the inflorescence of ‘PIIHP-I’.
DETAILED DESCRIPTION
In the following description, color references are made to The Royal Horticultural Society Colour Chart, 2001 Edition, except where general terms of ordinary dictionary significance are used. Plants used for the description were approximately 3 years old and were grown in 11.8 L containers under outdoor conditions in Watkinsville, Ga.
Botanical classification: Hydrangea paniculata , cultivar ‘PIIHP-I’. Parentage: female, or seed, parent Hydrangea paniculata ‘HYPMAD I’ (U.S. Plant Pat. No. 19,082), male, or pollen, parent unknown (open-pollinated). Propagation: Vegetatively by stem cuttings. Time to initiate roots in summer: About 21 days at 32° C. Plant description: Deciduous flowering shrub; multi-stemmed; compact rounded growth habit. Freely branching; removal of the terminal bud enhances lateral branch development.
Root description .—Medium, well-branched. Plant size .—The original plant, now about 5 years-old in the ground, is about 122 cm high from the soil level to the top of the inflorescences and about 122 cm wide. First year stems .—Have a diameter of about 5 mm. Shape: round. Pubescence: few coarse hairs. Exfoliation: none. First year stem color.— 145B when young and N199B when mature. Second year and older stems .—Have a diameter of about 6 mm or more. Shape: round to oval. Lenticels: approximately 5 per cm of stem length, about 1 mm in diameter and N199C in color. Second year and older stem color.— 197B. Stem strength .—Somewhat flexible when young becoming more easily broken as they mature. Internode length .—About 3 cm. Trunk diameter .—About 1.5 cm at the soil line. Color.— 197B. Lenticels .—Approximately 10 per cm of stem length, about 2 mm in length, about 1 mm in width, and 200D in color.
The surface texture of young, first year stems is smooth, while older stems and the trunk have a rough surface texture.
Vegetative bud description:
Arrangement .—Opposite. Shape .—Imbricate, rounded to globose. Size .—About 1 mm in length, about 1 mm in width. Color.— 200D.
Foliage description:
Arrangement .—Opposite, simple. Length .—About 8.5 cm. Width .—About 4.5 cm. Shape .—Ovate. Apex .—Acute. Base .—Acute. Margin .—Finely serrate. Texture ( upper and lower surfaces ).—Thick, pubescent, like fine sandpaper. Venation pattern .—Pinnate. Venation color ( upper and lower surfaces ).—145C. Color of emerging foliage.— 144A on the upper surface and 145B on the lower surface. Color of mature foliage.— 137A on the upper surface and 138B on the lower surface. Color of foliage in fall ( upper and lower surfaces ).—3C. Petiole length .—About 1.2 cm. Petiole diameter .—About 2 mm. Petiole texture .—Pubescent. Petiole color ( upper and lower surfaces ).—145B.
Flower description:
Flower type and arrangement .—Inflorescence is a panicle about 13 cm in diameter and about 13 cm high. An inflorescence contains about 250 individual sterile flowers and about 350 individual fertile flowers. Inflorescence bloom period: Summer, usually late July in Watkinsville, Ga. The sterile flowers retain their color and are showy for about 6 weeks. The sterile flowers have showy sepals but no petals or reproductive organs. The fertile flowers are mostly hidden by the sterile flowers and are not showy. The fertile flowers have petals and reproductive organs but no sepals. The peduncle is about 10 cm long, 3 mm wide, finely setose, and 155B in color.
Fertile flowers:
Flower bud length .—About 3 mm. Flower bud diameter . —About 2 mm. Flower bud shape .—Round. Color: 155C. Flower diameter .—About 7 mm. Flower height .—About 5 mm. The fertile flowers within an inflorescence open over a period of one to two weeks and are persistent on the plants. Pedicels .—About 2 mm in length, about 1 mm in width, finely setose, and 155B in color. Petals.— 5 petals per flower. Petal length .—About 3 mm. Petal width .—About 2 mm. Petal shape and texture .—Elliptical, with acute apex, cuneate base, and entire margin. Texture of upper and lower surfaces .—Smooth with no pubescence. Petal color .—At peak of bloom the upper and lower surfaces of the petals are 155A. Stamens .—Quantity: usually 10 per flower. Anthers: about 1 mm in length and about 1 mm in width, and 197C in color. Filaments: about 2.5 mm in length and about 0.5 mm in width, and 155A in color. Pollen: produced in very small quantities per flower (scarce), and 155B in color. Pistils .—Quantity/arrangement: 1 per flower, superior, globose in shape. Pistil length: about 3 mm. Pistil width: about 2 mm. Pistil color: 160C. Stigma: 3 per pistil, round in shape and 158A in color. Style: about 2 mm in length, columnar in shape, and 158A in color. Ovary: 1 per flower, about 1 mm in height and width, round in shape, and 158A in color.
Sterile flowers:
Flower diameter .—About 1.8 cm. The sterile flowers within an inflorescence open over a period of about one to two weeks and are persistent on the plant. Pedicels .—About 1.3 cm in length, about 1 mm in width, finely setose, and 155B in color. Sepals.— 3 to 5 (usually 4) sepals per flower. Sepal length .—About 1 cm. Sepal width .—About 8 mm. Sepal shape and texture .—Broad elliptical with obtuse to rounded apex, acute to rounded base, and entire margin. Texture of upper and lower surfaces .—Smooth with no pubescence. Sepal color .—Upper and lower surfaces are 157D at peak bloom and age to 145B with tinges of 51D.
Fruit:
Type and shape .—The fruit is a persistent dehiscent capsule, ovoid in shape. Length .—About 4 mm. Width .—About 2 mm. Color .—N199C at maturity. Quantity .—About 350 or more per infructescence. Seeds .—Linear in shape, about 2 mm in length and about 1 mm in width, N199D in color, and each capsule contains about 50 or more seeds.
Disease/pest resistance: Plants of the claimed Hydrangea cultivar grown in the garden have not been noted to be susceptible to pathogens and pests common to Hydrangea. Weather and temperature tolerance: Plants of the new hydrangea have been observed to be cold hardy in USDA Hardiness Zones 4-8.
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A new and distinct cultivar of Hydrangea paniculata plant named ‘PIIHP-I’, characterized by its compact rounded growth habit; strong stems that hold the inflorescences upright and do not splay; thick, dark green foliage; and solid inflorescences in which the showy white sepals cover the fertile flowers.
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This is a continuation of application Ser. No. 07/325,765, filed Mar. 17, 1989 now abandoned.
BACKGROUND OF THE INVENTION
The field of the invention relates to bio-telemetry in general and specifically to bio-telemetry systems capable of providing patient location information.
Bio-telemetry systems are now widely used to monitor patients in cardiac care and rehabilitation centers. Most existing telemetry monitors are capable of monitoring only cardiac rhythm and do not possess the requisite bandwidth and other features essential for an accurate analysis of a wide variety of cardiac arrhythmias. Development of a biotelemetry system suitable for providing a diagnostic quality multilead electrocardiogram (ECG) signal is highly desirable. Such a system would then permit use of modern real time analyses arrhythmia monitors on ambulatory patients.
Prior bio-telemetry systems are mostly single ECG channel systems. For example, the one disclosed in U.S. Pat. No. 3,953,848. A number of multi-lead ECG telemetry systems have also been described. Examples are those disclosed in U.S. Pat. Nos. 3,962,697; 3,815,109 and 4,356,486. These attempts are useful contributions to the field but the radio frequency bandwidth required by these systems does not permit monitoring of a large number of patients in the same hospital.
In an event of a detected serious arrhythmic episode, a patient must be located quickly so that life saving measures can be initiated. Thus, it is also desirable to have an automatic patient location capability in the monitoring system.
U.S. Pat. No. 4,593,273 discloses an out-of-range personnel monitor and alarm. Although this system may sound an alarm if a patient walks out of range, it does not help hospital personnel in locating the patient. It also implicitly limits the freedom of the patient to move about.
Further, the existing systems do not readily adapt to the transmission of other useful information, such as patient temperature, patient distress, pacer spikes, blood oxygen, electrodes and the status of the equipment itself.
SUMMARY OF THE INVENTION
The present invention relates to a multi-lead ECG telemetry systems, using PCM, to provide a diagnostic quality signal suitable for real time arrhythmia analysis monitors. More specifically the invention relates to an ECG telemetry system incorporating a patient location system which comprises one or more stationary location markers may transmit a presettable location code indicating the location of said location marker. An identification unit comprising a patient carried ECG transmitter unit communicates with the location marker via a low power communication link whose range defines a bounded space. The location code for a location marker and a patient identification signal produced by the patient identification unit is transmitted to a stationary receiver only when the location marker is in communication with the patient identification unit. The stationary receiver receives the location code and the patient identification signal so as to provide information as to the location of the patient wearing the patient identification unit.
Accordingly, one object of the invention is to permit hospital personnel to locate, ambulatory patients experiencing arrhythmic episodes rapidly.
A further object of the invention is to provide a method of monitoring physiological status of the patient. The patient carried ECG transmitter unit contains multilead ECG monitoring circuitry. The physiological signals from this monitoring circuitry are combined with the patient identification information. The stationary receiver includes circuitry to decode the physiological signals to provide real-time monitoring of the physiological signals.
It is another object of the invention is to prevent interference between the retransmitted signals of a number of ECG transmitter units operated within the same institution each monitoring a number of ECG signals. The physiological signals and location code are combined by using pulse code modulation (PCM). This allows narrow band Very High Frequency (VHF) channels for each patient, consequently allowing a large number of patients to be monitored on unused television (TV) frequency channels. The patient identification information is determined by the particular frequency channel used.
It is another object of the invention to allow the patient to simultaneously indicate his or her distress and location to a remote station. Each patient carried ECG transmitter unit contains a distress button that signals the stationary receiver of the patient's activation of that button. The stationary receiver also indicates the patients location by means of the location markers as described above.
It is a further object of this invention to efficiently combine high bandwidth physiological signals with low bandwidth circuit status data and location code data, with a minimum increase in bandwidth. The combined information is transmitted in a stream of data frames. Physiological data is transmitted in every frame, but location data and status data is spread among the frames according to its relative data rate. Therefore, the bandwidth of the system required to send physiological data and status and location data need not be markedly increased over that required by the physiological data alone.
The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference is made therefore to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a stationary location marker, a patient worn ECG transmitter unit and a central monitoring station;
FIG. 2 is a schematic diagram of the stationary location marker shown in FIG. 1;
FIG. 3 is a timing diagram of the signal generated by the stationary location marker of FIG. 2;
FIG. 4 is a block diagram showing the ECG transmitter unit shown in FIG. 1;
FIG. 5 is a schematic diagram of the electrode circuit of the ECG transmitter unit as shown in FIG. 4;
FIG. 6 is a schematic diagram of the Wilson Terminal and standard lead amplifiers of the ECG transmitter unit as also shown 4;
FIG. 7 is a schematic diagram of the ECG amplifiers and baseline correction switches of the ECG transmitter unit shown in FIG. 4;
FIG. 8 is a schematic diagram of the baseline error detection circuits of the ECG transmitter unit as shown in FIG. 4;
FIG. 9 is a schematic diagram of the pacer spike detector circuit of the ECG transmitter unit as shown in FIG. 4;
FIG. 10 is a schematic diagram of location code detector and the status encoder circuits of the ECG transmitter unit as shown in FIG. 4;
FIG. 11 is a schematic diagram of the ECG encoder circuits of the ECG transmitter unit as shown in FIG. 4;
FIG. 12 is a timing diagram showing the PCM data encoding protocol of the retransmitted signal of the present invention;
FIG. 13 is a schematic diagram of the radio frequency circuit used in the ECG transmitter unit as shown in FIG. 4 and;
FIG. 14 is a functional block diagram of the stationary receiver unit shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an ECG transmitter unit 1 is attached to the patient's clothing and electrically connected to the patient's body through ECG electrodes 6. Location markers 2 are installed at prominent locations (i.e. corridors, doors, etc.). Each location marker 2 continuously transmits a unique location code using a pulse code modulated infrared beam 4 of limited strength forming a low power link. The strength of this signal defines a bounded space associated with one location code. The patient carried ECG transmitter unit 1 is provided with a means to receive this infrared beam 4 provided that the strength of the beam is above a given power level. By limiting the power level of the infrared location markers 2 and by installing the markers far enough from each other, a number of bounded spaces may be established and it may be ensured that the patient carried ECG transmitter unit 1 receives a location code from only the nearest location marker 2 within a given bounded space.
The ECG transmitter unit 1 combines the location code with digitized ECG and status data and transmits the same on a pulse code modulated (PCM) radio frequency signal 5, which is received by a stationary receiver 3. The carrier frequency of the radio frequency signal is unique to the ECG transmitter unit 1 and therefore identifies that ECG transmitter from others. Thus the ECG transmitter unit 1 serves as a patient identification unit and the carrier frequency of its transmission carry patient identification information.
The status data, also transmitted in the PCM signal, will be described in detail below. The stationary receiver 3 decodes, separates and displays the multi-lead ECG data, patient location data, and the system status.
The Location Marker
Referring to FIGS. 2 , the location marker 2 includes a crystal controlled oscillator 7 which generates a 240 kHz clock signal 19 that is divided by a counter 8 to produce a 4 kHz S-clock signal 16. This 4 kHz clock signal 16 is further divided by the counter 9 to generate the R-clock signal 18. A parallel-in-serial-out shift register 10 is wired to load a 13-bit location code from the thumbwheel switch 12. The location code is arbitrary and set by the user to uniquely define the location of the bounded space around the location marker. Together with S-clock and R-clock inputs 16 and 18, shift register 10 produces a serial data signal 20. Referring to FIG. 3, the serial data signal 20 includes a 17-bit leader byte 25 used by the system for synchronization as is generally understood in the art. Following the 17 bit leader byte 25 is a 15-bit long data string 26 including a logic low start, a 13-bit location data word and also a logic low stop bit. The 13-bit location data word is selected by setting of the thumbwheel switch 12 and allows more than eight thousand (8000) locations to be identified by the location marker 2. The length of the location data word may be varied to suit the requirements of the hospital. Referring again to FIG. 2, a counter/divider 11 divides the 240 kHz clock signal 19 by five when the serial digital signal 20 is high and by six when the serial digital signal 20 is low. Thus, the output signal 21 from the counter divider 11 equals the 240 kHz clock signal 19 frequency shift key (FSK) modulated by the location code set by the thumbwheel switch 12. Output signal 21 drives an output amplifier 13 which, in turn, drives infrared light emitting diode (LED) 14 to produce an infrared beam carrying location code information. The power of the infrared beam is such as to confine the location code signal to the area of a single room or lobby of the hospital.
ECG Transmitter Unit
Referring to FIG. 4, a patient is connected to the ECG transmitter unit 1 through electrocardiograph electrodes 6. The electrode circuit 30, shown in detail in FIG. 5, contains wave trap RC filters and diode protection circuits 55 to 58, to stop RF signals from reentering the unit, and to limit current in-rush during patient defibrillation. Block 30 also contains electrode monitoring circuitry consisting of analog buffers 59 to 62 and comparator drivers 67 to 70 as shown in FIG. 5. This circuit monitors electrode fall-off condition. If an electrode fall-off is detected, it turns on corresponding LED indicators 71 to 74. The fall-off condition is indicated by an increase in the impedance of the electrodes. Logic OR circuit 75 generates an electrode fall-off alarm status signal 76. Buffered ECG signals 63 to 66 go to the Wilson terminal block 34.
Wilson terminal block 34 contains circuits shown in FIG. 6. Averaging amplifier 77 computes a Wilson ground 84 from the three limb lead inputs 63, 64 and 65. The difference amplifier 80 uses Wilson ground 84 and buffered ECG chest lead signal 66 to compute a standard ECG V lead 83. Difference amplifiers 78 and 79 use buffered ECG limb lead signals 63, 64 and 65 to compute standard ECG signals lead I 81, and lead II 82 and V lead 83. Signals 81, 82 and 83 are capacitively coupled to pacer input signal 36 for pacer spike circuits.
Block 37 of FIG. 4 contains ECG amplifiers and baseline correction circuits shown in detail in FIG. 7. Standard ECG signals 81, 82 and 83 are coupled through capacitors 84, 85 and 86 to the ECG amplifiers 90, 91 and 92 to produce signals 95, 96 and 97. Analog switches 87, 88 and 89 ground amplifier inputs whenever a baseline correction command pulse 94 is received from the baseline error detection circuit 45 described below.
The baseline error detection circuit 45, shown in detail in FIG. 8 receives amplified ECG signals 93 (comprised of 95, 96 and 97). Window comparators consisting of diodes 98 to 105 and difference amplifiers 106 and 107 and OR gate 108 generate a baseline error signal 109. The baseline error signal 109 is generated whenever the baseline of 95, 96 and 97 wanders outside the prescribed threshold of the window comparators of approximately 1.4 volts. Discriminator circuit consisting of monostable multivibrators 110 and 111 inhibit generation of correction pulse 94 unless the baseline error persists beyond a prespecified period of 5 seconds. The correction pulse 94 is used by the baseline correction circuit 37 as explained above.
Block 52 of FIG. 4 contains pacer spike detector circuit. The ECG signal measured from patients with pacemakers includes a pacer spike. It is clinically important to see that each pacer spike triggers the appropriate ECG response. The frequency content of the pacer spike is much higher than that of the ECG signal hence the pacer spike is first detected and filtered from the combined pacemaker plus ECG signal. If a pacemaker pulse is detected, a digital pacer status pulse is generated which is sent separately to the stationary receiver 3 and recombined with the ECG waveform. The pacer spike detector circuit is shown in detail in FIG. 9. Pacer signal 36 from Wilson terminal 34 is passed through an absolute value circuit 17. Output of 17 is passed through a slew rate filter circuit 22 and a difference amplifier 23. Pacer spike output of 23 is passed through a pulse stretcher monostable multivibrator 24 to generate a pacer status pulse output 51.
The signal 76 from electrode monitoring circuit, 51 from the spacer spike detection circuit, 54 from distress switch, and 50 from power control circuit comprise the status code which is combined with the location code and transmitted with the ECG signals by the status encoder shown in FIG. 10. Binary encoder 119 collects these signals into a 3-bit status code.
A location code detection circuit is also shown in FIG. 10 block 47, and consists of an infrared detector 112 that detects presence of an infrared location code radiated by a stationary location marker. Amplifier 113 amplifies output of the sensor that passes through filter 114 and a discriminator 115 to generate a serial PCM location code data 49. Sync separator circuit 116 uses data 49 together with clock signal 120 to produce a shift register clock signal 121. The serial-in-parallel-out shift register collects a 13-bit location code which is added to a 3-bit status code generated by the encoder 119 to produce a final 16-bit system status word 42.
The ECG encoder shown generally in block 41 of FIG. 4 receives analog ECG data 95, 96 and 97 from baseline correction circuit 37, and 16-bit status word 42 from status encoder 48 described above. A detailed schematic diagram of the ECG encoder is shown in FIG. 11. Sixteen-bit status word 42 is converted to two multiplexed 8-bit words 200 and 202 representing the most significant bits and the least significant bits of the sixteen bit status word 42 respectively. This conversion is performed by the 16 to 8 bus converter 121. The three lead ECG signals 95, 96 and 97 are multiplexed and converted to three 8-bit digital data words 95', 96', and 97' by the multiplexer converter 122 and concatenated with the 8-bit status bytes by the parallel-in-serial-out shift register 123 which serializes this 8-bit data as will be described below. The serialized data 126 from shift register 123 is sent to scrambler circuit 125 which "scrambles" the data stream to eliminate long strings of logical "ones" or logical "zeros" to improve transmission efficiency as is well understood in the art. The scrambled signal 43 is input to the RF modulator 44.
The method of combining the 16 bit system status word 42 and the ECG signals will now be described. Referring to FIG. 12, data are grouped in frames of 40-bit length. A set of four frames comprises a cluster. The four frames 128-131 of each cluster are numbered 1 to 4 as shown in FIG. 12. Each frame of a cluster starts with a 10-bit data string consisting of an 8-bit data byte from ECG lead one plus one start and one stop bit. This is followed by two similar 10-bit data strings from ECG leads two and three. Start bits of all ECG lead data strings are low. Stop bits of leads one and two are also always low. Stop bits of the third lead are low for frames one and three, and high for frames two and four. The thirty-first bit of each frame is low for frames one and three, and high for frames two and four. The thirty-second through thirty-ninth bits represent lower and higher order status bytes from 16 bit to 8 bit converter 121 in frame one (1) and three (3) respectively. These two bytes are followed by a low stop bit. Bits 30 to 40 in frames two and four are always high and form 11-bit long leader bytes used by the receiver to extract synchronization information. The preferred embodiment of the invention transmits 50 data clusters per second. That is equivalent to 200 frames per second. An important advantage of this protocol is the efficiency with which high frequency ECG data is combined with slow varying status and location data without increasing serial data rate substantially above that required by the ECG data alone.
Block 44 in FIG. 4 shown in detail in FIG. 13 represents the RF modulator stage of the transmitter. The voltage controlled crystal oscillator consists of an amplifying device 134, a quartz crystal of one-fourth the RF channel frequency 135, a varactor diode 136, and a current regulating diode 137. Output of 134 is tuned by an inductor 138 and capacitors 139 and 140, to the second harmonic of the crystal 135. Capacitors 139 and 140 also provide impedance matching to the output stage frequency doubler amplifier 141. Current regulator diode 142 and 137 provide added stability in frequency and power. The output of 141 is tuned by inductor 143 and capacitor 145 and coupled to the antenna circuit 144. Two of the ECG electrodes are used to form the antenna.
Referring to FIG. 14, the receiving antenna 145 of stationary receiver 3 feeds RF amplifier 146 tuned to the RF channel frequency of the ECG transmitter unit 1. The output of 146 is mixed by the mixer 147 with the output of the local oscillator 148. The local oscillator 148 is crystal controller to a frequency exactly 10.7 megahertz above the RF channel frequency of the transmitter. The output of the mixer passes through the 10.7 megahertz intermediate frequency (IF) filter 149. The output of 149 is amplified by the IF amplifier 150 and fed to the discriminator circuit 151. The output of 151 goes through a buffer 152 and a Schmitt trigger 153 to a monostable multivibrator 154. The output 155 of 154 is the serial data as shown in FIG. 12. This serial data is processed by sync separator and timing circuits consisting of 160, 161, 162, 163 and 164 to generate a data bit clock 159 and a frame sync clock 158. These clock signals, together with the frame decoder circuit 170, is used to lock in each data frame of each data cluster into the 40-bit serial-in-parallel-out shift register 157. The output of the decoder circuit 170 is also used to latch each ECG lead data byte and each status byte into the latches 165 through 169 as shown in FIG. 14.
Since certain changes may be made in the above method and embodiment without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. For example, it will be understood by one skilled in the art that the ECG unit could communicate its data to the stationary location marker which in turn could retransmit the location data and the ECG unit data to the stationary receiver using the circuitry described herein. Further, the invention need not be limited to ECG signals but may be used to transmit other physiological data in addition to or in lieu of the ECG data.
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A miniature multi-lead bio-telemetry and patient location systems includes one or more stationary location markers which transmit location data to an ECG unit worn by ambulatory patients. The electrocardiogram (ECG) unit monitors patient ECG data, a distress button and ECG unit status and combines this data with the location data received from one location marker and retransmits this combined data to a stationary receiver which may display the ECG data the system status data and the location data.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part application that claims the benefit of U.S. patent Ser. No. 14/058,323 filed on Oct. 21, 2013, entitled “Dual Compartment Walk-in Bathtub,” which claims the benefit of U.S. Provisional Application No. 61/719,120 filed on Oct. 26, 2012, entitled “Walk-in Bathtub.” The above identified patent applications are herein incorporated by reference in their entirety to provide continuity of disclosure.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to walk-in bathtubs for those with reduced mobility that allow for pre-filling thereof prior to entry. More specifically, the present invention pertains to a walk-in bathtub that allows a user to fill the tub without being positioned therein while having the entry door in an open position. The device facilitates setting the bathtub as would be possible with a traditional tub, whereafter the user can enter the bathtub without climbing over the bathtub wall.
For those with reduced mobility, including the elderly and disabled, moving into and exiting from a typical bathtub can be difficult. Most bathtubs include a raised wall used to contain the water within the bathtub interior. This wall presents an obstacle for some users as it requires the user to step over the wall to enter the bath. This can be difficult and even dangerous for those with reduced mobility from injury or impairment, as the user has to step over the bathtub wall one leg at a time while maintaining balance on a single foot. While this is readily accomplished for one of normal health and strength, physical impairments and age can quickly diminish one's capacity to engage in such routine activities.
To improve the safety and reduce the burden of exiting and entering a bathtub for those with limited mobility, different types of walk-in bathtubs are available that assist stepping into and exiting from a bathtub interior that do not require the user to step over an obstacle. The ability to walk directly into the shower without lifting a leg or shifting one's weight drastically reduces the chances of injury, and further enables one to easily enter or exit the shower without straining or slipping. Generally these bathtubs include an open layout or a raised wall having an entry door therealong to provide through-access. The open layout design is mostly used in shower stall settings, while entry doors are disposed on fillable bathtubs structures.
While many walk-in bathtubs exist in the art and are readily available to consumers, these devices retain an inherent drawback that has to be resolved, Notably, when filling a walk-in bathtub with bath water, the door must be in a closed position in order to retain the water therein. Generally the door is lined with a seal or gasket to prevent water leakage therethrough from the tub interior. When in a closed position, the door supports the pressure exerted on the door interior and the tub can be filled for the user to soak in the tub interior as desired.
This arrangement, while useful for providing an entryway into the tub, does not allow the user to first set the bathtub by filling the same and bringing the bath water to an appropriate temperature before entering thereinto. If the user desires to set the water before entering the bathtub, the door must be a closed position and the tub therefore returns to a traditional tub arrangement with a uniform outer wall for the user to climb over. This defeats the purpose of the entry door and therefore makes the exercise of first setting the tub not feasible for those with mobility problems who may require a walk-in arrangement in the first place.
The present invention is submitted as a new and novel walk-in bathtub arrangement that serves a long-felt need in the art. Specifically, the present invention contemplates a walk-in bathtub that is capable of being set before the user enters thereinto, wherein the user can fill the tub interior, place desired soaps and treatments into the water, and ensure a desired water temperature before being in the tub. The bathtub includes one or more removable dam elements that segment the tub interior into two or more compartments, whereby one compartment can be filled while the other compartment act as an operable entryway, operable seating area, or water-fillable compartment after the bathwater in the first compartment is set. This allows the user to set the bathwater prior to entry thereinto without being forced to close the entry door, while two separate drains and dam element allow the user to exit the tub from the second compartment while the first compartment is still being drained.
2. Description of the Prior Art
Devices have been disclosed in the prior art that relate to walk-in bathtub arrangements and entry doors therefor. These include devices that have been patented and published in patent application publication, and generally relate to different tub arraignments, those with operable entry doors, and other with interior seat accommodations. The following is a list of devices deemed most relevant to the present disclosure, which are herein described for the purposes of highlighting and differentiating the unique aspects of the present invention, and further highlighting the drawbacks existing in the prior art.
One such device in the prior art is U.S. Pat. No. 7,299,509 to Neidich, which discloses a door assembly for a walk-in bathtub, wherein the device comprises a first track that accommodates a gasket along the length of the door frame, and a second track for mounting the door hinge. The gasket forms a tight seal between the door and the walk-in bathtub, whereby the door will not leak fluid when the tub is filled with water. While teaching a novel door for a walk-in bathtub and disclosing a bathtub of the walk-in type, the Neidich device fails to teach the novel configuration of the present invention, which provides a user with flexibly with regard to preparing, entering, and thereafter using the walk-in bathtub.
Similar to the Neidich device, U.S. Pat. No. 8,375,478 to Luo discloses a walk-in bathtub having a bathtub frame, a doorjamb, a hingedly attached door attached to the door jamb, and a gasket disposed between the door and door jamb to prevent leaks therefrom. To secure the door to the door jamb, and thus create a flush seal that encloses the tub water within the bathtub frame, a movable handle and latching pin secure the door against the gasket. The Luo device, similar to the Neidich device, teaches of a new door and seal for a walk-in bathtub, and fails to disclose the novel operating functions and structural elements of the present invention.
Further related to walk-in bathtub doors is U.S. Patent Publication No. 2010/0263119 to Neidich, which describes a door assembly having a first and second door mount to provide a double axis hinge for the door connecting to the bathtub threshold. The double axis hinge allows the door to be removed from its closed position and placed in a position that faces the interior of the door towards the bathtub when in an open position, rather than a single hinge door that swing open in an arcing fashion. Similar to the aforementioned devices related to walk-in bathtub doors, the Neidich double axis door does not contemplate the novel features of the present invention and is limited to a new door type for walk-in bathtubs.
Finally, U.S. Patent No. 2005/0102746 to Wright discloses a walk-in bathtub that includes a unitary body forming an elevated seat portion and a lower floor region. A water-tight door is fitted to a door frame on the unitary body and adjacent to the lower floor region, whereby water can be filled into the floor region for the user to bath. A drain hole is positioned on the lower floor region to drain the bathwater between users and to allow for opening the door. The Wright device discloses a seated bathtub having a seat portion and lower leg portion. The Wright device is not capable of filling until the user has entered the bathtub and closed the water-tight door. The present invention contemplates an assembly that allows the user to fill the bathtub with water and prepare the same at a given temperature before entering for bathing activities. The user can freely enter and exit the bathtub, whereby one or more dam elements prevent water from entering the back portion of the tub and pressing against the entry door.
The present invention provides a walk-in bathtub that allows the tub to be first set and filled before the user enters the bathtub interior. The bathtub of the present invention can be utilized as a standup shower, as a soaking tub, or as a bathtub with an internal seat therein. Overall, the assembly provides an elderly or injured user with a more convenient means of taking baths or showers, whereby the bath can be filled and set prior to entry and the bathtub can be utilized in a number of different configurations.
It is submitted that the present invention is substantially divergent in design elements from the prior art, and consequently it is clear that there is a need in the art for an improvement to existing walk-in bathtub devices. In this regard the instant invention substantially fulfills these needs.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of walk-in bathtubs now present in the prior art, the present invention provides a new walk-in bathtub assembly that can be utilized for providing convenience for the user when setting a bath before entering the same, and further for using a walk-in bathtub as either a standup shower, a soaking tub, or a bathtub stall with interior seated support.
It is therefore an object of the present invention to provide a new and improved walk-in bathtub assembly that has all of the advantages of the prior art and none of the disadvantages.
It is another object of the present invention to provide a walk-in bathtub assembly that is useable as a standup shower, a seated bathtub stall, or a full soaking tub, while at the same time provide an entry door for walking directly into the bathtub interior.
Another object of the present invention is to provide a walk-in bathtub assembly that includes an interior dam element that allows a user to segment the bathtub into two or more compartments, whereafter the first compartment may be filled prior to the user entering the bathtub or closing the entry door.
Yet another object of the present invention is to provide a walk-in bathtub assembly that includes a deployable seat from the second compartment, whereby the seat allows users to sit and wash themselves without fully entering the tub or standing.
Another object of the present invention is to provide a walk-in bathtub assembly that has an entry door that does not require users to lift their legs to enter the bathtub interior.
A final object of the present invention is to provide a walk-in bathtub assembly that may be readily fabricated from materials that permit relative economy and are commensurate with durability, wherein the assembly is built to the standard of walk-in bathtubs and will not leak when in a working state.
Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.
FIG. 1A shows an overhead view of the bathtub assembly of the present invention with the entry door in an open configuration and the first compartment filled with water.
FIG. 1B shows an overhead view of a second embodiment of the bathtub assembly.
FIG. 2 shows another overhead view of the bathtub assembly of the present invention in a working state, wherein the deployable seat is in a downward position for use as a seated support within the bathtub interior.
FIG. 3 shows a view of the outer wall of the walk-in bathtub and the entry door in an open configuration while filling the first compartment with water.
FIG. 4 shows a view of the walk-in bathtub assembly in use by a seated user.
FIG. 5 shows a view of the walk-in bathtub assembly in use by a standing user.
FIG. 6A shows a cross section of the present invention during the initial stages of the bathtub filling, wherein the first compartment is being filled and set prior to user entry.
FIG. 6B shows a second cross section view after the user has entered the set bathtub and removed the central dam element to fill both compartments.
FIG. 6C shows a third cross section view of the bathtub being filled after the user has entered the tub, replaced the dam element, and placed the seat into a down position for seated bathing.
FIG. 6D shows a fourth cross section view of the tub being drained, wherein the dam element separates the first and second drains and allows the user to exit the second compartment even if the first compartment is still draining.
FIG. 7 shows an overhead perspective view of the tub of the present invention, whereby two dam elements are present to segment the tub into three distinct compartments.
DETAILED DESCRIPTION OF THE INVENTION
Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the walk-in bathtub assembly. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for providing a new and improved walk-in bathtub for the elderly or disabled. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.
Referring now to FIG. 1A , there is shown an overhead perspective view of the walk-in bathtub of the present invention in a working state with its first compartment 100 filled with water for bathing, and the entry door 41 in an open configuration. The bathtub comprises an upstanding front wall 40 , a pair of end walls 44 , and a rear wall 49 that surround an open bathtub interior having a base surface. To facilitate entry into the bathtub interior, an entry door 41 is provided along the front wall 40 to allow entry therethrough without lifting one's legs. The door 41 pivots from the front wall 40 by way of a hinge joint 20 , while the edges 42 of the door 41 align with a cutout in the front wall 40 when closed. Between the cutout and the door edges 42 is a seal or gasket 43 that prevents leaking therethrough. To secure the door 41 against the front wall 40 , a handled latch (not shown) is provided to prevent the door 41 from freely swinging open during use.
Within the bathtub interior is one or more laterally extending dam elements 50 that are adapted to segment the bathtub interior into two or more compartments. As shown in FIGS. 1A through 6 , an embodiment with one dam element 50 is used to segment the tub into a first 100 and second 101 compartment, thereby preventing water communication between the compartments when fully installed. The dam element 50 is an operably installed member that preferably slides into defined slots 51 along the walls of the bathtub interior to lock the dam element 50 into place and secure the same against the walls of the bathtub interior. This element 50 allows users to fill the first compartment 100 of the bathtub interior while the second compartment 101 remains dry and free of water. In use, the user can fill the first compartment 100 with warm or hot water and set the water with soap or any other additives, all without having to secure the entry door 41 closed.
The ability to set the bath before closing the entry door 41 is a unique ability in the art of walk-in bathtubs, as the user generally has to first enter into the bathtub, seal the entry door, and then start the flow of water. The present invention allows a user to fill the first compartment 100 with warm water and prepare it for use without physically entering the bathtub interior or sealing the entry door 41 closed against the outer wall 40 .
Referring now to FIGS. 1A, 1B, and 2 , the deployable seat 45 of the present invention is shown in a stowed configuration and in a deployed state. The deployable seat 45 is a hinged 48 support surface that is mounted to the rear end wall 44 of the bathtub and can pivot between an upright (stowed) position, and a horizontal (working) position. The seat 45 is preferably positioned within the second compartment 101 of the bathtub interior and allows the user to set the water in the first compartment 100 and rest on the seat 45 for washing oneself in a seated position. The user can further fill the first compartment 100 , enter the second compartment 101 while the seat 45 is stowed, closed the entry door 41 , and then deploy the seat 45 for resting on the same.
The seat 45 is supported along the bathtub interior such that the weight of the user is supported during use. The outer edge of the seat 45 may rest against the upper portion of the dam element 50 , as shown in FIG. 2 , or alternatively the seat 45 may not extend outward to the extent of the dam element 50 position. In this alternative, the user has room to place his or her legs between the dam element 50 and the seat 45 without removing the dam element 50 . If the seat rests against the dam element 50 , the user can step over the dam element 50 , supporting himself along the upper edge 49 of the bathtub sides for support. Thereafter the user can wash himself while seated using water prepared in the first compartment 100 . To assist the user during this motion, hand rails may be provided for the user to grasp along the shower sides (not shown).
Referring specifically to FIG. 1B , an alternate configuration for the dam element 50 and its attachment to the interior walls of the bathtub includes a hinged configuration. In this embodiment, the dam element 50 is secured across the bathtub interior when deployed and does not let water pass therethrough, while the dam element can be pivoted via a hinge joint 55 from a deployed state to a stowed state against the inner walls of the tub via a hinge joint along one side thereof. The hinge joint 55 allows the dam element 50 to swing into position or out of the way as desired by the user, and is submitted as an alternative to the slots 51 shown in FIG. 1A .
Referring now to FIG. 3 , there is shown a view of the walk-in bathtub of the present invention being filled in the first compartment 100 while the second compartment 101 remains dry and the entry door 41 can be opened for ease of entry. When entering, the deployable seat 45 is positioned in a stowed state and the user can enter the cutout in the bathtub front wall 40 to enter the bathtub interior without stepping over any obstacles. Once in the bathtub interior, the user can close the entry door 41 and use the shower in a stand-up configuration, in a seated configuration, or the user can lift the dam element to fill the entire interior with bathing water for use as a soaking tub. Also shown in FIG. 3 is the second drain 82 positioned within the second compartment 101 of the bathtub. The bathtub comprises a first 81 and second 82 drain, wherein each is positioned in corresponding compartments for independently draining the same. When the dam element is in position, the first 100 and second 101 compartments drain independently, allowing a user to exit the second compartment 101 if that compartment has drained before the first compartment 100 . This allows for quicker exiting without waiting for the entire tub to drain. Since the second compartment is a smaller volume, it will drain faster.
Referring now to FIGS. 4 and 5 , there are shown views of the walk-in bathtub of the present invention in a working state, first in a seated state ( FIG. 4 ), and then as a standing shower ( FIG. 5 ). In a seated state, users can rest on the deployed seat 45 and bathe themselves with the water in the first compartment 100 . If the user decides to use the entire tub and to soak therein, the user can stow the seat 45 and remove the dam element 50 to allow water to communicate from the first compartment 100 to the second compartment 101 . It is contemplated that the dam element 50 be secured seated within slots 51 along the sides of the bathtub interior.
Also shown in FIG. 4 is a view of the first drain 81 positioned within the first compartment 100 . As previously explained, the independent drains allow the bathtub compartments to drain at different rates, allowing a user to exit the second compartment 101 before the entire bathtub has drained to reduce waiting time during this period. It is further contemplated that the dam element may optionally include a fluid drain 54 and drainage plug for allowing water to communicate thereacross. This embodiment allows the user to equalize pressure on both sides of the dam 50 before lifting and removing the same. Yet another embodiment of the present invention is to provide a drain in both bathtub compartments for independent draining therefrom.
Referring now to the cross section views, FIGS. 6A-6D , there is shown a sequence of views that illustrate filling and setting the bathtub, filling the entire bathtub interior for soaking, and then draining the bathtub using the independent drains. Referring specifically to FIG. 6A , this cross section view illustrates the initial stage of the bathtub filing, wherein the user has installed the dam element 50 between the first 100 and second 101 compartments of the bathtub and is filling the first compartment 100 with a water of desired temperature. The second compartment remains empty for the user to enter the bathtub without spilling any water contents from the first compartment 100 . Once the first compartment 100 has been filled with water of a desired temperature and the user has entered the second compartment 101 , the dam element is removed to fill the entire bathtub interior, as is shown in FIG. 6B .
Once both compartments 100 , 101 are filled, the water level in the bathtub can be raised to the desired level. If the user desires, the tub can be utilized as a soaking tub, wherein the dam element 50 is replaced and the seat 45 is deployed. The water level can be maintained below the level of the seat 45 or filled to the capacity of the bathtub for complete body soaking, as is shown in FIG. 6C . After the user has finished soaking or bathing, the seat 45 is stowed and the dam element 50 is installed for draining the first 100 and second 101 compartments individually. The first 81 and second 82 drains then drain the compartments independently. To reduce the wait time for the user during the draining phase, the second compartment 101 is sized slightly smaller than the first compartment 100 to allow for swifter draining through the second drain 82 . This allows the user to exit from the second compartment 101 through the entry door before the entire tub is drained, as is shown in FIG. 6D . Therefore, the present invention offers a user a unique method of first setting the bathtub and thereafter draining the same when the user desires to exit the same.
Referring finally to FIG. 7 , there is shown yet another embodiment of the present invention, whereby the tub is segmented into three compartments by a first and second dam element 50 . In the same manner as the single dam embodiment, the multiple dam embodiment allows a user to further segment a tub into compartments for separate uses, or for preparation prior to entry into the tub. In this embodiment, the drains are disposed within the outermost compartments, while the central compartment can remain filled during draining. Each of the dams is operably placed in a working state, either using the slots 51 , hinge joint, or similar attachment arrangement.
Overall, the bathtub of the present invention is configured to allow preparation of the bathwater before entry thereinto, while also facilitating use of the tub in several different configurations. The size, shape, and materials of the bathtub may take on several forms, falling within the scope of the functional elements of its use and for providing a sealed, comfortable bathtub for use while standing, seated, or while soaking.
Senior citizens and those with joint pain, injuries or physical disabilities may struggle to step into a standard bathtub. Existing walk-in bathtubs require the individual to stand or sit inside the tub while it fills, and again as it drains. This process wastes the person's time and can leave the individual feeling cold and uncomfortable. The present invention describes a new walk-in bathtub assembly. The assembly comprises a walk-in bathtub that has one or more dam elements that divide the tub interior into two distinct compartments. A user can fill a first compartment without having to be inside the tub while waiting for the water to fill. Once the water reaches a desired level and temperature, the user can enter a secondary compartment, disrobe and release the dam, which will in turn fill the secondary compartment. The user can alternatively deploy the seat for use of the first compartment water without releasing the dam and without remaining in a standing position. Finally, the user can choose to use the bathtub assembly as a standard shower tub for upright cleaning.
It is submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A bathtub is provided of the walk-in type, wherein the bathtub includes an at least one internal dam element that allows a user to segment the bathtub into a two or more compartments and operably utilize the bathtub as a sit-down tub or as a standing shower. An entry door provides access into the bathtub without requiring users to lift their legs during entry, while the dam elements allow the user to fill the sectioned compartments of the tub and prepare it for use before entering the bathtub interior. Certain compartments may remain empty as the other compartments fill with water, whereafter the user can enter the empty the empty compartment and remove a dam element after closing the entry door. The bathtub further may also comprise a first and second drain for independently draining the compartments.
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[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 15/426,886, which is a continuation-in-part of U.S. patent application Ser. No. 15/144,653 filed on May 2, 2016, which is a divisional of U.S. patent application Ser. N., 14/559776, filed on Dec. 3, 2014, now issued U.S. Pat. No. 9,354,872 , which claims priority to U.S. Provisional Patent Application No. 61/983,944, filed on Apr. 24, 2014. This application also claims the benefit of priority to U.S. Provisional Application No. 62/400,559, filed on Sep. 27, 2016. These and all other extrinsic references referenced herein are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The field of the invention is memory storage devices.
BACKGROUND
[0003] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0004] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0005] Data saved on memory can be accessed via a byte-addressable means, which allows for rapid access with an optimized memory space but more processing power. Memory can also be accessed via a block-addressable means, which allows for rapid access with less processing power but a non-optimized memory space. Since non-volatile memory tends to be slower than volatile memory, non-volatile memory is traditionally accessed via only block-addressable means.
[0006] U.S. Pat. No. 6,850,438 to Lee teaches a combination EEPROM and Flash memory in one chip. Lee's Flash memory is block-erasable and stores data having less frequent update rates while the EEPROM memory is byte-erasable and stores data with a high update frequency rate, allowing data to be written to the EEPROM while the data is read from the Flash memory simultaneously. Lee's chip, however, fails to utilize the rapid speeds of volatile memory, which prevents its chip from being used in ultra-high-speed embodiments. In addition, Lee's system only allows data to be transferred to/from each memory, and does not allow data to be rapidly transmitted from one memory to another directly within Lee's chip itself.
[0007] U.S. Pat. No. 9,208,071 to Talagala teaches a volatile, natively byte-addressable auto-commit memory that writes the contents of the byte-addressable volatile memory media to non-byte-addressable memory media of the auto-commit memory in response to a trigger event. Talagala's system, however, utilizes a traditional system bus to commit data from the volatile memory buffer to the non-volatile backing media, which requires OS drivers to be written and utilized for transmitting data from Talagala's volatile byte-addressable memory to its non-volatile block-addressable memory.
[0008] Thus, there remains a need for a system and method to rapidly utilize both block-addressable and byte-addressable means within a single memory solution.
SUMMARY OF THE INVENTION
[0009] The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0010] The inventive subject matter provides apparatus, systems, and methods in which a hybrid memory system provides rapid, persistent byte-addressable and block-addressable memory access.
[0011] The hybrid memory system preferably interfaces with a host system via a host PMI (Parallel Memory Interface) that directly couples to a host system bus, such as a DIMM slot on a computer motherboard. Since the hybrid memory system provides the dual functionality of a byte-addressable and a block-addressable solution, the hybrid memory system could appear to the host system as a first segment of a volatile byte-addressable memory, such as a standard DRAM, and a non-volatile block-addressable memory, such as an SSD array.
[0012] The host PMI generally receives commands and controls that are forwarded to a traffic controller to handle data traffic with the host PMI. The commands could include, for example, read access and write access commands. The controls preferably identify the memory location that the host logical access refers to. In some embodiments, the controls could be a simple flag that identifies whether the memory is a byte-addressable memory or a block-addressable memory. In other embodiments, the controls could be a pair of flags, a first of which identifies whether the memory is byte-addressable or block-addressable, and a second of which identifies whether the memory is volatile or non-volatile. In still other embodiments, the controls could identify specific memory array locations, and could act as part of a memory address identifier.
[0013] The memory system comprises at least a volatile memory logically divided into a volatile byte-addressable memory and a volatile block-addressable memory, and a non-volatile block addressable memory. In some embodiments, the non-volatile memory could also be logically divided into a non-volatile byte-addressable memory and a non-volatile block-addressable memory. Each memory partition preferably comprises an array of memory devices that are separately addressable via a physical memory address, and preferably forms a single, addressable minimum data width for host read and write operations.
[0014] The traffic controller locally manages both incoming and outgoing host data traffic as a function of a received host address. As used herein, a “locally managed” traffic controller routes traffic between a memory of the hybrid memory system and the host PMI, and/or between the various memories of the hybrid memory system without traveling through the host PMI. The traffic controller responds to incoming commands and controls routed from the host PMI and routes data accordingly. For example, the traffic controller could route data between the volatile byte-addressable memory and the volatile block-addressable memory and route data between the volatile block-addressable memory and the non-volatile block addressable memory. Preferably, the traffic controller persists at least the data saved to the volatile block-addressable memory to the non-volatile block-addressable memory, and in some embodiments also persists data saved to the volatile byte-addressable memory to the non-volatile block-addressable memory (preferably via first saving the data to the volatile block-addressable memory).
[0015] An address translation circuit is also preferably provided that translates a logical host address to a physical address when the host address refers to a block-addressable address. In embodiments where the host address refers to a byte-addressable address, the host address is preferably already a physical address and merely needs to be forwarded to the volatile byte-addressable memory to identify the memory that the command refers to.
[0016] The hybrid memory system preferably also has two local memory controllers: a volatile memory controller that controls data traffic with the volatile block-addressable memory and a non-volatile memory controller that controls data traffic with the non-volatile memory. Since the local memory controller is utilized to control data traffic, data could be simultaneously read from one memory and written to another memory using the traffic controller and the memory controller.
[0017] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
[0018] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
BRIEF DESCRIPTION OF THE DRAWING
[0019] FIG. 1 is a hardware schematic of a contemplated hybrid memory system
[0020] FIGS. 2A-2C show flowcharts of logic for a contemplated hybrid memory system of FIG. 1 .
DETAILED DESCRIPTION
[0021] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0022] As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously. Electronic devices that are “functionally coupled to” one another are coupled to one another in such a manner to allow for electronic data to be transmitted between the electronic devices.
[0023] Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
[0024] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0025] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
[0026] It should be noted that any language directed to a computer system should be read to include any suitable combination of computing devices, including servers, interfaces, systems, databases, agents, peers, engines, controllers, or other types of computing devices operating individually or collectively. One should appreciate the computing devices comprise a processor configured to execute software instructions stored on a tangible, non-transitory computer readable storage medium (e.g., hard drive, solid state drive, RAM, flash, ROM, etc.). The software instructions preferably configure the computing device to provide the roles, responsibilities, or other functionality as discussed below with respect to the disclosed apparatus. In especially preferred embodiments, the various servers, systems, databases, or interfaces exchange data using standardized protocols or algorithms, possibly based on HTTP, HTTPS, AES, public-private key exchanges, web service APIs, known financial transaction protocols, or other electronic information exchanging methods. Data exchanges preferably are conducted over a packet-switched network, the Internet, LAN, WAN, VPN, or other type of packet switched network. Computer software that is “programmed” with instructions is developed, compiled, and saved to a computer-readable non-transitory medium specifically to accomplish the tasks and functions set forth by the disclosure when executed by a computer processor.
[0027] FIG. 1 shows a hybrid memory apparatus 100 with a host parallel memory interface 110 , a CRC (Cyclic Redundancy Check) circuit 112 , a traffic controller 120 , a volatile byte-addressable memory 132 , a volatile block-addressable memory 134 , a volatile memory controller 140 , an address translation circuit 150 , a data processing circuit 162 , a non-volatile memory controller 160 , a non-volatile memory 170 , and an internal processing unit(s) 184 .
[0028] The host computer system (not shown) preferably communicates with Host PMI 110 via a storage device driver installed on the host computer system (e.g. OS driver software). For example, the storage device driver could be programmed to allow hybrid memory apparatus 100 to be seen as both a volatile byte-addressable memory (e.g. DRAM, MRAM) and as a local cache for a non-volatile block-addressable memory (e.g. SSD cache, SSD buffer) (and hence a cache to a non-volatile SCM) to host applications, and controls queuing capabilities, out of order execution capabilities, commands, and responses of the controller to status queries to the host application.
[0029] Internal processing unit(s) 184 comprises any suitable processing unit capable of executing the functionality described herein. In some embodiments, internal processing unit(s) 184 comprises at least one off the shelf CPUs that is/are embedded into hybrid memory apparatus 100 to manage host PMI 110 , volatile memory controller 140 , non-volatile memory controller 160 , and other internal blocks via internal firmware executed by internal processing unit(s) 184 . The executed firmware could also manipulate incoming host data from host PMI 110 and perform in-controller computations on local data within the memories of hybrid memory apparatus 100 . While not shown in the drawing for reasons of complexity, internal processing unit(s) 184 preferably has control lines connected to each block of hybrid memory apparatus 100 , and at least has control lines connected to host PMI 110 , traffic controller 120 , volatile memory controller 140 , data processing circuit 162 , and non-volatile memory controller 160 . Internal processing unit(s) 184 also preferably receives the command and control signals from host PMI 110 .
[0030] Host PMI 110 functionally couples to a host system bus (not shown) to enable data communication between hybrid memory apparatus 100 and a host computer system (not shown). Host PMI preferably directly couples to the host system bus through any suitable electrical coupling, such as a DIMM slot, a SIMM slot, a SDRAM slot, a DRAM slot, a DDR slot, an SCM (Storage Class Memory) slot (e.g. SSD array), an ATI coupling, and a SCSI coupling.
[0031] Host PMI receives host commands, host addresses, and host controls from the host system bus and sometimes transmits host data to/from the host system bus. Contemplated commands include writes to volatile byte-addressable memory 132 , writes to the volatile block-addressable memory 134 , writes to the non-volatile memory 170 , reads from volatile byte-addressable memory 132 , reads from the volatile block-addressable memory 134 , reads from the non-volatile memory 170 , and copies between any of volatile byte-addressable memory 132 , volatile block-addressable memory 134 , and non-volatile memory 170 . Commands to copy data from a byte-addressable memory to a block-addressable memory are typically handled by traffic controller 120 by padding the destination block with empty or null data to fill the block with data. Commands to copy data from a block-addressable memory to a byte-addressable memory are typically handled by traffic controller 120 by ignoring any empty or null data when copying from a source to a destination.
[0032] Host PMI 110 routes the received host address to either traffic controller 120 or to address translation circuit 150 depending upon whether the host address refers to a byte-addressable address or the host address refers to a block-addressable address. A host address comprising a byte-addressable address preferably comprises a physical byte address that can be forwarded directly to traffic controller 120 , which then forwards the physical byte address to volatile byte-addressable memory 132 to identify the volatile byte-addressable memory that is written to or read from. While the host address referring to a byte-addressable memory is preferably a physical address, the host address could be a logical address that is translated by traffic controller 120 or by another address translation circuit (not shown) in some embodiments.
[0033] A host address comprising a block-addressable address comprises a logical address that is forwarded to address translation circuit 150 , which translates the logical address into a physical block address for an address block. This physical block address can then be forwarded either to volatile memory controller 140 to access volatile block-addressable memory 134 or to non-volatile memory controller 160 to access non-volatile memory 170 . While the host address referring to a block-addressable memory is preferably a logical address, the host address could be a physical address that need not be translated by address translation circuit 150 in some embodiments.
[0034] CRC 112 is programmed to add additional information to the incoming host data that is sent to traffic controller 120 and checks the internal data going back from traffic controller 120 to host PMI 110 against previously generated CRC checks for proper data transmission and error checking. In preferred embodiments, the CRC data added to incoming host data is added to the host data before the incoming host data is sent to traffic controller 120 .
[0035] Host PMI 110 could determine whether the received host address refers to a byte-addressable address or to a block-addressable address in any suitable manner, for example by identifying a header of the host address, but preferably makes this determination by analyzing the control signal received from the host system bus. The control signal could comprise any number of bits, for example a first bit with a first setting that identifies the host address as a byte address and a second setting that identifies the host address as a block address, a second bit with a first setting that identifies the memory as a volatile memory and a second setting that identifies the memory as a non-volatile memory, and so on and so forth. The control lines could also identify to the system which set of volatile memories an incoming command should be applied to. Preferably, the control signal will separately turn on or off a rank of a memory array to properly identify the memory array that needs to be accessed by the incoming command.
[0036] Host PMI 110 could have a set of command lines that dictate the operation being requested (e.g. write, read) by the host computer system. These command lines are forwarded to traffic controller 120 , which handles all data traffic in hybrid memory apparatus 100 , and forwards command signals and control signals accordingly. In some embodiments, traffic controller 120 merely forwards the command signals and control signals, while in other embodiments traffic controller 120 translates the command signals and control signals before forwarding. Traffic controller 120 preferably allows data traffic to flow through it in multiple directions simultaneously, for example by allowing a read from block-addressable memory 134 through traffic controller 120 to non-volatile memory 170 simultaneously as a write from host PMI 110 to volatile byte-addressable memory 132 . Such simultaneous data transfers can optimize use of data lines within hybrid memory apparatus 100 and drastically speed up operations.
[0037] Volatile byte-addressable memory could be any suitable volatile byte-addressable storage media, but is preferably a volatile byte-addressable storage array that is selectable via control lines from traffic controller 120 . Volatile block-addressable memory could be any suitable volatile block-addressable storage media, but is preferably a volatile block-addressable storage array that is selectable via control lines from traffic controller 120 (via volatile memory controller 140 ). Non-volatile memory 170 could be any suitable non-volatile memory of any kind (or kinds), but is preferably a non-volatile block-addressable memory array that is selectable via control lines from traffic controller 120 (via non-volatile memory controller 160 ).
[0038] Volatile memory controller 140 is programmed to control traffic to/from volatile block-addressable memory 134 while non-volatile memory controller 160 is programmed to control traffic to/from non-volatile memory 170 . Having memory controllers local to hybrid storage apparatus 100 that are not located on the host computer system allows data to be rapidly copied, moved, or otherwise transferred between the various memories of hybrid memory apparatus 100 without needing to offload the data to the host system bus via host PMI 110 .
[0039] Data processing circuit 162 performs standard data processing tasks necessary for persisting data onto non-volatile memory 170 , such as applying a security algorithm to the data, applying block compression and decompression algorithm to the data, applying an error correction algorithm to the data, or applying a data scrambling algorithm to the data.
[0040] Preferably, traffic controller 120 is programmed to only allow the host PMI to directly access volatile byte-addressable memory 132 or volatile block-addressable memory 134 , and does not allow the host PMI to directly access data from non-volatile memory 170 . When host PMI requests data that is located in non-volatile memory 170 , and is not located in either volatile byte-addressable memory 132 or in volatile block-addressable memory 134 , traffic controller 120 preferably copies data from non-volatile memory 170 to the appropriate volatile memory location for access by host PMI 110 . Such an infrastructure allows hybrid memory apparatus 100 to appear to be a persistent, non-volatile byte-addressable and block-addressable memory to host PMI 110 , while providing the rapid memory access abilities of volatile memory. Traffic controller 120 could be implemented using any suitable multiplexer, demultiplexer, digital logic, cross-bar, synchronous state machine, asynchronous state machine, microprocessor, or microcontroller with specific firmware to perform the aforementioned operations.
[0041] FIG. 2A shows an exemplary flowchart for a hybrid memory system to follow when it receives a write command from a host. FIG. 2B shows an exemplary flowchart for a hybrid memory system to follow when it receives a read command from a host. FIG. 2C shows an exemplary flowchart for a hybrid memory system to follow when it receives a copy command from a host.
[0042] As used herein, addresses that are forwarded to “corresponding” devices will be determined by which address is the host address and which address is the destination address. For example, a command to copy data from a volatile byte-addressable memory to a volatile block-addressable memory will necessitate the host source address to be forwarded to the traffic controller and the host destination address to be forwarded to the address translation circuit. On the other hand, a command to copy data from a volatile block-addressable memory to a volatile byte-addressable memory will necessitate the host source address to be forwarded to the address translation circuit and the host destination address to be forwarded to the traffic controller. Likewise, a command to copy data from a volatile block-addressable memory to a non-volatile block-addressable memory will necessitate the translated source address to be forwarded to the volatile memory controller and the translated destination address to be forwarded to the non-volatile memory controller. On the other hand, a command to copy data from a non-volatile block-addressable memory to a volatile block-addressable memory will necessitate the translated source address to be forwarded to the non-volatile memory controller and the translated destination address to be forwarded to the volatile memory controller.
[0043] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
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A hybrid memory system provides rapid, persistent byte-addressable and block-addressable memory access to a host computer system by providing direct access to a both a volatile byte-addressable memory and a volatile block-addressable memory via the same parallel memory interface. The hybrid memory system also has at least a non-volatile block-addressable memory that allows the system to persist data even through a power-loss state. The hybrid memory system can copy and move data between any of the memories using local memory controllers to free up host system resources for other tasks.
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FIELD OF THE INVENTION
[0001] The present invention relates to a flat-bed scanner in combination with a sheet feeder. The sheet feeder is placed on the flat-bed scanner so as to automatically feed the sheets and the scanner scan the sheets. The feeder has an optical module set which has a function of scanning so as to cooperate with the flat-bed scanner to scan the double sides of the documents.
BACKGROUND OF THE INVENTION
[0002] [0002]FIG. 1 discloses a feeder 10 being placed on a scanner 20 and the feeder 10 includes an upper guide plate 12 and two low guide plates 14 , 16 located therein so as to define a passage 18 for feeding the sheets. When the feeder 10 is installed on the scanner 20 , the low guide plates 14 , 16 contact the glass window 22 of the scanner 20 . When a document 24 is fed and pass the passage 18 , the document is scanned by a scanning module set 23 .
[0003] Because the low guide plate 16 has a certain thickness so that an end 17 of the low plate 16 protrudes from the glass window 22 and the document is blocked by the end 17 when it is fed.
[0004] The low guide plate 14 is located close to a surface of the glass window 22 and an end 15 of the low guide plate 14 protrudes from the glass window 22 . However, the height difference between the end 15 and the glass window 22 is helpful for the feed of the document 24 .
[0005] In order to resolve the problem of the jamming of the document 24 , arranging the end 17 of the low guide plate 16 to be lower than the glass window 22 is a reasonable way.
[0006] [0006]FIG. 2 discloses that a first glass window 26 and a second glass window 28 are installed on the scanner 20 . The first glass window 26 and the second glass window 28 are located in separate and a gap 25 is defined between the first glass window 26 and the second glass window 28 . By this arrangement, the end 17 of the low guide plate 16 can be extended into the gap 25 and is located below the surface of the first glass window 26 .
[0007] The two separate first glass window 26 and second glass window 28 make the volume of the scanner to be bulky and require two times of assembly for the assemblers.
[0008] [0008]FIG. 3 discloses a recess 27 is defined in the glass window 22 and a block 29 is engaged with the recess 27 . The end 17 of the low guide plate 16 contacts the block 29 . When the document 24 is fed, the block 29 guides the document 24 to move toward the low guide plate 16 smoothly.
[0009] The recess 27 requires two times of machining on the surface of the glass window 22 and this increases the manufacturing cost of the glass window 22 . The block 29 protrudes from the glass window 22 and jams the feeding of the document 24 .
[0010] Furthermore, U.S. Pat. No. 5,379,095 discloses a small piece of glass window is adhered on a large glass window so as to form a height difference in FIG. 8. The thickness of the small glass window is required to be thin so as to keep the scope of the area to be scanned in the effective focal depth, thereby causing breakage during adhering. Alternatively, the area where the small glass window is to be adhered has to be maintained in a high standard of cleanness, or the dust located between the two glass windows affects the quality of scanning.
SUMMARY OF THE INVENTION
[0011] The first object of the present invention is to provide a flat-bed scanner in combination with a sheet feeder, and which makes the documents to be fed smoothly.
[0012] The second object of the present invention is to provide a flat-bed scanner in combination with a sheet feeder, and the assembly processes are simplified.
[0013] The third object of the present invention is to provide a flat-bed scanner in combination with a sheet feeder, and a good quality of scanning is obtained.
[0014] The fourth object of the present invention is to provide a flat-bed scanner in combination with a sheet feeder, wherein the volume of the scanner is reduced.
[0015] The fifth object of the present invention is to provide a flat-bed scanner in combination with a sheet feeder, wherein the manufacturing cost is reduced.
[0016] According to the objects and features, the present invention uses the height difference to move the documents from the first glass window to the low guide plate and thereby getting rid of the jamming during feeding of the document.
[0017] The present invention provides a flat-bed scanner which is used with a sheet feeder which feeds sheets of documents to be scanned. The flat-bed scanner includes a first glass window and a second glass window. The first glass window is installed on the flat-bed scanner so as to support the sheets of documents and has a top surface and a bottom surface. The top surface faces the sheet feeder and the bottom surface faces the interior of the scanner. The second glass window is located adjacent the first glass window, and includes a top surface and a bottom surface. The top surface faces the sheet feeder and the bottom surface faces the interior of the scanner. A height difference is formed between the two respective top surfaces of the two glass windows.
[0018] The present invention will become more obvious from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, preferred embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 shows a conventional feeder and scanner.
[0020] [0020]FIG. 2 shows another conventional feeder and scanner.
[0021] [0021]FIG. 3 shows yet another conventional feeder and scanner.
[0022] [0022]FIG. 4 shows the combination of the flat-bed scanner and a sheet feeder of the present invention.
[0023] [0023]FIG. 5 is a top view to show the scanner of the present invention.
[0024] [0024]FIG. 6 shows another arrangement of the combination of the flat-bed scanner and a sheet feeder of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to FIG. 4 discloses a sheet feeder 30 which is installed above a scanner 40 and the sheet feeder 30 includes a top guide plate 32 and two low guide plates 34 , 36 . The top guide plate 32 faces the two low guide plates 34 , 36 so as to form a passage 38 therebetween. It is to be noted that the two low guide plates 34 , 36 are separated from each other and a scanning gap 35 is defined between the two low guide plates 34 , 36 .
[0026] Besides, a plurality of adjacent rollers 37 are located in the inside of the feeder 30 so as to transport the sheets 50 in the feeder 30 .
[0027] The scanner 40 is a flat-bed scanner and has a movable scanning module set 42 in the inside of the scanner 40 . The scanning module set 42 includes optical parts such as a light source, reflection mirror set and image sensor which can also be a contact-image-sensor (CIS) module set.
[0028] The scanner 40 has a first glass window 43 and a second glass window 46 which is adhered to the first glass window 43 . The adhering process can be done during the manufacturing of the glasses.
[0029] The surface of the first glass window 43 that faces the feeder 30 is defined as the top surface 44 , and the surface of the first glass window 43 that faces the interior of the scanner 40 is defined as the bottom surface 45 . Similarly, the surface of the second glass window 46 that faces the feeder 30 is defined as the top surface 47 , and the surface of the second glass window 46 that faces the interior of the scanner 40 is defined as the bottom surface 48 .
[0030] It is to be noted that the first glass window 43 is thicker than the second glass window 46 , and when the two glass windows 43 , 46 are adhered with each other, the two respective bottom surfaces 45 , 48 are located at the same horizontal plane. By this arrangement, the top surface 44 is higher than the top surface 47 . The height difference D is defined as the height difference 49 .
[0031] The feeder 30 is located above the scanner 40 and the scanning gap 35 faces the first glass window 43 . The end 39 of the bottom plate 36 is located in the height difference 49 such that the end 39 is located below the top surface 44 of the glass window 43 .
[0032] When proceeding scanning, the document 50 moves in the passage 38 and the scanning module set 42 is located below the first glass window 43 . When the document 50 moves over the scanning gap 35 , the scanning module set 42 scans the document 50 .
[0033] When the document 50 moves to the low guide plate 36 , because the end 39 of the low guide plate 36 is lower than the top surface 44 of the first glass window 43 , the document 50 can be smoothly moved to the surface of the low guide plate 36 by the height difference 49 . The document 50 is then moved out from the passage 38 by the rollers 37 .
[0034] The height difference 49 between the top surface 44 of the first glass window 43 and the top surface 47 of the second glass window 46 is described by the embodiment hereinabove makes the installation of the low guide plate 36 to be easy. The height difference 49 makes the end 39 of the low guide plate 36 to be below the top surface 44 such that the document 50 can be moved smoothly.
[0035] Furthermore, because the first glass window 43 and the second glass window 46 are adhered with each other when assembling the scanner 40 , so that the two glass windows 43 , 36 can be installed to the scanner 40 in one assembling action.
[0036] The first glass window 43 and the second glass window 46 are two individual parts so that there needs no second time machining and can be made conveniently. For the cost of the raw material of a scanner 40 , no extra cost is suffered.
[0037] Because the first glass window 43 has even physical characteristics and the document 50 can be move smoothly so that the scanning module set 42 can have a good quality of scanning images.
[0038] [0038]FIG. 5 shows a top view of the scanner 40 , a small adhering width 52 is existed between the first glass window 43 and the second glass window 46 . The adhering width 52 can be reduced to minimum under the precise adhering process, such that the whole volume of the scanner 40 is not increased too much. In other words, by adhering the first glass window 43 and the second glass window 46 , the scanner can be made smaller. Alternatively, the combination of the two glass windows can be made by using the casing of the scanner or any way that is alike the previous way. Whether or not the two glass windows are to be adhered depends on the need of design.
[0039] [0039]FIG. 6 discloses another structure that includes the height difference 49 . The first glass window 62 and the second glass window 64 have the same thickness so that when the two glass windows are adhered with each other, the first glass window 62 is arranged to be higher than the second glass window 64 . The top surface 66 of the first glass window 62 is higher than the top surface 68 of the second glass window 64 . The difference D of the two top surfaces 66 , 68 is defined as a height difference 49 which is helpful for assembling the low guide plate 36 and the movement of the document 50 .
[0040] In the embodiment above, the feeder 30 may have another scanning module set 42 which works in cooperation with the scanning module set 42 in the scanner 40 to proceed double-sided scanning.
[0041] While we have shown and described the embodiments in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention.
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A flat-bed scanner in combination with a sheet feeder. The flat-bed scanner includes a first glass window having a top surface and a second glass window having a top surface. A height step is formed without increasing the difficult between the top surfaces of the first and second glass windows. When the sheet feeder is placed on the flat-bed scanner, the scanned documents may pass the first glass window smoothly, consequently, good scanning quality may be obtained.
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DESCRIPTION
The invention relates to a process for packaging articles, particularly cigarettes, by combining them into groups (cigarette groups) and wrapping them in at least one blank of packaging material (tin-foil sheet, paper or the like), and in this process the group, taking with it the blank provided in a plane transverse relative to the conveying direction of the group, is introduced into a pack receptacle (pocket) of a (first) folding conveyor (folding turret) and, when conveyed further, is folded. The invention also relates to an apparatus for carrying out the process.
The subject of the invention is a packaging machine, particularly for cigarettes, to produce so-called soft-cup packs, with an inner blank consisting of tin-foil, which completely surrounds the cigarette group to form a tin-foil block, and with a cup-shaped outer wrapper consisting of a paper blank. This is open at the top, so that the tin-foil block projects slightly from the softcup pack.
Packs of this type are produced on high-performance packaging machines. Most of these contain rotating folding turrets for the successive folding of the blanks. Because the folding turrets are driven intermittently (i.e. indexed), the productive capacity of the packaging machine is limited.
The object on which the invention is based is to provide a packaging machine with intermittently driven (i.e. indexed) folding conveyors (folding turrets), in which the output is nevertheless increased considerably, without this requiring undesirably high indexing speeds for the individual folding conveyors.
To achieve this object, in the process according to the invention, to be used on packaging machines, the folding conveyor (folding turret) is preceded by a group conveyor (group turret) which conveys the articles (cigarette groups) into group receptacles (pockets), the articles being pushed into the pockets in the axial direction and pushed out of these in the axially transverse direction.
When the cigarette groups are pushed out of the group turret, thereby taking up the provided blank in the form of a U, the sensitive end faces of the cigarettes are not subjected to any load. On the contrary, because the cigarette groups are conveyed by being pushed out axially transversely, the blank can wrap itself round the less sensitive longitudinal side of the cigarette group. To make it possible to push in the cigarettes in the axial direction and push them out axially transversely, the pockets of the group turret are open at least on an axially directed side and on the side located on the outside in the axially transverse direction. During filling and during subsequent transport, the cigarettes are limited, guided or retained here.
In the region of an ejection station, the formed cigarette groups are ejected from the group turret in a horizontal plane at a distance below the horizontal midplane of the latter and, at the same time taking up a transversely directed blank, are pushed into the pocket of a first folding turret. In the region of the latter, parts of the blank are folded; during ejection or in the region of an adjoining folding track, further parts of the blank are folded.
According to an alternative embodiment of the apparatus and of the process, tin-foil blocks prefabricated at another time are supplied along two tracks to a block turret which is comparable in terms of design and function to the group turret and which each time receives two tin-foil blocks in the axial direction, next to one another. The tin-foil blocks are delivered to the pockets of this block turret by special transfer turrets of differing size, which are arranged in such a way that, each time, two tin-foil blocks are introduced into a pocket in succession.
Further features of the invention are contained in the sub-claims. Exemplary embodiments of the apparatus according to the invention are explained in detail with reference to the drawings. In the drawings:
FIG. 1 shows a diagrammatic side view of the apparatus as a whole,
FIG. 2 shows a detail, in particular a group turret, in a side view, on an enlarged scale,
FIG. 3 shows a detail of the group turret with a cigarette magazine, on a further-enlarged scale,
FIG. 4 shows the group turret with the cigarette magazine in a front view and in an end view,
FIG. 5 shows a plan view and horizontal section of the group turret,
FIG. 6 shows a cut-out of a group turret in a modified embodiment, partially in section,
FIG. 7 shows a horizontal section through a detail of the group turret according to FIG. 6 in the region of a pushing-out station,
FIG. 8 shows a side view of a cut-out of the apparatus with part of the first folding turret and with a second folding turret,
FIG. 9 shows a plan view and horizontal section of the detail of FIG. 8,
FIG. 10 shows a side view of a detail of the apparatus, in particular in the region of a pack tower following the second folding turret,
FIG. 11 shows a plan view and horizontal section of the detail according to FIG. 10,
FIG. 12 shows a representation corresponding to that of FIG. 11, with parts of the apparatus in a changed relative position,
FIG. 13 shows the detail according to FIGS. 10 to 12 in an end view and in a front view, partially in section,
FIG. 14 shows a diagrammatic side view of a detail of an apparatus according to a second exemplary embodiment with a block turret,
FIG. 15 shows an end view of the block turret according to FIG. 14,
FIG. 16 shows a representation of FIGS. 14 and 15 in the form of a plan view.
The exemplary embodiments and details illustrated in the drawings are devoted to the production of cigarette packs 20, specifically in the soft-pack design. In this pack construction, a cigarette group 21, which in the present case consists of three layers, is first wrapped in an inner blank, in particular in a tin-foil blank 22. This surrounds the cigarette group 21 completely, that is to say by means of end and bottom tabs. An outer blank, in particular a paper blank 23, is made cup-shaped, that is to say only with bottom tabs. The upper region is open, so that a part region of the cigarette group 21 wrapped in the tin-foil blank 22, in particular a tin-foil block 24, projects from the cup-shaped paper blank 23.
According to the exemplary embodiment shown in FIG. 1 ff., the apparatus or packaging machine for producing (cigarette) packs 20 of this type consists of several units.
Individual cigarettes 25 are extracted from a cigarette magazine 26, with cigarette groups 21 being formed. In the region of a pushing-in station 27, the cigarette groups 21 enter a group turret 28 rotating intermittently. The cigarette groups 21 are pushed out of this in the region of a pushing-out station 29 and, via a pushing-in station 30, are pushed into a first folding turret 31 together with a tin-foil blank 22.
In an opposite pushing-out station 32, the partly finished tin-foil blocks 24 enter a linear folding track 33 and, in the region of a further pushing-in station 34, pass from this into a second folding turret 35 with a paper blank 23 provided. The packs 20 leaving the folding turret 35 are ready-folded, in particular with regard to bottom tabs, in the region of a further folding track 36.
A collecting station 37 for the packs, with pack towers 38 and 39 directed upwards, then follows. In the region of these, special banding devices 40,41, which attach (revenue) bands 42 to the end faces of the packs, are used.
The cigarette magazine 26 and the group turret 28 are designed and coordinated with one another in a special way.
The cigarette magazine 26 consists, in a way which is conventional per se, of several cigarette shafts 43 which are intended and designed to receive the cigarettes in close-packed rows 44 resting on top of one another. In these cigarette shafts 43, the cigarettes 25 slide down under their own weight into the region of the pushing-out station. The cigarette shafts 43 are separated from one another by thin shaft walls 45.
Several cigarette shafts 43 are combined to form a particular shaft group 46,47,48,49. The number of cigarette shafts 43 per shaft group 46 to 49 corresponds to the number of cigarettes 25 per cigarette group 21 or the number of cigarettes per layer. In the present exemplary embodiment, the cigarette groups 21 each consist of three layers, the middle layer being offset relative to the outer layers (saddle arrangement).
The individual shaft groups 46 to 49 are divided off from one another by partition walls 50,51,52 (FIGS. 2 and 3). The shaft walls 45 tapering off very thinly are anchored in a lower bottom wall 53 of the shaft group 46 to 49. The particular cigarettes at the bottom or the lower layer of these rest on this bottom wall 53. The shaft groups 46 to 49 are limited laterally and on the end faces by side walls 54 and 55. These are provided in the lower region with orifices, through which rams or ram groups 56,57,58 and 59 (FIGS. 4 and 5) can pass to push out a cigarette group. Each ram group 56 to 59 consists of individual vertical rams, the height of which is such that, in the present case, three cigarettes resting on top of one another are ejected. The individual rams penetrate into the region between the shaft walls 45.
The finger-like projecting rams of the ram groups 56 to 59 are attached to common ram carriers 60 and 61 so as to project on one side. The upper ram groups 56,57 are attached to the upper ram carrier 60 and the lower ram groups 58 and 59 are attached to the lower ram carrier 61. These are moved to and fro simultaneously in the way also described.
By means of the ram groups 56 to 59 which can be moved to and fro, during each joint pushing-in stroke (directional arrows 62,63) a cigarette group 21 is pushed out of the associated shaft group 46 to 49 and pushed into a pocket 64 of the group turret 28. As can be seen, in this way at the same time, in particular by means of one stroke, four pockets 64 succeeding one another in the peripheral direction of the group turret 28 are supplied simultaneously with a cigarette group 21 in the region of the pushing-in station 27.
For this purpose, the group turret 28 is arranged laterally and offset downwards in relation to the cigarette magazine 26. The four particular pockets 64 located in the pushing-in station 27 are in the upper region of the group turret 28, specifically in a position in which they already participate in the downward movement. The upper pocket 64 assigned to the shaft group 46 is in a position following the highest position, whilst the lower pocket 64 assigned to the shaft group 49 has almost reached the horizontal mid-plane of the group turrets 28.
The pockets 64 of rectangular cross-section corresponding to the cross-section of the cigarette group 21 are aligned with their longitudinal extension (the longitudinal direction of the cigarettes 25) parallel to the axis. With their rectangular cross-section, they are arranged in a particular relative position, in such a way that each pocket 64 is directed exactly transversely relative to the lower region of the associated shaft group 46 to 49. In the pushing-out region of the cigarettes 25, the partially arcuate shaft walls 45 are directed perpendicularly relative to the bottom wall 53 and perpendicularly relative to the pocket 64 or its side walls 65 and 66.
For this purpose, the pockets 64 are directed with their longitudinal mid-plane (parallel to the side walls 65,66) at an angle both to the radial plane and to the tangential plane of the group turret 28, in particular in an oblique position. Their shape arises as a result of this relative position, on the one hand, and as a result of the alignment of the shaft groups 46 to 49 relative to the vertical. As is evident, the shaft groups 46 to 49 are arranged in a fan formation with slight angular deviations from the vertical, so that the downward movement of the cigarettes 25 in the cigarette shafts 43 is not disturbed. Only as a result of this special design of the shaft groups 46 to 49, on the one hand, and the relative position of the pockets 64, on the other hand, is it possible to supply four pockets 64 simultaneously from associated shaft groups 46 to 49 of a common cigarette magazine 46 without an intermediate conveyor member.
The cigarettes 25 are pushed into the pockets 64 in their longitudinal direction, specifically with filters 67 possibly present facing the ram groups 56 to 59. In the region of the pushing-out station 29, the cigarettes 25 or cigarette groups 21 are conveyed axially transversely out of the pockets 64 of the group turret 28. For this purpose, it is necessary for the pockets 64 to have a special design. In particular, these are open not only on one axial side (the pushing-in orifice 68), but also on the side located on the outside in the radial direction (the pushing-out orifice 69). The pushing-in orifice 68 and the pushing-out orifice 69 correspond to the full cross-section of the pocket 64.
The pockets 64 are arranged in a turret ring 70 of the group turret 28 in the angular position described. On the side located opposite the pushing-out orifice 69, a smaller (narrower) passage orifice 71 is formed opposite the cross-section of the pocket 64. This is intended for the entry or passage of an ejector slide 72 in the region of the pushing-out station 29. By means of this ejector slide 72 movable to and fro in the horizontal plane, the complete cigarette group 21 is conveyed out of the pocket 64 axially transversely via the pushing-out orifice 69 and, when this movement is continued, pushed into a pocket 73 of the first folding turret 31.
At the same time, the pushing-out station 29 is offset downwards in terms of height relative to the horizontal longitudinal mid-plane of the group turret 28 (drive shaft 74), in such a way that the particular pocket 64 located in the pushing-out station 29 is directed horizontally. As a result, the folding turret 31 is also mounted offset downwards relative to the group turret 28. The ejector slide 72 is provided with a slide head 75, the contour of which corresponds to the contour of the longitudinal side of the cigarette group 21 facing it, so that the three cigarettes located at the edge are grasped jointly by the ejector slide 72 or the slide head 75.
The cigarettes 25 of the cigarette groups 21 are prevented from shifting relative to one another in the pockets 64 and from falling out via the pushing-out orifice 69. In the exemplary embodiment according to FIG. 1 ff., each pocket 64 has assigned to it retaining members attached to the turret ring 70, in particular pivotable retaining fingers 76 and 77. These are respectively mounted above and below and next to the pockets 64. In the swung-back position (in the region of the pushing-in station 27), the retaining fingers 76,77 are located outside the region of the pushing-out orifice 69, as they are also in the region of the pushing-out station 29. In the retaining position, the particular outer cigarettes 25 located at the edge of the cigarette group 21 (the outer layers) are grasped by a retaining finger 76,77. Their ends match the contour of the cigarettes 25.
In the region of the pushing-in station 27, the open side of the pockets 64 is limited by fixed wall rams 78 movable to and fro. These plate-shaped members penetrate in an exact relative position into the pushing-out orifice 69 of the four pockets 64 located in the pushing-in station 27, in such a way that these are limited exactly to the dimensions of the cigarette group 21. Consequently, in this region, the pockets 64 have a continuously closed cross-section. When the group turret 28 is transported further the amount of one indexing stroke, the wall rams 78 are retracted. The co-rotating retaining fingers 76,77 take effect only outside the pushing-in station 27.
The units of the present packaging machine are designed for two-track operation to increase the output. This means that two packs lying next to one another are produced at the same time.
The group turret 28 is also organised for twotrack operation in terms of its design and function. This means, in the first place, that the dimensions of the pockets 64 in the axial direction are such that two cigarette groups 21 are accommodated next to one another in each pocket. As illustrated, the pockets have a design resembling that of a blind hole, with a pushing-in orifice 68 on one side. A cigarette group 21a pushed first into the pocket 64 is conveyed up to the end of pocket 64. The second cigarette group 21b remains in a position adjacent to the pushing-in orifice 68. In the present exemplary embodiment, the ends of the cigarettes 25 terminate flush with the side face of the group turret 28. Where filter cigarettes are concerned, the cigarette groups 21 are pushed into the pocket 64 with the filter 67 pointing to the rear.
The feeding of the group turret 28 with cigarette groups 21 is coordinated with the operating cycle in a special way. Each time, the group turret 28 moves the amount of a stroke corresponding to the distances between the pockets 64. The number of indexing strokes is, for example, 600 per minute. During a stop, the same number of cigarette groups 21 is pushed into the four pockets 64 in the region of the pushing-in station 27. Cigarette groups 21a are pushed into the two pockets 64a and 64b located at the top or at the rear in the direction of rotation of the group turret 28, up to the end of the pockets 64a and 64b. The associated rams or ram groups 56 and 57 are of appropriate dimensions and cover a conveying distance up to the above-mentioned end position of the cigarette groups 21a.
The pockets 64c and 64d are filled with cigarette groups 21b which are deposited in the entry region of the pockets 64c,64d, so that the last-mentioned pockets are each filled with two cigarette groups 21a, 21b as a result of this pushing-in operation.
After the ram groups 56 to 59 have been retracted, the group turret 28 moves further the amount of one stroke. In the next position, no cigarette groups 21 are pushed into the (four) pockets 64 which are in the pushing-in station 27. On the contrary, after the complete retraction of the ram groups, the cigarettes 25 in the cigarette shafts 43 of the shaft groups 46 to 49 have time to fall down into the lower position. Only after the group turret 28 has moved further again are two empty pockets 64a to 64d and two pockets already each provided with a cigarette group 21a positioned ready to receive in the region of the pushing-in station 27. The pushing-in operation for all (four) pockets 64 can now be repeated.
The cigarette groups 21a, 21b assume, in the pockets 64, a distance from one another which is coordinated with the further packaging process. In particular, in the region between the group turret 28 and the (first) folding turret 31, a double-width tin-foil blank is supplied transversely relative to the horizontal conveying direction, in the region of a pack track 80 (FIGS. 1, 2, 5 and 6). The blank 22 is severed from a continuous sheet of material 81 by severing knives 82. Here, the pack track 80 acts like a folding mouthpiece because of its limiting walls. As a result of the relative movement of the cigarette group 21 through the pack track 80 into an adjacent pocket 73 of the folding turret 31, the blank 22 is taken up with it, the front region of the cigarette group 21 thereby being wrapped in the form of a U.
The tin-foil blank 22 is provided with laterally projecting folding tabs, in particular upper and lower longitudinal tabs 83,84 and corner tabs 85,86. The longitudinal tabs 84 and corner tabs 86 in the region between the adjacent cigarette groups 21 are first connected to one another, so as to form a blank which is continuous in the transverse direction. Consequently, the distance between the cigarette groups 21a, 21b in a pocket 64 corresponds to double the width of the longitudinal tabs 84 and corner tabs 86 of the blank. During the further packaging process, the double blank 23 is divided into two single blanks along a longitudinal separating line 87.
The retaining members for the cigarette groups 21 in the pockets 64 are designed for two-track operation. On each of the two sides of a pocket 64, two pairs of retaining fingers 76,77 (FIGS. 2-5) are arranged on a rotary shaft 88. To-and-fro rotary movements of the latter are controlled by a fixed cam disc 89, in the control groove 90 of which runs a tracer wheel 92 connected to a crank arm 91. As a result of the shape of the control groove 90, the movements of the retaining fingers 76,77 are executed in the way described.
The turret ring 70 gives the group turret 28 open on one side a pot-like shape. Inside this hollow body, two ejector slides 72 located next to one another and movable simultaneously are arranged in the region of the pushing-out station 29. Matching these, each pocket 64 is provided with two slot-like passage orifices 71 located next to one another for the ejector slides 72 in the region of the cigarette groups 21a,21b. These passage orifices 21 of closed cross-section have a slightly smaller height than the corresponding dimension of the pocket 64.
An embodiment of the group turret 28 which is modified where the design of the pockets is concerned is shown in FIGS. 6 and 7. The pockets 64, in terms of the orientation of their longitudinal mid-plane, have the same relative position within the group turret 28 as in the exemplary embodiment described previously. The difference is that the cigarette groups 21 in the pockets 64 are exposed to a lateral pressure to give the cigarette group its proper shape and size.
For this purpose, one of the side walls of the pocket 64 is made movable in order to narrow or widen the pocket 64. In the actual exemplary embodiment, the side wall is part of a pressure lever 93 which is mounted pivotably as a one-armed lever on a pivot bearing 94 within the group turret 28. A radially outer wedge piece 95 forms that side wall of the pocket 64 which is at the front in the direction of rotation.
The pivotable pressure lever 93 and consequently the wedge piece 95 are under elastic pressure acting to reduce the width of the pocket 64. In the present case, a compression spring 96 is assigned to the pressure lever 93 in the region of the wedge piece 95. This compression spring 96 is supported on a likewise movable controllable actuating member, in particular on an actuating lever 105 which is likewise one-armed here. This is likewise mounted pivotably in the region of the pivot bearing 94 and is controlled via a tracer roller 106 by a curved track 107 extending within the group turret 28.
As a result of an appropriate design of the curved track 107, the actuating lever 105 is moved so that the cigarette groups 21 are subjected to pressure by the wedge piece 95 during their transport from the pushing-in station 27 to the pushing-out station 29. The actuating lever 105 is thereby laid against the pressure lever 93, at the same time compressing the compression spring 96.
The actuating lever 105 designed with an appropriate length has a further function, in particular that of retaining the cigarettes or a cigarette located at the corner of the cigarette group 21 facing it, instead of the retaining finger 77 which, in this exemplary embodiment, is lacking on the side of the pressure lever 93. For this purpose, the free end of the actuating lever 105, is provided with a laterally directed nose 108 engaging round the cigarette located at the corner.
In the region of the pushing-out station 29, the actuating lever 105 is swung back into an initial position, thereby relieving the compression spring 96. As a result, the pressure lever 93 with the wedge piece 95 is also lifted off from the cigarette group 21, thereby enlarging the pocket 64 correspondingly. The cigarette group can now be pushed out in the way described.
As is evident from FIG. 7, the pressure lever 93 and the actuating lever 105 extend over the entire length of the pockets 64 designed to receive two cigarette groups 21. At the same time, the pivot bearing 94, like the curved track 107, is located outside the region of the turret ring 70.
When the retaining fingers 76,77 or the actuating lever 105 and the pressure lever 93 are moved into the retracted initial position in the region of the pushing-out station 29, cigarette-holders 97,98 come into operation. These are elongate bar-shaped retaining members which, assigned to each cigarette group 21a, 21b in a pocket 64, enter the pushing-out orifice 69 of the pocket 64 from the sides. For this purpose, the cigarette-holders 97,98 are brought into their position from a lateral position (indicated by dot-and-dash lines in FIG. 5) by being moved transversely and then brought up to the group turret 28 along an arc. A part region of each cigarette-holder 97,98 then rests against the outer face of a cigarette group 21a,21b. The surface turned towards the cigarettes has a profile corresponding to the lateral contour of the cigarette group, so that the latter is supported positively. When the cigarette groups 21a,21b are ejected, the cigarette-holders 98 are moved in the opposite direction and accordingly travel together with the cigarette groups 21a,21b along a particular path of the latter, before they are drawn off laterally. The supporting function of the cigarette-holders 97,98 is thereby maintained beyond the transverse plane predetermined by the blank 22 provided, so that the take-up of the blank 22 by the cigarette group is carried out, during the initial phase, by the cigarette-holders 97,98 which thus protect the cigarettes from being subjected to excessive stress by the blank 22 pulled along with them.
The blank 22 is provided in such a relative position in relation to the pack track 80 that an asymmetric position relative to the cigarette group in the pocket 73 of the turret 31 is obtained. A blank leg 99 of the blank 22 projects from the pocket 73 in the radial direction. During the further movement of the folding turret 31 in the direction of rotation shown, this blank leg 99 is folded round by a fixed outer arcuate guide wall 100 and is placed in a position directed to the rear. When the cigarette group is pushed out of the pocket 73 in the region of the pushing-out station 32, part of the blank leg 99 is folded round into the radially directed plane, in particular to form part of the front or rear side of the inner wrapper.
The pack track 80 and, correspondingly, the pockets 73 of the first folding turret 31 are subdivided in the middle region by a partition wall 101 and by a folding web 102 respectively. As a result, on the one hand exact paths of movement for the cigarette groups are obtained, tilting being avoided. On the other hand, by means of the end faces of the folding web 102, the middle folding tabs, that is to say those located between the cigarette groups 21a,21b, are partially folded, in particular the corner tabs 86. On the outsides, the pocket 73 is provided with corresponding folding webs 103 which fold the outer corner tabs 85 into their position during the time when the cigarette groups 21 together with the blank 22 are pushed into the pocket 73, and which fix them laterally.
After the ejector slide 72 has been retracted into the initial position, the cigarettes in the pocket 73 are held in position on the radially outer side by a further retaining member. This is a supporting plate 104 in the form of a circular arc, which is movable to and fro concentrically relative to the folding turret 31 along the periphery of the latter. FIG. 2 shows the supporting position. When the turret 31 is moved further, the supporting plate 104 is taken with it during a part movement, before it returns to a lower initial position as a result of a concentric rotary movement. This ensures that the still not yet wrapped cigarettes are supported in the pockets 73 over the entire peripheral region of the cigarette group 21.
The cigarette groups 21 partially wrapped in the tin-foil blank 22 are transported by the folding turret 31 up to a pushing-out station 32 located opposite the pushing-in station 30. Here, the two cigarette groups 21a,21b located next to one another in a pocket 73 are jointly ejected from this, specifically by two interconnected and jointly movable rams 109,110. The cigarette groups, each with an associated (part) blank 22, now enter the folding track 33, where the longitudinal tabs 83 and 84 projecting in the middle region and laterally are folded round into the plane of the end faces by lateral folding members, in particular folding switches 111. As shown in FIG. 8, the lower longitudinal tabs 83, 84 are folded by the folding switches 111. Upper longitudinal tabs are likewise folded into the end face as a result of a subsequent upward movement of the cigarette groups, together with the blank, by means of a lifting ram 112 in relation to a fixed folding member, in particular lateral folding walls 113 and a common central folding wall 114. Accordingly, the folding track 33 consists of two portions offset relative to one another in terms of height. The upper portion at the same time forms the pushing-in station 34 for the following second folding turret 35. The cigarette groups 21 are now wrapped completely in the tin-foil blank 22 and thus form a tin-foil block 24. The two tin-foil blocks 24 now located next to one another are pushed into a pocket 116 of the folding turret 35 in the radial direction by a common pushing-in device 115 movable to and fro.
The folding turret 35 serves for attaching and (partially) folding the outer paper blank 23. In the present case, this is introduced into the pockets 116 before the pushing-in station 34 in the direction of rotation of the turret, specifically in a lower region, as a result of a radially directed upward movement. The paper blanks 23 are severed from a paper sheet 117 in the region of a horizontal feed-conveyor track 118 by knife rollers 119. A plunger 120 movable up and down introduces the paper blank 23 into the pocket 116 open at the bottom, thereby deforming it in the form of a U. The plunger 120 is provided with a suction bore 121 in the end face for fixing the paper blank 23. The pocket 116 is also provided, on its side faces, with suction bores 122 for retaining the paper blank 23 in the pocket 116 without any variation of the U shape. The axial dimensions of the paper blank 23 and consequently of the pockets 116 and the plunger 120 are such that two tin-foil blocks 24 located next to one another at a distance can be processed at the same time.
Accordingly, in the region of the pushing-in station 34, the two tin-foil blocks 24 are pushed into a U-shaped (double-width) paper blank 23 already located in the pocket 116.
Side-folding tabs 123 and 124 of the paper blank 23 which project from the pocket 116 laterally, in particular in the radial direction, are at the same time held in a position widening in the form of a funnel, that is to say diverging. For the lower shorter side-folding tab 123, a guide finger 125 is mounted pivotably below the conveying plane of the tin-foil blocks 24. The guide finger 145 is moved out of a lower initial position (indicated by dot-and-dash lines) into an oblique guide position which makes it easier to introduce the tin-foil blocks 24 and in which the associated side-folding tab 123 is pressed down slightly.
The opposite upper side-folding tab 124 is retained against a fixed guide wall 126 in the form of a circular arc by means of suction bores 127.
After the tin-foil blocks 24 have been pushed into the U-shaped paper blank 23 in the pocket 116, the lower side-folding tab 123 is first folded into the plane of the side face of the pack by a folding web 128 which can be moved upwards in a tangential plane. The folding turret 35 is now moved further the amount of one stroke, the folding web 128 initially being moved with it, until the side-folding tab 123 enters the region of the guide wall 126 and is retained by the latter. Beforehand, as a result of the relative movement, the upper side-folding tab 124 has already been folded round into the plane of the side face of the pack by the guide wall 126.
The side-folding tabs 123,124 are connected to one another by glueing. For this purpose, they are provided with hot-melt markings which are activated by fixed stamps 129 and 130 which can be brought up against the packs in the pockets 116. At the same time, the side-folding tabs 123,124 are connected to one another as a result of the pressure exerted.
In the region of a pushing-out station 131 located opposite the pushing-in station 34, the tin-foil blocks 24 provided with the paper blank 23 are pushed out of the pockets 116 in a horizontal plane and in the radial direction by appropriately designed slides 132 and are pushed into the folding track 36. Here, lower longitudinal tabs still projecting are folded round on one side by folding switches 133 to form the bottom. Upper longitudinal tabs 134 are folded round into the plane of the bottom wall during a new upward movement of the now finished packs 20 into the pack tower 38 or 39.
In the region of the pack towers 38,39 assigned to each track, revenue bands 42 are attached to the packs 20 in the region of the exposed end face of the tin-foil blocks 24. The revenue bands 42 extend transversely over the end face of the pack 20, in such a way that a middle part 135 rests against the end face and legs 136 rest against the front and rear walls.
As is evident from FIGS. 10 to 13, the packs 20 are arranged in the region of the folding track 36 in such a way that the upper end faces 137 to be provided with the revenue band 42 are directed towards the same side in both rows of packs 20. Part tracks 138,139 of the folding track 36 which are located next to one another in the conveying direction, end offset relative to one another. The part track 138 is longer than the part track 139 in the conveying direction. The pack towers 38,39 are thus arranged offset relative to one another. This produces, in the region of the part track 139, a recess 140, in which the revenue-band unit 40 assigned to the pack tower 38 is accommodated. The second revenue-band unit 41 is arranged laterally next to the associated pack tower 39.
Each revenue-band unit 40,41, consists of a transfer wheel 141 as its most important member. Individual revenue bands 42 are each extracted from an associated revenue-band magazine 142 by means of a known rolling-off device 143. The revenue bands 42 are laid on the periphery of the transfer wheel, specifically at intervals and in a predetermined exact relative position.
During the transport of the revenue bands 42 on the transfer wheel 141, the side to be connected to the packs 20 faces outwards. This is provided with glue, specifically by means of a segmental wheel 144, the periphery of which is provided with glue from a glue vessel 146 by a glue roller 145.
To transfer the revenue bands 42 to the packs 20, the transfer wheel 141 is provided with several, in the present case five transfer members, in particular radially movable transfer rams 147. These are fork-shaped, with two lateral supporting legs 148 and 149. Each supporting leg 148,149 is provided with suction bores 150 opening onto the radially outer receiving surface. The supporting legs 148,149 are so arranged at a distance from one another (in the peripheral direction) and the revenue bands 42 are laid on the periphery of the transfer wheel 141 in such a way that the ends of the revenue bands 42 are grasped by the suction bores 150 of the supporting legs 148,149 and are fixed on the transfer wheel 141.
Between the supporting legs 148,149 is located a pressure stamp 151 in the form of a circular arc on the outside. This fills the peripheral gap between the supporting legs 148, 149. The pressure stamp 151 is movable in the radial direction relative to the supporting legs 148,149 and is supported via a compression spring 153 on a radially inner supporting body 152 connecting the supporting legs 148,149 to one another. The supporting body 152 is made wedge-shaped in the radially inner region. A lateral extension 154, of arcuate cross-section, of the supporting body 152 projects from the region of the transfer wheel 141 and serves for supporting an actuating member in the form of a slide 155 with actuating legs 156, 157. The latter bear on the respective extensions 154 of the two transfer wheels 141. The slide 155 is movable to and fro, at the same time taking with it the transfer rams 147 which are both in the transfer position and which belong to the two transfer wheels 141.
In the transfer position, as a result of a radial movement of the transfer ram 147 or of the two supporting legs 148,149, the revenue band 42 is transferred to the pack 20 provided in the corresponding relative position. The middle part 135 thereby comes up against the end face 137 of the packs, whilst the legs 136 are pressed by the supporting legs 148,149 against the front and rear sides of the pack. For this purpose, the supporting legs 148, 149 are at a distance from one another which corresponds approximately to the width of the pack 20, so that the supporting legs 148,149 are moved along the front and rear sides of the pack 20 as a result of the radial movement of the transfer ram 147, thereby pressing down the legs 136 of the revenue band 42.
As a result of the above-described movement of the transfer ram 147, the revenue band 42 is also pressed against the end face 137 in the region of the middle part 135 because of the tension in the longitudinal direction. The compression spring 135 is thereby compressed (FIG. 12). When the slide 155 returns into the initial position (indicated by dot-and-dash lines in FIG. 12), as a result of the relaxation of the compression spring 153 the transfer ram 147, together with the supporting legs 148,149, is moved back into the initial position. The compression spring 153 is thereby supported on the supporting body 152 extending in the peripheral plane of the transfer wheel 141.
The revenue bands 42 are transferred to the particular pack 20 provided for this, in the plane of the folding track 36 or of the part tracks 138,139. A lifting stamp 158 acts to limit the bottom of each of the part tracks 138,139 in this region (pack tower 38,39). Its stamp plate 159 is provided with a cut-out 160 on the side facing the transfer wheel 141. The transfer ram 141 or the lower supporting leg 149 penetrates into this cutout 160 during the transfer of the revenue band 42. After the supporting legs 148,149 have been retracted, the now completed pack 20 is lifted by the lifting stamp 158, specifically up to the bottom of a pack stack 161 already formed. This is carried by supporting webs 162, 163 which each grasp the lower pack 20. The supporting webs 162, 163 are movable transversely relative to the pack tower 38,39, in particular out of the region of the pack stack 161, so that the lower pack can be delivered to the pack stack 161. By means of the cut-out 160 in the stamp plate 159 and by means of a further opposite cut-out 164, after a (lower) pack has been delivered to the pack stack 161, the supporting webs 162,163 can grasp the latter on the under side, before the lifting stamp 158 is moved downwards back into the initial position.
The upper packs 20, specifically in groups each consisting of two packs resting on top of one another, are conveyed out of the pack tower 138,139 by cross slides 165 into a horizontal pack conveyor 166.
An alternative solution for forming tin-foil blocks 24 and introducing them into the further packaging process is illustrated in FIGS. 14 to 16.
In this method, tin-foil blocks 24 produced somewhere else are supplied in pairs in two parallel tracks by block conveyors 167 and 168. In the region of these block conveyors 167, 168, the tin-foil blocks 24 are transported in a horizontal plane and at a distance from one another by suitable conveyor members, for example chain conveyors.
Assigned to each block conveyor 167, 168 is a transfer turret 169,170. These are arranged with their axes of rotation (shaft 171) in the conveying direction of the tin-foil blocks 24. Consequently, the transfer turrets 169,170 rotate in planes transverse relative to the block conveyors 167,168, specifically in the direction of rotation indicated by arrows 172.
The transfer turrets 169,170 serve for transferring the tin-foil blocks 24 from the block conveyors 167,168 to a common block turret 173. This is designed in a similar way to the group turret 28 of the exemplary embodiment described above. In a similar way, pockets 174 are arranged along the periphery of the block turret 173 in an oblique position, in particular at an angle between the tangential and the radial relative to the mid-plane. The tin-foil blocks 24 are introduced into the pockets 174 in the axial direction via lateral pushing-in orifices 175. In a similar way to the group turret 28, the design and dimensions of these in the axial direction are such that two tin-foil blocks 24a and 24b are accommodated next to one another in a pocket 174, specifically at a distance from one another.
The transfer turrets 169,170 are designed and arranged in such a way that, during a stop phase, each can simultaneously receive one tin-foil block 24 and transfer one tin-foil block to the block turret 173. For this purpose, the transfer turrets 169,170 are provided with pockets 176,177 which are temporarily made to coincide with one block conveyor 167,168 or the other and with a particular pocket 174 of the block turret 173.
The transfer turrets 169,170 are of differing size, in particular have different diameters. The smaller transfer turret 169 assigned to the block conveyor 167 is provided with three pockets 176 which, parallel to the tangential and at a distance from it, are designed as a chamber closed in the peripheral direction or as a channel of closed cross-section, open at both ends. Accordingly, the three pockets 176 are arranged at the same angles relative to one another and at the same distances from one another.
In a specific position of the transfer turret 169 (FIG. 14), a lower horizontally directed pocket 176 is in the path of movement of the block conveyor 167, so that a tin-foil block 24 can be pushed into the lower pocket 176 as a result of appropriate conveyance. A further pocket 176 of the transfer turret 169 coincides with a pocket 174 of the block turret 173, so that, likewise as a result of axial movement, the pack or the tin-foil block 24 can be transferred from the pocket 176 to the pocket 174. For this purpose, the transfer turret 169 is shifted slightly in the direction of rotation of the block conveyor 173 out of its vertical mid-plane.
The second transfer turret 170 is located on the other side of the vertical mid-plane of the block turret 173 at a greater distance from this mid-plane. The four pockets 177 arranged at right angles to and parallel to one another respectively are likewise coordinated with the block conveyor 168 and with a particular pocket or a specific relative position of a pocket 174 of the block turret 173. As illustrated, a lower horizontally arranged pocket 177 is in the path of movement of the tin-foil blocks 24 of the block conveyor 168 so that the tin-foil block 24 is introduced into the pocket 177 as a result of axial conveyance. The vertically directed pocket 177 following next in the direction of rotation coincides with a pocket 174 arranged in this position in the block turret 173. Accordingly, here again, the tin-foil block 24 can be transferred to the block turret 173 as a result of renewed axial displacement.
For the (simultaneous) transfer of a tin-foil block 24 from each of the transfer turrets 169,170 to the block turret 173, there are rams 183, 184 which are assigned to the two transfer turrets 169,170 or to the pockets 176,177 each located opposite a pocket 174 of the block turret 173.
Again in the present exemplary embodiment, the tin-foil blocks 24a, 24b are pushed into a pocket 174 of the block turret 173 in successive working strokes. Because of the arrangement and design of the transfer turrets 169,170, one pocket 174 always remains free between the particular filling positions. Accordingly, whilst the block turret 173 is driven at the maximum stroke rate (for example, 600 indexing strokes per minute), a tin-foil block 24 is pushed in only during every second indexing stroke or whenever the block turret 173 stops, specifically first in the region of the larger transfer turret 170, the tin-foil block 24a to be moved up to the inner end of the pocket 174, and then in the region of the transfer turret 169 the second tin-foil block 24b facing the pushing-in orifice 175. Consequently, even here, the pushing-in movements are slower and do not damage the cigarettes.
The tin-foil blocks 24 introduced into the pockets 174 in the axial direction are pushed out of the pocket 174 in the region of a pushing-out station 178 in the axial direction or approximately axial direction, but at all events axially transversely relative to the cigarettes, and are pushed into a pocket 179 of a folding turret 180. For this purpose, there is a double slide 181 which is movable to and fro within the block turret 173 and which penetrates into the pocket 174 in the region of the tin-foil blocks 24a, 24b via an inner pushing-out orifice 182. During the movement to transfer the tin-foil blocks 24a, 24b into the folding turret 180, a paper blank 23 provided in a transverse plane is taken up, thereby being folded round the two tin-foil blocks 24a, 24b in the form of a U. The further folding cycle for this (double) paper blank 23 corresponds to that of the exemplary embodiment already described.
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Packaging machines have to, on the one hand, achieve high levels of output but, on the other hand, take into account the sensitivity of the cigarettes to mechanical stresses. A two-track configuration of the packaging machine doubles the output at a given speed (number of strokes). By the special designing of a cigarette magazine (26) in conjunction with a group turret (28), it is accomplished that the formation of cigarette groups (21) and the insertion into the pockets (64) of the group turret (28) can be performed within adequately set stroke times at a high output of the packaging machine.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates primarily but not exclusively to a golfer's needs. More particularly, this invention relates both to the recognition of long-felt needs of a golfer, male or female and to novel conceptual designs for fulfilling those needs. More specifically, the invention relates to fulfilling those needs, the paraphernalia organizational needs of the typical golfer who belongs to a country club or who has a storage locker at such a private club or at a public golf course.
2. Description of the Prior Art
A patent search was carried out directed toward bags or storage devices having a series of pockets with means for closing and open pockets, which are expandable, fastened to a vertical rigid or semi-rigid backing that is equipped with a hanging device, for the storage of personal items.
The following patents were located:
______________________________________Des. 110,197 - Shapiro 6/21/38 71,598 - Woodland 6/6/05 2,710,638 - Ford 6/14/55 3,139,133 - Spector 6/30/64 4,585,127 - Benedict 4/29/86______________________________________
The design patent of Shapiro relates to a toilet dressing hanger and is not equipped to handle the locker storage needs of a golfer.
Woodland shows pockets attached to a hanger but the pouch of same is designed to satisfy the needs of rural letter carriers and would not satisfy the hereinafter specified storage requirements of the golf locker bag of the present invention.
The Ford patent discloses a combined utility bag and hanger with attached pockets and pouches. A specific object of the invention is to provide a bag particularly useful for over night and week-end guests in homes and the structure provides pockets for articles usually carried by travelers in order that such articles may not be misplaced and forgotten when the guest leaves. Also, one of the specific purposes of this invention is to have the hanger readily removeable from the bag section to allow for easy laundering of the article. These are not purposes of the golf locker bag of the present invention; nor, on the other hand, would the article of this patent satisfy the storage requirements of the golf locker bag of the present invention.
Spector discloses a portable unit that folds into an easily transportable unit for travel but is unrelated to satisfying the storage requirements of a golfer.
Benedict shows the use of a pocketed device for closet use, wherein the device is supported on a rod that slides into the closet. It also is unrelated to satisfying the storage requirements of a golfer.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a golfer's locker bag particularly suitable for fulfilling the paraphernalia organizational needs of the typical golfer who belongs to a country club or who has a storage locker at such a private club or at a public golf course.
It is another object of this invention to provide means for fulfilling such needs with highly efficient bag structures for accomplishing same while at the same time employing novel conceptual designs for fulfilling said needs.
It is another object of the present invention to accomplish the foregoing objectives for both male and female golfers.
It is another object of the present invention to provide safeguards against thievery of valuables in certain specifically designed bag embodiments of the present invention.
It is another object of the present invention to accomplish all of the foregoing with bag designs that are attractive and aesthetically pleasing to the eye of the golf locker bag user.
SUMMARY OF THE INVENTION
The invention relates to a locker bag specifically designed for golfers for storing and organizing the usual golf accessories, valuables and clothing items used by a golfer, male or female. The bag is designed to hang from the inside of the locker door and has a multiplicity of expandable pockets attached to a backing. The pockets are arranged in substantially horizontal rows and extend from the backing inwardly into the locker by means of expandable gussets. The pockets are of sufficient number and sufficiently limited in vertical depth that the contents placed in the various pockets of the bag can easily be extracted therefrom, and wherein commingling with undesired objects in any particular pocket is averted.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention as well as other objects and advantages thereof will become apparent upon consideration of the detailed disclosure thereof, especially when taken with the accompanying drawings, wherein:
FIG. 1 is a front elevational view of a typical golf locker storage bag of the present invention; the various compartments are labeled and typical dimensions are set forth but it should be understood for this figure and for others illustrated that these are exemplary only and may be varied, depending upon locker size and user performance, etc.
FIG. 2 is a cross-sectional view of the golf locker bag of FIG. 1, taken along the line 2--2 of FIG. 1;
FIG. 3 is a front elevational view of a modified golf locker bag wherein the top pocket or compartment is specially designed for improved protection against thievery and wherein the second pocket from the top is specially designed for holding typical toiletry articles;
FIG. 4 is a cross-sectional view of the golf locker bag of FIG. 3, taken along the line 4--4 of FIG. 3;
FIG. 5 is a front elevational view of another modified golf locker bag of the present invention wherein the bag may have modifications thereto to make it particularly suitable for portability and/or to hang laundry therefrom, as will be more particularly discussed hereinafter;
FIG. 6 is a cross-sectional view of the golf locker bag of FIG. 5 taken along the line 6--6 of FIG. 5;
FIG. 7 is a front elevational view of another modified golf locker bag of the present invention wherein the aesthetically pleasing considerations of the locker bag design are given emphasis by the placement of a smiling clown's face at the top of the bag and wherein the general overall shape of the bag is changed from substantially rectangular to substantially ovoid;
FIG. 8 is a cross-sectional view of the golf locker bag of FIG. 7, taken along the line 8--8 of FIG. 7; and
FIG. 9 is another modified golf locker bag of the present invention wherein the bag presents an alternative aesthetically pleasing design as its main distinction over the preceding locker bag configuration, the locker bag of this figure having a conical or frusto-conical shape, with its larger circular cross-section being at the top of the bag.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the foregoing Figures in more detail, the bag 100 illustrated in FIG. 1 is particularly designed for use by a lady golfer. It is multipocketed or has several expandable pockets or compartments, indicated generally by the numeral 1 with a letter following in descending order from top to bottom as 1a, 1b, 1c, 1d, 1e, and 1f as shown. The backing 2 of the bag possesses means 3, such as hooks, near the top thereof to attach to or to hang from the inside of the locker door, such as from the locker vent slits. The hooks extend upwardly and rearwardly from the backing and as seen, for example in FIGS. 1 and 5, are not visible from the side of the backing from which the pockets extend. The backing itself is substantially two-dimensional, said backing being of a width narrower than the width of the locker door and said backing being of a length shorter than the length of the locker door. The pockets or compartments are arranged is substantially horizontal rows and extend from the backing 2 inwardly into the locker by means of expandable gussets 4a, 4b, 4c, 4d, 4e and 4f respectively for the correspondingly lettered pockets 1a, 1b, etc. The pockets are of sufficient number and sufficiently limited in vertical depth that the contents placed in the various pockets of the bag can easily be extracted therefrom and wherein commingling with undesired objects in any particular pocket is averted. Preferably, all of the pockets of the bag are covered with flaps, correspondingly lettered as flaps 5a, 5b, 5c, 5d, 5e and 5f. In the bag figure illustrated, as well as in other bag designs of the invention, the inner faces of the flaps and/or the outer faces of the gussets are covered by self-adhering fabric Velcro so as to adhere the flaps to the pockets. Also, in this and other bag designs, a slot (not shown) may be provided between the top pocket 1a and the backing 2 for the bag, said slot being provided for holding score cards, blank cards or perhaps filled-in cards with scores retained as mementos for proud accomplishments etc.
In the embodiment of FIG. 1, and as is indicated on the drawing, pocket 1a is intended for holding jewelry or valuables such as currency or a wallet, etc.; pocket 1b is intended to hold golf gloves; pockets 1c and 1d for holding socks; pocket 1e for holding lingerie and pocket 1f for holding golf balls and tees and other possible golf accessories such as spare spikes and a spike wrench, etc. The flaps for the pockets may have suitable and attractive labels or insignia or adornments thereon to indicate the contents placed and/or intended to be placed in the various pockets. It is obvious that the arrangement indicated is optional and may be varied depending upon manufacturer and/or designer or user preference.
Also, as illustrated, pockets 1c and 1d in the third and fourth horizontal row of pockets, are each divided vertically near their mid-points so as to comprise double pockets in each row to accommodate the separate placement therein of differently colored or styled socks, or to separate clean from dirty socks etc. It should be appreciated that certain other modifications of construction may also be made while keeping within the spirit and scope of the invention. For example, pockets 1c may be varied in vertical depth to include the depth of pocket 1d; or this may be done for example on only one side of the bag etc. Or, the outward shape of the pockets may be changed to appear oval or round instead of square or rectangular.
To accomplish easy extraction of the intended articles from their pockets, and also to avoid co-mixing of separately categorized items to be placed therein, the vertical depth of at least some of the pockets of the locker bag is preferably a maximum no deeper than about 5 inches. The amount of "gusseting" employed for any particular pocket or row of pockets can be varied and/or increased in order to enable the placement therein of the bulkier items and still permit covering and closing the pockets with the hook and loop fabric type fastener secured to the flaps.
The backing 2 for the bag of FIG. 1 is essentially rectangular in shape, but as is apparent from the figures of other bag designs of the present invention, this is also a variable and the backing may be essentially frusto-conical in shape, with the wider dimension being at the top of the bag; or the backing may be tubular or ovoid in shape, etc.
The bag of FIG. 1 is made in the shape of a golf bag, with a vinyl (or other material) strap 6 attached to the top of the bag and to another part of the bag, (e.g. the bottom, or the middle, etc) wherever it's most convenient for manufacturing purposes and/or looks most attractive on said bag.
The illustrated bag of FIG. 1 is substantially 32 inches long and 10 inches wide, but this may obviously be varied depending upon locker size and user preference. The size may also be varied to place adornment at the top of the bag and/or attachments on the bottom, as will become clearer from description of other bag Figures which follow.
The dimensions shown for the pockets of the bag illustrated in FIG. 1 are typical for a locker bag of the size indicated; however, it should be appreciated that golf lockers are made in several sizes of various width and heighths, and bag dimensions and pocket sizes may be altered so as best to accommodate the needs and conveniences of the golfer. In any case, however, the bag will possess pockets in sufficient number and sufficiently limited in vertical depth that the contents placed in the various pockets of the bag can easily be extracted therefrom and wherein commingling with undesired objects in any particular pocket is averted. Typically, also, the bag will possess at least six horizontal rows of pockets in order to accomplish these objectives. As illustrated for the rows for socks, (but not restricted solely to rows for socks), such rows may be divided vertically near their mid-points into two pockets in each row; or, in the case of wider lockers, they may be divided into more than two pockets in each row.
All of the locker bags will be made from materials strong and durable enough to hold the contents of products used by the golfer and to last through reasonable wear and tear conditions. Fabric backed vinyl with stitched and sewn pockets and flaps is a typical material of construction.
The article may also have material put on the back of the backing as a means for attaching one or more handles to enable the golfer to use it as a carrying case for her or his golf needs. A slide fastener such as illustrated at element 60, FIG. 5, may be attached around the perimeter of the bag if it were to be structured for such possible additional use.
A snap 70, as illustrated for example in FIG. 1, or other attaching means may also be placed at the bottom of the locker bags of this invention for removable attachment of a generic laundry bag, to be used or filled if golfer so desires to take laundry home for washing.
The locker bag 200 illustrated in FIG. 3 and in FIG. 4 has several similarities to the locker bag 100 of FIG. 1 but is for a man's locker bag rather than for a woman's. The top compartment 10 is for the man's valuables, such as for his wallet and watch and other possible jewelry such as tie pins and cuff links, etc. Because of its intended contents, the compartment is provided with a slide fastener 16 which may be secured with a lock 17, preferably a combination lock so as to avoid the need for a separately held or stored key. This safeguard is for security reasons and to require the taking of additional time for pilferage in the case of potential thieves. Although such theft might be unlikely, it does occur, and this safeguard does offer additional deterrence against same, in addition to the lock on the locker door.
Pocket 11 of this bag is designed to hold bulky toiletry articles, such as shampoo, hair brush, comb, razor, tooth paste and tooth brush etc. and is therefore typically provided with more gussets 11a for expansion than the rest of the pockets. The balance of the construction of this bag is pocket 12 for golf gloves, pockets 13 for socks, pocket 14 for underwear and pocket 15 for balls and tees etc. Pocket 15 typically and preferably also has a slide fastener, 18.
As with the bag of FIG. 1 and any of the bags of this invention, the pockets of this bag may also have suitable and attractive labels or insignia or adornments thereon to indicate the contents placed and/or intended to be placed in the various pockets.
Alternatively, and as illustrated in FIGS. 5 and 6, the bag 300 may be designed as a "TOTE" bag, with a strap 20 attached across its top to enable its user to easily carry it and its contents in a vertical upright position from one location to another, such as from one golf club to another golf club where its owner might wish to use it on occasion. Hooks 21, shown in FIG. 6, enable the bag to be hung at either location. Such a bag will also have the same or very similar pockets and features as described in connection with the bag of FIGS. 1 and 2; and may be designed for use to hold dirty laundry at the bottom thereof in which case it will, for example, have hidden snaps or clips 71, similar to snap 70 on the bottom thereof to hold a laundry bag.
For design and aesthetic purposes, the locker bag of this figure, as well as the locker bags of FIGS. 1 and 3 may have thereon a vinyl strap 22 shaped like a golf club that turns diagnonally or crosswise across the face of the locker bag. It will be flexible and only attached to the rest of the bag near the top and bottom so as not to interfere with any function of the bag or with the opening or closing of any flaps or slide fasteners. Such a strap in the shape of a golf club may also be stitched onto the bag at the very edge of the bag. Such straps for design purposes may also be detachable from the main bag such as by means of snaps 23 or hook and loop fabric type fasteners.
The bags illustrated in FIGS. 7 and 9 show novel and more aesthetically pleasing designs for a golf locker bag; designs believed more attractive and pleasing particularly to the younger golfing set. The main body of the bag 400 of FIG. 7 is generally ovoid in shape and is topped with a smiling clown's face 80 and the head of the clown is topped with a hat 81. As illustrated in FIGS. 7 and 8, the attaching means 82 which are similar to hooks 3 are, in this embodiment, integrated with the ornamental clown design. The main body of bag 500 of FIG. 9 is conically or frusto-conically shaped like an ice cream cone. Bags 400 and 500 of FIGS. 7 and 9, respectively, also illustrate the formation of arcuate upper and lower edges, 91 and 92 respectively, on backing members 2. The pockets marked for "Jewelry" in each of these figures are provided with snap fasteners and small locks to safeguard against thievery. Obviously the placement of the jewelry pockets in these and other figures may be changed from top to bottom or from bottom to top or to elsewhere. The lock may be either a combination lock or a key lock since women may conveniently wear a small chain key around their neck while either golfing or showering, etc. It should also be appreciated that other aesthetically pleasing designs for golf locker bags are within the spirit and scope of the present invention. For example, the locker bags for ladies may have a doll-like figure (instead of a clown's face) sitting on the golf bag; or two doll-like figures sitting on the golf bag, dressed in golfing attire. Despite their novel design features, the bags illustrated and described for FIGS. 7 and 9 still possess most of the utilitarian aspects or features of the locker bag designs shown in FIGS. 1, 3 and 5.
ADVANTAGES OF THE INVENTION
A golfer's paraphernalia organizational needs are believed unique, particularly because of the variety of items involved and also because of the golfer's activities and the conditions which prevail pertaining to those activities.
Typically a woman or man golfer may arrive at "the club" attired in dress clothes, with a wallet in purse or pocket, and wearing jewelry or a watch, etc., and will then change into her or his golfing clothes. At that point she or he may decide to leave the "valuables" in the golf locker or take such valuables with him or her, thus having to look after or safeguard them during the time he or she is golfing.
After golfing, particularly on hot days, the golfer will typically remove his sport clothes, shower and then change back into the clothes he or she was wearing before getting to the golf club. At this time the safeguarding of valuables is uppermost in the golfer's concern while he or she is showering. Also, toiletry articles are required and/or desired both before and after showering and there is generally also a change, at least of lingerie or underwear and socks, with concomitant need for separating soiled or worn clothing from fresh and/or laundered clothing.
The golfer will typically also have a need for storing spare golf shoes, socks, golf balls and tees etc. and the typical locker will not have means for conveniently and efficiently separating such items from other items typically stored in the locker, such as sport shirts, sweaters, slacks, shirts etc.
The general result is, and informal observations of both men and women's lockers lead to the judgment that the average golf locker is very disorganized, with toiletries mixed in with jewelry and/or wallets, with clean and dirty clothing, with golf balls and tees and score cards strewn every which way. The locker bags of the present invention help avoid such disorganization, help allay concern over jewelry and valuables and the special care that they require, and reduce or eliminate the time involved in shuffling through a lot of disorganized or mixed items such as described.
Numerous modifications and variations of the invention are possible in light of the above teachings and therefore the invention may be practised otherwise than as particularly described.
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The invention relates to a locker bag specifically designed for golfers for storing and organizing the usual golf accessories, valuables and clothing items used by a golfer, male or female. The bag is designed to hang from the inside of the locker door and has a multiplicity of expandable pockets attached to a backing.
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The invention relates to a motor vehicle seat which is guided for longitudinal sliding movement on at least one lower stationary track, and which is provided with a releasable locking mechanism for locking the vehicle seat, by means of a handle, longitudinally in selectable positions.
BACKGROUND OF THE INVENTION
Since it is imperative that the seats in motor vehicles not be slideable in the event of a collision, the longitudinally adjustable seat is provided with a locking mechanism, wherein a pawl engages into an aperture provided on the lower track when the seat is in the locked position. The motor vehicle seat can be locked in various positions, because the lower track has several such apertures arranged therealong which can be selectively used for locking the seat into position.
If after releasing the handle of the longitudinal adjusting mechanism, the pawl of the seat locking mechanism happens to be positioned between two such spaced apart apertures, the pawl is temporarily unable to snap into latching engagement. In these instances, seat locking will usually occur during subsequent vehicle braking as a result of inertia induced forward seat displacement.
SUMMARY OF THE INVENTION
It is the object of the invention to incorporate features into a motor vehicle seat of the type described in the foregoing that will ensure that the seat, in the event of an accident, is automatically locked into position even if seat locking did not occur after a longitudinal seat adjusting movement.
In accordance with the invention, this object is accomplished in that a supplementary, inertia activated automatic locking device is provided which is able to lock the seat in the direction in which the seat slides.
It is common to employ inertia-operated locking devices in motor vehicle seat belt retracting mechanisms. These inertia locking devices permit the seat belt to be slowly withdrawn from the retractor reel by the seated occupant, but in the event of an accident, the seat belt is firmly retained to protect the seat belt wearer.
German patent DE-PS No. 962 574 already disclosed a motor vehicle seat with a foldable seat back which is provided with an inertia actuated locking device. Normally, the seat back can always be tilted forwardly, especially the vehicle. However, in the event of an inertia condition, the seat back of the front seat is locked into position, so that the rear seat occupants cannot push against the seat back of the front seat and thereby displace the front seat occupants in a forward direction.
No effort has been made in the past to provide motor vehicles with inertia actuated seat locking devices to enable seat locking in the longitudinal direction because vehicle seats must be locked in position even if no unusual deceleration occurs, especially during normal vehicle braking. The arrangement according to the invention, which encompasses the combination of a longitudinal seat locking mechanism and an inertia actuated seat locking device provides that the vehicle seat can be adjusted and reliably locked, as usual, in a number of predetermined longitudinal positions. However, if a vehicle occupant, after a longitudinal seat adjustment, forgets to ascertain that the seat is locked into position, the seat can not be displaced longitudinally because it will be locked into position, independently from its respective longitudinal position, by the inertia locking mechanism which is actuated in response to the high deceleration forces.
As a general rule, the high forces generated are acting in a forward direction. But in some instances, and especially when the vehicle is struck from the rear, the forces are acting in the rearward direction. If one wants to ensure that in this instance, too, the front seat, if it is not locked into position subsequent to longitudinal adjustment, is not displaced longitudinally, it is preferable that, in accordance with the invention, features be incorporated in the inertia actuated locking mechanism that provide automatic locking of the front seat in response to rearwardly as well as forwardly acting deceleration forces.
The locking arrangement according to the invention is relatively simple in design and therefore reliable in operation and economical to manufacture. A particular simple arrangement is one wherein the locking mechanism includes a slideable pendulum member which is mounted to the vehicle seat and is rigidly coupled with a latching element. The latching element is adapted for inertia induced pivoting movement from a normal position into a latching position wherein it is in engagement with the lower seat track.
According to one feature of the invention, the latching member of the locking mechanism is in the form of an eccentric disk which is provided on a portion of its circumferential surface area with saw-like toothing, and which in the latching position is adapted for pivoting movement towards the lower track. A disk of this type is able to interlock in any given position with the lower track and to thereby block any movement of the front seat.
According to another feature of the invention, the locking device is arranged in an upper track which is guided in the lower track and which is affixed to the motor vehicle seat, and the upper track is provided with a recess into which the lower track, during conditions of high deceleration, is urged by the eccentric disk when said disk is in the latching position. This arrangement has the advantage that latching is achieved by form-locking engagement.
Load balancing of the locking device and the lower track can be achieved by relatively simple means in that the locking device has on either side of the upper track an eccentric disk, and in that one recess is provided on each side of the upper track.
Another advantageous arrangement is one wherein the pendulum is biased, by means of a rearwardly pulling tension spring, which has one of its ends connected to one eccentric disk and the other end to the upper track, into a normal position wherein the eccentric disks are out of engagement with the lower track. This arrangement will enable, by way of tension spring dimensioning, the locking device to be calibrated so as to determine at which deceleration values the pendulum and thus the locking mechanism will respond.
In accordance with one arrangement, the pendulum has a latching element on two sides and, depending on the direction in which the deceleration forces are acting, is pivoting from a neutral position either forwardly or rearwardly to lock the front seat. Another arrangement is one wherein a pair of locking devices are arranged in a mirror-image-like fashion so that one is functioning in a forward and the other in a rearward direction.
It should be appreciated that a variety of arrangements may be utilized in the practice of the invention. To convey the concept of the invention, one exemplary embodiment is illustrated in the drawing and described in the following specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a motor vehicle seat guide means according to the invention.
FIG. 2 is a section along line 2--2 of FIG. 1 at an enlarged scale.
FIG. 3 is a pendulum of locking device of the guide means according to FIGS. 1 and 2.
FIG. 4 is a plan view of the pendulum according to FIG. 3.
FIG. 5 is an eccentric disk of the locking device which serves a latching element.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a lower track 2 with mounting ends 4 and 6 used for bolting the track, in a manner not illustrated in the drawing, to the sub-structure of the motor vehicle. The lower track 2 is guiding an upper track 8 which is rigidly attached to the base (not illustrated) of a motor vehicle seat.
As is apparent, especially from FIG. 2, the lower track 2 is comprised of an upwardly open box section and a downwardly extending flange 10. This flange has, as illustrated in FIG. 1, rectangular apertures which are denoted, for exemplary purposes, by the numerals 12 and 14. A plurality of rollers 17 are captured between the lower track 2 and the upper track 8 to mount the upper track for fore and aft sliding movement along the lower track. A locking device for longitudinal seat locking, which is rigidly connected with the upper track 8, is comprised of a bracket 18 which embraces the lower track 2 from above, and has two latching pawls 20 and 22 which are adapted to engage into apertures 12 and 14 and extend from one side of bracket 18 to the other side thereof. An unlatching bar 26, which is operable through handle 24, is adapted for pivoting movement so as to pivot the bracket 18 and cause the latching pawls 20 and 22 to be pivoted out of the apertures 12 and 14. The seat can then be displaced for effecting fore and aft adjustment. When the seat is adjusted to the new seating position and the pawls 20 and 22 are again lining up with two apertures 12 and 14, the pawls will snap into these apertures 12 and 14 so that the motor vehicle seat is locked into its new position.
The components described in the foregoing are conventional, but it should be appreciated that they may be of an entirely different configuration. The principal feature of the invention is a deceleration responsive locking device which is arranged on the upper track 8. This locking device is provided with a pendulum 30, which is arranged on the upper track 8 for pivoting movement about a pin 32, and which in the inoperative state assumes an upright position. A tension-type spring 34, which has one of its ends attached to the upper track 8 and the other end to a component connected with the pendulum or to the pendulum itself, urges the pendulum 30 in clockwise direction until a stop 36 of the pendulum engages the upper track 8.
The pendulum is affixed to two eccentric disks 38 and 40 in a non-rotatable relationship therewith. Each of these disks 38 and 40 forms with its circumferential surface a latching element. As apparent from FIGS. 1 and 2, the outer upwardly directed flanges 37 and 39 of the upper track 8 are provided in the area below the eccentric disks 38 and 40 with recesses 42 which are covered by inwardly directed arms 41 and 43 of the lower tracks 2. When subjected to high deceleration forces, the pendulum 30 will swing counter-clockwise. This will cause the eccentric disks 38, 40 to be seated on the upper side of the inwardly directed arms 41 and 43 of lower track 2, whereby said inwardly directed arms 41 and 43 of the lower track are pushed into engagement with the upwardly directed flanges 37 and 39 of the upper track 2 in the area of the recesses 42, so that a formlocking connection is established through which the upper track 8 is rigidly joined with the lower track 2.
FIGS. 3 and 4 illustrate in greater detail the configuration of the pendulum 30. One will recognize in FIG. 3 a hole 44 through which the pin 32, illustrated in the preceding figures, extends. The pendulum 30 is provided on its upper side with a cylindrical weight 46. In an area below the weight 46 and approximately at the level of the hole 44, the pendulum is provided with a stop 36 (see also FIG. 1), which is produced by bending a sheet metal blade.
FIG. 5 illustrates the eccentric disk 38 at an enlarged scale. One will notice that a portion of its circumference is provided with saw-like toothing 48. A hole 50, which is flattened on one side, is disposed off-center in the disk 38, and the pin 32 is extending through said hole 50. The pin 32 is provided with a corresponding flat, so that the eccentric disk 38 cannot move relative to pin 32. In the circumferential surface area opposite the toothing 48, the eccentric disc 38 has a shoulder 52 with which the stop 36 engages from underneath. When the pendulum 30 pivots in a counter-clockwise direction, it will drive the adjacent eccentric disk 38 counter-clockwise. The other eccentric disk 40 is turned in synchronism by way of the pin 32 because it, like the eccentric disk 38, has a hole 50 that is flattened on one side. As apparent from FIG. 5, the eccentric disk 38 also has a hole 54 into which one end of the spring 34 is hooked. If space permits, the eccentric disk 38 may be combined with the pendulum 30 so as to form a one-piece structure therewith.
The operation of the locking device is relatively simple. The locking device according to the invention is not being actuated as a result of normal deliberate seat adjustment movements. If the vehicle is subjected to extraordinary deceleration forces, the weight 46 on the pendulum 30 will cause the same to pivot in counter-clockwise direction. The toothing 48 on the eccentric disks 38 and 40 will then be urged onto the upper surface areas of the lower track 2. Due to the inertia forces, the toothing 48 will pierce and penetrate into the lower track 2 and thereby rigidly connect the upper track 8 with the lower track 2. Under conditions of extremely high deceleration, the eccentric disks 38 and 40 form depressions in the lower track 2 which extend into the recesses. This will cause a form-locking engagement to occur between the upper track 8 and the lower track 2. The deceleration value at which the pendulum 30 is intended to respond can be determined by the selection of the type of tension spring 34 and the position of the center of gravity of the pendulum 30.
It will be understood that the seat locking mechanism may include an additional locking mechanism including a second pendulum and eccentric disks which are arranged to lock the seat against an inertia condition in the opposite direction.
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A motor vehicle seat is guided, as is customary, with its upper tracks in lower tracks and is manually adjustable and lockable into selected longitudinally spaced seat positions. In addition to these seat position locking means, the seat is provided with at least one deceleration activated locking device which, under conditions of relatively high deceleration, will effect form-locking engagement between the upper track and the lower track.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional application that claims priority to provisional application No. 61/792,654 filed on Mar. 15, 2013, which is incorporated in its entirety herein.
TECHNICAL FIELD
[0002] This disclosure relates to stimulators using electrical pulses in a medical context, and more particularly, applying electrical pulse stimulators to the spinal cord to control pain.
BACKGROUND
[0003] A Spinal Cord Stimulator (SCS) is used to exert pulsed electrical signals to the spinal cord to control chronic pain. Spinal cord stimulation, in the simplest form, consists of stimulating electrodes, implanted in the epidural space, an electrical pulse generator, implanted in the lower abdominal area or gluteal region, conducting wires connecting the electrodes to the generator, the generator remote control, and the generator charger. Spinal cord stimulation has notable analgesic properties and, at the present, is used mostly in the treatment of failed back surgery syndrome, complex regional pain syndrome and refractory pain due to ischemia.
[0004] Electrotherapy of pain by neurostimulation began shortly after Melzack and Wall proposed the gate control theory in 1965. This theory proposed that nerves carrying painful peripheral stimuli and nerves carrying touch and vibratory sensation both terminate in the dorsal horn (the gate) of spinal cord. It was hypothesized that input to the latter could be manipulated to “close the gate” to the former. As an application of the gate control theory, Shealy et al. implanted the first spinal cord stimulator device directly on the dorsal column for the treatment of chronic pain in 1971.
[0005] Spinal cord stimulation does not eliminate pain. The electrical impulses from the stimulator override the pain messages so that the patient does not feel the pain intensely. In essence, the stimulator masks the pain. The stimulation must be done on a trial basis first before the stimulator is permanently implanted. Implanting the stimulator is typically done using a local anesthetic and a sedative. The physician will first insert a trial stimulator through the skin (percutaneously) to give the treatment a trial run. (A percutaneous stimulator tends to move from its original location, so it is considered temporary.) If the trial is successful, the physician can then implant a more permanent stimulator. The stimulator itself is implanted under the skin of the abdomen, and the leads are inserted under the skin to the point where they are inserted into the spinal canal. This placement in the abdomen is a more stable, effective location. The leads, which consist of an array of electrodes, could be percutaneous type or paddle type. Percutaneous electrodes are easier to insert in comparison with paddle type, which are inserted via incision over spinal cord and laminectomy.
[0006] There are a number of the problems that exist in currently available SCS systems that limit the full benefits of dorsal column stimulation from an effectiveness and patient user friendly perspective. For example, SCS systems are limited at the moment to only 16 electrodes with a maximum of 16 independent current sources. In addition, current SCS systems have complicated trialing methods that involve multiple gadgets and hardware even in current wireless SCS systems. Patients at the moment must carry an independent remote control in order to control the IPG in their daily lives.
SUMMARY
[0007] The present invention emphasizes the following specific features included within a spinal cord stimulation system: (1) a recharging system with self alignment, (2) a system for mapping current fields using a completely wireless system, (3) multiple independent electrode stimulation outsource, and (4) IPG control through a software on generic Smartphone/mobile device and tablet hardware during trial and permanent implants. Current SCS systems include multiple electrodes, multiple, independently programmable, stimulation channels within an implantable pulse generator (IPG) which channels can provide concurrent, but unique stimulation fields, permitting virtual electrodes to be realized. Current SCS systems include a replenishable power source (e.g., rechargeable battery), that may be recharged using transcutaneous power transmissions between antenna coil pairs. An external charger unit, having its own rechargeable battery can be used to charge the IPG replenishable power source. A real-time clock can provide an auto-run schedule for daily stimulation. An included bi-directional telemetry link in the system informs the patient or clinician the status of the system, including the state of charge of the IPG battery. Other processing circuitry in current IPG allows electrode impedance measurements to be made. Further circuitry in the external battery charger can provide alignment detection for the coil pairs. FIG. 1 depicts a SCS system, as described herein, for use during the trial in the operating room and the permanent implantation.
[0008] The newly invented SCS system is superior to existing systems. More particularly, the SCS system of the present invention provides a stimulus to a selected pair or group of a multiplicity of electrodes, e.g., 32 electrodes, grouped into multiple channels, e.g., 6 channels. Advantageously, each electrode is able to produce a programmable constant output current of at least 12 mA over a range of output voltages that may go as high as 16 volts. Further, in a preferred embodiment, the implant portion of the SCS system includes a rechargeable power source, e.g., one or more rechargeable batteries. The SCS system herein described requires only an occasional recharge; the implanted portion is smaller than existing implant systems and also has a self aligning feature to guide the patient while placing the charger over the implanted IPG for the most efficient power recharge; the SCS system has a life of at least 10 years at typical settings; the SCS system offers a simple connection scheme for detachably connecting a lead system thereto; and the SCS system is extremely reliable.
[0009] As a feature of the invention, each of the electrodes included within the stimulus channels may not only deliver up to 12.7 mA of current over the entire range of output voltages, but also may be combined with other electrodes to deliver even more current up to a maximum of 20 mA. Additionally, the SCS system provides the ability to stimulate simultaneously on all available electrodes in the SCS system. That is, in operation, each electrode is grouped with at least one additional electrode form one channel. The system allows the activation of electrodes to at least 10 channels. In one embodiment, such grouping is achieved by a low impedance switching matrix that allows any electrode contact or the system case (which may be used as a common, or indifferent, electrode) to be connected to any other electrode. In another embodiment, programmable output current DAC's (digital-to-analog converters) are connected to each electrode node, so that, when enabled, any electrode node can be grouped with any other electrode node that is enabled at the same time, thereby eliminating the need for the low impedance switching matrix. This advantageous feature thus allows the clinician to provide unique electrical stimulation fields for each current channel, heretofore unavailable with other “multichannel” stimulation systems (which “multi-channel” stimulation systems are really multiplexed single channel stimulation systems). Moreover, this feature, combined with multicontact electrodes arranged in two or three dimensional arrays, allows “virtual electrodes” to be realized, where a “virtual” electrode comprises an electrode that appears to be at a certain physical location, but really is not physically located at the apparent location. Rather, the virtual electrode results from the vector combination of electrical fields from two or more electrodes that are activated simultaneously.
[0010] As an additional feature of the invention, the SCS system includes an implantable pulse generator (IPG) that is powered by a rechargeable internal battery, e.g., a rechargeable Lithium Ion battery providing an output voltage that varies from about 4.1 volts, when fully charged, to about 3.5 volts.
[0011] A number of different new invented components are part of the newly invented SCS system herein. There are a number of different sub-components for each newly invented component that are part of the newly invented SCS system. Starting from a top hierarchal level, the newly invented SCS system is composed of an IPG, Trial generator, Wireless Dongle, IPG Charger, Clinical Programmer Software, Patient Programmer Software, Leads (percutaneous and paddle), Lead anchors, Lead Splitters, Lead Extensions, and Accessories. FIG. 1 depicts the components during trial and permanent implantation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 depicts various components that can be included in a spinal cord stimulation system, according to an embodiment.
[0013] FIG. 2 depicts an exploded view of an implantable pulse generator (IPG) assembly, according to an embodiment.
[0014] FIG. 3 depicts a feedthrough assembly of an implantable pulse generator (IPG) assembly, according to an embodiment.
[0015] FIG. 4 depicts a lead contact system of an implantable pulse generator (IPG) assembly, according to an embodiment.
[0016] FIG. 5 depicts a lead contact assembly of an implantable pulse generator (IPG) assembly, according to an embodiment.
[0017] FIG. 6 depicts a head unit assembly of an implantable pulse generator (IPG) assembly, according to an embodiment.
[0018] FIG. 7 depicts an RF antenna of an implantable pulse generator (IPG) assembly, according to an embodiment.
[0019] FIG. 8 depicts a percutaneous lead, according to an embodiment.
[0020] FIG. 9 depicts a paddle lead, according to an embodiment.
[0021] FIG. 10 depicts a lead extension, according to an embodiment.
[0022] FIG. 11 depicts a lead splitter, according to an embodiment.
[0023] FIG. 12 depicts a sleeve anchor, according to an embodiment.
[0024] FIG. 13 depicts a mechanical locking anchor, according to an embodiment.
[0025] FIG. 14 illustrates communication via a wireless dongle with a tablet/clinician programmer and smartphone/mobile/patient programmer during trial and/or permanent implantation, according to an embodiment.
[0026] FIG. 15 depicts a Tuohy needle, according to an embodiment.
[0027] FIG. 16 depicts a stylet, according to an embodiment.
[0028] FIG. 17 depicts a passing elevator, according to an embodiment.
[0029] FIG. 18 depicts a tunneling tool, according to an embodiment.
[0030] FIG. 19 depicts a torque wrench, according to an embodiment.
DETAILED DESCRIPTION
Implantable Pulse Generator (IPG)
[0031] The spinal cord stimulator (SCS) is an implantable device used to deliver electrical pulse therapy to the spinal cord in order to treat chronic pain. The implantable components of the system consist of an Implantable Pulse Generator (IPG) and a multitude of stimulation electrodes. The IPG is implanted subcutaneously, no more than 30 mm deep in an area that is comfortable for the patient while the stimulation electrodes are implanted directly in the epidural space. The electrodes are wired to the IPG via leads which keep the stimulation pulses isolated from each other in order to deliver the correct therapy to each individual electrode.
[0032] The therapy delivered consists of electrical pulses with controlled current amplitude ranging from +12.7 to −12.7 mA (current range 0-25.4 mA). These pulses can be programmed in both length and frequency from 10 μS to 2000 μS and 0.5 Hz to 1200 Hz. At any given moment, the sum of the currents sourced from the anodic electrodes must equal the sum of the currents sunk by the cathodic electrodes. In addition, each individual pulse is bi-phasic, meaning that once the initial pulse finishes another pulse of opposite amplitude is generated after a set holdoff period. The electrodes may be grouped into stimulation sets in order to deliver the pulses over a wider area or to target specific areas, but the sum of the currents being sourced at any one given time may not exceed 20 mA. A user can also program different stim sets (up to eight) with different parameters in order to target different areas with different therapies.
[0033] The IPG consists of two major active components, a battery, antenna, some support circuitry, and a multitude of output capacitors. The first of the major active components is the microcontroller transceiver. It is responsible for receiving, decoding, and execution both commands and requests from the external remote. If necessary it passes these commands or requests onto the second major component, the ASIC. The ASIC receives the digital data from the microcontroller and performs the entire signal processing to generate the signals necessary for stimulation. These signals are then passed onto the stimulation electrodes in the epidural space.
[0034] The ASIC itself is by far the most complex piece of the design. It is made up of a digital section and an analog section. The digital section if further divided into multiple sections including; Timing Generators, Arbitration Control, Pulse Burst Conditioner, and Electrode Logic. The analog section has the simple job of taking the incoming pulses from the digital section and simply amplifying them in order to deliver the correct therapy. There are also a multitude of digital register memory elements that each section utilizes, both digital and analog.
[0035] The digital elements in the ASIC are all made up of standard subsets of digital logic including logic gates, timers, counters, registers, comparators, flip-flips, and decoders. These elements are ideal for processing the stimulation pulses as all of them can function extremely fast—orders of magnitudes faster than the required pulse width. The one drawback is that they must all function at one single voltage, usually 5.0, 3.3, 2.5, or 1.8 volts. Therefore they are not suitable for the final stage in which the pulses are amplified in order to deliver the constant current pulses.
[0036] The timing generators are the base of each of the stimulation sets. It generates the actual rising and falling edge triggers for each phase of the bi-phasic pulse. It accomplishes this by taking the incoming clock that is fed from the microcontroller and feeding it into a counter. For the purpose of this discussion, assume the counter simply counts these rising clock edges infinitely. The output of the counter is fed into six different comparators. The comparators other input is connected to specific registers that are programmed by the microcontroller. When the count equals the value stored in the register, the comparator asserts a positive signal.
[0037] The first comparator is connected to the SET signal of a SR flip flop. The SR flip flop stays positive until the RESET signal is asserted, which the second comparator is connected to. The output of the SR flip flop is the first phase of the bi-phasic pulse. Its rising & falling edges are values stored in the registers and programmed by the microcontroller. The third and fourth comparators & registers work in exactly the same way to produce the second phase of the bi-phasic pulse using the second SR flip flop.
[0038] The fifth comparator is connected the RESET of the final SR-Flip flop in the timing generator. This flip flop is SET by the first comparator, which is the rising edge of the first pulse. The RESET is then triggered by the value the microprocessor programmed into the register connected to the comparator. This allows for a ‘holdoff’ period after the falling edge of the second pulse. The output of this third SR flip flop can be thought of as an envelope of the biphasic pulses indicating when this particular timing generator is active.
[0039] The final comparator of the system is once again connected to a register that stores the frequency values from the microprocessor. Essentially when the count reaches this value it triggers the comparator which is fed back to the counter to reset it to zero and beginning the entire pulse generation cycle again. The ASIC may contain many of these timing generators as each can control anywhere from two to all of the electrodes connected to the IPG at a time. However, when there is more than one timing generator and multiple channels have been actively programmed then there needs to be a mechanism for suppressing a second channel from turning on when another is already active.
[0040] This brings us to the next circuit block contained in the IPG, the arbitrator. The arbitrator functions by looking at each of the timing generators' envelope signals and makes sure only one can be active at a time. If a second tries to activate then the arbitrator suppresses that signal.
[0041] It accomplishes this by bringing each of the channel envelope signals into a rising edge detection circuit. Once one is triggered it is fed into the SET pin of an SR flip flop. The output of this SR-flip flop is fed into all of the other rising edge detectors in order to suppress them from triggering. The channel envelope signal is also fed into a falling-edge detector which is then fed into the RESET of the same SR flip flop. The output of the SR flip flops are then connected to switches whose outputs are all tied together that turn on/off that channels particular biphasic pulse train. Therefore the output of this circuit element is a single bi-phasic pulse train and a signal designating which timing generator that particular pulse train is sourced from. Essentially, the circuit looks for a channel to go active. Once it finds one it suppresses all others until that channel becomes inactive.
[0042] The next section of the circuit works very similarly to the timing generators to create a high speed burst pulse train that is then combined with the stimulation pulse train to create a bursted bi-phasic pulse train if desired.
[0043] It accomplishes this by taking the incoming clock that is fed from the microcontroller and feeding it into a counter. For the purpose of this discussion, assume the counter simply counts these rising clock edges infinitely. The counter is only active when during a single phase of the bi-phasic signal and begins counting as soon as the rising edge is detected. The output of the counter is fed into a comparator, along with a microcontroller-programmed register, whose output is connected to the reset pin on the counter. Therefore this counter will simply count to a programmed value & reset. This programmed value is the burst frequency.
[0044] The output of the comparator is then fed into an edge detection circuit and then a flip flop that combines it with the actual stimulation pulse train to create a single phase bursted stimulation pulse. The entire circuit is duplicated for the second phase of the signal resulting in the desired bursted bi-phasic pulse train. The stimulation signal is now ready to be handed over to the electrode logic stage.
[0045] The electrode logic conditions and directs the bi-phasic signals to the analog section of the ASIC. At this point, the bi-phasic signals contain all of the pertinent timing information, but none of the required amplitude information. The incoming signals include the bi-phasic pulse train and another signal designating which timing generator the current active train came from. Each electrode logic cell has a register for each timing generator that stores this particular electrode's amplitude values for that timing generator. The electrode logic cell uses the designation signal to determine which register to pull the amplitude values from, e.g. if the third timing generator is passed through the arbitration circuit then the electrode logic would read the value from the third register.
[0046] Once the value is pulled from the register, it goes through a series of logic gates. The gates first determine that the electrode should be active. If not, they proceed no further and do not activate the analog section of the electrode output, thereby saving precious battery power. Next they determine if this particular electrode is an anode or cathode. If it is deemed to be an anode, the electrode logic passes the amplitude information and the biphasic signal to the positive current (digital to analog converter) DAC in the analog section of the ASIC. If it is deemed to be a cathode, the electrode logic passes the amplitude information and the biphasic signal to the negative current DAC in the analog section of the ASIC. The electrode logic circuit must make these decisions for each phase of the bi-phasic signal as every electrode will switch between being an anode and a cathode.
[0047] The analog elements in the ASIC are uniquely designed in order to produce the desired signals. The basis of analog IC design is the field effect transistor (FET) and the type of high current multiple output design required in SCS means that the bulk of the silicon in the ASIC will be dedicated to the analog section.
[0048] The signals from the electrode output are fed into each current DAC when that specific electrode should be activated. Each electrode has a positive and a negative current DAC, triggered by the electrode logic and both are never active at the same time. The job of each current DAC is, when activated, to take the digital value representing a stimulation current amplitude and produce an analog representation of this value to be fed into the output stage. This circuit forms half of the barrier between the digital and analog sections of the ASIC.
[0049] The digital section of the ASIC is built upon a technology that only allows small voltages to exist. In moving to the analog section, the output of the current DAC (which is a low level analog signal) must be amplified to a higher voltage for use in the analog section. The circuit that performs this task is called a power level shifter. Because this circuit is built upon two different manufacturing technologies and requires high precision analog circuits built upon a digital base, it is extremely difficult to implement.
[0050] Once the voltages have been converted for usage in the analog portion of the ASIC they are passed on to the output current stages. There are two current sources per electrode output. One will source a positive current and one will sink a negative current, but they will never both be active simultaneously. The current sources themselves are made up of analog elements similar to a Howland current source. There is an input stage, and amplification stage with feedback through a sensing component to maintain the constant current. The input stage takes the analog voltage values from the power level shifter and produces an output pulse designated for the amplifier. The amplifier then creates the pulses of varying voltages but constant current flow. The sources are capable of sourcing or sinking up to 12.7 mA at 0.1 mA resolution into a load of up to 1.2 k Ohms. This translates into range of 15 volts, which will vary depending on the load in order to keep the current constant.
[0051] The microcontroller to ASIC interface is designed to be as simple as possible with minimal bus ‘chatter’ in order to save battery life. The ASIC will essentially be a collection of registers programmed via a standard I 2 C or SPI bus. Since the ASIC is handling all the power management, there will also be a power good (PG) line between the two chips in order to let the microcontroller know when it is safe to power up. The ASIC will also need to use a pin on the microcontroller in order to generate a hardware interrupt in case anything goes awry in the ASIC. The final connection is the time base for all of the stimulation circuitry. The ASIC will require two clocks, one for its internal digital circuitry which will be fed directly from the microcontroller clock output, and one to base all stimulation off of which will need to be synthesized by the microcontroller and fed to the ASIC. All commands and requests to the ASIC will be made over the I 2 C or SPI bus and will involve simply reading a register address or writing to a register. Even when the ASIC generates a hardware interrupt, it will be the responsibility of the microcontroller to poll the ASIC and determine the cause of the interrupt.
[0052] The wireless interface is based upon the FCCs MedRadio standard operating in the 402-405 Mhz range utilizing up to 10 channels for telemetry. The protocol is envisioned to be very simple once again in order to minimize transmission and maximize battery life. All processing will take place on the user remote/programmer and the only data transmitted is exactly what will be used in the microcontroller to ASIC bus. That is, all of the wireless packets will contain necessary overhead information along with only a register address, data to store in the register, and a command byte instructing the microcontroller what to do with the data. The overhead section of the wireless protocol will contain synchronization bits, start bytes, an address which is synchronized with the IPG's serial number, and a CRC byte to assure proper transmission. It is essential to keep the packet length as small as possible in order to maintain battery life. Since the IPG cannot listen for packets all the time due to battery life, it cycles on for a duty cycle of less than 0.05% of the time. This time value can be kept small as long as the data packets are also small. The user commands needed to run the system are executed by the entire system using flows.
[0053] The IPG uses an implantable grade Li ion battery with 215 mAHr with zero volt technology. The voltage of the battery at full capacity is 4.1 V and it supplies current only until it is drained up to 3.3 V which is considered as 100% discharged. The remaining capacity of the battery can be estimated at any time by measuring the voltage across the terminals. The maximum charge rate is 107.5 mA. A Constant Current, Constant Voltage (CCCV) type of regulation can be applied for faster charging of the battery.
[0054] The internal secondary coil L2 is made up of 30 turns of 30 AWG copper magnet wires. The ID, OD, and the thickness of the coil are 30, 32, and 2 mm, respectively. Inductance L2 is measured to be 58 uH, a 80 nF capacitor is connected to it to make a series resonance tank at 74 kHz frequency. Two types of rectifiers are considered to convert the induced AC into usable DC-a bridge full wave rectifier and a voltage doubler kind of full wave rectifier. To get higher voltage, later type of rectifier is used in this design. The rectifier is built with high speed Schottky diodes to improve its function at high frequencies of the order 100 kH. A Zener diode and also a 5V voltage regulator are used for regulation. This circuit will be able to induce AC voltage, rectify to DC, regulate to 5V and supply 100 mA current to power management IC that charges the internal battery by CCCV regulation.
[0055] The regulated 5V 100 mA output from the resonance tank is fed to, for example, a Power Management Integrated Circuit (PMIC) MCP73843. This particular chip was specially designed by Microchip to charge a Li ion battery to 4.1 V by CCCV regulation. The fast charge current can be regulated by changing a resistor; it is set to threshold current of 96 mA in this circuit. The chip charges the battery to 4.1 V as long as it receives current more than 96 mA. However, if the supply current drops below 96 mA, it stops to charge the battery until the supply is higher than 96 again. For various practical reasons, if the distance between the coils increases, the internal secondary coil receives lesser current than the regulated value, and instead of charging the battery slowly, it pauses the charging completely until it receives more than 96 mA.
[0056] All the functions of the IPG are controlled from outside using a hand held remote controller specially designed for this device. Along with the remote control, an additional control is desirable to operate the IPG if the remote control was lost or damaged. For this purpose a Hall effect based magnet switch was incorporated to either turn ON or turn OFF the IPG using an external piece of magnet. Magnet switch acts as a master control for the IPG to turn on or off. A south pole of sufficient strength turns the output on and a north pole of sufficient strength is necessary to turn the output off. The output is latched so that the switch continues to hold the state even after the magnet is removed from its vicinity.
[0057] The IPG is an active medical implant that generates an electrical signal that stimulates the spinal cord. The signal is carried through a stimulation lead that plugs directly into the IPG. The IPG recharges wirelessly through an induction coil, and communicates via RF radio antenna to change stimulation parameters. The IPG is implanted up to 3 cm below the surface of the skin and is fixed to the fascia by passing two sutures through holes in the epoxy header. The leads are electrically connected to the IPG through a lead contact system, a cylindrical spring-based contact system with inter-contact silicone seals. The leads are secured to the IPG with a set screw that actuates within locking housing. Set screw compression on the lead's fixation contact is governed by a disposable torque wrench. The wireless recharging is achieved by aligning the exterior induction coil on the charger with the internal induction coil within the IPG. The RF antenna within the remote's dongle communicates with the RF antenna in the IPG's epoxy header. FIG. 2 illustrates an exploded view of the IPG assembly.
[0058] The IPG is an assembly of a hermetic titanium (6Al-4V) casing which houses the battery, circuitry, and charging coil, with an epoxy header, which houses the lead contact assembly, locking housing, and RF antenna. The internal electronics are connected to the components within the epoxy head through a hermetic feedthrough, as shown in FIG. 3 . The feedthrough is a titanium (6Al-4V) flange with an alumina window and gold trimming. Within the alumina window are thirty-four platinum-iridium (90-10) pins that interface internally with a direct solder to the circuit board, and externally with a series of platinum iridium wires laser-welded to the antenna and lead contacts. The IPG has the ability to interface with 32 electrical contacts, which are arranged in four rows of eight contacts. Thirty two of the feedthrough's pins will interface with the contacts, while two will interface with the antenna, one to the ground plane and one to the antenna feed.
[0059] FIGS. 4 and 5 depict a lead contact system and assembly, respectively. The lead contacts consist of an MP35N housing with a platinum-iridium 90-10 spring. Each contact is separated by a silicone seal. At the proximal end of each stack of 8 contacts is a titanium (6Al-4V) cap which acts as a stop for the lead. At the distal end is a titanium (6Al-4V) set screw and block for lead fixation. At the lead entrance point there is a silicone tube which provides strain relief as the lead exits the head unit, and above the set screw is another silicone tube with a small internal canal which allows the torque wrench to enter but does not allow the set screw to back out. In addition to the contacts and antenna, the header also contains a radiopaque titanium (6Al-4V) tag which allows for identification of the device under fluoroscopy. The overmold of the header is Epotek 301, a two-part, biocompatible epoxy. FIGS. 4 , 5 , 6 , and 7 depict illustrations of lead contact system, lead contact assembly, head unit assembly, and RF antenna, respectively.
[0060] Internal to the titanium (6Al-4V) case are the circuit board, battery, charging coil, and internal plastic support frame. The circuit board will be a multi-layered FR-4 board with copper traces and solder mask coating. Non-solder masked areas of the board will be electroless nickel immersion gold. The implantable battery, all surface mount components, ASIC, microcontroller, charging coil, and feedthrough will be soldered to the circuit board. The plastic frame, made of either polycarbonate or ABS, will maintain the battery's position and provide a snug fit between the circuitry and case to prevent movement. The charging coil is a wound coated copper.
Leads
[0061] The percutaneous stimulation leads, as depicted in FIG. 8 , are a fully implantable electrical medical accessory to be used in conjunction with the implantable SCS. The primary function of the lead is to carry electrical signals from the IPG to the target stimulation area on the spinal cord. Percutaneous stimulation leads provide circumferential stimulation. The percutaneous stimulation leads must provide a robust, flexible, and bio-compatible electric connection between the IPG and stimulation area. The leads are surgically implanted through a spinal needle, or epidural needle, and are driven through the spinal canal using a steering stylet that passes through the center of the lead. The leads are secured mechanically to the patient using either an anchor or a suture passed through tissue and tied around the body of the lead. The leads are secured at the proximal end with a set-screw on the IPG which applies radial pressure to a blank contact on the distal end of the proximal contacts.
[0062] The percutaneous stimulation leads consist of a combination of implantable materials. Stimulation electrodes at the distal end and electrical contacts at the proximal end are made of a 90-10 platinum-iridium alloy. This alloy is utilized for its bio-compatibility and electrical conductivity. The electrodes are geometrically cylindrical. The polymeric body of the lead is polyurethane, which is chosen for its bio-compatibility, flexibility, and high lubricity to decrease friction while being passed through tissue. The polyurethane tubing has a multi-lumen cross section, with one center lumen and eight outer lumens. The center lumen acts as a canal to contain the steering stylet during implantation, while the outer lumens provide electrical and mechanical separation between the wires that carry stimulation from the proximal contacts to distal electrodes. These wires are a bundle of MP35N strands with a 28% silver core. The wires are individually coated with ethylene tetrafluoroethylene (ETFE), to provide an additional non-conductive barrier. The wires are laser welded to the contacts and electrodes, creating an electrical connection between respective contacts on the proximal and distal ends. The leads employ a platinum-iridium plug, molded into the distal tip of the center lumen to prevent the tip of the steering stylet from puncturing the distal tip of the lead. Leads are available in a variety of 4 and 8 electrode configurations. These leads have 4 and 8 proximal contacts (+1 fixation contact), respectively. Configurations vary by electrode number, electrode spacing, electrode length, and overall lead length.
[0063] The paddle stimulation leads, as depicted in FIG. 9 , are a fully implantable electrical medical accessory to be used in conjunction with the implantable SCS. The primary function of the paddle lead is to carry electrical signals from the IPG to the target stimulation area on the spinal cord. The paddle leads provide uni-direction stimulation across a 2-dimensional array of electrodes, allowing for greater precision in targeting stimulation zones. The paddle stimulation leads must provide a robust, flexible, and bio-compatible electric connection between the IPG and stimulation area. The leads are surgically implanted through a small incision, usually in conjunction with a laminotomy or laminectomy, and are positioned using forceps or a similar surgical tool. The leads are secured mechanically to the patient using either an anchor or a suture passed through tissue and tied around the body of the lead. The leads are secured at the proximal end with a set-screw on the IPG which applies radial pressure to a fixation contact on the distal end of the proximal contacts.
[0064] The paddle stimulation leads consist of a combination of implantable materials. Stimulation electrodes at the distal end and electrical contacts at the proximal end are made of a 90-10 platinum-iridium alloy. This alloy is utilized for its bio-compatibility and electrical conductivity. The polymeric body of the lead is polyurethane, which is chosen for its bio-compatibility, flexibility, and high lubricity to decrease friction while being passed through tissue. The polyurethane tubing has a multi-lumen cross section, with one center lumen and eight outer lumens. The center lumen acts as a canal to contain the steering stylet during implantation, while the outer lumens provide electrical and mechanical separation between the wires that carry stimulation from the proximal contacts to distal electrodes. These wires are a bundle of MP35N strands with a 28% silver core. The wires are individually coated with ethylene tetrafluoroethylene (ETFE), to provide an additional non-conductive barrier. At the distal tip of the paddle leads, there is a 2-dimensional array of flat rectangular electrodes, molded into a flat silicone body. Only one side of the rectangular electrodes is exposed, providing the desired uni-directional stimulation. The wires are laser welded to the contacts and electrodes, creating an electrical connection between respective contacts on the proximal and distal ends. Also molded into the distal silicone paddle is a polyester mesh which adds stability to the molded body while improving aesthetics by covering wire routing. The number of individual 8-contact leads used for each paddle is governed by the number of electrodes. Electrodes per paddle range from 8 to 32, which are split into between one and four proximal lead ends. Each proximal lead has 8 contacts (+1 fixation contact). Configurations vary by electrode number, electrode spacing, electrode length, and overall lead length.
[0065] The lead extensions, as depicted in FIG. 10 , are a fully implantable electrical medical accessory to be used in conjunction with the implantable SCS and either percutaneous or paddle leads. The primary function of the lead extension is to increase the overall length of the lead by carrying electrical signals from the IPG to the proximal end of the stimulation lead. This extends the overall range of the lead in cases where the length of the provided leads is insufficient for case. The lead extensions leads must provide a robust, flexible, and bio-compatible electric connection between the IPG and proximal end of the stimulation lead. The extensions may be secured mechanically to the patient using either an anchor or a suture passed through tissue and tied around the body of the extension. Extensions are secured at the proximal end with a set-screw on the IPG which applies radial pressure to a fixation contact on the distal end of the proximal contacts of the extension. The stimulation lead is secured to the extension in a similar fashion, using a set screw inside the molded tip of extension to apply a radial pressure to the fixation contact at the proximal end of the stimulation lead.
[0066] The lead extension consists of a combination of implantable materials. At the distal tip of the extension is a 1×8 array of implantable electrical contacts, each consisting of MP35 housing and 90-10 platinum-iridium spring. A silicone seal separates each of the housings. At the proximal end of the contacts is a titanium (6Al4V) cap which acts as a stop for the lead, and at the distal tip, a titanium (6Al4V) block and set screw for lead fixation. The electrical contacts at the proximal end are made of a 90-10 platinum-iridium alloy. This alloy is utilized for its bio-compatibility and electrical conductivity. The polymeric body of the lead is polyurethane, which is chosen for its bio-compatibility, flexibility, and high lubricity to decrease friction while being passed through tissue. The polyurethane tubing has a multi-lumen cross section, with one center lumen and eight outer lumens. The center lumen acts as a canal to contain the steering stylet during implantation, while the outer lumens provide electrical and mechanical separation between the wires that carry stimulation from the proximal contacts to distal electrodes. These wires are a bundle of MP35N strands with a 28% silver core. The wires are individually coated with ethylene tetrafluoroethylene (ETFE), to provide an additional non-conductive barrier. Each lead extension has 8 proximal cylindrical contacts (+1 fixation contact).
[0067] The lead splitter, as depicted in FIG. 11 , is a fully implantable electrical medical accessory which is used in conjunction with the SCS and typically a pair of 4-contact percutaneous leads. The primary function of the lead splitter is to split a single lead of eight contacts into a pair of 4 contact leads. The splitter carries electrical signals from the IPG to the proximal end of two 4-contact percutaneous stimulation leads. This allows the surgeon access to more stimulation areas by increasing the number of stimulation leads available. The lead splitter must provide a robust, flexible, and bio-compatible electrical connection between the IPG and proximal ends of the stimulation leads. The splitters may be secured mechanically to the patient using either an anchor or a suture passed through tissue and tied around the body of the splitter. Splitters are secured at the proximal end with a set-screw on the IPG which applies radial pressure to a fixation contact on the distal end of the proximal contacts of the splitter. The stimulation leads are secured to the splitter in a similar fashion, using a pair of set screws inside the molded tip of splitter to apply a radial pressure to the fixation contact at the proximal end of each stimulation lead.
[0068] The lead splitter consists of a combination of implantable materials. At the distal tip of the splitter is a 2×4 array of implantable electrical contacts, with each contact consisting of MP35 housing and 90-10 platinum-iridium spring. A silicone seal separates each of the housings. At the proximal end of each row of contacts is a titanium (6Al4V) cap which acts as a stop for the lead, and at the distal tip, a titanium (6Al4V) block and set screw for lead fixation. The electrical contacts at the proximal end of the splitter are made of a 90-10 platinum-iridium alloy. This alloy is utilized for its bio-compatibility and electrical conductivity. The polymeric body of the lead is polyurethane, which is chosen for its bio-compatibility, flexibility, and high lubricity to decrease friction while being passed through tissue. The polyurethane tubing has a multi-lumen cross section, with one center lumen and eight outer lumens. The center lumen acts as a canal to contain the steering stylet during implantation, while the outer lumens provide electrical and mechanical separation between the wires that carry stimulation from the proximal contacts to distal electrodes. These wires are a bundle of MP35N strands with a 28% silver core. The wires are individually coated with ethylene tetrafluoroethylene (ETFE), to provide an additional non-conductive barrier. Each lead splitter has 8 proximal contacts (+1 fixation contact), and 2 rows of 4 contacts at the distal end.
Anchors
[0069] The lead anchor, as depicted in FIGS. 12 and 13 , is a fully implantable electrical medical accessory which is used in conjunction with both percutaneous and paddle stimulation leads. The primary function of the lead anchor is to prevent migration of the distal tip of the lead by mechanically locking the lead to the tissue. There are currently two types of anchors, a simple sleeve, depicted in FIG. 12 , and a locking mechanism, depicted in FIG. 13 , and each has a slightly different interface. For the simple sleeve type anchor, the lead is passed through the center thru-hole of the anchor, and then a suture is passed around the outside of the anchor and tightened to secure the lead within the anchor. The anchor can then be sutured to the fascia. The locking anchor uses a set screw for locking purposes, and a bi-directional disposable torque wrench for locking and unlocking. Tactile and audible feedback is provide for both locking and unlocking.
[0070] Both anchors are molded from implant-grade silicone, but the locking anchor uses an internal titanium assembly for locking. The 3-part mechanism is made of a housing, a locking set screw, and a blocking set screw to prevent the locking set screw from back out. All three components are titanium (6Al4V). The bi-directional torque wrench has a plastic body and stainless steel hex shaft.
Wireless Dongle
[0071] The wireless dongle is the hardware connection to a smartphone/mobile or tablet that allows communication between the trial generator or IPG and the smartphone/mobile device or tablet, as illustrated in FIG. 14 . During the trial or permanent implant phases, the wireless dongle is connected to the tablet through the tablet specific connection pins and the clinician programmer software on the tablet is used to control the stimulation parameters. The commands from the clinician programmer software are transferred to the wireless dongle which is then transferred from the wireless dongle using RF signals to the trial generator or the IPG. Once the parameters on the clinician programmers have been set, the parameters are saved on the tablet and transferred to the patient programmer software on the smartphone/mobile device. The wireless dongle is composed of an antenna, a microcontroller (having the same specifications as the IPG and Trial Generator), and a pin connector to connect with the smartphone/mobile device and the tablet.
Charger
[0072] The IPG has a rechargeable Lithium ion battery to power its activities. An external induction type charger is necessary to recharge the included battery inside the IPG wirelessly. The charger consists of a rechargeable battery, a primary coil of wire and a printed circuit board (PCB) for the electronics—all packaged into a housing. When switched on, this charger produces magnetic field and induces voltage into the secondary coil in the implant. The induced voltage is then rectified and then used to charge the battery inside the IPG. To maximize the coupling between the coils, both internal and external coils are combined with capacitors to make them resonate at a particular common frequency. The coil acting as an inductor L forms an LC resonance tank. The charger uses a Class-E amplifier topology to produce the alternating current in the primary coil around the resonant frequency. Below are the charger features;
Charges IPG wirelessly Charges up to a maximum depth of 30 mm Integrated alignment sensor helps align the charger with IPG for higher power transfer efficiency Alignment sensor gives an audible and visual feedback to the user Compact and Portable
[0078] A protected type of cylindrical Li ion battery is used as the charger battery. A Class-E of the topologies of the power amplifiers has been the most preferred type of amplifier for induction chargers, especially for implantable electronic medical devices. It's relatively high theoretical efficiency made it the most favorable choice for devices where high efficiency power transfer is necessary. A 0.1 ohm high wattage resistor is used in series to sense the current through this circuit.
[0079] The primary coil L1 is made by 60 turns of Litz wire type 100/44-100 strands of 44 AWG each. The Litz wire solves the problem of skin effect and keeps its impedance low at high frequencies. Inductance of this coil was initially set at 181 uH, but backing it with a Ferrite plate increases the inductance to 229.7 uH. The attached ferrite plate focuses the produced magnetic field towards the direction of the implant. Such a setup helps the secondary coil receive more magnetic fields and aids it to induce higher power.
[0000] When the switch is ON, the resonance is at frequency
[0000]
f
=
1
2
π
L
1
C
2
[0000] When the switch is OFF, it shifts to
[0000]
f
=
1
2
π
L
1
C
1
C
2
C
1
+
C
2
[0000] In a continuous operation the resonance frequency will be in the range
[0000]
1
2
π
L
1
C
2
<
f
<
1
2
π
L
1
C
1
C
2
C
1
+
C
2
[0080] To make the ON and OFF resonance frequencies closer, a relatively larger value of C1 can be chosen by a simple criteria as follows
[0000] C1=nC2; a value of n=4 was used in the example above; in most cases 3<n<10.
[0081] The voltages in these Class-E amplifiers typically go up to the order of 300VAC. Capacitors selected must be able to withstand these high voltages, sustain high currents and still maintain low Effective Series Resistance (ESR). Higher ESRs result in unnecessary power losses in the form of heat. The circuit is connected to the battery through an inductor which acts as a choke. The choke helps to smoothen the supply to the circuit. The N Channel MOSFET acts as a switch in this Class-E power amplifier. A FET with low ON resistance and with high drain current I d is desirable.
[0082] In summary, the circuit is able to recharge the IPG battery from 0 to 100% in 2 Hr 45 Min with distance between the coils being 29 mm. The primary coil and the Class-E amplifier draws DC current of 0.866 A to achieve this task. To improve the efficiency of the circuit, a feedback closed loop control is implemented to reduce the losses. The loses are minimum when the MOSFET is switched ON and when the voltage on its drain side is close to zero.
[0083] The controller takes the outputs from operational amplifiers, checks if they meet the criteria, then it triggers the driver to switch ON the MOSFET for next cycle. The controller needs to use a delay timer, an OR gate and a 555 timer in monostable configuration to condition the signal for driver. When the device is switched ON, the circuit does not start to function right away as there will be no active feedback loop. The feedback becomes active only if the circuit starts to function. To solve this riddle, an initial external trigger is applied to jump start the system.
Alignment Sensor
[0084] The efficiency of the power transfer between the external charger and the internal IPG will be maximum only when they are properly aligned. An alignment sensor is absolutely necessary to ensure a proper alignment. This is a part of the external circuit design. The first design is based on the principle called reflected impedance. When the external is brought closer to the internal, the impedance of the both circuits change. The sensing is based on measuring the reflected impedance and test whether it crosses the threshold. A beeper is used to give an audible feedback to the patient; an LED is used for visual feedback.
[0085] When the impedance of the circuit changes, the current passing through it also changes. A high power 0.1 ohm resistor is used in the series of the circuit to monitor the change in current. The voltage drop across the resistor is amplified 40 times and then compared to a fixed threshold value using a operational amplifier voltage comparator. The output was fed to a timer chip which in turn activates the beeper and LED to give feedback to the user.
[0086] This circuit was successfully implemented in the lab on the table top version. The circuit was able to sense the alignment up to a distance of 30 mm. The current fluctuation in the circuit depends on more factors than reflected impedance alone and the circuit is sensitive to other parameters of the circuit as well. To reduce the sensitivity related to other parameters, one option is to eliminate interference of all the other factors and improve the functionality of the reflected impedance sensor—which is very challenging to implement within the limited space available for circuitry. Another option is to use a dedicated sensor chip to measure the reflected impedance.
[0087] A second design uses sensors designed for proximity detector or metal detectors for alignment sensing. Chips designed to detect metal bodies by the effect of Eddy currents on the HF losses of a coil can be used for this application. The TDE0160 is an example of such a chip.
[0088] The external charger is designed to work at 75 to 80 kHz, whereas the proximity sensor was designed for 1 MHz. The sensor circuit is designed to be compatible with rest of the external and is fine tuned to detect the internal IPG from a distance of 30 mm.
Programmer
[0089] The Clinician Programmer is an application that is installed on a tablet. It is used by the clinician to set the stimulation parameters on the Trial Generator or IPG during trial and permanent implantation in the operating room. The clinician programmer is capable of saving multiple settings for multiple patients and can be used to adjust the stimulation parameters outside of the operations room. It is capable of changing the stimulation parameters though the RF Wireless Dongle when the Trial generator or IPG in the patient is within the RF range. In addition, it is also capable of setting or changing the stimulation parameters on the Trial Generator and/or the IPG through the internet when both the tablet and the Patient Programmers on a smartphone/mobile device both have access to the interne.
[0090] The Patient Programmer is an application that is installed on a smartphone/mobile device. It is used by the patient to set the stimulation parameters on the Trial Generator or IPG after trial and permanent implantation outside the operating room. The clinician programmer is capable of saving multiple settings for multiple patients and can be transferred to the Patient Programmer wirelessly when the Clinician Programmer tablet and the Patient Programmer smartphone/mobile device are within wireless range such as Bluetooth from each other. In the scenario where the Clinician Programmer tablet and the Patient Programmer smartphone/mobile device are out of wireless range from each other, the data can be transferred through the internet where both devices have wireless access such as Wi-Fi. The Patient Programmer is capable of changing the stimulation parameters on the Trial Generator or IPG though the RF Wireless Dongle when the Trial generator or IPG in the patient is within the RF range. However, the Patient Programmer has limitations to changing the stimulation parameters.
Tuohy Needle
[0091] The tuohy needle, as depicted in FIG. 15 , is used in conjunction with a saline-loaded syringe for loss-of-resistance needle placement, and percutaneous stimulation leads, for lead placement into the spinal canal. The tuohy epidural needle is inserted slowly into the spinal canal using a loss-of-resistance technique to gauge needle depth. Once inserted to the appropriate depth, the percutaneous stimulation lead is passed through the needle and into the spinal canal.
[0092] The epidural needle is a non-coring 14 G stainless steel spinal needle and will be available in lengths of 5″ (127 mm) and 6″ (152.4). The distal tip of the needle has a slight curve to direct the stimulation lead into the spinal canal. The proximal end is a standard Leur-Lock connection.
Stylet
[0093] The stylet, as depicted in FIG. 16 , is used to drive the tip of a percutaneous stimulation lead to the desired stimulation zone by adding rigidity and steerability. The stylet wire passes through the center lumen of the percutaneous lead and stops at the blocking plug at the distal tip of the lead. The tip of the stylet comes with both straight and curved tips. A small handle is used at the proximal end of the stylet to rotate the stylet within the center lumen to assist with driving. This handle can be removed and reattached allowing anchors to pass over the lead while the stylet is still in place. The stylet wire is a PTFE coated stainless steel wire and the handle is plastic.
Passing Elevator
[0094] The passing elevator, as depicted in FIG. 17 , is used prior to paddle lead placement to clear out tissue in the spinal canal and help the surgeon size the lead to the anatomy. The passing elevator provides a flexible paddle-shaped tip to clear the spinal canal of obstructions. The flexible tip is attached to a surgical handle.
[0095] The passing elevator is a one-piece disposable plastic instrument made of a flexible high strength material with high lubricity. The flexibility allows the instrument to easily conform to the angle of the spinal canal and the lubricity allows the instrument to easily pass through tissue.
Tunneling Tool
[0096] The tunneling tool, as depicted in FIG. 18 , is used to provide a subcutaneous canal to pass stimulation leads from the entrance point into the spinal canal to the IPG implantation site. The tunneling tool is a long skewer-shaped tool with a ringlet handle at the proximal end. The tool is cover by a plastic sheath with a tapered tip which allows the tool to easily pass through tissue. Once the IPG implantation zone is bridge to the lead entrance point into the spinal canal, the inner core is removed, leaving the sheath behind. The leads can then be passed through the sheath to the IPG implantation site. The tunneling tool is often bent to assist in steering through the tissue.
[0097] The tunneling tool is made of a 304 stainless steel core with a fluorinated ethylene propylene (FEP) sheath. The 304 stainless steel is used for its strength and ductility during bending, and the FEP is used for its strength and lubricity.
Torque Wrench
[0098] The torque wrench, as depicted in FIG. 19 , is used in conjunction with the IPG, lead extension and lead splitter to tighten the internal set screw, which provides a radial force against the fixation contact of the stimulation leads, preventing the leads from detaching. The torque wrench is also used to lock and unlock the anchor. The torque wrench is a small, disposable, medical instrument that is used in every SCS case. The torque wrench provides audible and tactile feedback to the surgeon that the lead is secured to the IPG, extension, or splitter, or that the anchor is in the locked or unlocked position.
[0099] The torque wrench is a 0.9 mm stainless steel hex shaft assembled with a plastic body. The wrench's torque rating is bi-directional, primarily to provide feedback that the anchor is either locked or unlocked. The torque rating allows firm fixation of the set screws against the stimulation leads without over-tightening.
Trial Patch
[0100] The trial patch is used in conjunction with the trialing pulse generator to provide a clean, ergonomic protective cover of the stimulation lead entrance point in the spinal canal. The patch is also intended to cover and contain the trial generator. The patch is a large, adhesive bandage that is applied to the patient post-operatively during the trialing stage. The patch completely covers the leads and generator, and fixates to the patient with anti-microbial adhesive.
[0101] The patch is a watertight, 150 mm×250 mm anti-microbial adhesive patch. The watertight patch allows patients to shower during the trialing period, and the anti-microbial adhesive decreases the risk of infection. The patch will be made of polyethylene, silicone, urethane, acrylate, and rayon.
Magnetic Switch
[0102] The magnetic switch is a magnet the size of a coin that, when placed near the IPG, can switch it on or off. The direction the magnet is facing the IPG determines if the magnetic switch is switching the IPG on or off.
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Spinal cord stimulation (SCS) system having a recharging system with self alignment, a system for mapping current fields using a completely wireless system, multiple independent electrode stimulation outsource, and IPG control through software on Smartphone/mobile device and tablet hardware during trial and permanent implants. SCS system can include multiple electrodes, multiple, independently programmable, stimulation channels within an implantable pulse generator (IPG) providing concurrent, but unique stimulation fields. SCS system can include a replenishable power source, rechargeable using transcutaneous power transmissions between antenna coil pairs. An external charger unit, having its own rechargeable battery, can charge the IPG replenishable power source. A real-time clock can provide an auto-run schedule for daily stimulation. A bi-directional telemetry link informs the patient or clinician the status of the system, including the state of charge of the IPG battery. Other processing circuitry in current IPG allows electrode impedance measurements to be made.
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THE BACKGROUND OF THE INVENTION
The present invention relates to cleaning devices, and more particularly to an attachment to such devices which increases the efficiency of the brushes or other tools used in cleaning surfaces under fluid, such as swimming pool walls and floors and boat surfaces.
A major concern in the maintenance of tanks for holding liquids is the accumulation of deposits on the inner tank surfaces. For example, algae and other deposits will accumulate on swimming pool walls and floors, and must periodically be removed.
The typical device for cleaning such tanks or pools is comprised of a long pole having a handle at a first end and a brush at an opposite end. The user stands at the edge of the tank, above the liquid, and maneuvers the bristles of the brush in an upward and downward direction against the tank's inner walls and in a back and forth direction across its floor. A problem exists, however, in that the user must exert considerable strength to hold the brush against the wall or floor while at the same time moving the brush about.
U.S. Pat. No. 2,243,576 to Otto discloses a handle-type brush having a tiltable vane positioned in opposed relation to the brush bristles. The vane of Otto pivots upwardly when the brush is pushed downward through the fluid towards the tank floor and pivots downwardly when the brush is pulled upwards. The pressure exerted on the vane forces the brush against the wall during movement in each direction. However, while the Otto device enables the brush to be held against the wall, it does not remove all of the deposits.
Another concern in the maintenance of tanks, and particularly swimming pools, is the need to kill algae and other organisms present in the water. While some of these organisms float freely in the tank, a large number adhere to the tank inner surfaces. To kill these organisms, chemicals, such as chlorine, are added to the pool. The concentration of chemicals needed to kill the large accumulations of organisms along the inner surface is greater than that needed to kill those floating within the water. However, to date, the method of killing the organisms has been to provide an excessively large amount of chemicals to the water. In this way, the concentration of chemicals throughout the entire volume of water becomes so high that all the organisms, including those accumulating on the inner surfaces of the tank, are killed. This method results in a waste of chemicals, since the high concentration is only needed along the inner surfaces, while substantially lower concentration would suffice in the remainder of the water.
Therefore, there exists a need for a device which will increase the efficiency of brushes and other tools used in cleaning surfaces under fluid. There also exists a need for such a device which eliminates the need to use excessive amounts of chemicals in disinfecting a tank full of fluid, such as a swimming pool.
SUMMARY OF THE INVENTION
The present invention relates to a device for cleaning the interior surfaces of tanks, such as swimming pools, as well as boat surfaces. The device includes a pole, a tool attachable to the pole for cleaning the surface, and a wing member pivotally attached to the pole adjacent to the tool. The wing member is pivotable into an upwardly inclined position when the pole and tool are moved through the fluid in a downward direction along the tank wall, and into a downwardly inclined position when the brush and pole are moved in an upward direction along the tank wall. The wing member has jetting means for jetting fluid against the tank wall during the upward movement. The jetting means preferably comprise an aperture in the wing member surrounded by a nozzle and a rim portion extending from the wing member and adjacent to the aperture for gathering and directing water to the aperture. Reinforcing ridges are also provided for giving dimensional stability to the wing member, as well as for aiding the direction of water towards the aperture. A plurality of apertures may also be utilized, with a number of adjacent reinforcing ridges.
Attachment means are provided for pivotally attaching the wing member to the pole. In a first embodiment, a pair of attachment holes are provided on a clamping assembly through which the wing member may be removably attached. An upper attachment hole is located adjacent and below a first stopping flange having an approximately 45° angle relative to the transverse axis of the pole. A lower attachment hole is provided below the upper hole, and adjacent and above a second stopping flange which extends perpendicularly relative to the longitudinal axis of the pole. When the wing member is attached through the upper hole, it is pivotable upwardly and downwardly, preferably 45° relative to the transverse axis of the pole in each direction, until meeting one of the flanges. This configuration is preferred when the device is utilized against a vertical tank wall. When the wing member is attached through the lower hole, it will pivot a greater degree upwards until meeting the upper flange, and will be limited to a position perpendicular to the transverse axis of the pole by the lower flange. This configuration is preferred when the device is utilized for maintaining a vacuum or other tool on the floor of a tank.
In a second embodiment, a single attachment hole may be provided between a pair of flanges located on the attachment means, each flange having an angularly disposed surface facing the hole. In this configuration, the pivoting wing member will be limited by each flange.
In another embodiment of the present invention, the pole is preferably hollow or otherwise has a conduit running from its grip end to its brush end. Located at the grip end of the pole are means for delivering a chemical, such as a cleaning fluid, to the conduit. These means, for example, may be threading members capable of being threadingly attached to a container holding the cleaning fluid. Furthermore, means for expelling the cleaning fluid, such as an aperture, are provided at the brush end of the pole. In this manner, water being expelled from the jets of the wing member directs the cleaning fluid expelled from the expelling means towards and against the walls of the tank. This enables a high concentration of cleaning fluid to be controllably delivered to the tank surfaces.
Therefore, it is an object of the present invention to provide a device which increases the efficiency of brushes and other tools used in cleaning surfaces under fluid.
It is also an object of the present invention to provide a device which eliminates the need to use excessive amounts of chemicals for disinfecting or otherwise cleaning a tank full of fluid, such as a swimming pool.
These and other objects and advantages of the present invention will become more fully apparent when the detailed description of the preferred embodiments of the invention is read in conjunction with the accompanied drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1 and 2 are partial perspective views of the device of the present invention having a pair of attachment holes;
FIG. 3 is a side elevational view illustrating the utilization of one embodiment of the present invention;
FIG. 4 is a side elevational view of the present invention illustrating the utilization of an alternative embodiment of a device of the present invention; and
FIG. 5 is a perspective view of an alternative embodiment of the device of the present invention and also including a container for delivering fluids to the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates one embodiment of a device 10 of the present invention, including a pole 12, a bristled brush 14 attached to the lower or "brush" end 16 of the pole 12, and a wing member 18 pivotally attached to the pole 12 by attachment means 20 adjacent to but opposite the bristles 64 of the brush 14. The pole 12 may be of any length, and the term as used herein also includes relatively short handles.
The wing member 18 is preferably fan shaped, having a relatively narrow attachment side 22 and a relatively wide distal side 24. Furthermore, the wing member 18 is substantially flat and has an inner surface 26 and an outer surface 28 and is preferably made of a lightweight, yet rigid and non-corroding material such as plastic. The periphery of the outer surface 28 is defined by a rim portion 30 extending outwardly to the outer surface 28. The rim portion 30 is preferably widest at the distal side 24 of the wing member 18 and narrows toward the attachment side 22.
Jetting means are provided on the wing member 18 for delivering fluid towards the walls at high pressure. For example, the means may comprise a plurality of apertures 32 extending through the wing member 18 from the outer surface 28 to the inner surface 26 and located adjacent the length of the distal side 24. The aperture 32 is preferably tapered so as to be widest at the outer surface 28 and narrowest at the inner surface 26. Furthermore, nozzles 34 may be provided extending from the inner surface 26 of the wing member 18 and surrounding the apertures 32. A plurality of reinforcing ridges 36 may also be provided extending outwardly from the outer surface 28 between the distal and attachment sides 22,24 for giving dimensional stability to the wing member 18. The ridges 36 are preferably located adjacent the apertures 32 and are integral with the front rim portion 38, thereby forming, along with the front rim portion 38, means for directing fluids towards the aperture 32 when the wing member 18 is pivoted in a downward direction. The rim portion 30 also aids in forcing the wing member 18 towards the wall during the upward movement of the pole 12.
Any means for pivotally attaching the wing member 18 to the pole 12 may be used. For example, a yoke and post type of attachment assembly may be employed. A pair of support flanges 40 are provided at the attachment side 22 of the wing member 18. Each support flange 40 has an opening 42 through which a post may be simultaneously provided for pivotally securing the wing member 18 to the attachment means.
In a first embodiment of the invention, as set forth in FIGS. 1, 2, 3 and 4, the attachment means comprise a clamping assembly 46 having a first clamp member 48 attachable to a second clamp member 50 around the pole 12 by thumbscrews or other similar means. A pair of stopping flanges 52,54 are located on the first clamp member 48 for limiting the degree of pivot of the wing member 18. A first stopping flange 52 is provided at the upper portion of the first clamp member 48 and has a contacting surface 76 with an approximately 45° angle relative to the transverse axis of the pole 12. An upper attachment hole 56 is provided adjacent and below the first stopping flange 52 through which the post may be placed for pivotally securing the wing member 18 to the attachment means. As best seen in FIG. 2, a second stopping flange 54 is provided at the lower portion of the first clamp member 48. The second stopping flange 54 has a wing contacting surface 74 which is substantially parallel to the transverse axis of the pole 12, and a lower attachment hole 58 is provided adjacent and above the second stopping flange 54 for alternatively attaching the wing member 18 to the attachment means 20. In this manner, when the wing member 18 is attached to the upper attachment hole 56, it may pivot at 45° angles both upwardly and downwardly relative to the transverse axis of the pole 12. In the upward pivot, a contacting portion of the outer surface 28 of the wing member 18 will contact and be limited by the first stopping flange 52 and in the downward pivot the inner surface 26 of the wing member 18 will contact and be limited by the second stopping flange 54. This will cause the tool 66 to be held against the interior tank surface by hydrodynamic forces of the fluid pressing against the wing member 18.
Alternatively, as seen in FIG. 4, when the wing member 18 is secured in the lower attachment 58, it will pivot upwardly at a greater than 45° angle relative to the transverse axis of the pole 12 and will pivot downwardly to an angle perpendicular to the longitudinal axis of the pole 12. This will maximize fluid pressure to the outer surface 28 and will enable the device 10 to be used for maintaining a vacuum or other tool on the floor of the tank.
Alternatively, as seen in FIG. 5, the first clamp member 48 may have a single attachment hole 60 at its mid-point for providing the sole means for pivotally attaching the wing member 18 to the attachment means 20. Preferably, the hole 60 is provided on a stabilizing member 62 extending from the first clamp member 48 which provides additional stability to the wing member 18. Furthermore, a first stopping flange 52 may be provided at the upper portion of the first clamp member 48 and a second stopping flange 54 may be provided at the lower portion of the first clamp member 48. Similar to the embodiment shown in FIG. 3, the stopping flanges 52,54 will limit the pivoting movement of the wing member 18 to a predetermined path. The degree of pivot of the wing member 18 in the second embodiment depends upon the positioning of the stopping flanges 52,54. An auxiliary hole may be provided on the stabilizing member capable of having a removable flange placed therethrough. This will allow the downward path of pivot to be limited to a position relative to the pole 12, i.e. 50° to 60° or perpendicular depending upon use, such as seen in FIG. 4, and is useful in maintaining a tool 66 along the floor of the tank.
With reference to the foregoing, it is to be observed, as shown in FIGS. 3 and 5, that the pole 12 and tool 66 are to be first inserted into the tank and moved downwardly away from the operator through the fluid. When so moved, the wing member 18 will pivot upwardly towards the operator. Continued movement of the pole 12 and brush 14 downwardly is resisted by the water bearing on the wing member 18 and the transverse component of this resisting force is directed towards the wall so that the brush 14 is automatically forced into engagement with the wall, depicted as position A in FIG. 3. At the end of the movement, when the pole 12 and brush 14 are elevated towards the operator, the wing member 18 assumes the dotted line position B seen in FIG. 3 as the resistance of the water applied to the wing member 18 again serves to force the brush bristles 64 into engagement with the wall. Excess fluid will pass over the narrower side of the rim portion 30 to enhance the movement of the device 10 through the fluid. When the wing member 18 is placed in the lower attachment 58, as seen in FIG. 4, movement of the pole 12 and tool 66 away from the operator will force the wing member 18 upwards, thereby forcing the tool to the floor of the tank. When the pole 12 and tool 66 are moved backwards towards the operator, the wing member 18 will pivot to the position indicated in dotted lines in FIG. 4 and water pressure exerted against the inner surface 26 of the wing member 18 will again force the tool 66, such as a vacuum-type device, against the floor of the tank.
During the upward movements of the pole 12 and brush 14 in FIG. 3 or the backward movement of the pole 12 and tool 66 in FIG. 4, fluid is gathered by the extending rim portion 30 and reinforcing ridges 36 of the wing member 18 and is directed toward and through the apertures 32. The fluid is jetted through the nozzles 34 and dispelled at high pressure against either the wall or floor of the tank, thereby aiding the tool 66 in dislodging deposits from the tank's interior surfaces and forcing such removed material away from the inner wall or floor to prevent reattachment.
Means for providing cleaning fluid to the area adjacent the tool 66 may also be provided. Herein, the term cleaning fluid is defined as any fluid, such as liquid or powdered chlorine or other chemical, capable of passing through the device 10. As seen in FIG. 5, the pole 12 is preferably hollow or otherwise has a conduit 72 running its length. The uppermost end 68, or "grip end", of the pole 12 has means for delivering a cleaning fluid to the conduit 72. For instance, the uppermost end 68 of the pole 12 may be threaded and capable of receiving a correspondingly threaded container 70 holding the cleaning fluid. Means for expelling the cleaning fluid are provided adjacent the brush 14. For instance, a cleaning fluid expelling opening may be provided adjacent the brush 14 and receivable to the conduit 72. In this way, the container 70 will deliver cleaning fluid to the conduit 72, and the fluid will be expelled from the conduit 72 through the cleaning fluid expelling opening to the area adjacent the brush 14 and the wall or floor. This will enable the concentration of the cleaning fluid where it is most needed, i.e., along the walls and floor of the tank. For example, in a swimming pool, during the upward movement of the pole 12, water will be forced through the jetting means of the wing member 18 towards the wall and will concentrate the delivery of chlorine toward the brush bristles 64 and wall. Likewise, the jetted water will force deposits, such as algae, away from the wall so that they do not reattach themselves. The same effect is obtained when the device 10 is used to clean a tank floor when the pole 12 and vacuum are moved backwards, as seen in FIG. 4. It should be noted that while it is preferred that the embodiment of the device 10 incorporating means for delivering cleaning fluid to the tool area employ a wing member 18 which pivots both upwards and downward, it may also be used in conjunction in devices having member-like elements which pivot in only one direction.
Therefore, not only does the present invention hold the brush 14 or other tool 66 against the inner surface 26 of the tank during movement of the pole 12 both towards and away from the operator, but the jetting means provide enhanced efficiency to the cleaning operation. Also, the cleaning operation can be further enhanced when the embodiment including the means for delivering and expelling a cleaning fluid are provided in the device 10 along with the wing member 18.
The above disclosed invention has a number of particular features which should preferably be employed in combination, although each is useful separately without departure from the scope of the invention. While preferred embodiments are shown and described, it should be understood that the invention may be embodied otherwise as herein specifically illustrated or described, and that certain changes in the form and arrangements of the parts and its specific manner of practicing the invention may be made within the underlying idea or principals of the invention within the scope of the appended claims.
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A device for cleaning surfaces submerged in a fluid, such as pools and boat, comprising a handle, a brush attachable to the handle for cleaning an underwater surface and a wing member hingedly attached to the device adjacent the brush. The wing member is pivotable into an upwardly inclined position when the brush is moved in a downward direction along the and into a downwardly inclined position when the brush is moved in an upward direction along the surface, the wing member has jetting means for jetting fluid against the surface to be cleaned during the upward movement.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a non-provisional continuation application claiming priority to pending U.S. Nonprovisional application Ser. No. 13/267,479 titled “Exercise Bicycle Frame With Bicycle Seat and Handlebar Adjustment Assemblies” filed Oct. 6, 2011 which claims priority to U.S. Provisional Patent Application No. 61/390,570 titled “Exercise Bicycle Frame with Bicycle Seat and Handlebar Adjustment Assemblies,” filed on Oct. 6, 2010, and U.S. Provisional Patent Application Nos. 61/390,572 and 61/390,577 titled “Exercise Bicycle with Mechanical Flywheel Brake” and “Exercise Bicycle with Magnetic Flywheel Brake”, respectively, and each filed on Oct. 6, 2010, all of which are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] Aspects of the present disclosure involve an exercise bicycle and adjustment assemblies that provide fore and aft adjustment for a handlebar, a seat, or other component.
BACKGROUND
[0003] Indoor cycling is a very popular and excellent way for people to maintain and improve fitness. Generally speaking, indoor cycling revolves around an exercise bicycle that is similar to other exercise bicycles with the exception that the pedals and drive sprocket are connected to a flywheel rather than some other type of wheel. Thus, while a user is pedaling, the spinning flywheel maintains some momentum and better simulates the feel of riding a real bicycle. To further enhance the benefits of indoor cycling, fitness clubs often offer indoor cycling classes as a part of their group fitness programs. With such a program, an instructor guides the class through a simulated real world ride including simulating long steady flat sections, hills, sprints, and standing to pedal for extended periods. While numerous different forms of indoor cycles exist, many suffer from common problems. For example, many indoor cycles are hard to adjust in order to provide the proper handlebar height, seat height, and separation between the handlebar and seat for the myriad of different body sizes of the people that might use the indoor cycle. Such difficulties are exaggerated in a group setting or club environment where time is limited and people are constantly adjusting the equipment.
[0004] It is with these issues in mind, among others, that aspects of the present disclosure were conceived.
SUMMARY
[0005] One aspect of the present disclosure involves an exercise bicycle comprising a receiver comprising an elongate aperture. The receiver may be connected to a post, such as a seat post or handlebar post, and may be configured for vertical adjustment. Alternatively, the receiver may include a seat or handlebar, and be configured for fore and aft adjustment. The exercise bicycle further includes a slider positioned within the elongate aperture of the receiver, the slider defining a first channel receiving a first member, such as a wedge block, moveable within the channel, the first member defining an engagement surface. The slider may include a seat or handlebar and may be configured for relative movement to a horizontally fixed receiver. Alternatively, the slider may be connected to a post and horizontally fixed and the receiver includes a seat or handlebar, as mentioned immediately above. The exercise bicycle further includes a handle operably coupled with the first member to move the first member within the channel in a first direction or a second direction such that the engagement surface causes a coupling between the slider and the receiver when the slider is moved in the first direction and releases the coupling when the slider is moved in the second direction.
[0006] The slider may define a second channel transverse to the first channel. The second channel may receive a second member, such as a second wedge block configured to interact with the first wedge block such that horizontal motion of the first wedge block translates to vertical motion of the second wedge block, within the second channel. In this configuration, the handle is operably coupled with the first member to move the first member within the channel in the first direction to drive the second member to engage the receiver, the engagement with the receiver causing a frictional coupling between the slider and the receiver, the handle operably coupled with the first member to move the first member within the channel in the second direction to release the engagement between the second member and receiver to allow relative movement between the slider and the receiver.
[0007] Another aspect of the present disclosure involves an exercise bicycle comprising a down tube extending angularly and upwardly from a rear portion to a front portion. The exercise bicycle further includes a seat tube extending upwardly and rearwardly from the rear portion of the down tube. In one particular example, the down tube is orientated at an angle of between 40 and 44 degrees and the seat tube is angled rearwardly at an angle of between 70 and 74 degrees. A brace extends rearwardly from the rear portion of the down tube to a rear support member and extends forwardly to a front support member. The exercise bicycle further includes a fork assembly extending from a position rearward of the front portion of the down tube to the front support member. In one particular implementation, a flywheel s mounted between a first fork and a second fork of the fork assembly and the flywheel having a radius of about 430 millimeters. Finally, a head tube is coupled with the front portion of the down tube.
[0008] The exercise bicycle may further include adjustable seat and handlebar assemblies adjustably supported by the seat tube and head tube, respectively. The assemblies support a seat and handlebars for fore and aft movement. The assemblies are similar in form and include a receiver comprising an elongate aperture. A slider is positioned within the elongate aperture of the receiver. The slider defines a first channel receiving a member moveable within the first channel. The member defines a first engagement surface. Finally, a handle is operably coupled with the member to move the member within the channel in a first direction or a second direction such that the engagement surface causes a coupling between the slider and the receiver when the slider is moved in the first direction and releases the coupling when the slider is moved in the second direction. The exercise bicycle may provide a space separation between the adjustable seat assembly and the adjustable handlebar assembly in a range of about 527 millimeters and about 627 millimeters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing and other objects, features, and advantages of the present disclosure set forth herein will be apparent from the following description of particular embodiments of those inventive concepts, as illustrated in the accompanying drawings. It should be noted that the drawings are not necessarily to scale; however the emphasis instead is being placed on illustrating the principles of the inventive concepts. Also, in the drawings the like reference characters refer to the same parts or similar throughout the different views. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting.
[0010] FIG. 1 is an isometric view of an exercise bicycle;
[0011] FIG. 2 is a front view of the exercise bicycle shown in FIG. 1 ;
[0012] FIG. 3 is a left side view of the exercise bicycle shown in FIG. 1 ;
[0013] FIG. 4 is a rear view of the exercise bicycle shown in FIG. 1 ;
[0014] FIG. 5 is a top view of the exercise bicycle shown in FIG. 1 ;
[0015] FIG. 6A is a right side view of the exercise bicycle shown in FIG. 1 ;
[0016] FIG. 6B is a right side view of the exercise bicycle shown in FIG. 1 with a chain guard removed to illustrate a drive sprocket and a flywheel sprocket, along with a chain connected therebetween;
[0017] FIG. 7 is a bottom view of the exercise bicycle shown in FIG. 1 ;
[0018] FIG. 8 is an isometric view of a seat adjustment assembly, with certain components of the view transparent;
[0019] FIG. 9A is a section view taken along line 9 - 9 of FIG. 3 , and illustrating the seat assembly positioned about midway between its forward most and rearward most positions;
[0020] FIG. 9B is section view similar to FIG. 9A with the seat assembly in its forward most position;
[0021] FIG. 9C is a section view similar to FIG. 9A with the seat assembly in its rearward most position;
[0022] FIG. 10 is a section view taken along line 10 - 10 of FIG. 4 ;
[0023] FIG. 11 is an isometric view of a slider mechanism for supporting a seat;
[0024] FIG. 12 is an isometric view of a handlebar adjustment assembly, with certain components of the view transparent;
[0025] FIG. 13A is a section view taken along line 13 - 13 of FIG. 3 , and illustrating the handlebar assembly positioned about midway between its forward most and rearward most position;
[0026] FIG. 13B is a section view similar to FIG. 13A with the handlebar assembly in the forward most position;
[0027] FIG. 13C is a section view similar to FIG. 13A with the handlebar assembly in the rearward most position; and
[0028] FIG. 14 is an isometric view of a slider mechanism supporting a handlebar.
DETAILED DESCRIPTION
[0029] Aspects of the present disclosure involve an exercise bicycle. The exercise bicycle includes various features that provide adjustability of the seat and handlebar positions, provide space for riders of various sizes, and provide space for mounting and dismounting the exercise bicycle, among other advantages. The exercise bicycle includes fore and aft adjustment mechanisms for the seat and handlebars that improve on conventional arrangements. Fore and aft adjustment may be set along any fore and aft position and is not constrained as in conventional designs. Many of the moving components of the adjustment mechanism, except for a knob that a user turns are captured within a slider and a receiver, providing for an elegant design with many mechanical components hidden. The frame design provides exceptional space between the seat, handlebars and frame members, while maintaining industry standard dimensioning for proper rider use and ergonomic adjustment of the exercise bicycle. For example, a head tube is positioned forward of the handlebars and eliminated as a point of contact for a rider, rearward movement of the seat and forward movement of the handlebars opens space providing the rider with less contact points and the down tube is relatively low and positioned at a relatively shallow angle providing excellent step over height and space.
[0030] Referring now to FIGS. 1-7 , one example of an exercise bicycle 10 is shown. The exercise bicycle is configured for use by a variety of riders in a club environment or for a single or limited number of riders in a home or other personal use environment. The exercise bicycle includes a frame 12 adjustably supporting an adjustable seat assembly 14 at the rear of the frame and adjustably supporting an adjustable handlebar assembly 16 at the front of the frame. The adjustable seat and handlebar assemblies provide fore and aft adjustment of a respective seat 18 and handlebar 20 . Further, the seat and handlebar assemblies may be vertically adjusted and fixed at various possible positions. Hence, the exercise bicycle provides for many different possible seat and handlebar positions to fit different riders and to provide riders with different configurations depending on the exercise being performed.
[0031] The frame includes a seat tube 22 that receives a seat post portion 24 of the seat assembly 14 . The seat post may be moved up and down relative to the seat tube to adjust the height of the seat assembly, and particularly to adjust the height of the seat 18 that is a part of the seat assembly. A pop pin 26 is connected with the seat tube and is configured to engage one of a plurality of apertures 28 defined in the seat post, and thereby secure the seat at a desired height. The pop pin may be spring-loaded such that it is biased in the locked position engaging the aperture.
[0032] The pop pin is shown extending forwardly from the seat tube. This configuration provides easy access for a rider to move the seat up or down during exercise. For example, indoor cycling classes often include some time where the user is standing and pedaling rather than seated, and at such times the rider may move the seat to a lower position. The pop pin is positioned for easy access by the rider. It is possible, however, to position the pop pin on the back side of the seat tube or at another location. Additionally, it is possible to use other mechanisms to facilitate seat height adjustment with or without pop pins. For example, a pawl on the fore and aft seat and handlebar assemblies may be used to vertically adjust the seat post (or tube) as well as the handlebar post.
[0033] In one particular implementation, the seat tube is rearwardly angled at approximately 72 degrees. The seat tube angle, along with other adjustment and dimensional relationships discussed herein, is optimized so that riders of all sizes can best fit the exercise bicycle. The seat tube 22 , along with other frame members discussed herein, is extruded aluminum and defines a racetrack-shaped cross section 30 with opposing flat side walls 30 A and opposing semicircular side walls 30 B. The seat post 24 defines a substantially matching racetrack-shaped cross section of a smaller dimension in order to fit within the seat tube. Other frame member shapes and materials may be used, such as steel square tubing or steel round tubing, in the construction of the frame assembly. However, the extruded aluminum race track shaped tubing provides a unique balance between strength, overall exercise bicycle weight and aesthetic appearance. Additionally, while the seat post is shown as telescoping out of the seat tube, this relationship may be reversed such that the post fits over the tube. This relationship may also be reversed for other tube and post arrangements discussed herein.
[0034] Returning again to the discussion of the frame 10 , a down tube 32 extends from a lower rear area of the exercise bicycle to an upper forward area of the exercise bicycle. Particularly, the down tube extends between a bottom portion of the seat tube 22 and a head tube 34 . The down tube is also a racetrack type extruded aluminum member. The down tube, in one particular arrangement, is at angle of about 42 degrees. The angular relationship of the down tube may be measured relative to a horizontal surface upon which the exercise bicycle sits or relative to a line between a front support member 36 and a rear support member 38 . The down tube is welded to the bottom of the seat tube, although other means of attachment and arrangements are possible. Further, a triangular rear gusset 40 with a substantially flat top 42 is connected to and above the intersection of the seat tube 22 and the down tube 32 . The rear gusset, like other frame members and arrangements, may be altered or removed. In the exercise bicycle frame illustrated, the gusset provides structural support to the seat tube and seat assembly, and also provides a step for riders mounting the exercise bicycle as well as other advantages. In the example shown, the flat top portion of the gusset, which provides the step, is slightly longer than 10 inches measured between the seat tube and down tube, a dimension not achievable by other designs which employ different frame configurations, larger flywheels and different gearing configurations.
[0035] A brace 44 extends from the rear support member 38 upward to the bottom of the seat tube 22 and then forward and downward to the front support member 36 . A lower gusset 46 is connected between the rear portion of the brace, the top of the rear support member 44 , and the lower rear portion of the seat tube 22 . The lower gusset is in substantial alignment and of substantially similar dimension as the down tube. The front support member 36 is connected to the front forks 48 and extends outwardly and transversely from each fork.
[0036] The head tube 34 is connected to the front of the down tube 32 . A portion 34 A of the head tube extends upwardly from the down tube and a portion 34 B of the head tube extends downwardly from the head tube. A front gusset 50 is connected between the downwardly extending portion 34 B of the head tube and the down tube 32 . The head tube receives a handlebar post 52 that extends downwardly from the fore and aft adjustable handlebar assembly 16 . The handlebar post may be moved vertically relative to the head tube to adjust the height of a handlebar assembly, and particularly to adjust the height of a handlebar 20 of the handlebar assembly. A second pop pin 54 is connected with the head tube 34 and is configured to engage one of a plurality of apertures (not shown) defined in the handlebar post, and hence secure the handlebars at a desired height. Other mechanisms may also be used in place of the pop pin, and the position of the pop pin or any other mechanism may be altered in alternative exercise bicycle implementations.
[0037] In the frame configuration illustrated herein, the front fork assembly 48 , which supports a flywheel 56 between opposing left 58 and right 60 fork legs, is coupled to the down tube 32 at a point between the head tube 34 and the seat tube 22 . In the particular arrangement shown, the down tube is about 561 mm between the rear of the head tube and the intersection between the rear gusset 40 and the down tube, and the fork is about 315 mm between the rear of the fork and the same intersection.
[0038] In the frame configuration shown, the forks are set at about the same angle as the seat tube. A pair of mounting brackets 62 , also referred to as “drop outs”, are integrated in the fork legs to support a flywheel axle 64 and the flywheel. The exercise bicycle discussed herein is particularly configured for indoor cycling and therefore includes a flywheel. It is nonetheless possible to deploy the frame and other components discussed, whether alone or in combination, in an exercise bicycle that does not include a flywheel. The drop outs have matching forwardly opening channels 66 that are perpendicular to the long axis of the fork legs, in one embodiment. Thus, the forward opening of the channels is higher than the rear of the channels. An adjustment screw 68 protrudes into the opening. The design is advantageous in that it allows a user to mount the flywheel from the open front area of the exercise bicycle without any hindrance, such as if the channels opened rearwardly. Moreover, the channels receive the axle and support the flywheel while a user adjusts the axle position by way of the adjustment screws to tension the chain and center the flywheel, such as during assembly or maintenance. It is also possible to orient the channels in other ways, such as horizontally and level, and include a lip or other retaining member at the opening of the channel to help retain the flywheel before the axle is locked in.
[0039] In many conventional exercise bicycle designs, the head tube is aligned with the forks. The exercise bicycle shown herein, however, has the head tube positioned at the front of the frame and forward of the fork assembly 48 . Additionally, as discussed herein, fore and aft adjustment of the handlebars occurs relative to the head tube such that the rear of the handlebars (and the adjustment knob) is the rearward most component of the handlebar assembly 16 relative to the user rather than the fixed head tube and handle bar post (stem) in conventional designs. Hence, the handlebars may be moved forward relative to the user opening up space between the handlebars and the seat. In many conventional designs, the handlebars are above and forward the head tube and the head tube is the rearward most component; thus, any possible fore or aft adjustment of the handlebars occurs with the head tube remaining stationary and does not provide additional space for the user between the seat and the handlebar.
[0040] The frame assembly 12 further includes a crank assembly 70 configured to drive the flywheel 56 . The drive sprocket is rotably supported in a bottom bracket 55 supported in the down tube 32 . In one example, the crank assembly includes a single drive sprocket 72 and the flywheel similarly includes a single flywheel sprocket 74 of a smaller diameter than the drive sprocket. A chain 76 connects the drive sprocket to the flywheel sprocket, although other mechanisms, such as a belt, may be used to connect the sprockets. The drive sprocket is fixed to a pair of crank arms 78 and the flywheel is fixed to the flywheel sprocket such that the drive sprocket and flywheel sprocket do not freewheel. Hence, with reference to FIG. 6B , clockwise rotational force on the crank arms, such as in conventional forward pedaling, rotates the flywheel in a clockwise manner. However, if the rider discontinues exerting a pedaling force on the cranks, the spinning flywheel will continue, via the chain, to drive the crank arms. It is, however, possible to include freewheel mechanisms with the drive or flywheel sprocket or other components.
[0041] In one particular implementation, the drive sprocket 72 includes 72 teeth and the flywheel sprocket 74 includes 15 teeth. A range of sprocket teeth counts are possible such as 70-74 teeth and 13 to 17 teeth, and an even broader range of 45 to 75 teeth on the drive sprocket. Moreover depending on the design, other sprocket arrangements are possible, as well as arrangements with a derailleur and multiple sprockets at both ends. This particular sprocket arrangement facilitates the use of a smaller flywheel 56 of 430 mm radius, relative to other designs. With a smaller flywheel, a shallower down tube angle (e.g. 42 degrees) is possible providing a larger gusset step size (e.g. 10 inches) and a larger area between the seat and handlebar assemblies relative to other exercise bicycle frame designs.
[0042] As discussed above, the frame provides for the height adjustment of the seat assembly 14 (with seat 18 ) and the handlebar assembly 16 (with handlebars 20 ) by way of the interactions between the seat tube 22 , seat post 24 and rear pop pin assembly 26 and the head tube 34 , handlebar post 52 and front pop pin assembly 54 , respectively. The exercise bicycle discussed herein also provides fore and aft adjustment of the seat and/or the handlebars through respective fore and aft seat and handlebar adjustment assemblies. In one possible implementation and with reference to FIG. 6A , when the seat height is about the same as the handlebar height, a range of about 527 mm (where the handlebars are completely rearward and the seat is completely forward) to about 627 mm (when the handlebars are completely forward the seat completely rearward) separate the seat and handlebar assemblies providing exceptional open space for the rider to mount and dismount the cycle.
[0043] Turning first to the seat adjustment assembly 14 , FIGS. 8-11 illustrate the fore and aft adjustable seat assembly. In this example implementation, a receiver 82 is connected to the seat post 24 . The receiver, which is extruded aluminum in one particular implementation, defines a slider aperture 84 arranged along the horizontal center line of the exercise bicycle and roughly parallel with the surface that the exercise bicycle is set on. The slider aperture receives a slider 86 that may be moved fore and aft within the slider aperture. Additionally, the slider may be fixed at various positions relative to the receiver. The seat 18 is attached to the slider (such as at a front end of the slider); hence, by adjusting and fixing the slider relative to the receiver, the fore and aft position of the seat may be adjusted.
[0044] The slider aperture, in cross section as shown in FIG. 10 , defines a complex shape with curved sides 88 connected by a substantially flat top 90 and an inverted W-shaped bottom 92 . The bottom surface includes two bearing or engagement surfaces ( 92 A, 92 B) that form a frictional engagement to matching surfaces ( 94 A, 94 B) on the slider 86 . The outer surface of the slider substantially matches the complex shape of the slider aperture albeit with a slightly smaller shape so that the slider may move horizontally relative to the slider aperture.
[0045] A lower wedge 96 and an upper wedge 98 are positioned within the slider 86 . Particularly, the slider defines a lower wedge aperture 100 along the longitudinal center of the slider and a top wedge aperture 102 intersecting the lower wedge aperture. The lower wedge 96 is configured to move horizontally within the slider, particularly within the lower wedge aperture 100 , while the upper wedge is trapped within and configured to move vertically within the top wedge aperture 102 . The top wedge aperture extends through the substantially flat top surface of the slider. Stated differently, the first wedge (lower wedge) moves within a first aperture transverse to a second aperture (the upper wedge aperture) where the second upper wedge moves.
[0046] As shown in the FIG. 8 , the lower wedge 96 has a sloped upper surface 104 and the upper wedge 98 has a matching sloped lower surface 106 . These surfaces are in contact. With the upper wedge constrained in the vertical wedge aperture, aft or rearward horizontal movement of the sloped surface of the lower wedge presses on the sloped surface of the upper wedge driving the upper wedge upward to lock the slider relative to the receiver. On the other hand, fore or forward horizontal movement of the lower wedge allows the upper wedge to drop down to release the slider so that the horizontal position of the slider and the seat can be adjusted. Therefore, fore and aft movement of the lower wedge translates into down and up movement of the upper wedge to release or unlock the slider for adjustment and to lock the slider into position when the seat is properly positioned.
[0047] The slider 86 is trapped within the slider aperture 84 of the receiver 82 . A strike plate, in one particular example, 108 is positioned above the wedge aperture 102 and is of sufficient length so that the upper wedge 98 will press on the strike plate in the forward most and rearward most positions. The strike plate is steel and is constrained in a channel 110 extruded in the aluminum receiver. The upper wedge pushes upward against the strike plate when the slider is being locked relative to the receiver. When the seat assembly 14 is being locked into a particular fore or aft position, the lower wedge also presses down on the slider 86 causing the outer lower surface ( 94 A, 94 B) of the slider to frictionally engage the respective bearing surfaces ( 92 A, 92 B) of the receiver. Particularly, the slider and the receiver engage on the outer portions of the inverted W but do not engage between the outer portions, as shown in FIG. 10 . Hence, in one particular implementation, the fore or aft position of the slider relative to the receiver may be locked in position through a frictional engagement between the upper wedge and the strike plate and along the opposing lower surfaces of the slider and slider aperture of the receiver.
[0048] A knob 112 is positioned at the rear of the slider 86 or otherwise at an end of the slider. The knob is fixed to a threaded shaft 114 that is threaded into a threaded aperture 116 in the bottom wedge 96 . The shaft is captured in the slider such that rotation of the shaft engages the threaded aperture of the lower wedge to move the wedge fore and aft. In one particular arrangement, an end cap 118 defining a smooth bore or tube section 120 is fixed to the end of the receiver. A bearing 122 is pressed in the tube section of the end cap and the bearing rotatably supports the shaft 114 . A clip 124 or shoulder is positioned on the shaft adjacent the bearing and end cap. The clip prohibits the shaft from moving rearward relative to the slider. The knob 112 is fixed to the end of the shaft, with the bearing and the end cap sandwiched between the clip and the knob. Hence, the knob prevents the shaft from moving forward relative to the slider. Thus, the shaft can only be rotated by turning the knob and does not move fore and aft relative to the slider. When a user rotates the knob, the knob and shaft rotate relative to the slider, end cap, bearing, etc. The rotating shaft, in turn, moves the lower wedge fore and aft through engagement between the shaft and the threaded aperture of the lower wedge. The lower wedge, in turn, engages or disengages the upper wedge to lock the fore and aft position of the seat or release the assembly so the seat can be moved.
[0049] A stub 126 extends upwardly at the forward end of the slider 86 . The seat is attached to the stub. A cap 128 prevents the slider from being completely withdrawn rearwardly from the receiver. Hence, in the rearward most aft position, the cap 130 abuts the receiver, as shown in FIG. 9C . Similarly, the stop cap at the opposing end of the receiver prevents the slider from being completely withdrawn forwardly from the receiver. Hence, in the forward most position, the stop cap abuts the receiver, as shown in FIG. 9B .
[0050] While in both the adjustable fore and aft seat and handlebar assemblies, two wedges are shown, it is also possible to eliminate the upper wedge or alter the shape of either or both wedges. For example, the lower wedge and the strike plate can be dimensioned so that the lower wedge directly engages the strike plate with increasing or decreasing force as the wedge is moved aft or fore. In such an arrangement, the engagement of the lower wedge directly with the strike plate will push the strike plate upward and drive the slider down to create the appropriate frictional engagement. Similarly, the lower wedge may include a sloped surface as currently shown and the upper wedge may be a square or rectangular block, where the sloped, or otherwise oblique surface of the lower wedge, engages a corner of the block to press the block upward. The engaged corner of the block may include a bevel to distribute the load imparted by the lower wedge.
[0051] One example of a handlebar adjustment assembly 16 is illustrated in FIGS. 12-14 . The handlebar adjustment assembly is similar in form and function to the seat adjustment assembly and therefore like components will be referenced as such. The handlebar fore and aft adjustment assembly includes a slider 86 that may be positioned fore and aft within and relative to a receiver 82 . The receiver is attached to the handlebar post 52 . Accordingly, the receiver may be moved up and down relative to the head tube. The handlebar 20 is positioned at one end of the slider and an end cap 132 is positioned at the opposing end of the slider. As shown in FIGS. 13B and 13C , the handlebar or the end cap abuts the receiver depending on whether the handlebar is positioned most forwardly ( FIG. 13B ) or most rearwardly FIG. 13C ).
[0052] In the implementation discussed above, the slider mechanism moves relative to the receiver, and the receiver is attached to the seat post or handlebar post. Further, the seat or handlebars are connected to the slider mechanism. It is possible to alter this relationship and use the wedge (cam block) mechanism discussed herein. For example, in such an alteration, the slider structure is coupled to the post, at the forward or rearward end of the slider structure. Hence, the slider is fixed relative to the frame. At the end opposite the coupling to the post, the knob and shaft are supported. The slider includes substantially the same wedge block configuration or the alternative discussed herein. The receiver, in the altered implementation, has the seat or handlebars attached to it and it is configured to move fore and aft relative to the slider. A user locks or unlocks the receiver and moves it fore and aft to adjust the position in a like manner as discussed herein.
[0053] It also possible, to replace the knob shaft fore and aft lower wedge block actuation with a lever arm and with a camming surface configured to engage the receiver strike plate or the upper wedge block. In such an implementation, the lever arm is fixed to the slider or the receiver, and is configured push the camming surface up against the upper wedge block to create the same form of frictional engagement between the slider and the receiver. It is also possible to replace the knob and shaft with a lever arm and shaft coupled with the lower wedge block. The lever arm would act to move the shaft fore and aft rather than rotate the shaft. The shaft is fixed to the lower wedge block, and hence fore and aft movement of the lower wedge block would act to force the upper wedge block upward to allow it to fall downward, locking or unlocking engagement between the slider and receiver.
[0054] Although various representative embodiments of this disclosure have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of the inventive subject matter set forth in the specification. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the embodiments and do not create limitations, particularly as to the position, orientation, or use of the disclosure unless specifically set forth in the claims. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other.
[0055] In some instances, components are described with reference to “ends” having a particular characteristic and/or being connected to another part. However, those skilled in the art will recognize that the present disclosure is not limited to components which terminate immediately beyond their points of connection with other parts. Thus, the term “end” should be interpreted broadly, in a manner that includes areas adjacent, rearward, forward of, or otherwise near the terminus of a particular element, link, component, member or the like. In methodologies directly or indirectly set forth herein, various steps and operations are described in one possible order of operation, but those skilled in the art will recognize that steps and operations may be rearranged, replaced, or eliminated without necessarily departing from the spirit and scope of the present invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.
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An indoor cycling device including a unique frame arrangement with fore and aft adjustable seat and handlebar assemblies. The assemblies support a seat and handlebars for fore and aft movement. The assemblies may include a receiver with an elongate aperture with a slider positioned therein. The slider defines a first channel receiving a moveable member. A handle is operably coupled with the member to move the member within the channel in a first direction or a second direction such that a frictionally coupling is caused between the slider and the receiver when the slider is moved in the first direction and releases the coupling when the slider is moved in the second direction.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a 35 USC 371 application of PCT/EP 2008/050016 filed on Jan. 2, 2008.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a check valve and to an injector.
2. Description of the Prior Art
Such check valves are well known from the prior art. These check valves typically have a valve housing, in which a bore is made, and a valve seat is embodied in the bore. These check valves furthermore have a spherical valve member, which is disposed in the bore, and a stroke stop element for the valve member is provided, on which the valve member comes to rest when the check valve is open.
These check valves are suitable for many applications, but particularly in use in injectors with a hydraulic pressure booster, of the kind used in modern fuel injection systems for internal combustion engines, applications exist in which the conventional check valves have proven insufficiently durable. In conventional check valves, the lateral deflection of the valve member in the open position of the check valve has the effect that not until the valve member meets the valve seat is the valve member centered again by the valve seat. This leads to a relative motion between the valve member and the valve seat. This relative motion causes wear and shortens the service life of the valve seat and valve member considerably.
ADVANTAGES AND SUMMARY OF THE INVENTION
The check valve of the invention has the advantage that the valve member in the open state is centered in the indentation in the stroke stop element, and as a result, the valve member of the check valve of the invention strikes the valve seat precisely centrally when the check valve closes again, so that no significant wear between the valve seat and the valve member can be found. Moreover, in this exemplary embodiment, a valve spring can be dispensed with, which reduces the production costs and space required for the check valve of the invention considerably. Because of the reduced masses, this check valve responds especially fast. Because of the at least indirect axial fixation of the stroke stop element by means of a welded connection, no additional component is required for this, and as a result the production costs and space required for the check valve of the invention are likewise reduced.
In order to move the fuel past or through the valve member and the stroke stop element when the valve member is open, at least one transverse bore is provided in the stroke stop element, and the transverse bore connects an annular gap between the stroke stop element and the bore with a longitudinal bore in the stroke stop element. The longitudinal bore is preferably embodied as a throttle bore toward the indentation, and the transition from the indentation to the throttle bore is embodied with sharp edges, in order upon opening of the check valve to damp the motion of the valve member before it strikes the stroke stop element. The transition from the throttle bore to the region of the longitudinal bore remote from the indentation, by comparison, is embodied in streamlined fashion, to enable a rapid lifting of the valve member from the stroke stop element upon closure of the check valve.
The check valve of the invention can be used especially advantageously in an injector with a hydraulic pressure booster for an internal combustion engine.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages will become apparent in the description of the preferred embodiment below in conjunction with the accompanying drawing, in which:
FIG. 1 is a longitudinal section through one exemplary embodiment of a check valve of the invention; and
FIG. 2 is an injector of the invention with a hydraulic pressure booster and a check valve of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 , a component, which may for instance be a pressure booster piston of a hydraulic pressure booster, is identified by reference numeral 1 . In this component 1 , there is a check valve, described in further detail hereinafter, and the component 1 forms a valve housing for the check valve. In the valve housing 1 , a stepped bore 3 is provided. A valve seat 5 is embodied between two portions of the bore 3 that have different diameters.
An at least approximately spherical valve member 7 is disposed in the bore 3 . The valve member 7 cooperates with the valve seat 5 in the valve housing 1 and closes the check valve as soon as the valve member 7 rests on the valve seat 5 . Adjoining the valve seat 5 , the bore 3 has a portion 3 a with a diameter that is somewhat greater than the diameter of the valve member 7 . Toward the end of the valve housing 1 , the bore 3 is open and has a portion 3 b with a greater diameter compared to the portion 3 a . Because of the change in diameter from the portion 3 a to the portion 3 b, an annular shoulder 10 facing away from the valve seat 5 is formed in the bore 3 .
For limiting the opening stroke of the valve member 7 , a stroke stop element 12 is inserted into the bore 3 , from an open end of the valve housing 1 . The stroke stop element 12 has a stepped diameter and has a portion 12 a , disposed in the portion 3 a of the bore 3 , whose diameter is somewhat smaller than the diameter of the portion 3 a of the bore 3 , so that there is an annular gap 14 between the portion 12 a of the stroke stop element 12 and the portion 3 a of the bore 3 . The stroke stop element 12 furthermore has a portion 12 b , disposed in the portion 3 b of the bore 3 , with a greater diameter compared to the portion 12 a . The diameter of the portion 12 b of the stroke stop element 12 is only slightly less than the diameter of the portion 3 b of the bore 3 . As a result of the change in diameter of the stroke stop element 12 , an annular shoulder 13 facing toward the valve seat 5 is formed on the stroke stop element.
On the side of the stroke stop element 12 toward the valve member 7 , a funnel-shaped indentation 16 is made, which is embodied for instance as approximately frustoconical or domelike. The diameter of the indentation 16 is less than the diameter of the valve member 7 , so that the valve member 7 can dip partway into the indentation 16 . The indentation 16 is disposed at least approximately coaxially to the longitudinal axis 4 of the bore 3 , and the valve member 7 is disposed at least coaxially in the bore 3 and is movable in the direction of the longitudinal axis 4 .
A continuous longitudinal bore 20 with a multiply graduated diameter is made in the stroke stop element 12 and discharges on one end into the indentation 16 and on the other at the open end of the bore 3 on the stroke stop element 12 . In its region extending toward the indentation 16 , the longitudinal bore 20 has a small diameter and thus forms a throttle bore 20 a . An orifice 20 b of the longitudinal bore 20 into the indentation 16 has a substantially greater diameter than the throttle bore 20 a . The transition from the orifice 20 b into the throttle bore 20 a is abrupt and is embodied with sharp edges, so that the flow, beginning at the indentation 16 , into the throttle bore 20 a is severely hindered. The throttle bore 20 a is adjoined, on its side remote from the indentation 16 , by a further region 20 c of the longitudinal bore 20 , which has a greater diameter than the throttle bore 20 a . The transition from the region 20 c of the longitudinal bore 20 to the throttle bore 20 a is embodied in streamlined fashion; for instance, as shown in FIG. 1 , an approximately conical or rounded transition is provided. At least one transverse bore 22 is made in the portion 12 a of the stroke stop element 12 , and through this transverse bore, the region 20 c of the longitudinal bore 20 is in communication with the annular gap 14 . Preferably, a plurality of transverse bores 22 , distributed over the circumference, are provided in the stroke stop element 12 .
The stroke stop element 12 is preferably made from hardened steel, to assure low wear, since when the check valve opens, the valve member 7 strikes the stroke stop element 12 . The valve member 7 is likewise preferably made from hardened steel; conventional balls for ball bearings, which are available as standard parts, can for instance be used as the valve member 7 . By means of the funnel-shaped indentation 16 , the valve member 7 is centered in its reciprocal motion, and as a result it is attained that upon its closing motion, the valve member 7 strikes the valve seat 5 at least approximately centrally, so that the wear to the valve seat 5 can be kept low as well.
In the open state of the check valve, the orifice 20 b of the longitudinal bore 20 in the indentation 16 in the stroke stop element 12 is closed by the valve member 7 . An outflow of fluid is made possible by the annular gap 14 , the at least one transverse bore 22 , and the longitudinal bore 20 in the stroke stop element 12 . Because of the sharp-edged transition from the orifice 20 b of the longitudinal bore 20 in the indentation 16 into the throttle bore 20 a, the positive displacement of fluid from the indentation 16 into the longitudinal bore 20 is made more difficult, and there is increased flow resistance there. Upon opening of the check valve, the valve member 7 enters into the indentation 16 and positively displaces fluid from it into the longitudinal bore 20 . Because of the increased flow resistance, the motion of the valve member 7 is damped, so that its impact on the stroke stop element 12 is less powerful. Upon closure of the check valve, fast lifting of the valve member 7 from the stroke stop element 12 is assured, since the inflow of fluid from the longitudinal bore 20 into the indentation 16 is made possible by the streamlined transition from the region 20 c to the throttle bore 20 a.
Upon installation of the check valve in the valve housing 1 , the valve member 7 is first introduced into the bore 3 . Next, the stroke stop element 12 is inserted from the open side of the valve housing 1 into the bore 3 , in the direction of the longitudinal axis 4 , until the annular shoulder 13 of the stroke stop element 12 comes into contact with the annular shoulder 10 of the valve housing 1 . The maximum stroke of the valve member 7 that the valve member can execute between its contact with the valve seat 5 and with the stroke stop element 12 is fixed by the axial position of the stroke stop element 12 .
The stroke stop element 12 is fixed at least indirectly in the axial direction in the bore 3 of the valve housing 1 by means of a welded connection. Preferably, the stroke stop element 12 itself is joined by material engagement on its circumference to the valve housing 1 by means of a welded connection 26 in the bore 3 , as shown in the upper half of FIG. 1 . The check valve is disposed near the open end of the valve housing 1 . Alternatively, it can also be provided that after the insertion of the stroke stop element 12 into the bore 3 , as shown in the lower half of FIG. 1 , a welded ring 28 is inserted, by which the stroke stop element 12 is fixed in the axial direction and which is joined by material engagement to the valve housing 1 by means of a welded connection 30 .
In FIG. 2 , an example of the use of the check valve of the invention is shown schematically. An injector is identified in its entirety by reference numeral 55 . The injector 55 is supplied with fuel at high pressure from a common rail 57 via a high-pressure line (not identified by reference numeral). A hydraulic pressure booster 59 is provided in the injector 55 . The hydraulic pressure booster 59 includes a booster piston 61 , which divides a low-pressure chamber 63 from a high-pressure chamber 65 . In the booster piston 61 , there is a longitudinal bore 3 . In the bore 3 , there is a check valve 67 , shown in stylized fashion, which prevents fuel from being able to flow out of the high-pressure chamber 65 into the low-pressure chamber 63 . This check valve 67 is a check valve in accordance with the exemplary embodiment of FIG. 1 described above.
The high-pressure chamber 65 communicates hydraulically with a drum 69 in which a nozzle needle 71 is disposed. Via a first magnet valve 73 , which is embodied as a 3/2-way valve and which controls the hydraulic pressure booster 59 , and a second magnet valve 75 , which controls the pressure in the drum 69 , the nozzle needle 71 is opened and closed.
The booster piston 61 is preferably made from a roller bearing steel having a carbon content of approximately 1%. The booster piston 61 is guided with very little play and has a wear protection layer on its outer surface. The heat input into the booster piston 61 in the production of the welded connection 26 , 30 for fixation of the stroke stop element 12 in the bore 3 of the booster piston 61 must therefore be kept as slight as possible. As a result, the guidance play of the booster piston 61 and damage to the wear protection layer of the booster piston 61 from thermal factors in welding and/or thermal warping is minimized, and subsequent overly slight guidance play of the booster piston 61 and accordingly increased wear is avoided.
The foregoing relates to the preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
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The invention relates to a check valve with a spherical valve element whose service life and operating reliability is considerably increased in relation to conventional check valves. The improved check valve is used in an injector for a fuel injection system of an internal combustion engine, having a hydraulic pressure booster.
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RELATED APPLICATION
This application is a continuation-in-part of my earlier filed U.S. application Ser. No. 523,117 filed Nov. 12, 1974, now abandoned.
BACKGROUND OF THE INVENTION
A non-woven fabric or fibrous web obtained from a needle loom and constituting a starting material for the practice of this invention will remain comparatively fluffy, even if the fibers comprising such web were absolutely perfectly randomly oriented, as is evident from the fact that, when using 100 percent of synthetic fiber of circular cross section in such a web, the resulting product is a web containing more than 50 percent, by volume of air, for example, according to some measurements, about 53 percent. A comparison of such a prior art web with natural leather, which, depending on the tanning and treatment methods used, may contain from 85 to 96 percent by volume of fibrous material, shows that the prior art non-woven web is quite airy and consequently has modest strength properties. A closer scrutiny of natural leather reveals that the fibers therein are not circular, but are rather of such various random surface configurations that they tightly engage one with another and bond together, principally by the friction therebetween, to form a supple and soft leather. This very observation constitutes the basis of the practice according to the present invention.
BRIEF SUMMARY OF THE INVENTION
Accordingly, in one aspect, this invention relates to a process for preparing a non-woven web of fibrous material from a starting material comprising a needle punched non-woven web of fibrous material such as one made in a needle loom, and comprising partially or exclusively thermoplastic fibrous material. The invention involves the subjection of the starting needle punched web to a pulsating, sharp blow mechanical pressure and release action effect sufficient to raise the temperature of the thermoplastic fibers to their softening temperature, whereby the pulsating mechanical pressure simultaneously reduces the original interstices between the fibers and compacts the fibers, softened at least at their surfaces, to a more intimate contact with each other. This starting needle punched web can optionally be subjected to preheating by a heat conduction treatment for raising the fiber temperature to a level below the melting and also the softening temperature of the fibers to permit a quicker further raise of temperature to a level where at least the surface layer of the fibers soften because of such a pulsating mechanical pressure effect to the thus possibly preheated web. Deformation of the fiber surfaces results, and because of the substantially increased interfiber frictional bond brought about by such treatment, the fibers become locked one to another.
In another aspect, the invention relates to the product non-woven felted, needled, compacted web produced in accord with the teachings of this invention. Such a product typically has improved strength properties compared to a starting web and may be compared to a natural leather.
Other and further aspects, aims, objects, advantages, features, and the like will be apparent to those skilled in the art from the present specification with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 shows schematically an embodiment of the present invention employing an impact or hammering arrangement;
FIG. 2 shows schematically an alternative embodiment employing such arrangement;
FIG. 3 is a detail view of an alternative anvil drive assembly for the embodiment shown in FIG. 2; and
FIG. 4 is a detail view of an anvil assembly for the embodiment shown in FIG. 2.
DETAILED DESCRIPTION
According to this invention, all or a portion of a non-woven, needle punched web of fibrous material incorporating thermoplastic fibers is subjected to a pulsating, sharp blow mechanical treatment by and during which the web is heated and the thermoplastic fibers therein are passed and deformed against the adjacent surfaces of other fibers without, however, adhering to the same, whereby, after cooling of the so-treated fibrous web, the resulting web, because of interfiber friction, will not revert to the density of the starting web but rather constituted a felted product considerably resembling natural leather.
A needle punched starting web may consist exclusively of synthetic thermoplastic fibers, or may have mixed therewith other materials, such as natural fibers, in various proportions, for instance up to a weight ratio of about 50:50 of synthetic thermoplastic fibers to natural fibers. Suitable thermoplastic fibers include, for examples, those derived from such organic polymers as polypropylene, polyester, polyvinyl alcohol, polyamide, polyacrylonitrile, polyvinyl chloride, and the like. Inorganic fibers of glass and the like, particularly those which soften in temperature ranges comparable to those over which organic polymeric fibers soften, can also be included in the group of suitable thermoplastic fibers. It will be appreciated that suitable thermoplastic fibers also may include conventional organic polymeric heat shrinkable fibers. Typically a starting web contains more than 50% by volume of air.
In the practice of the present invention, use can be made of any suitable conventional machines or apparatus, as will be self-evident for any person skilled in the art from the present teachings of this invention which will produce the desired pulsating mechanical effect desired and described herein.
In continuous commercial scale production, a semifinished product obtained from a needle loom may be passed, possibly for a required heating as may be utilized in a non-woven, needle punched web conventional manufacture, or optionally for preheating to a desired temperature, preceding a pulsating mechanical treatment in accord with this invention. Suitable heating means include heating ovens, infrared heating fields, and the like. Thereafter, the starting web of fibrous material is passed into a pulsating mechanical treatment apparatus forcing the fibers into intimate engagement with each other. It is, however, to be appreciated that during such a treatment, the fibers must not bond or adhere to each other, because this would result in a comparatively stiff and hard final product which is not desired by this invention. When required or desirable, a suitable finishing agent may optionally be used at the fiber surfaces to prevent adhesion.
The elevated temperature to which a web is heated during such a treatment thus must not be so great as to melt the thermoplastic fibrous material and/or to agglomerate the fibers comprising a web. The heating must be controlled so as to maintain a temperature below the melting point of the thermoplastic fibrous material, but must be maintained and sustained for a time and at a temperature sufficient to cause at least a surface layer of the fibers to soften and to be almost, or to be even fully plastic, during the pulsating mechanical treatment, according to this invention. The optimum temperature and temperature exposure time in any given pulsating mechanical treatment operation is somewhat variable owing not only to the particular type and characteristics of the particular synthetic thermoplastic fibers involved, but also to the particular equipment and processing considerations involved, as those skilled in the art will readily appreciate, so that no particular temperature, for example, can be specified herein as being optimum for all treatment situations within the spirit and scope of this invention.
The pulsating mechanical treatment can be achieved by means of mechanical impacts and hammerings, i.e., sharp blows against web faces. During such treatment, the web can continuously pass through the hammering zone. The web being treated can, if desired, travel between supporting belts, preferably steel belts, such as a paper web travels between the drying felts of a paper making machine.
The thermoplastic fibers in a web being treated in accord with this invention can be heated as indicated above by repeated mechanical impacts only using sufficient impact pressures applied for sufficient periods of time, thereby to generate internal heat between web fibers because of such factors as inter-fiber friction deformation work subjected onto the fibers, and the like. However, to reduce the quantity of such mechanical energy needed, and also the duration of such mechanical treatment, a given web being treated can be heated to some chosen elevated temperature which is not above the melting but below the softening point of the thermoplastic fibers present, as explained, either before, or simultaneously during, mechanical treatment thereof.
Thus, according to one embodiment of the invention, a starting web is preheated to just such an extent that the desired softening of thermoplastic fibers in such web almost commences (e.g. preferably to a temperature of from about 80° to 100° C, the thermoplastic synthetic fibers being so chosen so as to soften as desired above this temperature range) whereafter such preheated web is subjected to a mechanical impact or hammering treatment which causes the fibrous material comprising the web undergoing treatment to become more close or dense, while its temperature, as a result of the mechanical treatment, is raised further, for example, by from about 25° to 50° C more. The fibers thus reach a softening temperature necessary for the required plasticity. Mechanical energy is thus converted to heat which brings to the fibrous material the additional amount of calories necessary for the desired temperature rise. Such a combination of applied heat and applied mechanical energy is advantageous from the point of view of heat economy and in addition, the fibers as a result of the impact effect, become as if riveted to each other when so compacted.
This mechanical treatment with web at such an elevated temperature compacts the fibers of the web, reduces the interstices therebetween, and causes adherence between the subsequently cooled fibers due to the remaining non-regular shape of the fiber surfaces and cross sections. The term "adherence" is used herein to indicate a rather firm gripping action between fibers exists without having them fused together, such as would result if the thermoplastic fibers melted during such mechanical treatment. In any event, there is no intent to be bound by theory herein.
A product obtained by the practice of this invention is dense, its content of air being characteristically down to below about 20 percent by volume by measurement, and it possesses improved mechanical strength (compared to a starting web) to a desirable extent in every direction. The product can successfully be used for purposes for which it has heretofore been necessary to use sheet materials, such as leather, sturdy woven fabric, strong felt, or the like, while it, like all such prior art materials, is permeable to gases, such as air, or the like. A product of this invention is thus "breathable, " which is a requirement in many applications.
The density or closeness of the resulting product is apparent also by observation of its surface, which is so smooth that it can be finished by conventional surface coloring techniques. It may be mentioned that fiber end portions which tend to project outwardly initially beyond a face of a starting web characteristically tend to become during the processing treatment in accord with this invention clubbed flat, in a manner of speaking, so that such ends at the web surface become somewhat expanded and resemble the end of a club, or the head of a rivet, from the effects of the heat and of the hammering. This, in turn, brings about the indicated great surface closeness and smoothness.
The impact or hammering frequency is conveniently and preferably in the range of from about 200 to 1500 per minute, though other frequencies can be employed. Such an impacting can be brought about either by any convenient means, such as by means of a hammer plate mounted on a shaft extending transversely to the travel direction of the web being treated wherein one end, suitably the upstream end of such plate, is connected by means of a connecting rod or the like, to a crank shaft, wheel or the like. The stroke length can range, for instance, from about 5 to 10 mm or the like, depending on the product being produced. Below this impact plate, there is provided an optionally heated and/or vibrating spring mounted support anvil. The web being heated can travel over or between an optional preheating station located between the hammer plate and the support anvil. After impact treatment, a product web is wound or subjected to a repeated impact treatment. The impact can obviously be brought about by various other art known means, for instance, by means of pneumatic devices.
It should be further appreciated that the above discussed mechanical treatments can of course be repeated once or several times, as desired for a given web, in order to obtain a desired product.
Typically and preferably, the pulsating mechanical pressure has an application force in the range of from about 100 to 500 kilograms per square centimeter of treated web area.
Referring to FIG. 1, a needle punched starting web 10 is passed (see arrows indicating travel path) through an optional heating zone 11 onto a vibrating support 12 which preferably is mounted in a stiffly sprung manner, such as on a vibration absorbing rubber cushion 13. This support 12 can optionally be heated to slightly below the softening temperature of the fibers in web 10. Above the support 12, an impact plate 15 having a width equal to that of the web 10 is positioned. Plate 15 is connected to a horizontal shaft 14 so that the plate 15 is adapted to receive a reciprocating vertical movement from a rotatably driven crank wheel 17 through a connecting rod 16. The fibrous material web 10 travels between the support 12 and the impact plate 15 driven by a pair of feed rolls 18 in the analogous manner as a conventional needle punched web may be repeatedly needled.
Referring to FIG. 2, a web 20 being treated is passed from a supply roll 23 through an optional preheating zone 21 over an anvil 22 and to a take up roll 24. Conventional drive means (not shown) is provided for advance and coiling of web 20. Preheating zone 21 is here provided with an electrically resistance-heated coiled wire (shown diagramatically). Anvil 22 has a flattened upper surface and a generally cylindrically curved lower surface which rests in mating engagement with a seat 26, so that anvil 22 can "float" and move responsively to web 20 movements and impacts thereagainst of hammer head 27. The respective widths of anvil 22 and hammer head 27 are such as to be at least equal to the width of web 20.
An optional heating zone in the impact region of anvil 22 and hammer head 27 is provided by mounting internally in each of anvil 22 and hammer head 27 respective electrically resistance heated coiled wires 28 and 29, respectively. Thus, if desired, web 20 can be heated by the preheating zone 21 and by the heating zone in the impact region, as described, if desired. It is noted with particularity that such preheating and heating is not necessary to the practice of this invention. If such zones are utilized, they are employable separately or in combination with one another. The temperature generated by such zones is controlled by conventional temperature regulation means (not shown); the temperature of a web 20 is not permitted to reach the softening temperature of thermoplastic fibers incorporated into web 20.
Hammer head or plate 27 is secured on its back face to a reciprocatorily moveable drive shaft 31 which terminably connects at its upper end to a yoke 32. A connecting rod 33 mounted between the opposed upper ends of yoke 32 extends through a mid portion of fulcrum 34. A guide plate 36 for shaft 31 is provided. A connecting rod 37 interconnects functionally the swinging end of fulcrum 34 to revolvably driven crank wheel 38. A holding plate 39 extends longitudinally outwardly from the pivoting end of fulcrum 34 to a mounted, clamped position between a pair of opposed compressed coil springs 41.
A U-shaped bracket 42 threadably mounts in opposed relationship through terminal regions of the arms thereof a pair of adjusting screws 43 which are adapted to maintain an adjustable tensioning of springs 41 upon opposing faces of plate 39. Pressure of springs 41 upon plate 39 regulates the force exerted by hammer plate 27 upon web 20 and also provides a floating pivot point for fulcrum 34. The assembly of bracket 42, screws 43 and springs 41 thus provides a resilient cushion which is desirable because seat 26 is rigid. Adjustment of screws 43 regulates both the minimum space between hammer head 27 and anvil 22 over which web 22 travels and also the impact pressure exerted between head 27 and anvil 22 upon a web 20 during operation of such apparatus. Phantom lines 44 illustrate a lower position which fulcrum 34 can occupy during apparatus operation.
Referring to FIG. 3, there is seen an alternative apparatus similar to that in FIG. 2, except that here the connecting rod 37 and crank wheel 38 are replaced by a double acting pneumatic cylinder assembly 46 whose piston rod 47 functionally joins with fulcrum 34'. Control valve 48 interconnects functionally with cylinder 46 via tubing 49. Valve 48 is employed to control reciprocal movements of shaft 31' by regulating pneumatic fluid charging rates, etc., to cylinder 46 as those skilled in the art will readily appreciate. Components in the apparatus of FIG. 3 which are like corresponding components in the apparatus of FIG. 2 are similarly numbered but with the addition of prime marks thereto. Observe that the FIG. 3 apparatus employs no heating means.
Referring to FIG. 4, there is seen an alternative apparatus similar to that in FIG. 2 except that here drive shaft 31" is provided with a hammer head 51 having defined across the front face 52 thereof and extending in the direction of travel of web 20" a set of three channels 53. Channels 53 are profiled so as to bring about a desired pattern in the surface of a product web treated in accordance with the present invention, the pattern here being produced being in the nature of stripes. The stripes may be laterally spaced from one another by a discrete distance, for example, from 6 to 8 or 10 mm. Components in the apparatus of FIG. 3 which are like corresponding components in the apparatus of FIG. 2 are similarly numbered but with the addition of double prime marks thereto.
A starting needle punched web as obtained from the needle loom may, when desired, thus be treated only at selected areas of the same. In this manner, even a fairly thick floor carpet may be given the softness and springiness necessary for it, immediately after application, to adjust itself to the floor and stay in place even without glueing. Between these dense stripes, there thus are zones of the material web which are in the state the web was in when it came out from the needle loom.
It will be appreciated that the product obtained by the process of the invention is softenable, for instance, lubricatable or impregnatable, and otherwise dinishable in the same manner as natural leather, so that, with respect to softness and porosity, it may be made comparable with, for instance, nappa (a very soft grain) leather.
The impacting or hammering of a web as taught herein produces a change of pressure with time in relation to a web comparable to spaced squares or rectangles in a graph where pressure is shown as abscissae and time as ordinates which is in sharp and non equivalent contrast to less sharply defined changes of pressure with respect to time, such as is characteristic of pressures exerted in a nip region between rolls, where, in relation to a web, the changes are comparable to a sine curve in a comparable graph. It is only by the teachings of the present invention that one can achieve the class of "concentrated" blows needed to reach the sort of fiber deformation described earlier achieved in product webs of this invention, such fiber deformation being believed to be an important factor in obtaining the properties characteristically associated with product webs of this invention.
EMBODIMENTS
The present invention is further illustrated by reference to the following examples. Those skilled in the art will appreciate that other and further embodiments are obvious and within the spirit and scope of this invention from the teachings of these present examples taken with the accompanying specification.
When the present process was compared with the known prior art needling-shrinking process, it was found that the density of the non-woven product web was generally increased about 2.5 times and the tensile strength from about 4 to 5 times. These trials were carried out making product webs of different thicknesses.
EXAMPLE 1
Apparatus as shown in FIG. 2 is constructed wherein the head 27 has a width of 15 centimeters in the direction of movement of web 20. Web speed is adjusted to 1.5 meters per minute. At a frequency of 900 blows per minute, each cross section of web receives 90 blows in 6 seconds (i.e., 15 blows per second). Each blow has a pressure of 200 kilograms per square centimeter.
In the following examples, some numerical values obtained when testing a product resulting from the practice of this invention are provided when using apparatus as described above in relation to FIGS. 1 or 2.
EXAMPLE 2
The raw material used was polyester heat shrinkable fiber of 1.5 denier and 50 mm fiber length. In a needle loom, this fiber was converted to a twice-needle punched web weighing 280 grams per square meter. Thereafter, in two successive heat with impact treatments, this starting web was hammered to a thickness of 0.4 mm. The tensile strength values of this non-woven starting fabric product after the conventional heat treatment but before processing according to the invention were as follows: In the transverse direction 42 kg/cm 2 , and in the longitudinal direction, 71 kg/cm 2 . After processing according to this invention, these values were respectively, 124 kg/cm 2 and 250 kg/cm 2 .
EXAMPLE 3
The starting web of Example 1 is similarly processed as in Example 1 but so as to produce a product of 0.8 mm thickness. The strength values obtained were 174 kg/cm 2 and 289 kg/cm 2 , respectively. The density of the product was further increased by the process to a specific gravity value of 1.17 (the specific gravity of the fiber itself was 1.38) while the same product when shrunk by means of hot water reached a specific gravity value of only 0.48, which indicates that the density obtained by the process of the invention was about 2.5 times that of the conventionally prepared product (the starting web). For the sake of comparison, it may be mentioned that the tensile strength of good chromium salt tanned leather is from 200 to 350 kg/cm 2 , and, as an average with respect to grain split leather, values ranging from 100 to 150 kg/cm 1 are often seen.
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Preparation of a non-woven web of fibrous material so as to obtain a product having considerably better mechanical characteristics than the "breathable" non-woven fabrics of the prior art, without any substantial loss of its softness, drape or porosity characteristics. A starting needle punched non-woven web consisting substantially of thermoplastic synthetic fibers is subjected to pulsating sharp blow mechanical pressure applied transversely to web surface sufficient to generate heat by inter-fiber friction and deformation work subjected on the fibers to increase the temperature of fibers to soften them and bring the fibers tightly to adhere one with another and lock together because of the non-regular shape of fiber surface and cross section caused by said treatment. Simultaneously the interstices between the fibers are reduced and the web is compacted resulting in a relatively close natural leather-like non-woven fabric. Surface density and smoothness are attained by clubbing of the fiber ends, which tend to project outwardly initially beyond a face of the web, into substantially expanded form.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/485,674 filed Jul. 9, 2003, which is incorporated herein by reference.
[0002] The following U.S. Patent Applications are cited by reference and incorporated by reference herein: U.S. patent application Ser. No. 10/255,564 titled “CONTAINER” filed Sep. 25, 2002, which is a continuation-in-part of U.S. patent application Ser. No. 10/132,682 titled “CONTAINER” filed Apr. 25, 2002, which is a continuation-in part of U.S. patent application Ser. No. 10/006,985 titled “PAINT CONTAINER” filed Dec. 5, 2001.
FIELD
[0003] The present invention relates generally to the field of a paint container and more particularly to a system for containing paint having a locking mechanism for inhibiting movement of a handle in at least two planes.
BACKGROUND OF THE INVENTION
[0004] It is generally known to provide a container for paint. Such known containers are typically a cylindrical one gallon metal container. The metal container includes a round base and a cylindrical side wall attached to and extending from the base.
[0005] The handle of such known containers is a thin curved wire member comprised of a 0.105 gauge material. However, such handle digs into a user's hand under the weight of the paint and the container, and makes such known metal containers difficult to carry. Further, the curved wire handle requires handle pivot or “ear” supports to be added to the outer surface of the cylindrical can, which add assembly and material costs to the container. In addition, the handle may be inadvertently removed from the pivot supports. Furthermore, the pivot supports affect how such known containers must be packed for shipping and for display. Since the pivot supports extend outward from such known containers, additional space between containers (or placement such that the pivot supports are in the “dead” space zone between the containers) is required.
[0006] It would be desirable to provide a paint container that is easy to hold using a handle. It would further be desirable to provide a paint container having a handle that is easy to install. It would further be desirable to provide a paint container having a handle that is securely locked to the container in the use and the storage positions. It would also be desirable to provide a container well-suited for packaging and shipping. It would still further be desirable to provide a paint container having one or more of these or other advantageous features.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a system for containing paint. The system comprises a body between a cover and a base. The system also comprises a handle configured for attachment to the body and selectively configurable between a first position and a second position. The system also comprises a locking mechanism. The locking mechanism comprises a protrusion configured for insertion into a recess of the body. The locking mechanism also comprises a tab of the handle configured for selective insertion into a track of the body. The locking mechanism is configured to inhibit movement of the handle in at least two planes when the handle is in the first position.
[0008] The present invention also relates to a method of using a container for paint. The container comprises a body having a side wall between a cover and a base. The container also comprises a handle configured for attachment to the side wall. The container also comprises a first protrusion and a second protrusion of the handle each configured for insertion into at least one recess of the side wall. The container also comprises a tab of the handle configured for selective insertion into a track of the body. The method comprises positioning the handle in an installation position. The method also comprises biasing the first protrusion away from the second protrusion. The method also comprises inserting the first protrusion in the recess of the side wall to inhibit movement of the handle between a forward position and a rearward position relative to the base.
[0009] The present invention also relates to a system for containing paint. The system comprises a body. The system also comprises a handle configured for attachment to the body and selectively configurable between a first position and a second position. The system also comprises means for locking the handle to the body. The means for locking is configured to inhibit movement of the handle in at least two planes when the handle is in the first position.
[0010] It is important to note that the term “paint” as used in this disclosure is intended to be a broad term and not a term of limitation. The term “paint” as used in this disclosure may include, without limitation any decorative or functional surface treatment, liquid dispersion, finish, surface finish, varnish, pigment, colorant, other coating, etc.
[0011] It is also important to note that the terms “up,” “down,” “forward,” “aft,” etc. as used in this disclosure with reference to the embodiments shown in the FIGURES are intended to be broad terms and not terms of limitation. It will be understood, however, that the paint container and the handle shown in the FIGURES may be positioned in any of a variety of orientations and the orientations illustrated in the FIGURES is not intended to be limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded perspective view of a system for containing paint according to a preferred embodiment.
[0013] FIG. 2 is a perspective view of the system for containing paint of FIG. 1 showing a handle in a storage position according to an exemplary embodiment.
[0014] FIG. 3 is a perspective view of the system for containing paint of FIG. 1 showing the handle in a use position according to an exemplary embodiment.
[0015] FIG. 4 is a side elevation view of the system for containing paint of FIG. 1 showing the handle in the use position according to an exemplary embodiment.
[0016] FIG. 5 is a fragmentary exploded perspective view of the system for containing paint of FIG. 1 according to a preferred embodiment.
[0017] FIG. 6 is a fragmentary sectional view of a locking mechanism of the system for containing paint of FIG. 1 showing the handle in the use position according to an exemplary embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Referring to FIG. 1 , a system for containing paint (shown as a paint container 10 ) is shown according to a preferred embodiment. Container 10 includes a body 12 formed by a vertical side wall 14 extending between a horizontal cover 28 and a horizontal base 16 . A bail or handle 18 is attached to side wall 14 of body 12 by a locking system or mechanism 30 . Handle 18 is selectively configurable between a horizontal “down” or closed storage position 20 (see FIG. 2 ) and a vertical “up” or open use position 22 (see FIG. 3 ). A cap or lid 24 is shown in FIG. 2 threadably attached to a neck 26 having a pour spout 56 (see FIG. 1 ) which may be selectively inserted into neck 26 for removing paint from container 10 .
[0019] Referring to FIGS. 2 and 5 , locking mechanism 30 includes a first butt or male portion 32 a and a second male portion 32 b , each respectively terminating from an end of handle 18 . Locking mechanism 30 also includes a first female portion 40 a and a second female portion 40 b , each respectively in side wall 14 of body 12 . Male portions 32 a and 32 b each comprise a cylindrical member or first protrusion 34 a and a second protrusion 34 b . A distance 50 extends between first protrusion 34 a and second protrusion 34 b of the respective ends of handle 18 (see FIG. 1 ). Male portions 32 a and 32 b each also comprise a wedge-shaped “ear” or a first tab 36 a and a second tab 36 b , each respectively extending from the respective ends of handle 18 (see FIG. 4 ). Protrusion 34 a and a corresponding protrusion 34 b may have a cutout 38 as shown in FIGS. 5 and 6 according to an alternative embodiment. The protrusion also may have a “+” or cross shape according to another alternative embodiment.
[0020] Referring further to FIGS. 1 and 5 , female portions 40 a and 40 b of locking mechanism 30 comprise a cylindrical shaped cavity or first recess 42 a and a second recess 42 b , each respectively in side wall 14 . Recess 42 a and recess 42 b each may have a “+” or cross shape corresponding to the shape of the protrusion according to an alternative embodiment as shown in FIGS. 1 and 5 .
[0021] A first horizontal land 44 a and a second horizontal land 44 b are each respectively offset from side wall 14 according to a preferred embodiment as shown in FIGS. 1 and 5 . A track or first groove 46 a and a track or second groove 46 b each respectively extend into horizontal land 44 a and horizontal land 44 b according to a preferred embodiment as shown in FIGS. 1 and 5 . A first vertical land 48 a and a second vertical land 48 b are each respectively offset from side wall 14 according to a preferred embodiment as shown in FIGS. 1 and 5 . A first recess 42 a and a second recess 42 b each respectively extend into vertical land 48 a and vertical land 48 b according to a preferred embodiment as shown in FIGS. 1 and 5 .
[0022] According to a preferred embodiment as shown in FIGS. 1 and 5 , horizontal land 44 a and horizontal land 44 b are each respectively generally perpendicular to vertical land 48 a and vertical land 48 b . According to a preferred embodiment as shown in FIGS. 1 and 5 , handle 18 in storage position 20 rests against a portion 64 of horizontal land 44 a . The horizontal and vertical lands may be in any part of the body, including the side wall or the cover according to any preferred or alternative embodiment. According to a preferred embodiment as shown in FIG. 1 , horizontal land 44 b is contiguous with side wall 14 and vertical land 48 b , and vertical land 48 b is contiguous with cover 28 .
[0023] A non-circular cross-section of protrusion 34 a and protrusion 34 b each respectively provide an interference fit with recess 42 a and recess 42 b (respectively) as handle 18 is pivoted between storage position 20 and use position 22 (see FIG. 5 ). The interference fit between protrusion 34 a in recess 42 a and tab 36 a in groove 46 a each respectively assists in maintaining or retaining handle 18 in any position (e.g. an intermediate position between the fully closed position and the fully opened position). The interference fit acts to both hold the handle at a given position as well as resist movement relative to the body.
[0024] Handle 18 may be pivoted (e.g. manually by a user) between storage position 20 and use position 22 . In use position 22 , protrusion 34 a is inserted in recess 42 a , and tab 36 a is in groove 46 a as shown in FIG. 6 . Tab 36 a travels in groove 46 a as handle 18 is pivoted between storage position 20 and use position 22 .
[0025] In use position 22 , the top surface of protrusion 34 a engages the outer wall of recess 42 a to support the weight of container 10 (see FIG. 6 ). Protrusion 34 a inhibits handle 18 from fore and aft movement along a vector 52 in a plane parallel to base 16 . Tab 36 a in groove 46 a inhibits protrusion 34 a from being removed from recess 42 a (e.g. due to helical or twisting motion of handle 18 in use position 22 when container 10 is carried by a user)—thus inhibiting handle 18 from being moved in an inward and outward direction in a plane parallel to side wall 14 along a vector 54 . Length 62 of protrusion 34 a and protrusion 34 b each respectively in recess 42 a and recess 42 b also inhibit handle 18 from being moved in the inward and outward direction in a plane parallel to side wall 14 along vector 54 .
[0026] According to alternative embodiments, other mechanical fastening structures may also be employed for the locking mechanism. Additionally, a snap in feature that releasably locks the handle in the rest or in the use position may be helpful to ensure the handle does not move. The snap or lock feature may be accomplished by irregular geometry of the handle tabs and land apertures, or any other known means for securing a handle in specific position relative to the container.
[0027] According to a preferred embodiment as shown in FIG. 1 , side wall 14 includes an inward recess 58 providing a display area for indicia (e.g. label). According to a preferred embodiment as shown in FIG. 2 , handle 18 is “flush” or even with side wall 14 (i.e. does not extend beyond the outer periphery of body 12 ) which may assist in storage and shipping of container 10 . According to a preferred embodiment as shown in FIG. 1 , a region 66 of body 12 is “label free,” intended in part to inhibit paint from spilling onto the label in the area proximate to spout 56 .
[0028] According to a particularly preferred embodiment, the container has a perimeter that is “D”-shaped, a cross-section that is substantially “D”-shaped, and a substantially flat bottom that is substantially “D”-shaped. According to a particularly preferred embodiment, the container is configured to hold a volume of about one gallon of paint, and may have other volumes (e.g. one quart) according to other alternative embodiments. According to a particularly preferred embodiment, the lid of the container has an area of about 12.4 square inches. According to a particularly preferred embodiment, the container is of the type disclosed in U.S. patent application Ser. No. 10/255,564 titled “CONTAINER” filed Sep. 25, 2002, which is a continuation-in-part of U.S. patent application Ser. No. 10/132,682 titled “CONTAINER” filed Apr. 25, 2002, which is a continuation-in part of U.S. patent application Ser. No. 10/006,985 titled “PAINT CONTAINER” filed Dec. 5, 2001.
[0029] Referring further to FIGS. 1 and 5 , to install handle 18 on side wall 14 , handle 18 is placed in storage position 20 . Protrusion 34 a is inserted into recess 42 a . Protrusion 34 b is biased away from protrusion 34 a beyond vertical land 48 b . Protrusion 34 b is then inserted in recess 42 b . According to a preferred embodiment, protrusion 34 a may be biased toward protrusion 34 b when handle 18 is in storage position 20 (e.g. due to an elastic or resilient property of the material or shape of the handle). Tab 36 b is outside of groove 46 b (and tab 36 a is outside of groove 46 a ) when handle 18 is in storage position 20 as shown in FIG. 2 according to an exemplary embodiment.
[0030] To remove handle 18 from side wall 14 , handle 18 is moved to storage position 20 . Protrusion 34 a is biased away from protrusion 34 b (e.g. manually by a user). A length 62 of protrusion 34 a is removed from recess 42 a . Protrusion 34 a is offset from recess 42 a (e.g. by twisting or pivoting handle 18 ). Protrusion 34 b is then removed from recess 42 b.
[0031] It is important to note that the construction and arrangement of the elements of the paint container as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g. variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims.
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A system for containing paint is disclosed. The system comprises a body between a cover and a base. The system also comprises a handle configured for attachment to the body and selectively configurable between a first position and a second position. The system also comprises a locking mechanism. The locking mechanism comprises a protrusion configured for insertion into a recess of the body. The locking mechanism also comprises a tab of the handle configured for selective insertion into a track of the body. The locking mechanism is configured to inhibit movement of the handle in at least two planes when the handle is in the first position. A method of using a container for paint is also disclosed. A system for containing paint comprising means for locking the handle to the body is also disclosed.
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CROSS-REFERENCE TO RELATED APPLICATIONS(S)
This application is a division of U.S. patent application Ser. No. 09/821,240, filed on Mar. 29, 2001, now is U.S. Pat. No. 6,357,107 which is a division of U.S. patent application Ser. No. 09/350,601, filed on Jul. 9, 1999, now issued as U.S. Pat. No. 6,240,622, the specifications of which are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to inductors, and more particularly, it relates to inductors used with integrated circuits.
BACKGROUND OF THE INVENTION
Inductors are used in a wide range of signal processing systems and circuits. For example, inductors are used in communication systems, radar systems, television systems, highpass filters, tank circuits, and butterworth filters.
As electronic signal processing systems have become more highly integrated and miniaturized, effectively signal processing systems on a chip, system engineers have sought to eliminate the use of large, auxiliary components, such as inductors. When unable to eliminate inductors in their designs, engineers have sought ways to reduce the size of the inductors that they do use.
Simulating inductors using active circuits, which are easily miniaturized, is one approach to eliminating the use of actual inductors in signal processing systems. Unfortunately, simulated inductor circuits tend to exhibit high parasitic effects, and often generate more noise than circuits constructed using actual inductors.
Inductors are miniaturized for use in compact communication systems, such as cell phones and modems, by fabricating spiral inductors on the same substrate as the integrated circuit to which they are coupled using integrated circuit manufacturing techniques. Unfortunately, spiral inductors take up a disproportionately large share of the available surface area on an integrated circuit substrate.
For these and other reasons there is a need for the present invention.
SUMMARY OF THE INVENTION
The above mentioned problems and other problems are addressed by the present invention and will be understood by one skilled in the art upon reading and studying the following specification. An integrated circuit inductor compatible with integrated circuit manufacturing techniques is disclosed.
In one embodiment, an inductor capable of being fabricated from a plurality of conductive segments and interwoven with a substrate is disclosed. In an alternate embodiment, a sense coil capable of measuring the magnetic field or flux produced by an inductor comprised of a plurality of conductive segments and fabricated on the same substrate as the inductor is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cutaway view of some embodiments of an inductor of the present invention.
FIG. 1B is a top view of some embodiments of the inductor of FIG. 1 A.
FIG. 1C is a side view of some embodiments of the inductor of FIG. 1 A.
FIG. 2 is a cross-sectional side view of some embodiments of a highly conductive path including encapsulated magnetic material layers.
FIG. 3A is a perspective view of some embodiments of an inductor and a spiral sense inductor of the present invention.
FIG. 3B is a perspective view of some embodiments of an inductor and a non-spiral sense inductor of the present invention.
FIG. 4 is a cutaway perspective view of some embodiments of a triangular coil inductor of the present invention.
FIG. 5 is a top view of some embodiments of an inductor coupled circuit of the present invention.
FIG. 6 is diagram of a drill and a laser for perforating a substrate.
FIG. 7 is a block diagram of a computer system in which embodiments of the present invention can be practiced.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
FIG. 1A is a cutaway view of some embodiments of inductor 100 of the present invention. Inductor 100 includes substrate 103 , a plurality of conductive segments 106 , a plurality of conductive segments 109 , and magnetic film layers 112 and 113 . The plurality of conductive segments 109 interconnect the plurality of conductive segments 106 to form highly conductive path 114 interwoven with substrate 103 . Magnetic film layers 112 and 113 are formed on substrate 103 in core area 115 of highly conductive path 114 .
Substrate 103 provides the structure in which highly conductive path 114 that constitutes an inductive coil is interwoven. Substrate 103 , in one embodiment, is fabricated from a crystalline material. In another embodiment, substrate 103 is fabricated from a single element doped or undoped semiconductor material, such as silicon or germanium. Alternatively, substrate 103 is fabricated from gallium arsenide, silicon carbide, or a partially magnetic material having a crystalline or amorphous structure. Substrate 103 is not limited to a single layer substrate. Multiple layer substrates, coated or partially coated substrates, and substrates having a plurality of coated surfaces are all suitable for use in connection with the present invention. The coatings include insulators, ferromagnetic materials, and magnetic oxides. Insulators protect the inductive coil and separate the electrically conductive inductive coil from other conductors, such as signal carrying circuit lines. Coatings and films of ferromagnetic materials, such as magnetic metals, alloys, and oxides, increase the inductance of the inductive coil.
Substrate 103 has a plurality of surfaces 118 . The plurality of surfaces 118 is not limited to oblique surfaces. In one embodiment, at least two of the plurality of surfaces 118 are parallel. In an alternate embodiment, a first pair of parallel surfaces are substantially perpendicular to a second pair of surfaces. In still another embodiment, the surfaces are planarized. Since most integrated circuit manufacturing processes are designed to work with substrates having a pair of relatively flat or planarized parallel surfaces, the use of parallel surfaces simplifies the manufacturing process for forming highly conductive path 114 of inductor 100 .
Substrate 103 has a plurality of holes, perforations, or other substrate subtending paths 121 that can be filled, plugged, partially filed, partially plugged, or lined with a conducting material. In FIG. 1A, substrate subtending paths 121 are filled by the plurality of conducting segments 106 . The shape of the perforations, holes, or other substrate subtending paths 121 is not limited to a particular shape. Circular, square, rectangular, and triangular shapes are all suitable for use in connection with the present invention. The plurality of holes, perforations, or other substrate subtending paths 121 , in one embodiment, are substantially parallel to each other and substantially perpendicular to substantially parallel surfaces of the substrate.
Highly conductive path 114 is interwoven with a single layer substrate or a multilayer substrate, such as substrate 103 in combination with magnetic film layers 112 and 113 , to form an inductive element that is at least partially embedded in the substrate. If the surface of the substrate is coated, for example with magnetic film 112 , then conductive path 114 is located at least partially above the coating, pierces the coated substrate, and is interlaced with the coated substrate.
Highly conductive path 114 has an inductance value and is in the shape of a coil. The shape of each loop of the coil interlaced with the substrate is not limited to a particular geometric shape. For example, circular, square, rectangular, and triangular loops are suitable for use in connection with the present invention.
Highly conductive path 114 , in one embodiment, intersects a plurality of substantially parallel surfaces and fills a plurality of substantially parallel holes. Highly conductive path 114 is formed from a plurality of interconnected conductive segments. The conductive segments, in one embodiment, are a pair of substantially parallel rows of conductive columns interconnected by a plurality of conductive segments to form a plurality of loops.
Highly conductive path 114 , in one embodiment, is fabricated from a metal conductor, such as aluminum, copper, or gold or an alloy of a such a metal conductor. Aluminum, copper, or gold, or an alloy is used to fill or partially fill the holes, perforations, or other paths subtending the substrate to form a plurality of conductive segments. Alternatively, a conductive material may be used to plug the holes, perforations, or other paths subtending the substrate to form a plurality of conductive segments. In general, higher conductivity materials are preferred to lower conductivity materials. In one embodiment, conductive path 114 is partially diffused into the substrate or partially diffused into the crystalline structure.
For a conductive path comprised of segments, each segment, in one embodiment, is fabricated from a different conductive material. An advantage of interconnecting segments fabricated from different conductive materials to form a conductive path is that the properties of the conductive path are easily tuned through the choice of the conductive materials. For example, the internal resistance of a conductive path is increased by selecting a material having a higher resistance for a segment than the average resistance in the rest of the path. In an alternate embodiment, two different conductive materials are selected for fabricating a conductive path. In this embodiment, materials are selected based on their compatibility with the available integrated circuit manufacturing processes. For example, if it is difficult to create a barrier layer where the conductive path pierces the substrate, then the conductive segments that pierce the substrate are fabricated from aluminum. Similarly, if it is relatively easy to create a barrier layer for conductive segments that interconnect the segments that pierce the substrate, then copper is used for these segments.
Highly conductive path 114 is comprised of two types of conductive segments. The first type includes segments subtending the substrate, such as conductive segments 106 . The second type includes segments formed on a surface of the substrate, such as conductive segments 109 . The second type of segment interconnects segments of the first type to form highly conductive path 114 . The mid-segment cross-sectional profile 124 of the first type of segment is not limited to a particular shape. Circular, square, rectangular, and triangular are all shapes suitable for use in connection with the present invention. The mid-segment cross-sectional profile 127 of the second type of segment is not limited to a particular shape. In one embodiment, the mid-segment cross-sectional profile is rectangular. The coil that results from forming the highly conductive path from the conductive segments and interweaving the highly conductive path with the substrate is capable of producing a reinforcing magnetic field or flux in the substrate material occupying the core area of the coil and in any coating deposited on the surfaces of the substrate.
FIG. 1B is a top view of FIG. 1A with magnetic film 112 formed on substrate 103 between conductive segments 109 and the surface of substrate 103 . Magnetic film 112 coats or partially coats the surface of substrate 103 . In one embodiment, magnetic film 112 is a magnetic oxide. In an alternate embodiment, magnetic film 112 is one or more layers of a magnetic material in a plurality of layers formed on the surface of substrate 103 .
Magnetic film 112 is formed on substrate 103 to increase the inductance of highly conductive path 114 . Methods of preparing magnetic film 112 include evaporation, sputtering, chemical vapor deposition, laser ablation, and electrochemical deposition. In one embodiment, high coercivity gamma iron oxide films are deposited using chemical vapor pyrolysis. When deposited at above 500 degrees centigrade these films are magnetic gamma oxide. In an alternate embodiment, amorphous iron oxide films are prepared by the deposition of iron metal in an oxygen atmosphere (10 −4 torr) by evaporation. In another alternate embodiment, an iron-oxide film is prepared by reactive sputtering of an Fe target in Ar+O 2 atmosphere at a deposition rate of ten times higher than the conventional method. The resulting alpha iron oxide films are then converted to magnetic gamma type by reducing them in a hydrogen atmosphere.
FIG. 1C is a side view of some embodiments of the inductor of FIG. 1A including substrate 103 , the plurality of conductive segments 106 , the plurality of conductive segments 109 and magnetic films 112 and 113 .
FIG. 2 is a cross-sectional side view of some embodiments of highly conductive path 203 including encapsulated magnetic material layers 206 and 209 . Encapsulated magnetic material layers 206 and 209 , in one embodiment, are a nickel iron alloy deposited on a surface of substrate 212 . Formed on magnetic material layer layers 206 and 209 are insulating layers 215 and 218 and second insulating layers 221 and 224 which encapsulate highly conductive path 203 deposited on insulating layers 215 and 218 . Insulating layers 215 , 218 , 221 and 224 , in one embodiment are formed from an insulator, such as polyimide. In an alternate embodiment, insulating layers 215 , 218 , 221 , and 224 are an inorganic oxide, such as silicon dioxide or silicon nitride. The insulator may also partially line the holes, perforations, or other substrate subtending paths. The purpose of insulating layers 215 and 218 , which in one embodiment are dielectrics, is to electrically isolate the surface conducting segments of highly conductive path 203 from magnetic material layers 206 and 209 . The purpose of insulating layers 221 and 224 is to electrically isolate the highly conductive path 203 from any conducting layers deposited above the path 203 and to protect the path 203 from physical damage.
The field created by the conductive path is substantially parallel to the planarized surface and penetrates the coating. In one embodiment, the conductive path is operable for creating a magnetic field within the coating, but not above the coating. In an alternate embodiment, the conductive path is operable for creating a reinforcing magnetic field within the film and within the substrate.
FIG. 3 A and FIG. 3B are perspective views of some embodiments of inductor 301 and sense inductors 304 and 307 of the present invention. In one embodiment, sense inductor 304 is a spiral coil and sense inductor 307 is a test inductor or sense coil embedded in the substrate. Sense inductors 304 and 307 are capable of detecting and measuring reinforcing magnetic field or flux 309 generated by inductor 301 , and of assisting in the calibration of inductor 301 . In one embodiment, sense inductor 304 is fabricated on one of the surfaces substantially perpendicular to the surfaces of the substrate having the conducting segments, so magnetic field or flux 309 generated by inductor 301 is substantially perpendicular to sense inductor 304 . Detachable test leads 310 and 313 in FIG. 3 A and detachable test leads 316 and 319 in FIG. 3B are capable of coupling sense inductors 304 and 307 to sense or measurement circuits. When coupled to sense or measurement circuits, sense inductors 304 and 307 are decoupled from the sense or measurement circuits by severing test leads 310 , 313 , 316 , and 319 . In one embodiment, test leads 310 , 313 , 316 , and 316 are severed using a laser.
In accordance with the present invention, a current flows in inductor 301 and generates magnetic field or flux 309 . Magnetic field or flux 309 passes through sense inductor 304 or sense inductor 307 and induces a current in spiral sense inductor 304 or sense inductor 307 . The induced current can be detected, measured and used to deduce the inductance of inductor 301 .
FIG. 4 is a cutaway perspective view of some embodiments of triangular coil inductor 400 of the present invention. Triangular coil inductor 400 comprises substrate 403 and triangular coil 406 . An advantage of triangular coil inductor 400 is that it saves at least a process step over the previously described coil inductor. Triangular coil inductor 400 only requires the construction of three segments for each coil of inductor 400 , where the previously described inductor required the construction of four segments for each coil of the inductor.
FIG. 5 is a top view of some embodiments of an inductor coupled circuit 500 of the present invention. Inductor coupled circuit 500 comprises substrate 503 , coating 506 , coil 509 , and circuit or memory cells 512 . Coil 509 comprises a conductive path located at least partially above coating 506 and coupled to circuit or memory cells 512 . Coil 509 pierces substrate 503 , is interlaced with substrate 503 , and produces a magnetic field in coating 506 . In an alternate embodiment, coil 509 produces a magnetic field in coating 506 , but not above coating 506 . In one embodiment, substrate 503 is perforated with a plurality of substantially parallel perforations and is partially magnetic. In an alternate embodiment, substrate 503 is a substrate as described above in connection with FIG. 1 . In another alternate embodiment, coating 506 is a magnetic film as described above in connection with FIG. 1 . In another alternate embodiment, coil 509 , is a highly conductive path as described in connection with FIG. 1 .
FIG. 6 is a diagram of a drill 603 and a laser 606 for perforating a substrate 609 . Substrate 609 has holes, perforations, or other substrate 609 subtending paths. In preparing substrate 609 , in one embodiment, a diamond tipped carbide drill is used bore holes or create perforations in substrate 609 . In an alternate embodiment, laser 606 is used to bore a plurality of holes in substrate 609 . In a preferred embodiment, holes, perforations, or other substrate 609 subtending paths are fabricated using a dry etching process.
FIG. 7 is a block diagram of a system level embodiment of the present invention. System 700 comprises processor 705 and memory device 710 , which includes memory circuits and cells, electronic circuits, electronic devices, and power supply circuits coupled to inductors of one or more of the types described above in conjunction with FIGS. 1A-5. Memory device 710 comprises memory array 715 , address circuitry 720 , and read circuitry 730 , and is coupled to processor 705 by address bus 735 , data bus 740 , and control bus 745 . Processor 705 , through address bus 735 , data bus 740 , and control bus 745 communicates with memory device 710 . In a read operation initiated by processor 705 , address information, data information, and control information are provided to memory device 710 through busses 735 , 740 , and 745 . This information is decoded by addressing circuitry 720 , including a row decoder and a column decoder, and read circuitry 730 . Successful completion of the read operation results in information from memory array 715 being communicated to processor 705 over data bus 740 .
CONCLUSION
Embodiments of inductors and methods of fabricating inductors suitable for use with integrated circuits have been described. In one embodiment, an inductor having a highly conductive path fabricated from a plurality of conductive segments, and including coatings and films of ferromagnetic materials, such as magnetic metals, alloys, and oxides has been described. In another embodiment, an inductor capable of being fabricated from a plurality of conductors having different resistances has been described. In an alternative embodiment, an integrated test or calibration coil capable of being fabricated on the same substrate as an inductor and capable of facilitating the measurement of the magnetic field or flux generated by the inductor and capable of facilitating the calibration the inductor has been described.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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The invention relates to an inductor comprising a plurality of interconnected conductive segments interwoven with a substrate. The inductance of the inductor is increased through the use of coatings and films of ferromagnetic materials such as magnetic metals, alloys, and oxides. The inductor is compatible with integrated circuit manufacturing techniques and eliminates the need in many systems and circuits for large off chip inductors. A sense and measurement coil, which is fabricated on the same substrate as the inductor, provides the capability to measure the magnetic field or flux produced by the inductor. This on chip measurement capability supplies information that permits circuit engineers to design and fabricate on chip inductors to very tight tolerances.
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BACKGROUND
[0001] This invention relates to a device for heating the contents of a container and for keeping it warm. More particularly, the invention relates to a self-contained heater device that allows the contents such as food in a container to be heated.
[0002] Often times, it is desirable to heat food and other items at a location remote from a source of heat such as a stove or oven. Other times it is desirable to take warmed or hot food and other items from the place of heating to another location, such as a picnic, school or church basement, scout meeting and any of the myriad of events that do not meet or gather where heat is available. Sometimes the location is in a location where fire is not permitted, such as a class room or outdoors during the dry season. It is also important for military personnel to have access to warm food, particularly when deployed in locations remote from their base or station.
[0003] One such self-contained warmer is disclosed in U.S. Patent Application Publication No. US 2007/0034202, to Punphrey et al. in which a container with an exothermic composition is used to heat a vessel. A membrane is used to cover the exothermic composition, which is then activated by removal of the membrane. Various compositions are disclosed that are based on iron oxidation chemistry. The heater is in direct contact with the container and must be put on a heat-resistant surface to be used without damage.
[0004] U.S. Pat. No. 6,705,309 discloses a self-heating or self-cooling container in which tubular walls defining an internal cavity into which steam or hot air is placed as a source of heat. This, of course, requires a source of that heated material.
[0005] Other heater devices for food generate heat by chemical reaction, and in so doing generate hot gases, steam or hot water vapor, which is potentially hazardous to the user and which may, in some instances, contribute to pollution of the environment.
[0006] It would be a great advantage if a way of heating containers could be developed that has a controlled release of heat that is within acceptable safety limits.
[0007] Another advantage would be to provide a way of heating containers that produces heat over an extended period of time, rather than simply having an exothermic reaction that lasts a few minutes or less.
[0008] Yet another advantage would be to provide a way to generate heat by an exothermic reaction without releasing any gas, steam or hot water vapor to outside the device.
[0009] Other advantages will appear hereinafter.
SUMMARY
[0010] The unique aspect of this invention is that a controlled, dispersed exothermic reaction can be used to heat or cook the contents of a container quickly and effectively while maintaining the heat for an extended period of time without releasing any of the reaction products to outside of the device.
[0011] It its simplest form, the invention comprises a container or pouch that contains a quantity of heat generating material that can be activated by the addition of an activation agent. The container or pouch includes a removable seal at one end that can be opened to add the activation agent and a seal that can be closed once the activation agent has been added to contain steam, vapor or other reaction products.
[0012] In the preferred embodiment, the removable seal and the seal to re-close the end can be the same seal, such as like those found on Ziplock® brand food storage bags, manufactured and sold by S.C. Johnson & Sons, Inc. Such seals include Alternatively and also preferred are removable seals that can be pulled or torn off, with or without score lines to assist in its removal, and are-able to be re-closed. A zipper that is vapor tight is also useable. The function of the seal or seals is to prevent moisture from entering the pouch until activation is desired and then to contain any vapor, steam or other gas that might be generated during the activation of the heat generating material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic view of one embodiment of this invention.
[0014] FIG. 2 is a schematic view of a second component of the embodiment in FIG. 1 .
[0015] FIG. 3 is a schematic view of another embodiment of this invention.
[0016] FIG. 4 is a schematic view an embodiment in a package.
DETAILED DESCRIPTION
[0017] The heater device of this invention is shown generally in FIGS. 1 and 2 . The device includes a container or pouch 11 formed from a vapor impervious material. Preferred is a container 11 made from Aclar®, which is a polychlorotrifluoroethylene (PCTFE) material manufactured and sold by Honeywell International Inc. A clear film is crystal clear, biochemically inert, chemical-resistant, nonflammable, and plasticizer- and stabilizer-free. Aclar laminates provide a wide range of gauges and thus barrier levels to allow flexibility in selecting the optimum barrier level for the chemical system chosen. Other similar pouch materials may be used as well. All that is required is that the material has a functional moisture and vapor barrier for the other components of the invention. The container 11 includes a quantity of heat generating materials 13 , described in detail herein below.
[0018] The heat generating materials are activated once the device has been placed proximate an object to be heated by opening seal 15 and adding a quantity of an activation agent, followed by quickly closing the seal 15 to contain any reaction products such as steam, other vapors, and the like.
[0019] In a preferred embodiment, seal 15 includes a pair of elongated mating strips across the top of the container, wherein one strip has a tongue disposed thereon and the other strip includes a mating groove thereon, wherein the tongue and groove engage to form a seal and disengage to open. This is often described as a “zip lock” seal. Ziploc® is a brand of disposable, re-sealable zipper storage bags and containers originally developed by Dow Chemical Company, and now produced by S. C. Johnson & Son. According to Dow's website, the bags were originally test marketed in 1968. The bags and containers come in different sizes for use with different products. The brand offers sandwich bags, snack bags and other bags for various purposes.
[0020] In FIG. 2 , a second container 17 contains an activation agent 19 , described in detail below, that is accessed by removing the top of second container 17 , such as by pulling the top so that gap 21 starts a tear alone the line extending from gap 21 .
[0021] FIG. 3 illustrates an alternative embodiment where container 31 is similar to bag 11 with a heat activation material 13 inside. The seal in FIG. 3 includes a tear tab 35 that moves along container end 36 to provide access to container 31 . Once the activation agent has been added, a second seal 37 is closed. Seal 37 may be similar to seal 15 of FIG. 1 , with or without the tab portion.
[0022] FIG. 4 illustrates the use of this invention with a box 41 that contains food or other material that is to be heated. Typical food boxes 43 and 45 are what is known in the military as MRE, which is an acronym for “meals ready to eat.” A heater 47 of the type shown in FIGS. 1 and 3 is placed proximate the boxes 43 and 45 , and seals 15 or 35 or the like are opened and an activation agent is placed inside container 47 and the seal 15 or 37 is closed as described above.
[0023] There are a number of combinations of heat generating materials and activating agents that are suitable for use in the present invention. The selection of specific components is to be based upon cost, compatibility, ease of control of the exotherm, and other factors.
[0024] The preferred activating material of this invention is water. This is plentiful and safe, and reacts with a number of materials to produce an exothermic reaction.
[0025] The preferred heat generating material is a solid formed from several components that, when free from moisture, are stable for up to three to five years or more, and which react when moisture is present to generate heat. The preferred solid is made from crystalline calcium oxide, a zeolite powder, and a polyalkyl glycol such as polyethylene glycol. The amount of activation material, such as water, is preferably from about 75 to 125 weight percent, based upon the total weight of heat generating material. Approximately equal amounts by weight of water and heat generating material is the preferred ratio.
[0026] The amount of calcium oxide ranges from about 30 to 70 weight percent, the amount of polyethylene glycol ranges from about 15 to about 35 weight percent, and the amount of zeolite ranges from about 15 to about 35 weight percent, based on the total weight of heat generating material. Preferred is about 25 weight percent each of the polyethylene glycol and zeolite and about 50 weight percent calcium oxide.
[0027] The heat generation material most preferred, using the above components includes a calcined calcium oxide. This material is available as a small particle size, with a diameter less than about 0.2 mm, and as a particle of somewhere between 0.2 and 0.8 mm. Larger particles are ground and smaller ones sieved, and the calcium oxide is then calcined. It has been found to be effective to calcine for at least 60 to 120 minutes, and preferably about 90 minutes, at temperatures above 500° C., and most preferably at about 550° C. for that period of time. The calcined calcium oxide is, of course, desiccated to prevent any contamination by moisture.
[0028] More than 150 zeolite types have been synthesized and 48 naturally occurring zeolites are known. They are basically hydrated alumino-silicate minerals with an “open” structure that can accommodate a wide variety of positive ions, such as Na+, K+, Ca 2 +, Mg 2 + and others. These positive ions are rather loosely held and can readily be exchanged for others in a contact solution. Some of the more common mineral zeolites are: analcime, chabazite, heulandite, natrolite, phillipsite, and stilbite. An example mineral formula is: Na 2 Al 2 Si 3 O 10 -16H 2 O. Zeolites, by their nature, are finely porous structures that are “hungry” for water and that have the ability to hold heat. In the present invention, the activation agent, water in the preferred embodiment, enters into the zeolite pores, trapping the water as it is heated by reacting with the calcium oxide, thus storing heat, providing a longer, more evenly distributed supply of useable heat.
[0029] The polyethylene glycol component of the heat generating material is admixed with the calcium oxide and zeolite and placed in the outer container as described above. When the activation agent, water, is introduced into the heat generating material, the polyethylene glycol coats the calcium oxide and zeolite, further delaying the exothermic reaction between calcium oxide and water, and adding to the utility of this invention.
[0030] The present invention provides a significant advantage over the prior art in several ways. Because the outer container is sealed, as described above, the exothermic reaction when heat is generated does not release steam or other vapor as do presently available heaters. In addition, the heater device of this invention is much more effective that what has been done in the past. The heater of this invention has been used to heat products to 150° F. within 5 minutes and maintained the heat at or above 140° F. for 50 minutes. Prior art devices take 12 minutes to reach only 140° F. and only hold that temperature for 20 minutes.
[0031] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A heater device includes a container formed from a vapor impervious material and having a quantity of heat generating material therein. Also provided is an activation material proximate the container. A seal on the container is adapted to be opened to transfer the activation material into contact with the heat generating material to generate heat and be resealed to contain the reaction products generating the heat.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a catalyst composition showing a high activity for homopolymerizing or copolymerizing olefins. More particularly, it relates to a catalyst composition and a process for the preparation thereof which catalyst composition provides a highly stereoregular polymer in a high yield when the catalyst composition is used for the polymerization of an α-olefin having at least 3 carbon atoms, and a process for the polymerization of olefins.
2. Description of the Related Art
Many proposals have been made on the process for the preparation of a catalyst component where a solid catalyst component comprising magnesium, titanium and halogen compounds and an electron donor, (i.e., an internal donor) as indispensable ingredients. In most of these proposals, an organic carboxylic acid ester is used as the electron donor, and there is a problem in that an ester smell is left in the formed polymer unless the ester is removed by washing with an organic solvent or the like means. Moreover, these catalyst components have a poor catalytic activity and provide a low stereospecificity. Methods using specific esters, that is, esters having an ether portion as the electron donor have been proposed as the means for overcoming these defects. For example, there can be mentioned a method using an anisic acid ester (Japanese Unexamined Patent Publication No. 48-18986), a method using a furancarboxylic acid ester (Japanese Unexamined Patent Publication No. 59-129205 and No. 54-136590; U.S. Pat. No. 452,555. U.S. Pat. No. 4,255,280 and U.S. Pat. No. 4,330,650), and a method using 2-ethoxyethyl acetate (Japanese Unexamined Patent Publication No. 61-287908). Even if these esters are used, however, industrially satisfactory performances cannot be obtained with respect to the catalytic activity and stereospecificity, and development of a catalyst having further enhanced performances is desired.
SUMMARY OF THE INVENTION
A primary object of the present invention to provide a catalyst system having a high catalytic activity and being capable of providing a highly stereoregular olefin polymer, which is difficult to obtain by the conventional technique.
In accordance with the present invention, there is provided a process for the preparation of a catalyst component for use in the polymerization of olefins, which comprises, during or after the formation of solid catalyst component derived from a magnesium compound, a titanium compound and a halogen-containing compound as indispensable ingredients, treating the solid catalyst component with at least one member selected from the group consisting of esters represented by the following formula (I):
(R.sup.1 O).sub.i (R.sup.2 O).sub.j (R.sup.3 O.sub.k --Z--COOR.sup.4 (I)
wherein
R 1 , R 2 , R 3 and R 4 independently represent an aliphatic hydrocarbon group, an alicyclic hydrocarbon group, an aromatic hydrocarbon group, a polycyclic hydrocarbon group, or a heterocyclic compound group,
Z represents an aliphatic or alicyclic hydrocarbon group in which a hydrogen atom may be substituted with an aromatic group or a polycyclic group,
and i, j and k are integers of from 0 to 3 with the proviso that the sum of i, j and k is at least 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As the magnesium compound used for the preparation of the solid catalyst component in the present invention, there can be mentioned magnesium halides such as magnesium chloride and magnesium bromide, magnesium alkoxides such as magnesium ethoxide and magnesium isopropoxide, magnesium salts of carboxylic acids such as magnesium laurate and magnesium stearate, and alkyl magnesium such as butylethyl magnesium. These magnesium compounds can be used alone or as a mixture of two or more thereof. A magnesium halide or a compound capable of forming a magnesium halide at the step of preparing the catalyst is preferably used. The compound having chlorine as the halogen is especially preferably used.
As the titanium compound used for the preparation of the solid catalyst component in the present invention, there can be mentioned titanium halides such as titanium tetrachloride, titanium trichloride, and titanium tetrabromide, titanium alkoxides such as titanium butoxide and titanium ethoxide, and alkoxytitanium halides such as phenoxytitanium chloride. These compounds can be used alone or as a mixture of two or more thereof. A tetravalent titanium compound containing a halogen is preferably used, and titanium tetrachloride is most preferably used.
As the halogen of the halogen-containing compound used for the preparation of the solid catalyst component in the present invention, there can be mentioned fluorine, chlorine, bromine and iodine, and chlorine is preferable. The kind of the halogen-containing compound practically used depends on the catalyst-preparing process, and as typical instances, there can be mentioned titanium halides such as titanium tetrachloride and titanium tetrabromide, silicon halides such as silicon tetrachloride and silicon tetrabromide, and phosphorus halides such as phosphorus trichloride and phosphorus pentachloride. In some preparation processes, halogenated hydrocarbons, halogen molecules and hydrohalogenic acids such as HCl, HBr and HI can be used.
The ester compound used in the present invention is represented by the following general formula (I):
(R.sup.1 O).sub.i (R.sup.2 O).sub.j (R.sup.3 O).sub.k --Z--COOR.sup.4 (I)
In the above general formula (I), R 1 , R 2 , R 3 , and R 4 , which may be the same or different, represent one or more of aliphatic hydrocarbon groups, alicyclic hydrocarbon groups, aromatic hydrocarbon groups, polycyclic hydrocarbon groups, and heterocyclic compound groups. When they are aliphatic or alicyclic hydrocarbon groups, those having 1 to 12 carbon atoms are preferable. For example, there can be mentioned methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, sec-butyl, tert-butyl, pentyl, hexyl, 3-methylpentyl, tert-pentyl, heptyl, i-hexyl, octyl, nonyl, decyl, 2,3,5-trimethylhexyl, undecyl, dodecyl, vinyl, allyl, 2-hexenyl, 2,4-hexadienyl, isopropenyl, cyclobutyl, cyclopentyl, cyclohexyl, tetramethylcyclohexyl, cyclohexenyl, and norbornyl groups. Hydrogen atoms of these groups may be substituted with halogen atoms.
If any of R 1 , R 2 , R 3 , and R 4 is an aromatic or polycyclic hydrocarbon group, an aromatic or polycyclic hydrocarbon group having 6 to 18 carbon atoms is preferable. As specific examples, there can be mentioned phenyl, tolyl, ethylphenyl, xylyl, cumyl, trimethylphenyl, tetramethylphenyl, naphthyl, methylnaphthyl, and anthranyl groups. Hydrogen atoms of these groups may be substituted with halogen atoms. If any of R 1 , R 2 , R 3 , and R 4 is a heterocyclic compound group, a heterocyclic compound group having 4 to 18 carbon atoms is preferable. As specific examples, there can be mentioned furyl, tetrahydrofuryl, thienyl, pyrrolyl, imidazolyl, indolyl, pyridyl, and piperidyl groups. Hydrogen atoms of these groups may be substituted with halogen atoms.
If any of R 1 , R 2 , R 3 , and R 4 is a group of an aromatic hydrocarbon, polycylic hydrocarbon, or heterocyclic compound, connected to an aliphatic hydrocarbon, a group of an aromatic hydrocarbon or polycyclic hydrocarbon having 6 to 18 carbon atoms or a group of a heterocyclic compound having 4 to 18 carbon atoms, connected to an aliphatic hydrocarbon having 1 to 12 carbon atoms, is preferable. As specific examples, there can be mentioned benzyl, diphenylmethyl, indenyl, and furfuryl groups. Hydrogen atoms of these groups may be substituted with halogen atoms.
A divalent aliphatic or alicyclic hydrocarbon group having 1 to 20 carbon atoms, in which a hydrogen atom may be substituted with an aromatic or polycylic group having 6 to 18 carbon atoms, is preferable as Z in formula (I). As specific examples, there can be mentioned methylene, ethylene, ethylidene, trimethylene, tetramethylene, pentamethylene, hexamethylene, and propenylene groups. As examples of the substituted hydrocarbon groups, there can be mentioned methylmethylene, n-butylmethylene, ethylethylene, isopropylethylene, tert-butylethylene, sec-butylethylene, tert-amylethylene, adamantylethylene, bicyclo[2,2,1]heptylethylene, phenylethylene, tolylethylene, xylylethylene, diphenyltrimethylene, 1,2-cyclopentylene, 1,3-cyclopentylene, 3-cyclohexen-1,2-ylene, dimethylethylene, and inden-1,2-ylene groups. Hydrogen atoms of these groups may be substituted with halogen atoms.
As specific examples of the ester compound of formula (I), there can be mentioned methyl methoxyacetate, ethyl methoxyacetate, butyl methoxyacetate, phenyl methoxyacetate, methyl ethoxyacetate, ethyl ethoxyacetate, butyl ethoxyacetate, phenyl ethoxyacetate, ethyl n-propoxyacetate, ethyl i-propoxyacetate, methyl n-butoxy acetate, ethyl i-butoxyacetate, ethyl n-hexyloxyacetate, octyl sec-hexyloxyacetate, methyl 2-methylcyclohexyoxyacetate, methyl 3-methoxypropionate, ethyl 3-methoxypropionate, butyl 3-methoxypropionate, n-octyl 3-ethoxypropionate, dodecyl 3-ethoxypropionate, pentamethylphenyl 3-ethoxypropionate, ethyl 3-(i-propoxy)propionate, butyl 3-(i-propoxy)propionate, allyl 3-(n-propoxy)propionate, cyclohexyl 3-(n-butoxy)propionate, ethyl 3-neopentyloxypropionate, butyl 3-(n-octyloxy)propionate, methyl 3-(2,6-dimethylhexyloxy)propionate, octyl 3-(3,3-dimethyldecyloxy)propionate, ethyl 4-ethoxybutyrate, cyclohexyl 4-ethoxybutyrate, octyl 5-(n-propoxy)valerate, ethyl 12-ethoxylaurate, ethyl 3-(1-indenoxy)propionate, methyl 3-methoxyacrylate, methyl 2-methoxyacrylate, methyl 2-ethoxyacrylate, ethyl 3-phenoxyacrylate, ethyl 2-methoxypropionate, n-butyl 2-(i-propoxy)butyrate, methyl 2-ethoxyisobutyrate, phenyl 2-cyclohexyloxyisovalerate, butyl 2-ethoxy-2-phenylacetate, allyl 3-neopentyloxybutyrate, methyl 3-ethoxy-3-(o-methylphenyl)propionate, ethyl 2-(o-methylphenyl)propionate, ethyl 3-ethoxy-2-mesitylpropionate, ethyl 3-ethoxy-2-tert-butylpropionate, ethyl 3-ethoxy-2-tert-amylpropionate, ethyl 3-ethoxy 3-ethoxy-2-adamantylpropionate, ethyl 3-ethoxy-2-bicyclo[2,2,1]heptylpropionate, ethyl 3-ethoxy-3-phenylpropionate, ethyl 3-ethoxy-3-mesitylpropionate, ethyl 3-ethoxy-3-tert-butylpropionate, ethyl 3-ethoxy-3-tert-amylpropionate, propyl 4-ethoxy-2-(t-butyl)butyrate, ethyl 5-methoxy-2-methyl-l-naphthylnonanoate, ethyl 2-methoxycyclopentanecarboxylate, butyl 2-ethoxycyclohexanecarboxylate, isopropyl 3-(ethoxymethyl)tetralin-2-acetate, ethyl 8 -butoxydecalin-l-carboxylate, methyl 3-ethoxynorbornane-2-carboxylate, methyl 2-(phenoxy)acetate, ethyl 3-(p-cresoxy)propionate, methyl 4-(2-naphthoxy)butyrate, butyl 5-carbazoloxyvalerate, methyl 2-phenoxypropionate, ethyl 3-(4-methylphenoxy)-2phenylpropionate, ethyl 2-phenoxycyclohexanecarboxylate, ethyl thiophen-3-oxyacetate, ethyl 2-(2-picolinoxymethyl)-cyclohexanecarboxylate, and ethyl 3-furfuryloxypropionate.
Among them, an alkoxy ester compound represented by the following general formula (II) ##STR1## is preferable. In the above formula (II), R 5 and R 6 independently represent an aliphatic hydrocarbon group having 1 to 20 carbon atoms, R 7 and R 8 independently represent a hydrogen atom or an aliphatic hydrocarbon group having 1 to 20 carbon atoms. Y represents a divalent linear hydrocarbon group having 1 to 4 carbon atoms, which is substituted with an aliphatic hydrocarbon group having 1 to 18 carbon atoms, an aromatic hydrocarbon group having 6 to 18 carbon atoms or a polycylic hydrocarbon group having 6 to 18 carbon atoms, or a divalent alicyclic hydrocarbon group having 3 to 12 carbon atoms. An alkoxy ester in which Y represents a linear hydrocarbon group having a bulky substituent having at least 4 carbon atoms at the second or third position counted from the carboxyl group is especially preferable. Furthermore, an alkoxy ester compound having a 4- to 8-membered cycloalkane is preferable. As specific examples, there can be mentioned ethyl 3-ethoxy-2-phenylpropionate, ethyl 3-ethoxy-2-tolylpropionate, ethyl 3-ethoxy-2-mesitylpropionate, ethyl 3-butoxy-2-(methoxyphenyl)propionate, methyl 3-i-propoxy-3-phenylpropionate, ethyl 3-ethoxy-3-phenylpropionate, ethyl 3-ethoxy-3-tert-butylpropionate, ethyl 3-ethoxy-3-adamantylpropionate, ethyl 3-ethoxy-2-tert-butylpropionate, ethyl 3-ethoxy-2-tert-amylpropionate, ethyl 3-ethoxy-2-adamantylpropionate, ethyl 3-ethoxy-2-bicyclo[2,2,1]heptylpropionate, ethyl 2-ethoxycyclohexanecarboxylate, methyl 2-(ethoxymethyl)cyclohexanecarboxylate and methyl 3-ethoxynorbornane-2-carboxylate.
The process for the preparation of the catalyst used in the present invention is not particularly critical. A method can be adopted in which a magnesium compound such as a magnesium halide, a titanium compound such as a titanium halide and the ester of formula (I) are co-pulverized and the halogenation treatment is then carried out to increase the activity. Alternatively, a method can be adopted in which the magnesium compound is pulverized alone or in combination with a silicon compound or phosphorus compound and the titanium compound treatment and the halogenation treatment are carried out in the presence of the ester of formula (I).
Moreover, a method can be adopted in which a magnesium carboxylate or magnesium alkoxide, the titanium compound, the halogenating agent and the ester of formula (I) are heat-treated to enhance the performances, or a method in which a magnesium halide is dissolved in an organic solvent and the ester of formula (I) is reacted in the presence of the titanium compound at or after the precipitation.
Still further, a catalyst formed by adding the ester of formula (I) and titanium compound when the alkyl magnesium is reacted with the halogenating agent can be used.
Still in addition, a catalyst formed by adding the ester of formula (I) and titanium compound when the halogenated hydrocarbon is reacted with metallic magnesium can be used.
The amount of the ester of formula (I) left in the catalyst differs according to the preparation process, but the titanium/magnesium/ester molar ratio is preferably in the range of 1/(1 to 1,000)/(10 -6 to 100), more preferably 1/(2 to 100)/(10 -4 to 10). If the amount of the ester of formula (I) is too small and below the above-mentioned range, the stereospecificity of the olefin polymer is reduced, but if the amount of the ester of formula (I) is too large, the catalytic activity is reduced.
The polymerization of olefins will now be described.
An olefin can be polymerized by using the thus-obtained solid catalyst component of the present invention in combination with an organic aluminum compound.
As typical examples of the organic aluminum compound used in the present invention, there can be mentioned compounds represented by the following general formulae (III) through (V):
AlR.sup.9 R.sup.10 R.sup.11 (III)
R.sup.12 R.sup.13 Al--O--AlR.sup.14 R.sup.15 (IV)
and ##STR2##
In formulae (III) through (V), R 9 , R 10 and R 11 , which may be the same or different, represent a hydrocarbon group having up to 12 carbon atoms, a halogen atom or a hydrogen atom, with the proviso that at least one of R 9 , R 10 and R 11 represents a hydrocarbon group. R 12 , R 13 , R 14 , and R 15 , which may be the same or different, represent a hydrocarbon group having up to 12 carbon atoms, R 16 represents a hydrocarbon group having up to 12 carbon atoms, and l is an integer of at least 1.
As typical examples of the organic aluminum compound represented by formula (III), there can be mentioned trialkylaluminum compounds such as triethylaluminum, tripropylaluminum, tributylaluminum, trihexylaluminum and trioctylaluminum, alkylaluminum hydrides such as diethylaluminum hydride and diisobutylaluminum hydride, and alkylaluminum halides such as diethylaluminum chloride, diethylaluminum bromide, and ethylaluminum sesquichloride.
As typical examples of the organic aluminum compound represented by formula (IV), there can be mentioned alkyldialumoxanes such as tetraethyldialumoxane and tetrabutyldialumoxane.
Formula (V) represents an aluminoxane, which is a polymer of an aluminum compound. R 16 includes methyl, ethyl, propyl, butyl, and pentyl groups, but methy and ethyl groups are preferable. Preferably, l is from 1 to 10.
Among these organic aluminum compounds, trialkylaluminum compounds, alkylaluminum hydrides and alkylalumoxanes are preferably used, and trialkylaluminum compounds are especially preferably used because they give especially good results.
In the polymerization reaction of α-olefins having at least 3 carbon atoms, to improve the stereoregularity of formed polymers, various compounds having a stereoregularity-improving effect, use of which has been proposed for Ziegler catalysts, can be added to a catalyst system comprising the titanium-containing solid catalyst component of the present invention and a catalyst component comprising an organic aluminum compound. As the compound used for this purpose, there can be mentioned aromatic monocarboxylic acid esters, silicon compounds having an Si-O-C or Si-N-C bond, acetal compounds, germanium compounds having a Ge-O-C bond and nitrogen- or oxygen-containing heterocyclic compounds having an alkyl substituent.
As specific examples, there can be mentioned ethyl benzoate, butyl benzoate, ethyl p-toluylate, ethyl p-anisate, phenyltrimethoxysilane, phenyltriethoxysilane, diphenyldimethoxysilane, diphenyldiethoxysilane, di-n-propyldimethoxysilane, cyclohexylmethyldimethoxysilane, tetraethoxysilane, t-butylmethyldimethoxysilane, benzophenonedimethoxyacetal, benzophenonediethoxyacetal, acetophenone dimethoxyacetal, t-butylmethylketone-dimethoxy-acetal, diphenyldimethoxygerman, phenyltriethoxygerman, 2,2,6,6-tetramethylpiperidine and 2,2,6,6-tetramethylpyrane. Among these compounds, silicon compounds having an Si-O-C or Si-N-C bond and acetal compounds are preferably used, and silicon compounds having an Si-O-C bond are especially preferably used.
In the polymerization of olefins, the amount of the organic aluminum compound in the polymerization system is generally at least 10 -4 millimole/l and preferably at least 10 -2 millimole/l. The molar ratio of the organic aluminum compound to the titanium atom in the solid catalyst component is generally at least 0.5, preferably at least 2 and more preferably at least 10. If the amount of the organic aluminum compound is too small, the polymerization activity is drastically reduced. If the amount of the organic aluminum compound used is larger than 20 millimoles/l and the molar ratio to the titanium atom is higher than 1,000, the catalyst performances are not further increased even by increasing these values.
When the titanium-containing solid catalyst component of the present invention is used, even if the amount of the above-mentioned stereoregularity-improving agent used for improving the stereoregularity of an α-olefin polymer is very small, the intended object can be attained. This agent is generally used, however, in an amount such that the molar ratio to the organic aluminum compound is 0.001 to 5, preferably 0.01 to 1.
In general, olefins having up to 18 carbon atoms are used. As typical instances, there can be mentioned ethylene, propylene, butene-1, 4-methylpentene-1, hexene-1 and octene-1. These olefins can be homopolymerized, or two or more of these olefins can be copolymerized a typical example is copolymerization of ethylene with propylene.
In carrying out the polymerization, the solid catalyst component of the present invention, the organic aluminum compound and optionally, the stereoregularity-improving agent can be independently introduced into a polymerization vessel, or two or more of them can be premixed.
The polymerization can be carried out in an inert solvent, a liquid olefin monomer or a gas phase. To obtain a polymer having a practically adoptable melt flow rate, a molecular weight modifier (ordinarily, hydrogen) can be made present in the polymerization system.
The polymerization temperature is preferably -10° to 180° C. and more preferably 20° to 130° C.
The shape of the polymerization vessel, the polymerization controlling procedure and the post-treatment procedure are not particularly limited in the present invention, and known procedures can be adopted.
The present invention will now be described in detail with reference to the following examples that by no means limit the scope of the invention.
In the examples and comparative examples, the heptane index (H.R.) means the amount (%) of the residue obtained when the obtained polymer was extracted with boiling n-heptane for 6-hours. The melt flow rate (MFR) was measured with respect to the polymer powder containing 0.2% of 2,6-di-tert-butyl-4-methylphenol incorporated therein at a temperature of 230° C. under a load of 2.16 kg according to JIS K-6758.
In the examples, all of the compounds (organic solvents, olefins, hydrogen, titanium compounds, magnesium compounds, stereoregularity-improving agents) used for the preparation of the solid catalyst component and the polymerization were in the substantially anhydrous state.
The preparation of the solid catalyst component and the polymerization were carried out in a substantially anhydrous nitrogen atmosphere.
EXAMPLE 1
PREPARATION OF SOLID CATALYST COMPONENT
A stainless steel cylindrical vessel having an inner volume of 1 liter, in which magnetic balls having a diameter of 10 mm were filled in an amount of about 50% based on the apparent volume, was charged with 20 g (0.21 mole) of anhydrous magnesium chloride (obtained by heating to dry commercially available anhydrous magnesium chloride at about 500° C. for 15 hours in a dry hydrogen chloride gas), 11.1 g (0.05 mole) of ethyl 3-ethoxy-2-phenylpropionate, 3.3 ml of titanium tetrachloride and 3.0 ml of a silicone oil (TSS-451.20CS supplied by Shin-Etsu Chemical) as the pulverizing assistant in a dry nitrogen current. The vessel was attached to a shaking ball mill having an amplitude of 6 mm and the co-pulverization was carried out for 15 hours to obtain a co-pulverized solid. Then, 15 g of the co-pulverized solid was suspended in 150 ml of 1,2-dichloroethane, and the suspension was stirred at 80° C. for 2 hours. The solid was recovered by filtration and thoroughly washed with hexane until free 1,2-dichloroethane was not detected in the washing liquid. The solid was dried at a low temperature to 30° to 40° C. under a reduced pressure to remove hexane, whereby a solid catalyst component was obtained. The titanium atom content in the solid catalyst component was 2.3% by weight.
POLYMERIZATION AND PHYSICAL PROPERTIES OF POLYMER
A stainless steel autocrave having an inner volume of 3 l was charged with 20 mg of the solid catalyst component prepared by the above-mentioned method, 91 mg of triethylaluminum and 20 mg of diphenyldimethoxysilane, and immediately, 760 g of propylene and 0.1 g of hydrogen were charged into the autocrave. The inner temperature of the autocrave was elevated and maintained at 70° C. After 1 hour, the gas in the autocrave was discharged to stop the polymerization. As the result, 314 g of powdery polypropylene was obtained. The polymerization activity was thus 15,700 g/g of solid catalyst component.hour and 683 kg/g of Ti.hour. The H.R. of the powdery polypropylene was 95.9%, and the MRF was 8.6 g/10 min.
EXAMPLE 2
Using the solid catalyst component prepared in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that the polymerization temperature was changed to 80° C. As the result, 408 g of a powdery polymer was obtained. The polymerization activity was 20,400 g/g of solid catalyst component.hr and 887 kg/g of Ti.hour, the H.R. of the powdery polypropylene was 97.1%, and the MFR was 3.4 g/10 min.
EXAMPLE 3
Using the solid catalyst component used in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that 20 mg of phenyltriethoxysilane was used at the polymerization instead of diphenyldimethoxysilane. The polymerization activity was 14,300 g/g of solid catalyst component.hr and 622 kg/g of Ti.hr, the H.R. of the obtained polymer was 95.8%, and the MFR was 12.3 g/10 min.
EXAMPLES 4 THROUGH 7
Using the solid catalyst component used in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that the stereoregularity-improving agent added was changed as shown in Table 1. The results are shown in Table 1.
TABLE 1__________________________________________________________________________ Amount added Polymeriza- Polymeriza-ExampleStereoregularity-improving (molar ratio tion activity tion activity H.R. MFRNo. agent to Al) (g/g · cat* · hr) (kg/g · Ti · (%) (g/10 min)__________________________________________________________________________4 Phenyltriethoxysilane 0.3 13,800 600 97.1 5.45 t-Butylmethyldimethylacetal 0.3 8,210 357 94.1 2.36 Benzophenonedimethylacetal 0.3 7,990 347 94.0 3.77 2,2,6,6-tetramethylpiperidine 0.15 18,300 796 95.1 2.7__________________________________________________________________________ *solid catalyst component
EXAMPLE 8
In a round-bottom flask, 9.5 g of anhydrous magnesium chloride (treated in the same manner as described in Example 1) was heated and dissolved at 130° C. for 2 hours in 50 ml of decane and 46.8 ml of 2-ethylhexyl alcohol in an N 2 atmosphere. Then, 2.1 g of phthalic anhydride was added to the mixture, and the mixture was heated at 130° C. for 1 hour. The liquid mixture was cooled to room temperature and 20 ml of the liquid mixture was charged in a dropping funnel and dropped into 80 ml of titanium tetrachloride maintained at -20° C. over a period of 30 minutes. The temperature was elevated to 110° C. over a period of 4 hours, and a solution of 3.3 g of ethyl 3-ethoxy-2-phenylpropionate was gradually dropped into the reaction mixture. After termination of the dropwise addition, the reaction was carried out at 100° C. for 2 hours. The supernatant was removed, 80 ml of TiCl 4 was added to the residue, and the mixture was heated at 110° C. for 2 hours. Then, the formed solid was washed with 100 ml of n-decane three times and then with n-hexane to obtain a solid catalyst in which the amount of Ti supported was 2.8% by weight.
Using the thus-obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. The polymerization activity was 12,600 g/g of solid catalyst.hr and 450 kg/g of Ti.hr, the H.R. was 96.7%, and the MFR was 2.0 g/10 min.
EXAMPLE 9
A round-bottom flask having a capacity of 300 ml, which was sufficiently dried in a nitrogen current, was charged with 100 ml of n-heptane, 9.5 g of MgCl 2 and 68 g of Ti(O-nB) and the reaction was carried out at 100° C. for 2 hours to form a homogeneous solution. After termination of the reaction, the temperature was lowered to 40° C. and 15 ml of methylhydrodiene polysiloxane (20 cSt) was added to the solution, and the reaction was carried out for 3 hours. The formed solid catalyst was washed with n-heptane, 150 ml of heptane was added to the solid catalyst, and a solution of 28 g of SiCl 4 in 80 ml of n-heptane was dropped at room temperature over a period of 1 hour. After termination of the dropwise addition, the reaction was further conducted for 30 minutes. The obtained solid component was washed with 200 ml of n-heptane three times and cooled to -10° C. Then, 100 ml of TiCl 4 was introduced into the solid, the resulting mixture was thoroughly stirred, and 2.82 g of ethyl 3-ethoxy-2-phenylpropionate was added dropwise to the mixture. After termination of the dropwise addition, the reaction was carried out at 90° C. for 2 hours. The supernatant was removed, 100 ml of TiCl 4 was introduced, and the reaction was carried out at 90° C. for 2 hours. After the reaction, the formed solid was washed with n-heptane to obtain a solid catalyst. From the results of the analysis, it was found that the amount of Ti supported was 2.4% by weight.
Using the thus-obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. The polymerization activity was 12,900 g/g of solid catalyst.hr and 538 kg/g of Ti.hr, the H.R. was 95.0%, and the MFR was 23 g/10 min.
EXAMPLE 10
A round-bottom flask having a capacity of 300 ml, which was sufficiently dried in a nitrogen current, was charged with 5 g of magnesium diethoxide, 1.22 g of ethyl 3-ethoxy-2-phenylpropionate and 25 ml of methylene chloride, and the mixture was stirred under reflux for 1 hour. The formed suspension was introduced under pressure into 200 ml of TiCl 4 maintained at room temperature, the temperature of the mixture was gradually elevated to 110° C., and the reaction was carried out with stirring for 2 hours. After termination of the reaction, the precipitated solid was recovered by filtration and washed with 200 ml of n-decane maintained at 110° C. three times. Then, 200 ml of TiCl 4 was added to the solid and the reaction was carried out at 120° C. for 2 hours. After termination of the reaction, the precipitated solid was recovered by filtration, washed with 200 ml of n-decane maintained at 110° C. three times and then washed with hexane until the chlorine ion was not detected. The content of the titanium atom in the obtained catalyst component was 3.2%.
Using the thus-obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. When the calculation was made from the results, it was found that the polymerization activity was 20,800 g/g of solid catalyst component.hr and 650 kg/g of Ti.hr, the H.R. was 96.8%, and the MFR was 1.7 g/min.
EXAMPLES 11 THROUGH 21
Solid catalyst components were prepared in the same manner as described in Example 10 except that ester compounds shown in Table 2 were used instead of ethyl 3-ethoxy-2-phenylpropionate. Using the thus-prepared solid catalyst components, the polymerization was carried out in the same manner as described in Example 1. The results are shown in Table 2.
TABLE 2__________________________________________________________________________Preparation of Solid Catalyst PolymerizationExample activityNo. Esters of formula (I) (g/g · cat* · hr) H.R. MFR__________________________________________________________________________11 Ethyl 3-ethoxypropionate 11,000 94.7 1.212 Methyl 4-ethoxybutyrate 10,700 93.0 10.113 Ethyl 3-ethoxy-2-(2-methylphenyl)propionate 21,000 96.9 1.314 Ethyl 3-ethoxy-2-sec-butylpropionate 25,900 96.4 3.715 Ethyl 3-ethoxy-2-tert-butylpropionate 32,600 97.2 4.816 Ethyl 3-ethoxy-2-tert-amylpropionate 31,700 97.5 8.317 Ethyl 3-ethoxy-3-phenylpropionate 17,100 96.1 1.618 Ethyl 2-ethoxycyclohexylcarboxylate 19,000 96.5 1.219 Ethyl 3-phenoxypropionate 13,400 93.1 8.720 Butyl 3-(4-methylphenoxy)propionate 12,800 93.3 7.121 Ethyl furanyloxypropionate 7,800 92.1 15.5 ##STR3##__________________________________________________________________________ *solid catalyst component
COMPARATIVE EXAMPLES 1 THROUGH 4
Solid catalyst components were prepared in the same manner as described in Example 10 except that the esters shown in Table 3 were used instead of ethyl 3-ethoxy-2-phenylpropionate used in Example 10. Using these solid catalyst components, the polymerization was carried out in the same manner as described in Example 1. The results are shown in Table 3.
TABLE 3__________________________________________________________________________Preparation of Solid CatalystComparative Polymerization activityExample No. Esters (g/g · cat* · hr) H.R. MFI__________________________________________________________________________1 Ethyl 2-ethoxybenzoate 18,900 78.3 8.32 2-Ethoxyethyl 2-methoxybenzoate 17,500 79.1 12.13 2-Ethoxyethylacetate 15,400 78.7 7.94 Ethyl furan-2-carboxylate 2,410 73.1 13.7__________________________________________________________________________ *solid catalyst component
EXAMPLE 22
Using the solid catalyst component used in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that diphenyldimethoxysilane was not used. It was found the polymerization activity was 17,300 g/g of solid catalyst component.hr and 752 kg/g of Ti.hr, the H.R. of the obtained polypropylene powder was 51.3%, and the MFR thereof was 15.1 g/10 min.
COMPARATIVE EXAMPLE 5
A solid catalyst was prepared in the same manner as described in Example 1 except that ethyl 3-ethoxy-2-phenylpropionate was not used. Using the obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1 except that diphenyldimethoxysilane was not used. It was found that the polymerization activity was 9,110 g/g of solid catalyst component.hr and 285 kg/g of Ti.hr, the H.R. of the obtained polypropylene powder was 23.7%, and the MFR thereof was 7.9 g/10 min.
COMPARATIVE EXAMPLE 6
A solid catalyst was prepared in the same manner as described in Example 1 except that ethyl 3-ethoxy-2-phenylpropionate was not used. Using the obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. It was found that the polymerization activity was 4,910 g/g of solid catalyst component.hr and 213 kg/g of Ti.hr, the H.R. of the obtained polypropylene powder was 71.2%, and the MFR thereof was 3.8 g/10 min.
When olefins are polymerized by using the catalyst component of the present invention, since the catalyst has a very high activity, the content of the catalyst residue in the formed polymer can be reduced to a very low level and therefore, the ash-removing step can be omitted. Furthermore, since the amount (concentration) of the residual halogen is small, the degree of corrosion of a molding machine or other apparatuses at the polymer-processing step can be greatly lowered. The deterioration and yellowing of the polymer caused by the residual catalyst can be minimized. Moreover, since the obtained polymer has a high stereoregularity, a polymer having a practically acceptable mechanical strength can be obtained even without removing an atactic portion.
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Disclosed is a catalyst composition for use in the polymerization of olefins, which is comprised of (a) a catalyst component containing magnesium, titanium, a halogen, and an ingredient derived from an ester compound, and (b) an organic aluminum compound. The catalyst activity and capability of providing a highly stereroregular polymer are enhanced by preparing the catalyst component (a) by a process wherein, during or after the formation of a solid catalyst component containing magnesium, titanium, and a halogen, the solid catalyst component is treated with an ester of the formula:
(R.sup.1 O).sub.i (R.sup.2 O).sub.j (R.sup.3 O).sub.k --Z--COOR.sup.4 (I)
wherein
R 1 , R 2 , R 3 and R 4 are an aliphatic, alicyclic, aromatic, polycyclic or heterocyclic compound group,
Z is an aliphatic or alicyclic hydrocarbon group in which hydrogen may be substituted with an aromatic or polycyclic group,
and i, j and k are integers of 0 to 3 with the proviso that the sum of i, j and k is at least 1.
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This application is a 371 of PCT/EP2014/077532 filed 12 Dec. 2014.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a woven-fabric belt which is suitable for employment in a machine producing and/or processing a fibrous web, in particular a paper, cardboard, tissue or non-woven machine.
Woven-fabric belts of the generic type comprise longitudinal threads which are interwoven with cross threads, while configuring thread intersection points. Such woven-fabric belts are typically manufactured in a flat weave and have an upper side and a lower side opposite thereto. In the intended use of such woven-fabric tapes in the machine, the longitudinal threads run in the MD direction, and the cross threads run in the CMD direction of the machine. Furthermore, the upper side points toward the fibrous web, and the lower side toward the machine. For employment in a machine producing and/or processing a fibrous web such woven-fabric belts which are originally produced in a flat shape are rendered endless on a woven-fabric seam region such that said woven-fabric belts are able to be operated as endless belts in the machine. Such a woven-fabric seam region may be provided by longitudinal threads which in the region of the longitudinal thread end portions thereof are woven in reverse so as to configure seam loops, for example. Such a woven-fabric seam region may also be formed by longitudinal thread end portions of longitudinal threads which are each gathered in pairs and which, while configuring a woven seam fabric having cross threads which often is identical to the flat-woven fabric portion are collectively interwoven with cross threads, often in portions along a common weaving path.
The tensile strength of the seam in the case of woven-fabric seam regions formed by seam loops as well as in those formed by the woven seam fabric depends inter alia on the number of cross threads with which the longitudinal thread end portions are interwoven during reverse weaving, or on the number of cross threads with which the gathered longitudinal thread end portions are collectively interwoven so as to follow a common weaving path. Here, the strength of the seam increases with the number of cross threads with which the longitudinal thread end portions are interwoven. However, physical properties such as, for example, the permeability and thickness of the woven-fabric belt, in the woven-fabric seam region are influenced by reverse weaving or by the common weaving path, respectively, such that these physical properties in the woven-fabric seam region vary from one location to another and are dissimilar to the remaining part of the woven-fabric belt.
In order for high tensile strength to be achieved, on the one hand, and for there to be no excessive variation in permeability and/or thickness, for example, on the other hand, it is proposed in the prior art that the longitudinal threads in the region of the longitudinal thread end portions thereof are connected in a materially integral manner to cross threads at least at some thread intersection points.
For example, in this way it is known from U.S. Pat. No. 8,062,480 and from EP1749924 for the longitudinal threads and cross threads to be connected in a materially integral manner at the thread intersection points by welding, using the influence of laser radiation.
However, it has now been demonstrated that the materially integral connection, for example the welded connection, between the longitudinal threads and cross threads at the thread intersection points is often inadequately durable. As has been demonstrated in research by the applicant, this issue arises in particular in the case of woven-fabric belts having an open and/or single-layer weaving structure. In order to produce a durable woven-fabric seam it has therefore been proposed that entire regions of the woven-fabric seam portion are connected in a materially integral manner, this in turn leading to undesirable rigidity of the woven-fabric belt in the longitudinal direction thereof.
BRIEF SUMMARY OF THE INVENTION
It is therefore the object of the present invention to propose a woven-fabric thread having an improved materially integral connection between the longitudinal threads and cross threads at thread intersection points.
The object is achieved by a woven-fabric belt which is suitable for employment in a machine producing and/or processing a fibrous web, having longitudinal threads which while configuring thread intersection points are interwoven with cross threads, and having an upper side and a lower side opposite thereto. In the case of the woven-fabric belt according to the invention, each longitudinal thread when viewed in the length thereof has two end-side longitudinal thread end portions having a respective thread end. The woven-fabric seam portion is formed by interweaving the longitudinal thread end portions with cross threads which are referred to as woven-fabric seam cross threads. Here, at least some of the longitudinal thread end portions upon interweaving with the woven-fabric cross threads follow a weaving path along which the respective longitudinal thread end portion when viewed in the direction toward the thread end thereof repeatedly and alternatingly configures floats on the upper side and floats on the lower side, one float on the lower side being disposed between two directly adjacent floats on the upper side, and one float on the upper side being disposed between two directly adjacent floats on the lower side. Furthermore, the weaving path has a last float before the thread end, which runs on one of the upper and lower side, wherein the longitudinal thread end portion, subsequent to the last float before the thread end, changes from the one of the upper and lower side to the other of the upper and lower side. Furthermore, the longitudinal thread end portion at least at one thread intersection point is connected in a materially integral manner to a woven-fabric seam cross thread.
The woven-fabric belt according to the invention is characterized in that the at least one thread intersection point at which the longitudinal thread end portion is connected in a materially integral manner to a woven-fabric seam cross thread is disposed in at least one float which in the weaving path lies before the last float.
Research by the applicant has demonstrated that inadequate contact between the longitudinal thread end portions and the woven-fabric seam cross threads at the thread intersection points is often responsible for an inadequate materially integral connection in the production of the materially integral connection. Research by the applicant has furthermore established that this issue arises in particular when the materially integral connection is produced at a thread intersection point in the last float before the thread end since the longitudinal thread end portion at this point is often no longer under sufficient tensile stress in order to be firmly pressed against the woven-fabric seam cross thread during the production of the materially integral connection at the thread intersection point.
On account of it being proposed by the invention that at least one thread intersection point of the at least one thread intersection point at which the longitudinal thread end portion is connected in a materially integral manner to a woven-fabric seam cross thread is disposed in a float which in a weaving path of said longitudinal thread end portion lies before the last float, the materially integral connection between the longitudinal thread end portion and at least one woven-fabric seam cross thread is produced at a thread intersection point at which the longitudinal thread end portion is still under sufficient tensile stress in order to be reliably pressed against the woven-fabric seam cross thread during the production of the materially integral connection. The materially integral connection is thus durable and firm, and the woven-fabric belt according to the invention has a seam of high strength. By providing a firm materially integral connection at the thread intersection points, the number of materially integral connection points may be significantly reduced while maintaining or improving strength in comparison with woven-fabric belts having a “non-targeted” selection of the thread intersection points which are connected in a materially integral manner.
It should be noted at this point that the respective longitudinal thread end portion, once the latter subsequent to the last float has been guided from the one side to the other side, is not interwoven with any further woven-fabric seam cross thread. This means that the longitudinal thread end portion before the thread end of the latter is not guided any more from the other side of upper and lower side to the one side of upper and lower side.
In the context of the present invention, a first and a second thread are mutually interwoven when the first thread continuously intersects the second thread on one side, and the first thread before and after the second thread in each case intersects at least one further thread on another side lying opposite the one side. Here, the at least one further thread need not be disposed so as to be directly adjacent to the second thread.
A float on the upper side is formed in that the longitudinal thread end portion on the upper side continuously intersects one or a plurality of directly adjacent woven-fabric seam cross threads, and a float on the lower side is formed in that the longitudinal thread end portion on the lower side continuously intersects one or a plurality of directly adjacent woven-fabric seam cross threads.
It may be assumed in the context of the invention that the longitudinal direction of the woven-fabric belt and the longitudinal direction of the longitudinal threads are mutually parallel or extend so as to deviate from one another by a maximum of +/−20°. Furthermore, it may be assumed in the context of the invention that the cross direction of the woven-fabric belt and the longitudinal direction of the cross threads are mutually parallel or extend so as to deviate from one another by a maximum of +/−20°. Furthermore, the longitudinal direction and the cross direction of the woven-fabric belt extend so as to be mutually orthogonal.
Advantageous design embodiments and refinements of the invention are stated in the dependent claims.
In the intended use of the woven-fabric belt in the machine, the longitudinal threads in particular by way of the longitudinal direction thereof run in the MD direction, and the cross threads by way of the longitudinal direction thereof run in the CMD direction of the machine, the upper side facing toward the fibrous web and the lower side facing toward the machine.
It goes without saying that the respective longitudinal thread end portion is connected in a materially integral manner to a plurality of woven-fabric seam cross threads. Therefore, one design embodiment of the invention provides that in the weaving path of the at least some longitudinal thread end portions the respective longitudinal thread end portion at thread intersection points is connected in a materially integral manner to further woven-fabric seam cross threads. This may also comprise a materially integral connection between a longitudinal thread end portion and a woven-fabric seam cross thread in the last float in the weaving path of the longitudinal thread end portion, as long as it is guaranteed that a materially integral connection is also produced in a float preceding the last float.
Here, the respective longitudinal thread end portion is preferably connected in a materially integral manner to a plurality of woven-fabric seam cross threads which are disposed in at least one float lying before the last float in the weaving path. The respective longitudinal thread end portion is preferably connected in a materially integral manner to all woven-fabric seam cross threads which are disposed in a float lying before the last float in the weaving path. On account thereof, a simple production of the materially integral connection is possible since the materially integral connection may be produced on directly adjacent woven-fabric seam cross threads.
According to one preferred design embodiment of the invention, it is provided that in the weaving path of the at least some longitudinal thread end portions the at least one thread intersection point at which the respective longitudinal thread end portion is connected in a materially integral manner to a woven-fabric seam cross thread is disposed in at least one of the floats which is one of the six, in particular one of the four, floats which directly precede the last float in the weaving path of the longitudinal thread end portion. It is achieved by this measure that the longitudinal thread end portion in the weaving path thereof up to the thread end does not cover an excessive distance across which the longitudinal thread end portion is not connected in a materially integral manner to a woven-fabric seam cross thread if and when a materially integral connection is produced only at a few thread intersection points in the weaving path of the respective longitudinal thread end portion.
In this context, it may be specifically provided that in the weaving path of the at least some longitudinal thread end portions the at least one thread intersection point at which the respective longitudinal thread end portion is connected in a materially integral manner to a woven-fabric seam cross thread is disposed in a float which is a penultimate float directly preceding the last float. Alternatively or additionally, it may be provided that in the weaving path of the at least some longitudinal thread end portions at least one thread intersection point at which the respective longitudinal thread end portion is connected in a materially integral manner to a woven-fabric seam cross thread is disposed in a float which is an antepenultimate float preceding the last float.
This measure is particularly purposeful in the case of woven fabric belts having an open and/or single-layer weaving structure since in the case of such woven-fabric belts the longitudinal thread end portions are often only loosely anchored in the woven fabric and the longitudinal thread end portions thus at least in part may egress from the woven fabric, and in particular may project beyond the upper side which faces toward the fibrous web and typically provides the web-contact side, or beyond the lower side which faces toward the machine and typically provides the machine-contact side.
In order for the egression of a thread end as described above to be suppressed, it may furthermore be purposeful that at least one of the further woven-fabric seam cross threads which at the thread intersection point is connected in a materially integral manner to the longitudinal thread end portion is disposed in the last float.
In order for the woven-fabric belt in the woven-fabric seam portion not to be rendered excessively rigid by the materially integral connection, it is particularly purposeful that not more than six, in particular not more than four, directly adjacent woven-fabric seam cross threads are connected in a materially integral manner to the respective longitudinal thread end portion. On account thereof, it is achieved that the permeability of the woven-fabric belt in the woven-fabric seam portion is not excessively reduced.
The weaving structure of a woven-fabric belt is often of such a design that floats of the longitudinal threads of dissimilar lengths are formed when the longitudinal threads are interwoven with the cross threads. Since, according to one preferred design embodiment of the invention, the weaving structure of the woven-fabric belt continues into the woven-fabric seam region, the longitudinal thread end portions in particular in such a case form floats of dissimilar lengths in the woven-fabric seam portion. Therefore, according to one preferred refinement of the invention, it is provided that in the weaving path of the at least some longitudinal thread end portions floats of dissimilar lengths are formed, wherein the at least one thread intersection point at which the respective longitudinal thread end portion is connected in a materially integral manner to a woven-fabric seam cross thread is disposed in a float which is of shorter length than other floats. Tests by the applicant have demonstrated that in the case of longer floats the longitudinal thread end portion runs across the woven-fabric seam cross threads in a more arcuate shape than in the case of shorter floats, and that therefore poorer contact often prevails at the thread intersection point between a woven-fabric seam cross thread and a longitudinal thread end portion in the case of longer floats as compared with shorter floats, on account of which a less durable materially integral connection is achieved in the case of the longer floats than in the case of the shorter floats. The durability of the materially integral connection is thus further increased by the above-mentioned measure. In this context it is particularly purposeful when the float of shorter length extends across at maximum four, in particular at maximum two directly adjacent woven-fabric seam cross threads. The length of a float of a longitudinal thread end portion is understood to be the number of woven-fabric seam cross threads which are continuously intersected by the longitudinal thread end portion on the same side of the woven-fabric seam cross threads.
The above-mentioned embodiment may also represent a separate invention according to which a woven-fabric belt having longitudinal threads which are interwoven with cross threads intersecting the former while configuring thread intersections points is claimed, the woven-fabric belt having an upper side and a lower side lying opposite thereto, wherein at least some of the longitudinal threads during interweaving with the cross threads follow a weaving path along which the respective longitudinal thread repeatedly and alternatingly configures floats on the upper side and lower side, wherein at least some of the floats are of dissimilar lengths, wherein the at least one thread intersection point at which the respective longitudinal thread end portion is connected in a materially integral manner to a woven-fabric seam cross thread is disposed in a float which is of a shorter length than that of other floats.
In order to increase contact between woven-fabric seam cross threads and a longitudinal thread end portion at the thread intersection point and thus to improve the materially integral connection, it may be purposeful that the at least some longitudinal threads and/or at least some woven-fabric seam cross threads have a flattened cross-sectional shape. This aspect too may represent a separate invention.
Woven-fabric belts are produced in a weaving process in which the warp or cross thread, respectively, is woven so as to be perpendicular to the warp or longitudinal threads, respectively. To this end, the weft thread is drawn off a package, on account of which the weft thread may be twisted about its own axis. Such twisting is not a problem when the weft thread is one with a circular cross-sectional shape. However, this may lead to problems when the cross-sectional shape deviates from the circular shape. Therefore, one particularly preferable design embodiment of the invention provides that the at least some longitudinal threads have a flattened, for example rectangular or elliptic cross-sectional shape, and the woven-fabric seam cross threads in particular have a circular cross-sectional shape. However, the use of longitudinal threads having a flattened cross-sectional shape may have yet other advantages. In this way, flattened longitudinal threads have a larger cross-sectional area than longitudinal threads of the same thickness having a circular cross-sectional shape. Furthermore, flattened longitudinal threads provide a larger contact surface on the upper and/or lower side than circular longitudinal threads. This may be of advantage for example in the case of TAD wires which are intended to provide a large contact surface to the fibrous web.
Various possibilities for producing the materially integral connection are conceivable. According to one particularly preferable refinement of the invention it is provided that the materially integral connection is effected by the influence of radiation energy having a specific wavelength or a specific wavelength range, in particular by laser radiation energy. Producing a materially integral connection in this way has the advantage that an effect may take place in a very localized manner, without the entire woven-fabric belt being impinged with temperature, for example. It is particularly conceivable in this context that the wavelength or the wavelength range, respectively, is in the infrared range, in particular in the range from 700 nm to 1200 nm.
It is specifically conceivable that at least in the case of some threads which are connected in a materially integral manner a material which absorbs more radiation energy than the material of the threads has been incorporated at the thread intersection points between the threads prior to the effect of the radiation energy. Such an absorbent material may be present in liquid form, for example, and be sprayed between the parts to be connected. Such a liquid absorbent material is marketed under the “Clearweld” brand by Gentex Corp., for example.
Alternatively thereto, it is conceivable that the longitudinal threads and/or the woven-fabric seam cross threads comprise/comprises a first thread type and a second thread type, wherein the first thread type is from a material which absorbs more radiation energy than the material of the second thread type. Specifically, the threads of the first type may thus be from a material which comprises carbon black and/or color pigments and/or CNT (carbon nanotubes), for example.
In this context it is particularly conceivable that the woven-fabric seam cross threads which at the thread intersection points are connected in a materially integral manner to the longitudinal thread end portions are threads of the first thread type. It is particularly conceivable in this case that the longitudinal threads and the remaining cross threads are threads of the second thread type.
According to one preferred embodiment of the invention it is provided that in the case of at least some of the longitudinal thread end portions, in particular in the case of all longitudinal thread end portions, the float in which the at least one woven-fabric seam cross thread which is connected in a materially integral manner to the longitudinal thread end portion at the thread intersection point runs on the same side of upper and lower side. By way of this design embodiment a materially integral connection is possible in that the effect of the radiation energy for producing the materially integral connection may be applied from a single side. This significantly facilitates and simplifies the production of the woven-fabric belt according to the invention, in particular when the weaving paths of all longitudinal thread end portions are configured in such a design.
In this context, if the longitudinal threads are threads of the second thread type, and the woven-fabric seam cross threads which are connected in materially integral manner are threads of the first thread type, the effect of radiation energy in this case may be performed in order to produce a materially integral connection on one side of upper and lower side, specifically on that side on which the above-mentioned float runs.
Alternatively, it is conceivable that at least some longitudinal threads are threads of the first thread type.
The solution according to the invention is employable in particular in a woven-fabric belt which is formed by only one system of longitudinal threads and/or by only one system of cross threads, since the thread end portions in the case of such woven fabrics are held by other threads so as to be under tensile stress to a lesser degree, and since the thread end portions in the case of such woven fabrics are mutually held by friction locking to a lesser extent.
The woven-fabric belt according to the invention is preferably a woven-fabric belt having a permeability in the range of 450 to 850 cfm, in particular 450 to 750 cfm, and/or a thickness in the range from 0.7 to 1.1 millimeters. Furthermore, the woven-fabric belt is preferably a dryer wire, in particular suitable for use in a drying installation in which the wire is perfused with hot air. Such a dryer wire is usually referred to as a “through-air dryer” wire, or as a TAD wire.
According to one specific design embodiment of the invention it may be provided that in the weaving path of all longitudinal thread end portions the respective thread end is disposed within the woven fabric or on the other side of upper and lower side.
According to one potential specific design embodiment of the invention, the woven-fabric belt is an endless woven-fabric belt which is formed by a flat-woven main woven-fabric portion and the woven-fabric seam portion. Here, the main woven-fabric portion is formed by the longitudinal threads and cross threads which are interwoven therewith and which are referred to as main woven-fabric cross threads. Furthermore, the main woven-fabric portion in the longitudinal extent thereof is delimited by a first and a second face-side portion end. Furthermore, one of the two end-side longitudinal thread end portions of a longitudinal thread is referred to as the first longitudinal thread end portion, and the other of the two end-side longitudinal thread end portions of a longitudinal thread is referred to as the second longitudinal thread end portion, wherein the first longitudinal thread end portion when viewed in the longitudinal direction of the woven fabric protrudes beyond the first face-side portion end of the main woven-fabric portion, and the second longitudinal thread end portion when viewed in the longitudinal direction of the woven-fabric belt protrudes beyond the second face-side portion end. In the case of such an endless woven-fabric belt the two face-side portion ends of the main woven-fabric portion are interconnected by that woven-fabric seam portion that is formed by collecting the first and second longitudinal thread end portions and interweaving the latter with woven-fabric seam cross threads. It should still be noted in this context that each first longitudinal thread end portion is terminated by a first thread end, and each second longitudinal thread end portion is terminated by a second thread end. A refinement of the invention that is based on the previous design embodiment provides in particular that the woven-fabric belt is rendered endless in that first and second longitudinal thread end portions are each gathered in pairs while configuring so-called “meeting points”.
Here, the first and second longitudinal thread end portions which are gathered in pairs may in each case be the first and second longitudinal thread end portion of one and the same longitudinal thread. However, it is also conceivable that the first and second longitudinal thread end portions which are gathered in pairs are the first longitudinal thread end portion of a first longitudinal thread and the second longitudinal thread end portion of a second longitudinal thread which is disposed so as to be offset in relation to the first longitudinal thread by at maximum 20, in particular at maximum ten, longitudinal threads.
One further specific refinement of the invention may provide that at least some of the first and second longitudinal thread end portions which are gathered in pairs are collectively interwoven with one or a plurality of woven-fabric seam cross threads. If first and second longitudinal thread end portions which are gathered in pairs are collectively interwoven with one or a plurality of woven-fabric seam cross threads, the length of a meeting point is determined by the number of woven-fabric seam cross threads with which the gathered longitudinal thread end portions are collectively interwoven. The weaving paths of the longitudinal thread end portions which are gathered in pairs, at the location where these threads are collectively interwoven, in particular have the same profile.
It is to be noted in this context that collective interweaving is preferably performed with at maximum ten woven-fabric seam cross threads, preferably with at maximum four woven-fabric seam cross threads. However, it is also conceivable that the longitudinal thread end portions which are gathered in pairs are not collectively interwoven with any woven-fabric seam cross thread.
If at least some of the first and second longitudinal thread end portions which are gathered in pairs are collectively interwoven with at least one woven-fabric seam cross thread, it is particularly conceivable that the at least one collectively interwoven woven-fabric seam cross thread is disposed in the weaving path of the first and in the weaving path of the second longitudinal thread end portion in the last float. Here, it is particularly conceivable that the last float in the weaving path of the first longitudinal thread portion, and the last float in the weaving path of the second longitudinal thread end portion are mutually overlapping at least in portions.
Additionally and/or alternatively, the solution according to the invention is preferably employable in woven-fabric belts which have a “relatively open” weaving structure. Consequently, according to one design embodiment of the invention, this may be a woven-fabric belt which has a thread count of at maximum 60 longitudinal threads per inch, in particular 30 to 60 longitudinal threads per inch, preferably 40 to 55 longitudinal threads per inch, and/or a thread count of at maximum 60 cross threads, in particular per inch, 30 to 60 cross threads per inch, preferably 40 to 55 cross threads per inch. In this context, it is to be noted in particular that such woven-fabric belts in particular have identical thread counts in the woven-fabric seam portion and in the main woven-fabric portion.
One refinement of the invention provides that at least some of the first and second longitudinal thread end portions which are gathered in pairs are collectively interwoven with at maximum six directly adjacent woven-fabric seam cross threads, wherein the collectively interwoven woven-fabric seam cross threads are disposed in the weaving path of the first longitudinal thread end portion in the last float and in the penultimate float directly preceding the last float, and wherein the collectively interwoven woven-fabric seam cross threads are disposed in the weaving path of the second longitudinal thread end portion in the last float and in the penultimate float directly preceding the last float.
Specifically, the woven-fabric seam portion may be woven in a weaving pattern having a longitudinal thread repeat and a cross thread repeat, wherein the longitudinal thread repeat is formed by the equal number of or more woven-fabric seam cross threads to/than the number of woven-fabric seam cross threads with which the first and second longitudinal thread end portions which are gathered in pairs are collectively interwoven. By interweaving the gathered longitudinal thread end portions with common woven-fabric seam cross threads over such relatively short distances, physical properties such as permeability, for example, in the woven-fabric seam region vary to a lesser extent than if collective interweaving extends across more woven-fabric seam cross threads than there are woven-fabric seam cross threads in the longitudinal thread repeat. Preferably, the longitudinal thread repeat of the woven-fabric seam region is the same as that of the main woven-fabric portion, and the cross thread repeat of the woven-fabric seam portion is the same as that of the main woven-fabric portion.
Alternatively thereto, the woven-fabric seam portion may be woven in a weaving pattern having a longitudinal thread repeat and a cross thread repeat, wherein the longitudinal thread repeat is formed by fewer woven-fabric seam cross threads than the number of woven-fabric seam cross threads with which the first and second longitudinal thread end portions which are gathered in pairs are collectively interwoven.
According to a further alternative design embodiment it is also conceivable that at least some of the first and second longitudinal thread end portions which are gathered in pairs are not collectively interwoven with any woven-fabric seam cross thread, wherein the last float in the weaving path of the first longitudinal thread end portion and the last float in the weaving path of the second longitudinal thread end portion are either directly adjacent to one another or are spaced apart by at maximum two directly adjacent woven-fabric seam cross threads. In this context, directly adjacent means that there is no woven-fabric seam cross thread disposed between the two last floats.
By this measure too, intense variation of the physical properties such as, for example, permeability or planarity of the upper and/or lower side in the woven-fabric seam region is counteracted, wherein it has been demonstrated that a larger spacing in the MD direction between the first and second longitudinal thread end portions which are gathered in pairs than the spacing described above entails disadvantageous weakening of the woven-fabric seam and often too large a difference in permeability at this point as compared with other fabric regions. If first and second longitudinal thread end portions which are gathered in pairs are not collectively interwoven with any woven-fabric seam cross threads, the length of a meeting point is determined by the number of woven-fabric seam cross threads which are disposed between the two ends of the weaving paths of the two gathered longitudinal thread end portions.
In order for the strength of the seam to be improved it is purposeful that the points at which the first and second longitudinal thread end portions are gathered in pairs, when viewed in the longitudinal direction of the woven-fabric belt, are disposed so as to be mutually offset for various pairs of gathered first and second longitudinal thread end portions. In this context, it is particularly conceivable that the woven-fabric seam cross threads by which first longitudinal thread end portions are connected in a materially integral manner for dissimilar first longitudinal thread end portions are at least in part provided by dissimilar woven-fabric seam cross threads. It is likewise conceivable that the woven-fabric seam cross threads by which second longitudinal thread end portions are connected in a materially integral manner for dissimilar second longitudinal thread end portions are at least in part provided by dissimilar woven-fabric seam cross threads.
Specifically, the last floats in the weaving path of in each case directly adjacent first and second longitudinal thread end portions, respectively, may be disposed so as to be mutually offset by at least one woven-fabric seam cross thread, in particular by leaving at least one woven-fabric seam cross thread unoccupied therebetween.
In this context, it is conceivable, for example, that the last floats in the weaving path of in each case directly adjacent first longitudinal thread end portions are disposed so as to be mutually offset by at least one longitudinal thread repeat. Likewise, the last floats in the weaving path of in each case directly adjacent second longitudinal thread end portions may be disposed so as to be mutually offset by at least one longitudinal thread repeat.
In this context, the woven-fabric seam cross threads with which a first pair of gathered first and second longitudinal thread end portions is collectively interwoven are preferably offset by a plurality of woven-fabric seam cross threads in relation to the woven-fabric seam cross threads with which a pair of gathered first and second longitudinal thread end portions which is directly adjacent to the first pair is collectively interwoven. If the woven-fabric seam cross threads therein, which are to be connected in a materially integral manner, are of the first type, the possibility is established thereby that the threads of the first type which are to enter into a materially integral connection to the first pair are disposed so as to be spaced apart from the threads of the first type which are to enter into a materially integral connection to the second pair. On account thereof, the rigidity of the woven-fabric belt in the longitudinal direction of the woven-fabric belt may be reduced since a materially integral connection is performed in striped regions which when viewed in the longitudinal direction of the woven-fabric belt are mutually spaced apart.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention will be discussed in more detail hereunder by means of schematic drawings in which:
FIG. 1 shows a photograph of a weaving path of two longitudinal thread end portions according to a first embodiment of the invention, in the longitudinal direction of the longitudinal threads;
FIG. 2 shows the embodiment of the woven-fabric belt according to the invention of FIG. 1 , in an illustration of portions of the woven-fabric seam region in a plan view;
FIG. 3 shows a photograph of a weaving path of two longitudinal thread end portions according to a second embodiment of the invention, in the longitudinal direction of the longitudinal threads; and
FIG. 4 shows various embodiments of weaving paths of two longitudinal thread end portions which are gathered in pairs, according to further embodiments of the invention, in the longitudinal direction of the longitudinal threads.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a photograph of the weaving path of two longitudinal thread end portions 1 , 2 which are gathered in pairs, according to a first embodiment of a woven-fabric belt 100 according to the invention, in the longitudinal direction of the longitudinal threads.
The woven-fabric belt 100 has longitudinal threads which are interwoven with cross threads, while configuring thread intersection points KA to KI, and an upper side 3 , and a lower side 4 lying opposite thereto. In the intended use of the woven-fabric belt in a paper, cardboard, tissue or non-woven machine, the longitudinal threads extend in the MD direction MD, and the cross threads extend in the CD direction CD of the machine.
The woven-fabric belt 100 here is formed by only one system of longitudinal threads and by only one system of cross threads.
The longitudinal threads when viewed along the length thereof have two end-side longitudinal thread end portions, specifically one first longitudinal thread end portion 1 , and one second longitudinal thread end portion 2 , wherein each longitudinal thread end portion 1 , 2 in terms of the length thereof is delimited by a thread end 5 , 6 . Presently, the first longitudinal thread end portion 1 is delimited by the first thread end 5 , and the second longitudinal thread end portion is delimited by the second thread end 6 .
The woven-fabric belt 100 is an endless woven-fabric belt which is formed by a flat-woven main woven-fabric portion (not illustrated) and a partially illustrated woven-fabric seam portion 101 . Here, the main woven-fabric portion is formed by the longitudinal threads and by cross threads which are interwoven therewith and are referred to as main woven-fabric cross threads, and the main woven-fabric portion in terms of the longitudinal extent thereof is delimited by a first and a second face-side end portion, wherein the first longitudinal thread end portions 1 in the MD direction protrude beyond the first face-side portion end, and the second longitudinal thread end portions 2 protrude beyond the second portion end. Here, the two face-side portion ends are interconnected by the woven-fabric seam portion. The woven-fabric seam portion 101 is formed by gathering first and second longitudinal thread end portions and interweaving the latter with cross threads which are referred to as woven-fabric seam cross threads, wherein presently the two longitudinal thread end portions 1 , 2 , and the woven-fabric seam cross threads A to I can be seen.
FIG. 2 shows the woven-fabric seam portion 101 of the woven-fabric belt 100 according to the invention of FIG. 1 , in an illustration of portions in a plan view, wherein the weaving paths of the two longitudinal thread end portions of FIG. 1 run along the section line A-A.
Presently, the longitudinal threads and thus also the longitudinal thread end portions 1 , 2 , and the woven-fabric seam cross threads A, B, H, and I, shown in FIG. 1 , are threads of the second type. The woven-fabric seam cross threads C to G are threads of the first type, that is to say that these threads absorb more radiation energy of a specific wavelength than the threads of the second type. Presently, the woven-fabric seam cross threads C to G are from a mixture containing PET and CNT (carbon nanotubes), the material of the threads of the second type not containing any CNT.
As can be seen from the illustration of FIG. 1 , the two longitudinal thread end portions 1 , 2 during interweaving with the woven-fabric seam cross threads A to I each follow a weaving path, viewed along which the respective longitudinal thread end portion 1 , 2 in the direction W 1 , W 2 to the thread end 5 , 6 thereof, repeatedly and alternatingly configures floats F 11 , F 12 , F 21 , F 22 on the upper side 3 and on the lower side 4 . It can be seen that each of the floats F 11 to F 22 is formed in that the longitudinal thread end portion 1 , 2 , running on the same side of upper side 3 and lower side 4 , intersects one or a plurality of directly adjacent woven-fabric seam cross threads. Specifically, the first longitudinal thread end portion 1 forms the float 11 in that the former, running on the lower side 4 , intersects the two directly adjacent woven-fabric seam cross threads G and H, and forms the float F 12 in that said longitudinal thread end portion 1 , running on the upper side 3 , intersects the woven-fabric seam cross thread F. Furthermore, the second longitudinal thread end portion 2 forms the float F 21 in that the former, running on the lower side 4 , intersects the two directly adjacent woven-fabric seam cross threads B and C, and forms the float F 22 in that said longitudinal thread end portion 2 , running on the upper side 3 , intersects the woven-fabric seam cross thread E.
Here, the weaving path of the first longitudinal thread end portion 1 runs in the direction W 1 to the first thread end 5 , the weaving path of the second longitudinal thread end portion 2 likewise running in the direction W 2 to the second thread end 6 .
As can be seen, the first longitudinal thread end portion 1 , in the weaving path thereof running in the direction W 1 , before the first thread end 5 configures the last float F 12 , and subsequent to the last float F 12 before the first thread end 5 , runs from the upper side 3 to the lower side 4 . Furthermore, the second longitudinal thread end portion 2 , in the weaving path thereof running in the direction W 2 , before the second thread end 6 configures the last float F 12 , and subsequent to the last float F 12 , before the second thread end 5 , runs from the upper side 3 to the lower side 4 . Neither longitudinal thread end portion 1 , 2 after the last float F 12 , F 22 is interwoven with any further woven-fabric seam cross thread.
According to the invention, the first longitudinal thread end portion 1 at the thread intersection point KG is connected in a materially integral manner to the woven-fabric seam cross thread G, wherein the thread intersection point KG is disposed in the float F 11 lying before the last float F 12 in the weaving path. Presently, the float 11 is that float which in the weaving path of the first longitudinal thread end portion 1 directly precedes the last float 12 , and is specifically the penultimate float 11 in the weaving path of the first longitudinal thread end portion 1 .
Additionally thereto, the first longitudinal thread end portion 1 at the thread intersection points KF and KE is connected in a materially integral manner to the woven-fabric seam cross threads F and E, wherein these connections often cannot be produced in a readily reproducible manner.
Furthermore, according to the invention, the second longitudinal thread end portion 2 at the thread intersection point KC is connected in a materially integral manner to the woven-fabric seam cross thread C, wherein the thread intersection point KC is disposed in the float F 21 which in the weaving path lies before the last float F 22 . Presently, the float 21 is that float which in the weaving path of the second longitudinal thread end portion 2 directly precedes the last float 22 , and is specifically the penultimate float 21 in the weaving path of the second longitudinal thread end portion 2 .
Additionally thereto, the second longitudinal thread end portion 2 at the thread intersection points KD and KE is connected in a materially integral manner to the woven-fabric seam cross threads D and E, wherein these connections often cannot be produced in a readily reproducible manner.
This means that in the weaving path of the two longitudinal thread end portions 1 , 2 the respective longitudinal thread end portion 1 , 2 is connected in a materially integral manner to further woven-fabric seam cross threads F, E and D, E, respectively, at the thread intersection points KF, KE, KD.
Presently the materially integral connection at the thread intersection points KC to KG is a welded connection, produced by the effect of infrared radiation energy from the wavelength range of 700 to 1200 nm.
As can be seen from the illustration of FIG. 1 , the two first and second longitudinal thread end portions 1 , 2 which are gathered in pairs are not collectively interwoven with any woven-fabric seam cross thread A to I, wherein presently the last float F 12 in the weaving path of the first longitudinal thread end portion 1 , and the last float F 22 in the weaving path of the second longitudinal thread portion 2 are mutually spaced apart by the woven-fabric seam cross thread E.
In the present exemplary embodiment, both the longitudinal threads as well as the woven-fabric seam cross threads have a circular cross-sectional shape.
FIG. 3 shows a photograph of the weaving path of two longitudinal thread end portions 1 , 2 which are gathered in pairs, according to a second embodiment of a woven-fabric belt 100 according to the invention, in the longitudinal direction of the longitudinal threads.
Hereunder, only the points of difference to the first embodiment shown in FIGS. 1 and 2 will be addressed.
In the case of the embodiment of FIG. 3 the woven-fabric seam cross threads G and H are threads of the first type, such that in the weaving path of the first longitudinal thread end portion 1 both woven-fabric seam cross threads of the penultimate float F 11 are threads of the first type, which at the thread intersection points KG and KH are connected in a materially integral manner to the first longitudinal thread end portion 1 . Furthermore, the only woven-fabric seam cross thread F of the last float F 12 in the weaving path of the first longitudinal thread end portion 1 is a thread of the second type.
Furthermore, the woven-fabric seam cross threads B and C are threads of the first type, such that in the weaving path of the second longitudinal thread end portion 2 both woven-fabric seam cross threads of the penultimate float F 21 are threads of the first type, which at the thread intersection points KB and KC are connected in a materially integral manner to the second longitudinal thread end portion 2 . Furthermore, the only woven-fabric seam cross thread D of the last float F 22 in the weaving path of the second longitudinal thread end portion 2 is a thread of the second type.
FIG. 4 shows various embodiments of weaving paths of two longitudinal thread end portions which are gathered in pairs, according to further embodiments of woven-fabric belts according to the invention. The illustration of FIG. 4 shows the weaving paths in the longitudinal direction of the longitudinal threads.
In the case of all embodiments of FIG. 4 , the woven-fabric belt has an upper side 3 and a lower side 4 lying opposite thereto.
FIG. 4 a shows an embodiment of the weaving paths of two longitudinal thread end portions 1 , 2 which are gathered in pairs, during interweaving with woven-fabric seam cross threads A to R in part of a woven-fabric seam portion. It can be seen that floats F 10 , F 11 , F 12 , F 20 , F 21 , F 22 , F 23 of dissimilar lengths are formed in the weaving path of both longitudinal thread end portions. It can furthermore be seen that the woven-fabric seam cross threads A to F, J, K, and N to R, and the two longitudinal thread end portions 1 , 2 , are threads of the second type, and that the woven-fabric seam cross threads G, H, I, and L, M are threads of the first type. Here, the weaving path of the first longitudinal thread end portion 1 runs in the direction toward that thread end thereof that is referred to as the first thread end 5 , in the direction W 1 , the weaving path of the second longitudinal thread end portion 2 likewise running in the direction toward that thread end thereof that is referred to as the second thread end 6 , in the direction W 2 .
The weaving path of the first longitudinal thread end portion 1 has a float F 11 running on the lower side 4 and having the float length 2 , and floats F 10 , F 12 running on the upper side 3 and having the float length three, wherein the float F 11 in the weaving path of the first longitudinal thread end portion 1 is the penultimate float before the first thread end 5 , the float F 12 providing the last float.
According to the invention, in the weaving path of the first longitudinal thread end portion 1 , in at least one float F 22 lying before the last float F 12 , the longitudinal thread end portion 1 at the thread intersection points KL, KM is connected in a materially integral manner to at least one woven-fabric seam cross thread L, M. Specifically, the first longitudinal thread end portion 1 at the thread intersection points KL, KM is connected in a materially integral manner to the woven-fabric seam cross threads L and M lying in the penultimate float F 11 . Additionally, the first longitudinal thread end portion 1 in the last float F 12 at the thread intersection point KI is connected in a materially integral manner to the woven-fabric seam cross thread I. It can further be seen that the woven-fabric seam cross threads L, M to which the first longitudinal thread end portion 1 is connected in a materially integral manner at the thread intersection points KL, KM are disposed in a float F 11 which in relation to the other floats F 12 , F 10 is of shorter length.
When observing the weaving path of the second longitudinal thread end portion 2 , it can be seen that the latter has floats F 20 and F 22 running on the lower side 4 and having the float length 2 , a float F 21 running on the upper side 3 and having the float length three, and a float F 23 running on the upper side 3 and having the float length one, wherein the float F 22 in the weaving path of the second longitudinal thread end portion 2 is the penultimate float before the second thread end 6 , the float F 23 providing the last float.
According to the invention, in the weaving path of the second longitudinal thread end portion 2 , in at least one float F 22 lying before the last float F 23 , the second longitudinal thread end portion 2 at the thread intersection point KG, KH is connected in a materially integral manner to at least one woven-fabric seam cross thread G, H. Specifically, the second longitudinal thread end portion 2 at the thread intersection points KG, KH is connected in a materially integral manner to the woven-fabric seam cross threads G and H lying in the penultimate float F 22 . Additionally, the second longitudinal thread end portion 2 in the last float F 23 at the thread intersection points KI is connected in a materially integral manner to the woven-fabric seam cross thread I. It can further be seen that the woven-fabric seam cross threads G, H to which the second longitudinal thread end portion 2 is connected in a materially integral manner at the thread intersection points KG, KH are disposed in a float F 22 which in relation to the float F 21 is of shorter length.
Furthermore, the first and second longitudinal thread end portions 1 , 2 which are gathered in pairs are collectively interwoven with the woven-fabric seam cross threads I, wherein the collectively interwoven woven-fabric seam cross thread I in the weaving path of both longitudinal thread portions 1 , 2 are disposed in the last float F 12 (for the first longitudinal thread end portion 1 ) and F 23 (for the second longitudinal thread end portion 2 ). The weaving paths of the two longitudinal thread end portions 1 , 2 when collectively interwoven with the woven-fabric seam cross thread I have the same profile.
FIG. 4 b shows a further embodiment of the weaving paths of two longitudinal thread end portions 1 , 2 which are gathered in pairs during interweaving with woven-fabric seam cross threads A to K in part of a woven-fabric seam portion. It can be seen that floats F 10 , F 11 , F 12 , F 20 , F 21 , F 22 of dissimilar lengths are formed in the weaving path of both longitudinal thread end portions. It can further be seen that the woven-fabric seam cross threads A to E and H to K, and the two longitudinal thread end portions 1 , 2 are threads of the second type, and the woven-fabric seam cross threads F and G are threads of the first type. The weaving path of the first longitudinal thread end portion 1 here runs in the direction toward the thread end thereof which is referred to as the first thread end 5 , in the direction W 1 , the weaving path of the second longitudinal thread end portion 2 likewise running toward the thread end thereof which is referred to as the second thread end 6 , in the direction W 2 .
The weaving path of the first longitudinal thread end portion 1 has a float F 11 running on the lower side 4 and having the float length 2 , a float F 10 running on the upper side 3 and having the float length three, and a float F 12 running on the upper side 3 and having the float length one, wherein the float F 11 in the weaving path of the first longitudinal thread end portion 1 is the penultimate float before the thread end 5 , the float F 12 providing the last float.
According to the invention, in the weaving path of the first longitudinal thread end portion 1 , in at least one float F 11 lying before the last float F 12 , the longitudinal thread end portion 1 at the at least one thread intersection point KF, KG is connected in a materially integral manner to at least one woven-fabric seam cross thread F, G. Specifically, the first longitudinal thread end portion 1 at the thread intersection points KF, KG is connected in a materially integral manner to the woven-fabric seam cross threads F and G lying in the penultimate float F 11 . It can further be seen that the woven-fabric seam cross threads F, G to which the first longitudinal thread end portion 1 is connected in a materially integral manner at the thread intersection points KF, KG are disposed in a float F 11 which in relation to the other floats F 10 , with the exception of the last float F 12 , is of shorter length.
When observing the weaving path of the second longitudinal thread end portion 2 , the latter has a float F 21 running on the lower side 4 and having a float length 2 , a float F 20 running on the upper side 3 and having a float length three, and a float F 22 running on the upper side 3 and having a float length one, wherein the float F 21 in the weaving path of the second longitudinal thread end portion 2 is the penultimate float before the second thread end 6 , the float F 22 providing the last float.
According to the invention, in the weaving path of the second longitudinal thread end portion 2 , in at least one float F 21 lying before the last float F 22 , the second longitudinal thread end portion 2 at least at one thread intersection point KF, KG is connected in a materially integral manner to at least one woven-fabric seam cross thread F, G. Specifically, the second longitudinal thread end portion 2 at the thread intersection points KF, KG is connected in a materially integral manner to the woven-fabric seam cross threads F and G lying in the penultimate float F 21 . It can furthermore be seen that the woven-fabric seam cross threads F, G to which the second longitudinal thread end portion 2 at the thread intersection points KF, KG is connected in a materially integral manner are disposed in a float F 21 which in relation to the float F 20 is of shorter length.
Furthermore, the first and second longitudinal thread end portions 1 , 2 which are gathered in pairs are collectively interwoven with the woven-fabric seam cross threads E to H, wherein the collectively interwoven woven-fabric seam cross threads F, G are disposed in the weaving path of both longitudinal thread end portions 1 , 2 in the penultimate float F 11 (for the first longitudinal thread end portion 1 ) and F 21 (for the second longitudinal thread end portion 2 ), and the woven-fabric seam cross thread E is disposed in the weaving path of the first longitudinal thread end portion 1 in the last float F 12 , and the woven-fabric seam cross thread H is disposed in the weaving path of the second longitudinal thread end portion 2 in the last float F 22 , respectively. The weaving paths of the two longitudinal thread end portions 1 , 2 when collectively interwoven with the woven-fabric seam cross threads E to H have the same profile.
FIG. 4C shows yet a further embodiment of the weaving paths of two longitudinal thread end portions 1 , 2 which are gathered in pairs during interweaving with woven-fabric seam cross threads A to M in part of a woven-fabric seam portion. It can be seen that floats F 10 , F 11 , F 12 , F 13 , F 20 , F 21 , F 22 of dissimilar lengths are formed in the weaving path of both longitudinal thread end portions. It can furthermore be seen that the woven-fabric seam cross threads A, B, and G to M, and the two longitudinal thread end portions 1 , 2 are threads of the second type, and that the woven-fabric seam cross threads C to F are threads of the first type. The weaving path of the first longitudinal thread end portion 1 here runs in the direction toward the thread end thereof which is referred to as the first thread end 5 , in the direction W 1 , the weaving path of the second longitudinal thread end portion 2 likewise running toward the thread end thereof which is referred to as the second thread end 6 , in the direction W 2 .
The weaving path of the first longitudinal thread end portion 1 has floats F 10 , F 12 running on the lower side 4 and having the float length 2 , a float F 11 running on the upper side 3 and having the float length three, and a float F 13 running on the upper side 3 and having the float length one, wherein the float F 12 in the weaving path of the first longitudinal thread end portion 1 is the penultimate float before the thread end 5 , the float F 13 providing the last float.
According to the invention, in the weaving path of the first longitudinal thread end portion 1 , in at least one float F 12 lying before the last float F 13 , the longitudinal thread end portion 1 at at least one thread intersection point KD, KE is connected in a materially integral manner to at least one woven-fabric seam cross thread D, E. Specifically, the first longitudinal thread end portion 1 at the thread intersection points KD, KE is connected in a materially integral manner to the two woven-fabric seam cross threads D and E lying in the penultimate float F 12 . It can furthermore be seen that the woven-fabric seam cross threads D, E to which the first longitudinal thread end portion 1 at the thread intersection points KD, KE is connected in a materially integral manner are disposed in a float F 12 which in relation to the other floats F 11 , with the exception of the last float F 13 , is of shorter length.
When observing the weaving path of the second longitudinal thread end portion 2 the latter has a float F 21 running on the lower side 4 and having the float length 2 , a float F 20 running on the upper side 3 and having the float length three, and a float F 22 running on the upper side 3 and having the float length one, wherein the float F 21 in the weaving path of the second longitudinal thread end portion 2 is the penultimate float before the second thread end 6 , the float F 22 providing the last float.
According to the invention, in the weaving path of the second longitudinal thread end portion 2 , in at least one float F 21 lying before the last float F 22 , the second longitudinal thread end portion 2 at at least one thread intersection point KD, KE is connected in a materially integral manner to at least one woven-fabric seam cross thread D, E. Specifically, the second longitudinal thread end portion 2 at the thread intersection points KD, KE is connected in a materially integral manner to the two woven-fabric seam cross threads D and E lying in the penultimate float F 21 . It can furthermore be seen that the woven-fabric seam cross threads D, E to which the second longitudinal thread end portion 2 at the thread intersection points KD, KE is connected in a materially integral manner are disposed in a float F 21 which in relation to the float F 20 is of shorter length.
Furthermore, the first and second longitudinal thread end portions 1 , 2 which are gathered in pairs are collectively interwoven with the woven-fabric seam cross threads C to F, wherein the collectively interwoven woven-fabric seam cross threads D, E are disposed in the weaving path of both longitudinal thread end portions 1 , 2 in the penultimate float F 12 (for the first longitudinal thread end portion 1 ) and F 21 (for the second longitudinal thread end portion 2 ), and the woven-fabric seam cross thread C is disposed in the weaving path of the first longitudinal thread end portion 1 in the last float F 13 , and the woven-fabric seam cross thread F is disposed in the weaving path of the second longitudinal thread end portion 2 in the last float F 22 , respectively. The weaving paths of the two longitudinal thread end portions 1 , 2 when collectively interwoven with the woven-fabric seam cross threads C to F have the same profile.
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A woven-fabric belt for a fibrous web machine includes longitudinal and cross threads forming crossing points, top and bottom sides and a seam segment. Each longitudinal thread has end segments with ends. A segment is formed by weaving end segments with cross threads. Some end segments follow a weaving path with the cross threads, along which an end segment forms floats on the sides in alternation in direction of the thread end and a float is disposed on the bottom side between two adjacent floats on the top side and vice versa. A last float before the thread end is formed on one side and the end segment switches from one side to the other following the last float before the thread end. The end segment is bonded to a cross thread at one thread crossing point in one float lying before the last float in the weaving path.
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FIELD OF THE INVENTION
[0001] This invention relates generally to creped paper. More particularly, it relates to creped tissue paper such as facial tissue and bathroom tissue products, and processes for producing such products and other forms of crepe paper.
DESCRIPTION OF THE RELATED ART
[0002] Tissue products such as facial tissues, toilet tissues and absorbent towels are well-known in the art and widely used. The softness properties of such paper products is of utmost importance, and can be conferred upon paper via many mechanical and chemical means. “Creping” and “Through-Air-Dry” (TAD) usually refer to the mechanical means for achieving softness, and the chemical means are carried out by inclusion of de-bonders and/or softeners during the normal processing of pulp and paper used to make such products. In addition to conferring softness properties, creping processes generally increase the absorbency of such paper products by increasing the void volume in the sheet.
[0003] In a popular conventional process of making tissue, the wet web (60-65% moisture) is conveyed to the dryer by means of a felt, and is subsequently transferred to a drying cylinder which is commonly referred to as a “Yankee” dryer by those skilled in the art, at a pressure nip. The surface temperature of the dryer is often very near 100° C., and machine speeds in the range of 800 to 2000 n/min are common. Creping paper involves spraying the dryer cylinder with a suitable amount of adhesive via a spray boom at its 6 o'clock position (FIG. 1, below) and pressing the paper web against the surface of the dryer cylinder. The sheet is dried as it travels around the circumference of the dryer and is subsequently removed from the dryer surface by a metal “doctor” blade. This action ruptures some fiber-to-fiber bonds within the webs, and causes the web to expand somewhat and become soft.
[0004] At the time of creping, the sheet contains about 5% moisture. A loop structure within the paper called a microfold is formed as the doctor blade removes the sheet . Subsequently, other loops or microfolds form on top of the first one creating a pile or macrofold. The degree of the effects of the creping process depends on factors such as the strength of the adhesive (i.e., the degree of adhesion of the sheet to the dryer), the difference in speed between the Yankee dryer and the final selection of the paper machine, doctor blade geometry, and the raw fiber materials used in the stock. Inadequate adhesion of the sheet to the dryer surface will result in inferior quality, and possible problems at the reel such as wrinkling, foldovers, and weaved edges.
[0005] An effective chemical creping aid must provide a uniform tacky coating across the entire face of the dryer so that the sheet is evenly adhered to the surface of the dryer. High levels of adhesion of the paper web to the dryer will cause the web to dry faster, enabling higher energy efficiency and higher speed operation. In addition to proper adhesion, a coating of a thin layer of organic and inorganic material deposited on the dryer by the action of the evaporation of the water serves to protect the dryer and blade surfaces from excessive wear. While some amount of buildup of the creping aid on the surface is necessary, excessive buildup can cause humps, wrinkles, or holes in the sheet.
[0006] Another important characteristic of an effective creping aid is that it be re-wettable. “Re-wettability” refers to the ability of the adhesive film remaining on the Yankee dryer surface to be activated by absorbing water from the fresh application as well as from the moisture which is released from the fibrous structure at the pressure roll nip of the Yankee dryer. Re-wettability is an important property of an effective creping aid as only very small amounts of adhesive are added per revolution of the Yankee dryer.
[0007] Recently, drying of the web by the “throughdrying” or “through-air”method has received considerable attention because it improves bulk and softness of the web during drying. In such a process, hot air is passed through the web to effect partial drying prior to pressing the web against the Yankee dryer to finish the drying process. However, one disadvantage of partial drying prior to the dryer is that the resulting partially dried web requires the addition of a creping adhesive to the surface of the dryer in order to provide adequate adhesion of the web to the cylinder necessary to obtain proper creping. This was not required in some conventional processes in which the high moisture content of the web provides sufficient adhesion of the web to the dryer.
[0008] Polyamide polyamine epichlorohydrin (PAE) resins derived from secondary amine have been found to be effective creping aids in paper machine systems using the conventional wet press section. However, they are not efficacious in the paper machine systems which employ through-air drying. Creping aids derived from polyaminoamide (“PAA”) secondary amine resin chemistry are also efficacious; however, insomuch as they are thermosetting, they have a tendency to cure on the heated surface of the dryer. As a result, the coating formed on the dryer using through-air drying tends to be brittle, and exhibits poor adhesion of the sheet to the dryer surface.
[0009] Additionally, the thermosetting wet strength resins will crosslink with creping aids which contain a secondary amine backbone, causing the formation of a hard coating on the surface of the dryer with poor adhesion characteristics. As a result, specialized thermoplastic resins have been developed to diminish these problems.
[0010] Poly(aminoamide)-epichlorohydrin (PAE with secondary amine) resins are commonly used as creping aids, as described in U.S. Pat. Nos. 5,388,807, 5,786,429, 5,902,862 and Canada Patent No. 979,579, the entire contents of each of which each of these, and all other patent documents cited in this specification, are herein expressly incorporated by reference thereto.
[0011] These resins prove to exhibit good adhesion; however, since they are thermosetting, upon heating they will eventually cross-link and irreversibly harden. As a result, the addition of moisture is no longer able to soften the coating sufficiently to optimally bond with the web at the pressure roll nip. In other words, their re-wettability is poor. To improve the wettability, PAE is combined with polyvinyl alcohol (PVA), and a synergy is observed for the mixture (U.S. Pat. No. 4,501,640 and U.S. Pat. No. 4,528,316). PVA is known to exhibit a re-wet mechanism and has been claimed as a creping aid (U.S. Pat. No. 3,926,716); however, PVA alone is not as effective as PAE. Since PAE resins contain a relatively high content of chloride ion, they eventually will corrode the dryer surface. Another problem associated with PAE resins is the coating buildup.
[0012] U.S. Pat. No. 5,179,150 discloses a creping composition comprising (a): a thermosetting glyoxylated vinyl amide polymer (e.g., glyoxylated acrylamide/DADAMAC co-polymer) and (b) polyvinyl alcohol.
[0013] U.S. Pat. No. 5,187,219 discloses a thermosetting creping aid comprising glyoxylated vinyl amide polymers (e.g., glyoxylated acrylamide/DADAMAC co-polymer) in combination with polyols as plasticizers. The polylols are compatibles with the polymers and they form a uniform coating.
[0014] U.S. Pat. No. 6,214,932 discloses a creping adhesive comprising a mixture of polyamide derived from a dibasic acid (e.g., adipic acid) and polyalkylene polyamine (diethylene triamine) and polyvinyl alcohol and reacting this polymer mixture with epichlorohydrin. This particular crepe aid exhibits better adhesion than the physical blends of polyamide resin with polyvinyl alcohol as disclosed in U.S. Pat. Nos. 4,501,640, 4,528,316, 4,784,439, and 4,788,243.
[0015] U.S. Pat. No. 5,490,903 discloses a creping adhesive which contains a blend of an ethoxylated acetylenic diol surfactant, polyaminoamide, and polyvinyl alcohol. The dynamic surface tension is shown to be less than 40 dynes/cm at 5 bubbles/sec. As a result, more uniform coating is achieved, as described therein.
[0016] U.S. Pat. No. 5,833,806 discloses a creping composition which contains (a) a polyamine epichlorohydrin or polyaminoamide epichlorohydrin resin and (b) a release agent that is a plasticizer for the above resin, e.g., ethylene glycol, triethanolamine.
[0017] U.S. Pat. Nos. 4,684,439 and 4,788,243 disclose an improved wettable creping adhesive comprises a mixture of PVA and water soluble thermoplastic polyamide resin which is the reaction product of a polyalkylene polyamine (e.g., diethylene triamine), a saturated aliphatic dibasic carboxylic acid (e.g., adipic acid), and a poly(oxyethylene) diamine (e.g., JEFFAMINE® ED 600 polyetheramine).
[0018] U.S. Pat. No. 5,370,773 discloses a creping adhesive comprising (a) a non-self crosslinkable polymer (e.g., polyvinyl alcohol); (b) mulltivalent cation crosslinking agents; and (c) phosphate surfactant as an internal lubricant to improve creping blade wear and protect the dryer from corrosion.
[0019] U.S. Pat. No. 4,440,898 discloses a creping adhesive for use in a throughdrying process comprising mixture of an ethylene oxide/propylene oxide co-polymer and a high molecular weight thermoplastic polymer selected from the group of polyvinyl alcohol and polyvinyl pyrrolidone.
[0020] U.S. Pat. No. 4,886,579 discloses a method of applying the creping adhesive comprising 10-100% by weight of a polymer or co-polymer having a glass transition temperature greater than 50° C. (e.g., polymethyl acrylate) to the web prior to its contact with the creping surface.
[0021] U.S. Pat. No. 4,994,146 discloses a creping method in which a water soluble polyacid such as polyacrylic acid (not polyacrylate), styrene maleic acid co-polymer, mixture of polyvinyl alcohol and polyacrylic acid is applied to the surface of the cylinder and a second water soluble polymer selected from polyether (e.g., polyethylene oxide), polyacrylamide is applied to the surface of the web. When the two components are in contact at the pressure roll nip, an adhesive complex is formed.
[0022] U.S. Pat. No. 5,234,547 teaches a creping adhesive which contains an anionic co-polymer of acrylamide and acrylic acid.
[0023] While the materials and processes of previous workers in this field have attempted to provide materials which satisfy all of the requirements of the processors of crepe papers, each is not without its own shortcomings, the most common of which are cost, corrosiveness to equipment, and ease of use and maintenance of mill equipment.
[0024] The co-polymers of the present invention have a low glass transition temperature, are not corrosive to the dryer or other equipment, are relatively low in cost to produce, and have been found to be extremely effective at enhancing the quality of crepe paper, which makes them the model materials for this employment as of this writing.
SUMMARY OF THE INVENTION
[0025] The present invention provides a composition of matter useful in the creping of paper products such as facial tissues and bathroom tissue which comprises: a) water; and b) an alkanolamine salt of a styrene-methacrylic acid co-polymer. The salt is preferably made by combining an alkanolamine with a styrene-methacrylic acid co-polymer. The co-polymer has a styrene content in the range of between 10.00% and 90.00% by weight based upon the total weight of said co-polymer, and a weight-average molecular weight in the range of between 3,000 and 500,000. According to one form of the invention, the alkanolamine is selected from the group consisting of: mono-alkanolamines; di-alkanolamines; and tri-alkanolamines. The alkanolamine preferably includes at least one C 1 to C 14 alkyl chain bonded to a nitrogen atom, wherein the alkyl chain further includes at least one hydroxy group bonded to one of the carbon atoms in the alkyl chain. Two or three such “hydroxy alkyl chains” may be bonded to the nitrogen atom in alternate forms of the invention.
[0026] In another embodiment, the present invention comprises a composition as previously stated, and further comprises cellulose fibers.
[0027] The invention also provides a process for creping tissue paper, comprising: contacting an adhesive to the dryer used in the manufacture of tissue paper, wherein the adhesive comprises an aqueous dispersion comprising any amount of water in the range of 60% to 99.9% and from about 40% to about 0.1% solids. The solids comprise an alkanolamine salt of a styrene-methacrylic acid co-polymer having a styrene content in the range of between 10.00% and 90.00% by weight based upon the total weight of the co-polymer, and a weight-average molecular weight in the range of between 3,000 and 500,000. The alkanolamine is selected from the group consisting of: mono-alkanolamines; di-alkanolamines; and tri-alkanolamines. The alkanolamine includes at least one C 1 to C 14 alkyl chain bonded to a nitrogen atom, wherein the alkyl chain further includes at least one hydroxy group bonded to one of the carbon atoms in the alkyl chain. A tissue paper web is caused to be adhered to the surface of said dryer; and is subsequently removed from the dryer via a doctor blade.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention is directed at compositions of matter useful as creping additives. A composition according to a preferred form of the invention comprises an amine salt of styrene-methacrylic acid co-polymer, in which the co-polymer has a styrene content from about 10% to about 90% by weight based on the total weight of the co-polymer. The molecular weight of the co-polymer is preferably in the range of 3000 to 500,000 weight-average molecular weight (all molecular weights disclosed in this specification are weight-average molecular weights, unless otherwise noted), and the co-polymer has a glass transition temperature which is below 100° C. Compositions according to one preferred form of the invention comprise an amine salt of styrene-methacrylic acid co-polymer in which the co-polymer has a styrene content between about 10 and 90 percent by weight based on the total weight of the polymer. According to one preferred form of the invention, the total amount of applied creping adhesive is from about 40 grams/ton to about 5 kilograms/ton of dry weight creping adhesive, based on the dry weight of the paper web.
[0029] The invention also includes a process for creping tissue paper, which process comprises:
[0030] a) applying an adhesive which comprises an aqueous dispersion comprising from about 75% to about 99.9% water and from about 25% to about 0.1% solids to a dryer, wherein said solids comprise an amine salt of styrene-methacrylic acid co-polymer; b) pressing a tissue paper web against the dryer to adhere the web to the surface of the dryer; and c) removing the web from the dryer via a doctor blade.
Amine Salt of Styrene/Methacrylic Acid Co-Polymer
[0031] The preparation of styrene/methacrylic acid co-polymers is known in the art. One method for their preparation involves charging a 3-necked 1 L flask equipped with a mechanical stirrer and heating mantle with 209.46 g of isopropanol and 200.86 g of water, and heating under mild agitation with a slow nitrogen purge of the headspace, until a gentle reflux is achieved, which occurs at about 80° C. A first stream comprising 24.74 g of a 14.3% aqueous sodium persulfate solution is slowly added to the content of the refluxing contents of the flask, simultaneously with a second stream comprising a liquid mixture of 70.68 g of styrene and 70.68 g of methacrylic acid, over the course of about 2 hours. Following the addition, the temperature is maintained at reflux for an additional 2 hours to ensure completeness of reaction. Then, an additional 15.4 g of 14.3% sodium persulfate is added, and the temperature maintained at reflux for one additional hour to digest residual quantities of the monomers.
[0032] To prepare an amine salt of a co-polymer produced as above, namely the triethanol amine salt (TEA), the flask from the above containing the crude reaction product mixture is set up for distillation by affixing a condenser and head thereto. The flask is heated until the azeotrope of isopropanol and water begins to distill, at which time 123.57 g of TEA is slowly added to the flask during the distillation at a rate which is approximately equal to the rate at which the azeotrope is being distilled. The reaction is completed when the temperature reaches 100° C., after which point the flask is cooled to 50° C. and 100 g of water is added, which lowers the viscosity of the mixture.
[0033] In the above-described method for preparing a styrene-methacrylic acid co-polymer, the styrene/methacrylic acid ratio is about 50:50. Other ratios of styrene/methacrylic acid in the range of 10:90 to 90:10 by weight are suitable for providing co-polymers useful in the present invention and are readily achievable by those of ordinary skill in the art by altering the ratio of monomers.
[0034] The weight average molecular weight of a styrene/methacrylic acid co-polymer useful in accordance with the present invention is in the range of about 1,000 to about 500,000, with molecular weights having any value in the range of 2,000 to 400,000 being preferred, and with molecular weights having any value in the range of about 3,000 to about 300,000 being most preferred. The molecular weight is controlled by the concentration of the initiator, and the chain transfer agent, as is known in the art. While in the present invention it is most preferred during the preparation of our polymer(s) that the chain transfer agent is isopropanol and the initiator is persulfate ion, we realize that other chain transfer agents and initiators are known to those skilled in the art are useful in preparing such polymers as those described herein; hence this should in no way be construed as delimitive of the present invention.
Adhesion Test
[0035] Materials useful as adhesives in creping paper need to function as adhesives, to a balanced degree. A suitable test for evaluating the adhesiveness of such agents involves heating a plate of 2×4 inch stainless steel on a hot plate to about 120° C., and then applying a 76 micron adhesive coating to the test plate using a suitable wire rod. A piece of filter paper is then quickly and carefully applied to the film and rolled 10 times with a paint roller to achieve uniform contact between the paper, adhesive and metal surface. Subsequent heating of the plate to 120° C. for 2 min, the metal coupon with the attached paper test strip is then removed and cooled to room temperature, after which the paper is peeled at an angle of 90° using an INSTRON® peel strength tester. Duplicate runs were made for each product, and the average values were calculated. A plot showing the average adhesion (lb/in) for various products is set forth below.
[0036] Interestingly, when compared to the sodium salt of styrene-methacrylic acid co-polymers (“STYMA”), the amine salt(s) of STYMA (and especially that of TEA) is much more efficacious, as reflected by much higher adhesion values for the latter. STYMA with amine salt also appeared to be more effective than the polyamide-epihalohydrin resins such as KYMEN® 557 H and SOLVOX® 681-A of the prior art (see for example U.S. Pat. Nos. 5,388,807, 5,786,429, 5,902,862, and Canada Pat. No. 979,579). HARTOMER® AFX is a blend of STYMA sodium salt, sorbitol and polyvinyl alcohol.
[0037] The glass transition temperature of the polymer also plays an important role in obtaining good creping properties. The glass transition temperature for an amorphous polymer is the temperature at which the material undergoes a phase change from being a glassy or brittle state to a plastic or rubbery state. To obtain adequate adhesion, the polymer's glass transition temperature has to be below the operating temperature, which in the case of paper creping processes is about 100° C. Above the glass transition temperature, sufficient contact between the adhesive and the dryer surface is achieved, while below the glass transition temperature, the polymer is too brittle and hard to function well. The glass transition temperatures of various crepe aids are listed in Table 1:
TABLE 1 Glass Transition Temperatures of Various Crepe Aids Product T g (° C.) STYMA (50:50) + TEA 24 STYMA (50:50) + NaOH >150 HARTOMER ® AFX >150 SOLVOX ® 681-A 88 Polyvinyl alcohol (AIRVOL ® 540) 68 KYMENE ® 557 H 58
[0038] As can be seen, STYMA+TEA has the glass transition temperature much lower than STYMA+NaOH. This may be one of the reasons for the excellent performance of the former.
[0039] Consideration must be given to the fact that although this invention has been described and disclosed in relation to certain preferred embodiments, obvious equivalent modifications and alterations thereof will become apparent to one of ordinary skill in this art upon reading and understanding this specification and the claims appended hereto. Accordingly, the presently disclosed invention is intended to cover all such modifications and alterations, and is limited only by the scope of the claims which follow.
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The present invention provides compositions a useful in the creping of paper products such as facial tissue and bathroom tissue. The compositions comprise an alkanolamine salt of a styrene-methacrylic acid co-polymer. According to a process according to the invention, a composition of the invention is contacted with the dryer cylinder in a creping process.
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[0001] This application is a continuation of application Ser. No. 09/964,529 filed Sep. 28, 2001, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to novel materials for attenuating sound, and in particular to such materials that are able to attenuate low frequency sounds without requiring excessive size or thickness.
BACKGROUND OF THE INVENTION
[0003] The general increase in noise in many environments, both at work and at home, means that noise is becoming a significant source of pollution, and a factor that can harm both the physical and mental health of many people who are exposed to unwanted noise for prolonged periods. Noise reduction techniques and materials are therefore becoming of increasing importance.
[0004] Noise reduction can be achieved by either active methods, such as electronically generated noise cancellation techniques, or by passive techniques such as simple barriers. Most passive barriers, such as those made of fibres or acoustic foam, attenuate the sound by forcing the sound waves to change direction repeatedly. With each change of direction a portion of the energy of the sound wave is absorbed (and is in fact converted to heat). Such materials tend to be relative lightweight and are quite effective at attenuating noise at medium and higher frequencies, such as for example about 500 Hz and above.
[0005] Passive barrier are less effective however, at lower frequencies. A particular problem for example is illustrated by the socalled “mass law” which requires the thickness of the barrier material to be in inverse proportion to the frequency of the sound. As an example, it takes five times more mass of material to be an effective barrier at 200 Hz than it does at 1000 Hz. A concrete wall, for example, must be about 30 cm thick to be an effective barrier at 150 Hz. This increase in thickness and weight means that simple barrier structures are not effective in practical terms for attenuating low frequency sounds. Attempts to design suitable barrier structures for low frequency sounds include, for example, the use of an air-space between two rigid panels. The amount of low-frequency attenuation depends on the spacing between the panel and thus this design again results in a physically large barrier.
PRIOR ART
[0006] An example of a prior design for a material for acoustic attenuation is described in U.S. Pat. No. 5,400,296 (Cushman et al). In Cushman et al particles are embedded in a matrix material, the particles including both high and low characteristic acoustic impedance particles. The idea in Cushman et al is that by creating such an impedance mismatch, a portion of the impinging acoustic energy is reflected and thus the energy transmitted is attenuated.
SUMMARY OF THE INVENTION
[0007] According to the present invention there is provided an acoustic attenuation material comprising outer layers of a stiff material sandwiching a relatively soft elastic material therebetween, and wherein means are provided within said elastic material for generating local mechanical resonances.
[0008] Preferably the resonance generating means comprises a rigid material located within the elastic material, and the rigid material has a volume filling ratio within the elastic material of from about 5% to 11%.
[0009] One example of a rigid material is a plurality of individual solid particles located within the elastic material. These solid particles may be any suitable shape such as spheres or discs.
[0010] Another possibility is that the rigid material may comprise a wire mesh. Such a mesh is preferably generally planar and the wire mesh lies in the plane of the material. In one embodiment means are provided for supporting the mesh within the elastic material, for example the material may include a surrounding frame member and means may be provided for securing the mesh to the frame member, such as elastic connection members.
[0011] In one possibility the rigid material comprises a plurality of wire mesh segments, and a plurality of frame members may be provided between the segments, and wherein means are provided for elastically connecting the segments to the frame members.
[0012] The stiff outer layers may be formed of any suitable building material such as gypsum, aluminum, cement, plywood, paperboard, polymer materials or any other stiff building materials.
[0013] The elastic material may be any relatively soft elastic material such as foam or foam-like materials, natural and synthetic rubber and rubber-like materials, fiberglass, elastic polymer materials and the like.
[0014] The rigid material may be a metal.
[0015] Viewed from another broad aspect of the invention there is provided an acoustic attenuation material comprising two outer layers of a stiff material sandwiching a layer of relatively soft elastic material therebetween, and a plurality of solid particles disposed throughout said elastic material.
[0016] The dimensions and material of the particles, and the thickness and material of the elastic layer, are chosen so as to define a plurality of local mechanical resonances at a frequency to be attenuated. The frequency is preferably in the range of 100 to 200 Hz.
[0017] Viewed from a still further aspect of the invention there is provided an acoustic attenuation material comprising two outer layers of a stiff material sandwiching a layer of relatively soft elastic material therebetween, and a wire mesh disposed throughout said elastic material.
[0018] The wire mesh is preferably parallel to the outer layers.
[0019] In this embodiment of the invention the dimensions and material of the mesh, and the thickness and the material of the elastic layer, may be chosen so as to define a plurality of local mechanical resonances at a frequency to be attenuated.
[0020] Viewed from a still further broad aspect the present invention provides a method of forming an acoustic attenuation material comprising:
(a) providing two outer layers of a stiff material sandwiching a layer of an elastic material, and (b) providing means within said elastic layer for generating local mechanical resonances at the frequency to be attenuated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Some embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, in which:
[0024] FIG. 1 is a side sectional view through a material according to a first embodiment of the invention,
[0025] FIG. 2 is a planar sectional view of the material of FIG. 1 ,
[0026] FIG. 3 is a plot showing the low frequency attenuation of materials according to the present invention in comparison with the prior art,
[0027] FIG. 4 is a plot illustrating the effect on the attenuation of varying the particle size,
[0028] FIG. 5 is a plot illustrating the effect on the attenuation of varying the material thickness,
[0029] FIG. 6 is a planar sectional view of a material according to a second embodiment of the invention,
[0030] FIG. 7 is a planar sectional view of a material according to a third embodiment of the invention,
[0031] FIG. 8 is a planar sectional view of a material according to a fourth embodiment of the invention,
[0032] FIG. 9 is a plot illustrating the effect on the attenuation of varying the shape of the particles, and
[0033] FIGS. 10 ( a ) and ( b ) are planar sectional views illustrating variations of the embodiments of FIGS. 6 and 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] Referring firstly to FIGS. 1 and 2 there is shown a first embodiment of an acoustic attenuation material according to an embodiment of the invention. In this embodiment an acoustic attenuation material 10 comprises two rigid outer layers 11 sandwiching a soft elastic layer 12 within which are located solid particles 13 having a relatively high density and a relatively high rigidity. The particles have a diameter that is preferably 0.1 mm or larger. As can be seen in FIG. 2 , the solid particles 13 are located in a regular grid array configuration.
[0035] Suitable materials for the rigid outer layers 11 include gypsum, aluminum, cement, plywood, paperboard, rigid polymer materials or any other conventional rigid building materials. The soft elastic layer 12 may be formed of a material such as foam or foam-like materials, natural and synthetic rubber and rubber-like materials, fiberglass, elastic polymer materials and the like. The solid particles 13 may be formed of metal such as lead, steel, iron or aluminum and aluminum alloys.
[0036] FIG. 3 plots the attenuation against frequency in a low frequency range for an embodiment of the present invention formed in accordance with FIGS. 1 and 2 , and with examples of the prior art for reference. In FIG. 3 , reference numeral 14 is used to identify the attenuation characteristics for an embodiment of the present invention formed of a 24 mm thick foam layer 12 in which are located 15 mm diameter lead balls 13 . The outer rigid layers 11 are formed of two half-inch gypsum boards. The volume filling ratio of the lead balls 13 is 11%. In this embodiment they are dispersed uniformly throughout the foam layer 12 , though this is not essential.
[0037] As can be seen from FIG. 3 , the embodiment of the invention indicated in that Figure by reference numeral 14 has a strong transmission loss that peaks at about 175 Hz. In FIG. 3 reference numeral 15 represents the same structure as this embodiment of the invention but without the lead balls, 16 is a 24 mm thick cement barrier, and 17 is an attenuator formed of two half-inch gypsum boards with a 24 mm air gap therebetween.
[0038] Comparing the four materials 14 , 15 , 16 and 17 it will be seen that at higher frequencies, eg above 250 Hz cement 16 is the best attenuator in terms of performance because it is the most dense. Below about 250 Hz the three prior art configurations 15 , 16 and 17 are all significantly less efficient than the embodiment of the invention 14 . In particular, at the peak of the absorption of the embodiment of the invention, an extra 20 dB transmission loss can be obtained using the embodiment of the invention.
[0039] It is believed that the present invention functions by the generation of built-in local resonances. By combining high-density solid particles within a softer foam matrix, a low frequency mechanical resonance is formed where the solid particles may be regarded as balls and the softer elastic foam represents a spring. When the frequency of the sound approaches the local mechanical resonances and energy is transferred from the impinging sound wave to the balls. Effectively therefore there is a band-gap surrounding the absorption peak corresponding to frequencies that cannot be transmitted through the material.
[0040] FIG. 4 shows the same plot as FIG. 3 but with the addition of a new curve 18 that corresponds to another embodiment of the invention. This embodiment is identical to curve 14 but with smaller lead balls 13 that are 10 mm in diameter. It can be seen that in this embodiment the attenuation peak is at a slightly higher frequency (approximately 220 Hz). This is consistent with the theory because with small balls there would be local resonances at higher frequencies. As shown in FIG. 5 , the attenuation peak may also be varied by changing the thickness of the foam elastic layer. In FIG. 5 reference numeral 19 refers to an acoustc attenuation materila of the same structure as reference numeral 14 but with a thickness of the elastic layer of 19 mm. It will be seen that the attenuation peak is shifted to a slightly higher frequency (approx 220 Hz).
[0041] In the abovedescribed first embodiment of the invention, the solid particles are in the form of solid balls arranged, preferably but not essentially, in a regular grid-like array. In the embodiment of FIG. 6 these balls are replaced by a wire mesh 23 , for example of iron with a 6 mm diameter and a filling ratio of 8.5%. FIG. 7 shows a further embodiment in which the wire mesh of FIG. 6 is divided into an array 24 of smaller mesh segments still with a wire diameter of 6 mm and a filling ratio of 5.6%. FIG. 8 shows a still further embodiment in which individual solid particles are provided, but of a different form from the balls of the first embodiment. In the embodiment of FIG. 8 a plurality of disks 25 are provided. These disks, which may be any of the same materials as the balls, may for example have a diameter of 26 mm and a thickness of 3 mm (filling ratio 5%).
[0042] It will be understood that the attenuation characteristics, such as the location and width of the attenuation peak, can be varied by appropriately selecting from parameters such as the shape and configuration of the particles, their size, filling ratio and material. For example, two or more different sizes of balls may be used to obtain more than one resonant frequency and thus a broader attenuation response. Similarly the size of the discs may be varied and two or more sizes may be provided. Effectively therefore the attenuation response of the material of the present invention is “tunable” to provide a desired attenuation characteristic. FIG. 9 shows the attenuation obtainable with the wire mesh 23 , wire mesh segments 24 and disks 25 as described above. All these embodiments show good attenuation properties at frequencies between 100 and 200 Hz.
[0043] FIG. 10 ( a ) shows an embodiment of the material in which the solid particles are constrained from “sinking”, ie shifting position, within the softer elastic material. In this embodiment, in which the solid material is in the form of a wire mesh 23 , the mesh 23 is connected at its edges to a surrounding frame 26 by elastic material such as springs 27 . Alternatively, as shown in FIG. 10 ( b ), especially when either mesh segments 24 are used or when a large number of individual solid particles are provided, individual supporting frame members 28 may be provided within the elastic material.
[0044] The present invention, at least in its preferred forms, provides effective low-cost acoustic attenuation materials that may be used effectively at low frequencies that in the prior art would require large and heavy acoustic barriers. The attenuation of the material can be selected by appropriate design of the size and shape of the rigid particles or mesh, the thickness of the elastic layer and the choice of materials. As such the invention can provide materials suitable for a wide range of domestic and industrial applications where noise reduction, especially at low frequencies, is required.
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Acoustic attenuation materials are described that comprise outer layers of a stiff material sandwiching a relatively soft elastic material therebetween, with means such as spheres, discs or wire mesh being provided within the elastic material for generating local mechanical resonances that function to absorb sound energy at tunable wavelengths.
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CROSS-REFERENCE TO RELATED APPLICATION
This utility patent application is based on U.S. provisional patent application No. 60/216,752, filed Jul. 7, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is a latch for actuation with both an electric motor and manually.
2. Description of the Related Art
Latch assemblies are relied on in many applications for securing items, such as panels, together. For example, containers, cabinets, closets, compartments and the like may be secured with a latch. An important use for latches is in the automotive field, where there is a desire and need to access automotive compartments, such as, for example, the trunk or passenger compartments of vehicles, as well as interior compartments such as a glove box.
Various latches for panel closures have been employed where one of the panels such as a swinging door or the like is to be fastened or secured to a stationary panel or compartment body. The prior art devices generally utilize a locking member which is spring-loaded externally by one or more separately provided torsion springs. For example, some prior art devices rely upon a lock which comprises rigid metal parts and requires additional biasing members for operation of the assembly. It has been increasingly more important and desirable to provide remote features for operation of latch mechanisms which permits a user to operate the latch from a location remote of that at which the latch is installed. For example, automobile latches often rely on the use of remote devices to open and close door locks, for example, using infrared, radio, or other wireless transmission modes. In addition, vehicle trunks often are provided so that they can be unlocked by remote means to permit the raising or opening of a panel.
In furnishing remote latching mechanisms, it must be taken into account that in some instances remote means may have failures, such as, for example, due to a loss of power supply (especially where electronic circuitry is employed). It is therefore also desirable to provide additional or secondary latching capabilities in order that the latch can be locked or opened manually, should the remote mechanism fail. In some instances, capped openings are provided in the vicinity of the latch which can permit a user to access the latch to open it should the remote mechanism not be operable. However, where security is concerned, it is not practical to provide an easy means for gaining an ability to open a latch. In these instances, complex mechanisms have been employed.
It is desirable to provide a latch which can be utilized both, by a remote locking mechanism and a key operated mechanism, and furthermore, where both the remote and the key operation can be used alternately as desired by the user. That is, it is desirable to have a latch with a locking capability where either a remote locking mechanism or a manual (key type) mechanism can be used to lock or unlock the latch, regardless of which one had previously been used.
The present invention provides a novel ratcheting pawl latch with the ability to lock and unlock the latch with remote and key operated mechanisms.
SUMMARY OF THE INVENTION
The present invention is a latch that may be operated either by an electric motor, possibly remotely, or manually. The latch includes a lockplug housing, a motor housing, a lockplug, a lockplug driver, a locking disk, a pawl, and a pair of roller switches.
The pawl includes a pair of arms and a locking disk engagement tooth. The pawl pivots between a latched and unlatched position, and is spring-biased towards its unlatched position. The pawl is dimensioned and configured to secure a wire keeper between its two arms.
The locking disk is pivotally secured between the lockplug housing and the motor housing. The locking disk defines a bearing surface around its circumference, which further defines a window dimensioned and configured to permit passage of the pawl, and a pair of cutouts. The locking disk pivots between a locked position and an open position, defining an unlocked range of positions therebetween. The locking disk is spring-biased away from the open position, but is not spring-biased in either the locked position or the unlocked range of positions. In the locked and unlocked positions, the edge of the locking disk abuts the locking disk engagement tooth of the pawl, thereby securing the pawl in its latched position. When the locking disk is rotated to the unlocked position, the window is aligned with the pawl, allowing the pawl to rotate to its unlatched position. The locking disk will then abut the pawl's locking disk engagement tooth, preventing the locking disk from rotating out of the locked position.
One side of the locking disk engages a gearbox, which in turn engages a motor. The motor is preferably a 12-volt DC motor, but is not limited to this type. The DC motor may be controlled by any of several means, including a programmable logic controller, a dashboard mounted switch, and/or a remote switch. The opposite side of the locking disk engages the lockplug driver.
The lockplug and lockplug driver turn as a single unit within the lockplug housing. The lockplug is spring-biased towards a central position. The lockplug driver engages the locking disk by means of a pin projecting from the locking disk into a slot in the lockplug driver. The slot extends for 90° around the lockplug driver. Therefore, the lockplug must be rotated 45° in either direction before engaging the locking disk. Likewise, when the motor rotates the locking disk, the locking disk is free to rotate 45° before engaging the lockplug driver. This is necessary because a force applied to rotate the lockplug will rotate the DC motor as well, but a force applied through the DC motor will have no way to rotate the lockplug.
The latch includes a pair of roller switches between the motor housing and lockplug housing. Each roller switch includes a cantilever with a roller end abutting the bearing surface of the locking disk. Depressing the cantilever closes an electrical circuit. When the roller abuts a cutout in the locking disk, the cantilever is extended, opening the circuit. Likewise, when the roller abuts the other portions of the disk's bearing surface, the cantilever is depressed. One cutout corresponds to the latch's locked position, and the other corresponds to the latch's open position. Therefore, the first of the two roller switches will be open when the latch is locked, and the second of the two roller switches will be open when the latch is open. The combined state of the two latches therefore indicates whether the latch is locked, unlocked, or open. This signal can be directed to a programmable logic controller (PLC), which, given the current state of the latch, and the desired state of the latch from a remote controller, will turn the motor the proper amount to bring the latch into the desired state. For example, if the latch is unlocked (both roller switches closed) and the user switches the latch to open, the PLC will rotate the motor until the second roller switch engages the corresponding cutout in the locking disk and opens. The PLC will then receive a signal that the latch is open, and stop rotating the motor.
It is a principal object of the present invention to provide a novel latch assembly which is selectively engagable with a keeper member, and includes a spring locking member which is spring-loaded with its own spring force for engaging and releasing a pawl from a keeper member when a handle is actuated.
It is another object of the present invention to provide a locking member which is comprised of spring steel or plastic.
It is another object of the present invention to provide a latch assembly with a locking component which can be operated with a key or other operator, such as radio, infrared, electronic or other means, which selectively engages the locking member against movement.
It is another object of the present invention to provide a latch assembly with a locking mechanism which can be operated with a key or other operator, such as, a solenoid controller, where the key and solenoid control the same locking element but provide independent ways to lock and unlock the latch.
These and other objects of the invention will become apparent through the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an electrically operated ratcheting pawl latch according to the present invention.
FIG. 2 is a rear view of an electrically operated ratcheting pawl latch according to the present invention.
FIG. 3 is a side view of an electrically operated ratcheting pawl latch according to the present invention.
FIG. 4 is an exploded perspective view of an electrically operated ratcheting pawl latch according to the present invention.
FIG. 5 is an exploded side view of an electrically operated ratcheting pawl latch according to the present invention.
FIG. 6 is a perspective view of a lockplug housing for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 7 is a bottom view of a lockplug housing for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 8 is a rear view of a lockplug housing for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 9 is a perspective view of a motor housing for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 10 is a side view of a motor housing for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 11 is a rear view of a motor housing for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 12 is a perspective view of a lockplug for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 13 is a front view of a lockplug for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 14 is a side view of a lockplug for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 15 is a perspective view of a lockplug driver for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 16 is a front view of a lockplug driver for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 17 is a rear view of a lockplug driver for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 18 is a perspective view of a locking disk for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 19 is a side view of a locking disk for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 20 is a rear view of a locking disk for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 21 is a perspective view of a pawl for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 22 is a perspective view of a pawl spring for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 23 is a perspective view of a roller switch for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 24 is a perspective view of a sungear for an electrically operated ratcheting paw latch according to the present invention.
FIG. 25 is a perspective view of a torsion spring for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 26 is a perspective view of a gearbox for an electrically operated ratcheting paw latch according to the present invention.
FIG. 27 is a perspective view of a motor for an electrically operated ratcheting pawl latch according to the present invention.
FIG. 28 is a perspective view of an electrically operated ratcheting pawl latch according to the present invention, showing the latch locked.
FIG. 29 is a perspective view of an electrically operated ratcheting pawl latch according to the present invention, showing the latch unlocked.
FIG. 30 is a perspective view of an electrically operated ratcheting pawl latch according to the present invention, showing the latch open.
Like reference numbers denote like elements throughout the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is an electrically operated ratcheting pawl latch. Referring to FIGS. 1-5, the latch 10 includes a lockplug housing 50 , a motor housing 100 , a lockplug 150 , a lockplug driver 200 , a locking disk 250 , a pawl 300 , a pair of roller switches 350 , at least one gearbox 400 , and a motor 450 .
Referring to FIGS. 6-8, the lockplug housing 50 is illustrated. The lockplug housing 50 includes a front 52 , a bottom 54 , a pair of sides 56 , 57 , and a top 58 . The front 52 defines a channel 60 dimensioned and configured to receive a lockplug driver 200 (described below) and a cylinder 62 dimensioned and configured to receive a lockplug 150 . The cylinder 62 defines a recess 64 for receiving a plurality of locking wafers of the lockplug 150 (described below). A pawl nest 66 protrudes from the bottom 54 , and a window 68 , dimensioned and configured to receive a pawl 300 (described below), is defined in that portion of the bottom 54 within the pawl nest 66 . The pawl nest 66 preferably includes a pair of coaxial apertures 67 . Referring specifically to FIG. 8, illustrating the rear or inside portion of the lockplug housing 50 , a locking disk wall 70 is illustrated surrounding the channel 60 . A lockplug torsion spring driving tooth 72 is defined within the channel 60 , adjacent to the cylinder 62 . A locking disk torsion spring tooth 74 is defined opposite the tooth 72 , adjacent to the cylinder 62 but outside the channel 60 . Adjacent to one side 56 , a plurality of risers 76 is positioned for retaining a pair of roller switches 350 (described below). The side 56 defines a pair of windows 78 for permitting access to the contacts on the roller switches 350 , best seen in FIG. 7 . The lockplug housing 50 preferably includes a plurality of mounting holes 80 for securing the lockplug housing 50 to the motor housing 100 .
The motor housing 100 is best illustrated in FIGS. 9-11. The motor housing 100 includes a panel 102 , from which a rearward portion 104 extends. The rearward portion 104 defines a motor-containing portion 106 and a gearbox-containing portion 108 . The motor-containing portion 106 preferably includes a window 110 for passage of the electrical contacts to the motor 450 . The opposite side of the panel 102 includes a perimeter wall 112 , dimensioned and configured to contain the locking disk 250 . The motor housing 100 includes risers 114 , dimensioned and configured to secure the roller switches 350 in place. A guide slot 118 is defined around a 90° section of the perimeter wall 112 . The panel 102 preferably includes mounting holes 116 for securing the motor housing 100 to the lockplug housing 50 .
A lockplug 150 is illustrated in FIGS. 12-14. The lockplug 150 includes a key slot 152 within its front end 154 . The rear of lockplug 150 may include a peg 156 . A plurality of wafers 158 extends from slots 160 within the side wall 162 of lockplug 150 . When a key is inserted and engages tumblers 164 , the wafers 158 are retracted. Likewise, removing the key extends the wafers 158 . A retention wafer 166 is spring-biased outward from a slot 168 within the side wall 162 .
A lockplug driver 200 is illustrated in FIGS. 15-17. The lockplug driver 200 includes a cylinder 202 , dimensioned and configured to receive the lockplug 150 . The cylinder 202 includes a slot 204 , dimensioned and configured to receive the retention wafer 166 . The rear portion 206 includes an aperture 208 , dimensioned and configured to receive the lockplug's peg 156 . Opposite the cylinder 202 , the rear portion 206 also defines a central aperture 212 , and a channel 214 , extending for 90° around the aperture 212 . The aperture 212 is dimensioned and configured to engage a center post of the locking disk 250 (described below). The channel 214 is dimensioned and configured to engage a driver post on the locking disk 250 . A spring retaining tab 210 protrudes outward to one side of the cylinder 202 .
The lockplug 150 is inserted into the lockplug driver 200 so that the retention wafer 166 engages the slot 204 , and the peg 156 engages the aperture 208 . In use, the lockplug 150 and lockplug driver 200 will rotate as a single unit, and will be biased towards the position wherein the wafers 158 will engage the recess 64 . The means for biasing the lockplug 150 and lockplug driver 200 is preferably a spring such as the spring 550 illustrated in FIG. 25 .
The locking disk 250 is best illustrated in FIGS. 18-20. The locking disk 250 includes a central post 252 and a driver post 254 on its front face 256 . The front face 256 also defines a cavity 258 , dimensioned and configured to receive a spring and the locking disk torsion spring tooth 74 of the lockplug housing 50 . A spring retention feature 272 is also defined within the cavity 258 . The rear face 260 includes an aperture 262 , dimensioned and configured to receive a sungear 500 (illustrated without teeth in FIG. 24 ), and a deadstop lug 264 , dimensioned and configured to engage the slot 118 within the motor housing 100 . The locking disk's circumference 266 defines a bearing surface having a pair of cutouts 268 , and a window 270 , dimensioned and configured to receive the pawl 300 .
The locking disk 250 is positioned immediately behind the lockplug driver 200 , with the central post 252 engaging the aperture 212 , and the driver post 254 engaging the slot 214 . In use, the locking disk 250 will pivot between an open position and a locked position, with an unlocked range of positions defined therebetween, and will be biased away from the open position. Preferred and suggested means for biasing the locking disk 250 away from the open position is the spring 550 .
The pawl 300 is illustrated in FIG. 21 . The pawl 300 includes a locking disk engaging tooth 302 , a first arm 304 , and a second arm 306 . The arms 304 , 306 are substantially parallel and opposite the locking disk engaging tooth 302 . A slot 310 is defined between arms 304 , 306 , and is dimensioned and configured to receive a wire keeper (not shown, and well-known). The pawl 300 also includes means for pivotally securing it within the latch 10 , with preferred and suggested means being pegs 308 , dimensioned and configured to mate within the apertures 67 within the pawl nest 66 . With the pawl 300 secured within the apertures 67 , the pawl 300 will pivot between a latched position and an unlatched position, and will be biased towards its unlatched position. Preferred and suggested means for biasing the pawl 300 towards its unlatched position are the spring 552 , illustrated in FIG. 22 . The locking disk 250 will abut locking disk engaging tooth 302 of the pawl 300 when the locking disk 250 is in the locked or unlocked positions. In the open position of the locking disk 250 , the pawl 300 will be aligned with the window 270 .
Located rearward of the locking disk 250 is at least one gearbox 400 , illustrated in FIG. 26, and a motor 450 , illustrated in FIG. 27 . The gearbox 400 is preferably a planetary gearbox. The motor 450 is preferably a 12 volt DC motor. The motor 450 is located within the motor containing portion 106 of the motor housing 100 , and is powered through electrical contacts passing through the window 110 . The motor 450 is connected through a sungear 500 to the gearbox 400 , located within the gearbox containing portion 108 of the motor housing 100 . The gearbox 400 is connected to the locking disk 250 by a second sungear 500 , fitting within the aperture 262 .
Referring to FIG. 23, a roller switch 350 is illustrated. Roller switch 350 includes a cantilever 352 , terminating in a roller 354 . A contact 356 is located beneath the cantilever 352 , so that depressing cantilever 352 closes an electrical circuit, and releasing cantilever 352 opens the circuit. Electrical contacts 358 allow connection of the roller switch 350 to an electrical circuit. Each of the two roller switches 350 is located adjacent to the locking disk 250 , so that the roller 354 abuts the locking disk's bearing surface 266 . The contacts 358 are adjacent to the windows 78 . Cantilever 352 is depressed unless the roller 354 has engaged one of the cutouts 268 . Therefore, the cantilever 352 of the roller switch 350 a is released when the locking disk 250 is in the locked position, and the cantilever 352 of the roller switch 350 b is released when the locking disk 250 is in the open position. Both cantilevers 352 are depressed when the locking disk 250 is in the unlocked position. Therefore, a distinct signal is generated designating the locking disk's locked, unlocked, and open positions.
Operation of the latch 10 is best illustrated in FIGS. 28-30. The latch 10 may be operated either manually or by the motor 450 . In the locked position, illustrated in FIG. 28, the locking disk 250 is rotated so that the window 270 is 90° to the pawl 300 , the roller switch 350 engages one cutout 268 so that it is open, and the deadstop lug 264 is at one end of the slot 118 . The keeper is secured between the pawl's arm 304 and the pawl nest 66 . The pawl's locking disk engaging tooth 302 abuts the locking disk 250 , thereby securing the pawl 300 in the latched position.
To operate the latch 10 manually, a key is first inserted into the key slot 152 of the lockplug 150 . The wafers 158 retract as the key is inserted, allowing the lockplug 150 to rotate. The key is rotated clockwise. The lockplug driver 200 will engage the driver post 254 , rotating the locking disk 250 . If merely unlocking the latch 10 is desired, the rotation may stop anywhere in the unlocked range, such as illustrated in FIG. 29 . As the locking disk 250 is rotated from the locked to the unlocked positions, the cantilever 352 of roller switch 350 a is depressed, so that both roller switches 350 are closed. The pawl 300 remains secured in the latched position.
Once the locking disk 250 is rotated to the unlocked position illustrated in FIG. 30, the window 270 is adjacent to pawl 300 , thereby permitting the pawl 300 to rotate from the latched to the unlatched position, releasing the keeper. The deadstop lug 264 reaches the opposite end of slot 118 , preventing further rotation of the locking disk 250 . The cantilever 352 of roller switch 350 b is released, opening the roller switch 350 b . As force is released from the key, the lockplug 150 and lockplug driver 200 rotate under spring pressure to their central position wherein the wafers 158 engage the recess 64 , allowing removal of the key. The locking disk 250 will be spring-biased away from the open position, but will be secured in the open position by abutting pawl 300 .
The latch may be closed by merely slamming it shut. The keeper will push against the arm 306 of the pawl 300 , thereby rotating the pawl 300 into the latched position. Once the pawl 300 is in the latched position, the keeper will be secured between the pawl nest 66 and pawl's arm 304 . The locking disk 250 is now free to rotate to the unlocked position of FIG. 29 under spring pressure. Both roller switches 350 are depressed, signaling the latch's unlocked position.
To manually move the locking disk 250 from the unlocked position to the locked position, a key is first inserted into the key slot 152 of the lockplug 150 . The wafers 158 retract as the key is inserted, allowing the lockplug 150 to rotate. The key is rotated counterclockwise. For the first 45° of rotation, the lockplug driver 200 will rotate without engaging the driver post 254 . For the second 45° of rotation, the end of slot 214 will abut the driver post 254 , so that the lockplug driver 200 will rotate the locking disk 250 . Once the locked position is reached, the deadstop lug 264 reaches the end of slot 118 , preventing further rotation of the locking disk 250 . The cantilever 352 of roller switch 350 a is released, opening the roller switch 350 a . As force is released from the key, the lockplug 150 and lockplug driver 200 rotate under spring pressure to their central position wherein the wafers 158 engage the recess 64 , allowing removal of the key.
Operation of the latch using the motor 450 is accomplished through a combination of switches indicating the desired action of the user, and the signals from the roller switches 350 a , 350 b indicating the present state of the latch 10 . These inputs can, for example, be directed to a programmable logic controller (PLC) which then controls the flow of electricity to the motor 450 . The following illustration assumes a dashboard mounted switch for moving the locking disk 250 between the unlocked and open positions only, and a remote key switch for moving the locking disk 250 between the locked and unlocked positions.
When the latch 10 is unlocked, both roller switches 350 a , 350 b will be closed. When the PLC receives a signal from either switch instructing it to open the latch 10 , it will activate the motor 450 until the roller switch 350 b is open, signaling that the latch 10 is now open. When the PLC receives a signal from the key switch instructing it to lock the latch 10 , it will activate the motor 450 , supplying power to rotate the motor 450 in the opposite direction, until the roller switch 350 a is open, signaling that the latch 10 is locked.
When the latch 10 is locked, and the PLC receives a signal from the dashboard switch instructing it to open the latch 10 , the PLC will not open the latch 10 , because the roller switches 350 a , 350 b will signal that the latch 10 is locked.
When the latch 10 is locked, and the PLC receives a signal from the key switch instructing it to unlock the latch 10 , the PLC will activate the motor 450 until the roller switch 350 a is closed. Similarly, when the latch 10 is locked, and the PLC receives a signal from the key switch instructing it to open the latch 10 , it will actuate the motor 450 until the roller switch 350 b is open.
Any time the latch 10 is manually operated, the motor 450 will simply rotate with the locking disk 250 as the force is transmitted through the gearbox 400 . However, throughout electronic operation of the latch 10 , the driver post 254 will move within the slot 214 without ever rotating the lockplug driver 200 or lockplug 150 .
It is to be understood that the invention is not limited to the preferred embodiments described herein, but encompasses all embodiments within the scope of the following claims.
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The present invention is directed to a latch that includes a housing, a pawl pivotally supported by the housing and movable between a latched position and an unlatched position, a spring biasing the pawl toward the unlatched position, and a locking member being rotationally movable about an axis of rotation between an open position and a locked position. The locking member interferes with the movement of the pawl such that the pawl is maintained in the latched position when the pawl is in the latched position and the locking member is in the locked position. The locking member allows the pawl to move to the unlatched position when the locking member is in the open position. The latch may further include a motor housing, a lockplug, a lockplug member, at least one roller switch, at least one gearbox, and a motor.
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BACKGROUND
[0001] This application relates to devices, such as potholders, oven mitts and similar devices for protecting a user's hand or other surfaces from contact with hot or cold articles, such as cooking pots, pans, lids, handles, grills, grill tools and the like.
[0002] Heretofore, thermal protective devices, such as potholders, mitts and the like, have been formed of suitable cloth or textile materials, such as cotton, the amount of thermal protection being afforded being essentially proportional to the thickness of the material. However, such cloth devices provide relatively poor temperature control, are subject to scorching or burning, and are not water-repellent or stain-resistant. Also, they can tend to be relatively slippery in use. Accordingly, it has been known heretofore to provide such cloth devices with coverings or coatings of thermally-insulating and/or grip-enhancing materials over all or portions of the outer surfaces of the devices. Alternatively, it is known to provide devices made entirely of such thermally insulating and/or grip-enhancing materials. However, such devices may tend to be relatively stiff or inflexible in use because of the nature of the material used or the additional thicknesses of the materials used, and may lack moisture control if formed of essentially non-absorbent and/or non-breathable materials. Thus, such devices may not provide optimal combinations of thermal insulation and grip-enhancing characteristics.
SUMMARY
[0003] There is disclosed herein an improved protecting and grip-enhancing device which avoids disadvantages of prior devices while affording additional structural and operating advantages.
[0004] An aspect of the disclosure is the provision of a device with both effective thermal insulation and improved grip enhancement, wherein the grip enhancement results from improved frictional or non-slip characteristics and/or improved flexibility to enhance dexterity.
[0005] Another aspect is the provision of a device of the type set forth which is double-sided and reversible.
[0006] Another aspect is the provision of a device of the type set forth which has improved patterns of thermally insulating and grip-enhancing features.
[0007] Certain ones of these and other aspects may be attained by providing a protecting and grip-enhancing device comprising an inner body formed of a first material and having opposite outer sides, a thermally insulating outer body formed of a second material secured to at least one outer side of the inner body and continuously covering a substantial portion thereof, and hinge structure joining two adjacent regions of the device to facilitate folding of the adjacent regions relative to each other along the hinge structure.
[0008] Other aspects may be attained by providing a device of the type set forth, wherein the outer body includes a first region having a first thickness and a second region peripheral to the first region and having a second thickness less than the first thickness.
[0009] Still other aspects may be attained by providing a device of the type set forth, wherein the outer body includes a plurality of alternating raised ribs and open-ended channels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.
[0011] FIG. 1 is a front elevational view of a mitt in accordance with a first embodiment;
[0012] FIG. 2 is a sectional view taken generally along the line 2 - 2 in FIG. 1 ;
[0013] FIG. 3 is a rear elevational view of a mitt in accordance with another embodiment;
[0014] FIG. 4 is a sectional view taken along the line 4 - 4 in FIG. 3 ;
[0015] FIG. 5 is a top plan view of a potholder in accordance with another embodiment;
[0016] FIG. 6 is an enlarged, fragmentary view of a circled portion designated 6 in FIG. 2 ;
[0017] FIG. 7 is an enlarged, fragmentary view of a circled portion designated 7 in FIG. 2 ;
[0018] FIG. 8 is an enlarged, fragmentary view of a circled portion designated 8 in FIG. 4 ; and
[0019] FIG. 9 is an enlarged, fragmentary view of a circled portion designated 9 in FIG. 4 .
DETAILED DESCRIPTION
[0020] Referring to FIGS. 1, 2 , 6 and 7 , there is illustrated a hand protecting and grip-enhancing device in the nature of a mitt 10 , which includes a body assembly 11 arranged to define a pocket 12 ( FIG. 2 ) having a finger-receiving portion 13 for receiving all of a user's fingers, a thumb-receiving portion 14 and a wrist-receiving portion 15 , the latter portion being open to permit insertion of the user's hand. The mitt 10 is designed to be reversible, having opposite outer sides 16 and 17 ( FIG. 2 ) which are substantially identical, so that the mitt can be worn on either hand. FIG. 1 shows the side 16 of the mitt 10 , which would be the side engaging a user's palm if the mitt is worn on the user's left hand. It will be appreciated that the opposite side 17 would be the palm-engaging side if the mitt were worn on the user's right hand.
[0021] The body assembly 11 includes an inner body 20 formed of fabric or textile materials, and an outer body 25 , which is secured to the outer surface of the inner body 20 , substantially along the finger-receiving and thumb-receiving portions 13 and 14 , since those are the portions most likely to come into contact with a hot or cold article. Referring in particular to FIGS. 2, 6 and 7 , the inner body 20 may include several layers of material, including, for example, an inner, hand-engaging layer 21 of a suitable soft, absorbent and comfortable material, such as terry cloth, a filler layer 22 , formed of a material such as cotton, and an outer liner 23 , which may formed of cotton or other suitable material. While an essentially three-layer inner body construction has been illustrated, it will be appreciated that any desired number of layers could be utilized and various types of fabric or textile materials could be used.
[0022] The outer body 25 is formed of a suitable frictional and thermally insulating material, such as silicone, which may be overmolded on the outer surface of the inner body 20 or, alternatively, could be applied by other techniques, such as suitable adhesive or bonding or stitching, and the like. The outer body 25 covers substantially all of the finger-receiving and thumb-receiving portions 13 and 14 , having a relatively thick region 26 which covers the majority of the area of the finger-receiving portion 13 and thumb-receiving portion 14 , particularly along the inner or facing portions thereof, and a thin region 27 , which is disposed along the outer periphery of the thick region 26 . It will be appreciated that the thick region 26 is that which is most likely to come into contact with the associated article being grasped and where most of the gripping pressure between thumb and fingers will be applied. While the thin region 27 may come into contact with hot or cold surfaces, such as when reaching into an oven or other confined space in order to grasp an object, it is not at a location where gripping pressure will be applied and, therefore, less thermal protection need be afforded. The relative difference in thickness between the thick and thin regions 26 and 27 may be seen from FIG. 2 , although it will be appreciated that other thickness differences could be utilized. The wrist-receiving portion 15 does not include the outer body 25 , since it is unlikely to come into contact with very hot or very cold surfaces and, therefore, the inner body 20 alone affords adequate protection. The free edges of the layers of the inner body 20 at the open end of the wrist-receiving portion 15 may be covered with a suitable trim piece 29 , which may be formed of any desired fabric material, such as cotton, and may be stitched in place to protect the free ends of the inner body layers and to provide a more decorative and attractive appearance.
[0023] Because of the thickness and relative stiffness of the outer body 25 , particularly the thick region 26 thereof, as compared to the inner body 20 , the mitt 10 may be somewhat difficult to manipulate. In order to enhance flexibility and dexterity to facilitate grasping of objects, there are provided a plurality of hinge structures 30 extending across each side of the finger-receiving portion 13 and the thumb-receiving portion 14 . Each hinge structure 30 essentially defines a hinge line 31 , most being straight lines, along which adjacent portions of the mitt may be relatively easily folded or bent. More specifically, referring in particular to FIGS. 2 and 6 , each hinge structure 30 includes a thinned outer body region 32 along which a line of stitching 33 is formed extending from the outer surface of the outer body 25 to the pocket 12 . Thus, there are defined a plurality of bend lines along which adjacent portions of the mitt 10 can relatively easily be bent or flexed. Additionally, if desired, a line of stitching 34 may be formed along the outer periphery of the thin region 27 to provide an enhanced attachment to the inner body 20 and inhibit delamination of the outer body 25 at its outer edge.
[0024] In fabrication, it will be appreciated that the two sides 16 and 17 of the mitt 10 may be separately formed as two different bodies which are then laid back to back in overlapping relationship, with the outer bodies 25 in facing contact with each other, and the two pieces may then be stitched together along a seam 35 along the entire periphery of the mitt 10 , except at the open end of wrist-receiving portion 15 . Then the seamed-together pieces may be turned inside out to result in the finished configuration shown in FIG. 2 , all in a known manner. In this regard, the thick region 26 of the outer body 25 may be provided with a very thin margin portion to facilitate stitching of the seam 35 therethrough and inversion of the seamed mitt.
[0025] Referring to FIGS. 3, 4 , 8 and 9 , there is illustrated an alternative embodiment of mitt, generally designated by the numeral 40 , which is substantially the same as the mitt 10 , described above, except that it has a differently configured outer body 45 . FIG. 3 shows the opposite side of the mitt from that shown in FIG. 1 . In this case, it can be seen that the outer body 45 has an end edge which defines a straight line at 44 , along which a line of stitching may be provided to inhibit delamination, as was explained above. The outer body 45 has a thick region 46 which extends along substantially the same area of the mitt 10 as the thick region 26 , described above, and a thin region 47 which, as can be seen, is slightly larger than the thin region 27 , described above. However, in this case, the thick region 46 is provided with a plurality of alternating ribs 48 and grooves 49 arranged along substantially straight lines which are substantially parallel to the adjacent ones of the hinge structures 30 . Since the hinge structures 30 are formed along non-parallel lines, some of the ribs and grooves are generally wedge-shaped, as at 43 . This ribbing provides a further improvement of the grip-enhancing function of the outer body 25 , and the grooves 49 , which are open-ended, define air flow channels to further enhance the thermal insulating characteristics of the outer body 45 .
[0026] While, in the illustrated embodiments, each of the mitts 10 and 40 is substantially identically configured on the opposite sides thereof, it will be appreciated that this need not be the case. For example, if desired, the outer body arrangement 25 could be disposed on one side of the mitt while the outer body 45 could be disposed on the other side thereof. Other arrangements could also be utilized.
[0027] Referring to FIG. 5 , there is illustrated another protecting device in the nature of a potholder 50 , which is shown as a substantially square, flat device, which may be formed of inner and outer bodies substantially in the same manner as the mitt, described above. More specifically, the potholder 50 could have an inner body of fabric or textile material either single-layered or multi-layered, covered on both sides thereof with an outer body 65 (one shown) of a non-slip and thermally insulating material, such as silicone. In the illustrated embodiment, the outer body 65 has an inner thick region 66 surrounded by a peripheral thin region 67 . Also, there are formed across the potholder 50 a plurality of hinge structures 70 , each of which may be substantially identical to the hinge structures 30 , described above in connection with FIGS. 1-4 , to facilitate flexing of the potholder 50 when it is used for manual grasping of an object. Thus, the potholder 50 provides two types of grip enhancement, viz., non-slip and flexibility. It will be appreciated that the potholder 50 could have any desired size and shape and, depending upon the thicknesses of the material used, the hinge structures 70 may or may not be desired. The potholder may, of course, be used to protect a user's hand while grasping an object or may be used as a trivet beneath an object to protect an underlying surface.
[0028] From the foregoing, it can be seen that there has been provided an improved protecting device which performs improved grip-enhancing and thermally insulating functions and is reversible in use.
[0029] The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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A protecting and grip-enhancing device includes an inner body formed of a first material and having opposite outer sides, a thermally insulating outer body formed of a second material and secured to at least one outer side of the inner body and continuously covering a substantial portion thereof, and hinge structure joining two adjacent regions of the device to facilitate folding of the adjacent regions relative to each other along the hinge structure. Plural hinge structures may be provided, each including a reduced thickness of outer body material and stitching extending through the reduced thickness and an underlying portion of the inner body. The outer body may include relatively thick and relatively thin regions and the thick region may include alternating raised ribs and open-ended channels. The device may be in the form of a mitt or a potholder.
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This application is a continuation-in-part of U.S. Patent application Ser. No. 34,989 filed May 10, 1979.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to weapons and weapon systems employed by ground-based personnel in defense against helicopter assault. The invention is particularly related to a weapons system intended to entangle the rotor systems of an enemy helicopter by means of a cable descending on the rotor system from above.
2. Description of the Prior Art
The Aviation Safety Board has data available on various types of rotor blade impacts with wires. The wires employed in the production of this data were restrained in the manner of high tension lines and the damage was inflicted on the rotor by the stoppage or catastrophic failure of the rotor system. In some cases, extraneous pieces of communications wire have caused helicopter crashes by becoming entangled in the rotor system. It is well recognized that the rotor system of a helicopter is extremely vulnerable for it constitutes not only the propulsion mechanism but also the lift generating mechanism of the aircraft. If the rotor of the helicopter is defeated while the helicopter is airborne at any significant altitude, the likelihood of safe landing on the part of the helicopter is very low.
The prior art does reveal weapon systems intended to defeat aircraft by means of interaction between a cable and a flight system of that aircraft. In particular, U.S. Pat. No. 2,805,622 to Cammin-Christy discloses a rocket missile having a line attached thereto for interaction with a fixed wing aircraft driven by a propeller. Since most modern fixed wing aircraft of military importance no longer employ propeller-driven engines but rather jet engines and since the wing structure of such aircraft typically employs a dramatic rake angle, the utility of the system shown in the Cammin-Christy patent is very limited. Nonetheless, the basic concept of downing aircraft by interaction with a length of cable is well known in the prior art and the means for deploying the cable other than rocket missiles are known. For example, barrage balloons and the like were employed extensively in the 1930s and 1940s and during the Battle of Britain, bomber crews sometimes threw cables at attaching fighter planes.
In the last six to eight years, dramatic developments in the use of helicopters as assault vehicles and fire support platforms have occurred.Further development of helicopter systems is an integral part of conventional armed force structure as expected. One of the major considerations of any ground-based forces defending against a helicopter-based invasion, is identifying the absolute minimum force necessary to defend against an enemy that has the advantage of numerical superiority as well as ability provided by the helicopter. In that context, it was intended that the present weapons system be one which can be very simply employed by ground troops and that it comprise essentially a minimum adjunct to already existing weapons systems. It was further intended that the present weapons system be usable in the vicinity of friendly troops with little or no hazard to those troops due to accidental overshoot, misfire, or the like.
The problem of close proximity of friendly troops is particularly relevant where the intended site of any helicopter assault operation is specific targets in the rear of a main resistance area such as command and control centers, logistical installations, air defense sites, and bridge heads which an enemy force might wish to secure to the rear of a main defense line so as to ensure a high momentum to any overall assault plan. The rear area target might be only lightly defended in view of its distance from the main line of assault but still might contain a significant population of friendly troops which would prevent the employment of a large amount of incoming firepower. It is further desired that the weapons system be employable against helicopters while at a moderate altitude over a landing zone.
SUMMARY OF THE INVENTION
The present invention employs an assemblage for use with a conventional field deployed weapon such as a rifle, cannon, or mortar. The assemblage can in certain circumstances include the projectile round to be fired by the field deployed weapon. The assemblage has as its major objective deploying an amount of cable in such a fashion as to defeat a helicopter rotor system. The assemblage includes a first wall member which defines a first cavity for receiving a projectile fired by the field deployed weapon. A second wall member joins the first wall member and defines at least a second cavity for receiving an amount of cable to be deployed. An amount of cable is situated within this second cavity. A snaring means is attached to the cable and situated over an opening above the first cavity so as to intercept the projectile when it is fired from the field deployed weapon.
The assemblage preferably includes as a part of the first wall member means for engaging the muzzle of the field deployed weapon. When the weapon is fired, this first wall member is intended to be retained on the muzzle of the weapon and thereafter manually removed prior to firing a subsequent round. Where the weapon selected is a mortar, the first cavity defined by the first wall member can be used as a transporting compartment for the mortar projectile. In this particular embodiment the assemblage constitutes a self-contained round to be used in combination with a conventional mortar cannon.
The assemblage can contain any number of cavities for receiving cables to be deployed. Preferably, two or more cavities exist which are spaced equally around the periphery of the first cavity so as to present the prior projectile with a balanced load during the trajectory path. The cable itself could be any material which would withstand the impact of the rotating helicopter rotor blade. While multi-filament steel cable of approximately 1/8 inch diameter is believed to be satisfactory, the preferred material would appear to be a synthetic composite of similar tensile strength but much less weight sold under the trademark KEVLAR. KEVLAR is representative of a class of materials typified by aromatic polyamides. Generically, Kevlar is poly-p-benzamide. The fiber is very strong and has a low extensibility and is difficult to break. The fiber has a tenacity of about 7 gm./denier, an extensibility of just under 2 percent and a very high initial modulus of about 300 gm./denier.
When the projectile is fired from the field deployed weapon, the projectile is snared by the snaring means as it exits from the muzzle of the weapon. The snaring means can simply comprise a ring having an inside diameter significantly less than the maximum outside diameter of the outside projectile. More advantageously, the snaring means can comprise an inelastically deformable patch which conformably engages the leading tip of the projectile. This deformable characteristic of the patch leads to a more smooth impulse and thus slightly lower acceleration extremes on the cable thereby ensuring a more smooth deployment of the cable upon firing the weapon. An inelastic shock absorbing means other than the deformable patch could also be employed and connected between the cable and the snaring means. Again, the function of this shock absorbing means would be to absorb the initial shock of impact between the snaring means and the projectile so as to present a more smooth acceleration curve to the cable.
Upon firing the field deployed weapon, whether rifle, cannon, or mortar, there is an initial outflow of gas from the muzzle of the weapon prior to the exit of the projectile itself. It is therefore necessary that apertures exist in the first wall member attached to the muzzle of the weapon so as to permit the escape of this gas without displacement of the snaring means. The apertures are most desirably located such that they are normally in a closed condition except immediately prior to firing the weapon. This is most advantageously achieved by having the assemblage comprise removable end caps or the like which seal the assemblage against adverse environmental conditions. Particularly where the assemblage is to be employed with a mortar, the assemblage may include a release or trigger means which engages the projectile when positioned above the muzzle of the mortar cannon. The release trigger means is manually actuable for releasing the projectile whereupon it falls in a normal manner down the mortar cannon to the bottom thereof where the projectile charge is ignited thereupon deploying the projectile and cable situated within the assemblage.
The cable itself can also comprise a drag increasing means situated at the end of the cable opposite that attached to the snaring means for significantly increasing the drag on the projectile-cable combination when it is fully deployed. Such a drag increasing means may not be necessary if the cable itself is of such a character as to present sufficient drag to properly cause the projectile to deploy the cable in a generally horizontal arc over the landing zone sought to be defended. Since it is most desirable that the cable once deployed over the landing zone descend essentially vertically, the projectile used for deploying the cable most desirably includes a time fuse which causes the destruction of the projectile once the cable is properly deployed over the enemy helicopter.
When the weapon employed, according to the present invention, is a mortar, such as the 81 millimeter M29 or M29A1, then illuminating cartridges such as M301A1 illuminating cartridges such as M301A1 might be employed in combination with time fuse M84 to not only deploy the cable successfully but also to provide night illumination in the event of night attack.
In accordance with the instant invention the weapon may also utilize a projectile such as a rocket or shell in which the cable and a submumision are contained and from which the submunition carries the cable after the projectile is aloft.
Other various features and advantages of a weapons system according to the present invention will become apparent to those skilled in the art upon consideration of the following description of preferred embodiments thereof together with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of one embodiment of a weapons assemblage according to the present invention positioned in proximity with the muzzle of a field deployed weapon with which the assemblage might be employed.
FIG. 2 is a top plan view of the assemblage illustrated in FIG. 1 with the top cap removed and further illustrating the section line employed in FIG. 1.
FIG. 3 is an illustration of the inelastic deformation of one embodiment of a snaring means employed in the present invention after that snaring means has been impacted by the projectile.
FIG. 4 is a graphic illustration of the deployment of the present cable weapons system with respect to an aircraft target.
FIG. 5 is an illustration of a shock-absorbing means which can be included between the cable and the snaring means.
FIG. 6 is an illustration of a second embodiment of a weapons assemblage, according to the instant invention, wherein a shell, such as a mortor shell, is used to carry a packaged snaring cable aloft and a submunition within the shell is used to extend the snaring cable.
FIG. 7 is a cross sectional view taken along lines 7--7 of FIG. 6.
FIG. 8 is a pictorial illustration showing deployment of the weapons assemblage of FIGS. 6 and 7.
FIG. 9 is an illustration of a third embodiment of a weapons assemblage, according to the instant invention, wherein a rocket is used to carry a packaged snaring cable aloft and a submunition within the rocket is used to thereafter extend the snaring cable.
FIG. 10 is a cross section taken on lines 10--10 of FIG. 9.
FIG. 11 is a pictorial illustration showing deployment of the weapon assemblage of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment, Cable Attachment--FIGS. 1-5
A first embodiment of the present invention is illustrated in the accompanying figures wherein similar portions of the illustrated embodiment of the invention carry the same reference numerals in each of the figures. The assemblage 10 is intended to deploy an amount of cable 12 in such a fashion as to defeat a helicopter rotor system. The assemblage 10 comprises generally a first wall member 14 defining a first cavity 16 for receiving a projectile 18. A second wall member 20 is joined to the first wall member 14 and defines at least a second cavity 22 for receiving an amount of cable 12. An amount of cable 12 is situated within the second cavity 22. A snaring means 24 is attached to the amount of cable 12 and situated over the first cavity 16 so as to intercept the projectile 18 when projected.
The first wall member 14 preferably includes means 26 for engaging the muzzle 28 of a field deployed weapon such as a rifle or mortar cannon. While it is intended that the assemblage 10 be employable with field weapons 30 of conventional design without any substantial modification thereof, it is recognized that it may be necessary that the field deployed weapons 30 be modified slightly so as to include cooperating means 32 for cooperating with means 26 of the assemblage 10 to assure retainment of the non-deployed elements of the assemblage 10 after firing of the projectile 18.
Appropriate capping means such as 34 can be conveniently employed and removably secured to at least one end of wall members 14 and/or 20 for sealing the assemblage 10 against adverse conditions of the environment when the assemblage is in an unarmed configuration. In actual use of the assemblage 10, the capping means 34 would preferably be removed prior to firing so as to ensure corect interaction between the projectile 18 and the snaring means 24. A similar capping means to that illustrated in FIG. 1 could be employed on the opposite end of the assemblage 10 although none is there illustrated in FIG. 1. It will be appreciated that this non-illustrated capping means would have to be removed prior to establishing the locking engagement between the muzzle 28 of the field deployed weapon 30 and the assemblage 10.
When the field deployed weapon is a mortar, such as the 60 millimeter model M19, the 81 millimeter mortar model M29, the 4.2 inch mortor model M30, or the like, the mortar round itself 18 could be included in the assemblage 10 as illustrated. Where the assemblage 10 is employed with a breech loading weapon such as a rifle, the assemblage would not contain projectile 18 except during that instant of time when the projectile left the muzzle of the weapon when fired. When used in combination with a mortar in the configuration illustrated in FIG. 1, the assemblage can be seen to constitute a completely self-contained field round inasmuch as the assemblage 10 consists essentially of a deployable aircraft interacting element 12, and means 18 for deploying that element 12 in operative position with respect to the target aircraft. Further, in this configuration, the assemblage 10 can include a release trigger means 36 which engages the projectile 18 prior to firing but when triggered releases the projectile from the first cavity 16 when withdrawn in the direction of arrow A.
When the weapons system is fired and projectile 18 is traveling vertically upward within the barrel of weapon 30, an amount of gas preceeds the projectile 18 which must be vented to the atmosphere. While apertures 38 can be provided in the snaring means 24 to permit the venting of this outward rush of gas, it is also preferred that additional apertures 40 be present in wall 14 so as to prevent premature displacement of the snaring means 24 from the end of the cavity 16. The particular design of the apertures 40 is not believed to be crucial and is believed to be within the design capability of those of ordinary skill in this art.
As illustrated in FIG. 2, the second wall member 20 can define a plurality of cavities 22', 22", 22"'. In a similar manner, the cavities thus formed will contain a like plurality of cables 12', 12", and 12"'. A first end 40 of each cable is attached to the snaring means 24. A drag increasing means 42 can be included in the assemblage 10 and connected to the end of the cable 12 opposite that end 40 attached to the snaring means 24. The purpose of the drag increasing means 42 is to significantly increase the drag on the projectile 18-cable 12 combination when the weapon is fully deployed. The cable itself may be made of any material having sufficient tensile strength to resist impact with the rotor blades of a helicopter. Materials which it is believed will satisfy this tensile strength condition yet permit deployment in the fashion are not limited by composition. Those materials which exhibit a high tensile strength comparable to steel wire or strong man-made fibers, such as carbon or polyamides, with tenacity values about 7 gm./denier and low extensibility, less than 5%, and high initial modulus, such as 300 gm./denier are very desirable.
The snaring means 24 connected to the cable 12 is illustrated in FIGS. 1-3 as an inelastically deformable patch which conformably engages the leading tip of the projectile 18 when projected as shown most dramatically in FIG. 3. This inelastic deformation of the snaring means 24 tends to smooth the abrupt exceleration which would otherwise be experienced by the cable 12.
The snaring means can also consist of a ring having an inside diameter of the projectile 18 as illustrated in FIG. 5. Other configurations for the snaring means may become apparent upon a study of the functional operation of the device by those skilled in the art. While the snaring means 24 is preferably inelastically deformable, this character is not necessary so long as some other inelastic shock absorbing means 44 is connected between the cable 12 and the snaring means 24 for absorbing the initial shock of impact between the snaring means 24 and the projectile 18 when the weapon is deployed. This inelastic shock absorbing means 44 can comprise a cyclinder 46 and piston 48 arrangement as illustrated in FIG. 5, the cylinder 46 containing an inelastically deformable material 50 which, upon impact between the projectile 18 and the snaring means 24, is inelastically deformed by the piston 48 traveling longitudinally through the cylinder 46.
It is most desirable that the cables 12 of the present weapon descend in a nearly horizontal fashion over the target aircraft 60 as illustrated in FIG. 4 so as to have the greatest probability of contacting and tangling with the main rotor 62 of the aircraft 60. It is therefore desirable for the cable 12 to have only a minimal or nominal horizontal component of velocity once fully deployed over the landing zone. This can be achieved by including on a terminal end of the cable a drag increasing means 42 which increases the drag once the cable is fully deployed. This can further be accomplished by employing as a projectile 18 one which will disintegrate when the cable 12 is appropriately deployed over the aircraft 60. The drag including means 42 then acts to dramatically slow the horizontal velocity component of the cable 12 and the cable 12 settles to earth in a nearly horizontal arcuate extension. The particular form of the drag enhancing means 42 will depend on the length and weight of the cable initially selected as well as velocity characteristics of the projectile 18 with which the cable is employed.
Second Embodiment, Cable Contained within Shell--FIGS. 6, 7 and 8
Referring now to FIGS. 6, 7 and 8, there is shown a second embodiment of the invention in which a shell, designated generally by the numeral 100, contains an amount of cable 101 within a cavity 102 in the shell. The cable 101 is preferably packaged in a plurality of coils 105', 105" and 105'" equally spaced around the axis 106 of the shell 100.
The embodiment of FIGS. 6 and 7 differs from that of FIGS. 1 through 5 in that the cable 101 is carried aloft by the shell in a packaged or coiled configuration instead of being carried aloft in strand form. As is seen in FIG. 7, the cable 101 is projected from the shell 100 preferably after the shell is positioned above a target helicopter 110.
In order to extend the cable 101 from the shell 100, a submunition 111 is carried within the cavity 102 of the shell and propelled therefrom by explosive or rocket means after a time interval determined by a fuse 112 contained within a time charge chamber 113. A capture patch 115 is connected to the ends of the coils 105'-105'" and positioned over and in the path of the submunition 111 so as to pull the cable 101 from the shell 100 in three strands. The shell 100 has a frangable nose 117 which is shattered as the submunition 111 leaves the shell.
In a first embodiment, shown in solid lines in FIG. 8, the submunition 111 does not explode and the ends of the three strands of cable remain secured to the shell 100 and to the submunition so that the cable will drop more rapidly over the helicopter due to the weight of the shell and submunition.
In accordance with a second embodiment of the invention, as shown in dotted lines in FIG. 8, the submunition 111 detonates after extending the three strands of cable 101 far enough to remove the cable completely from the shell 100. Accordingly, the cable 101 extends generally horizontally across the target helicopter 101 and is pulled into the helicopter blades by the downward suction of the helicopter's main rotor.
While a motar shell is disclosed as a prefered embodiment, other types of shells may utilize the aforesetforth principles to carry a cable or cables aloft in order to defeat helicopters.
The same considerations as to the structure and functions of capture patches and cables set forth in the description of the embodiment of FIGS. 1-5 apply to the embodiment of FIGS. 6-8.
Third Embodiment, Rocket Projectile Containing Snare Package--FIGS. 9, 10 and 11
Referring now to FIGS. 9, 10 and 11 wherein the third embodiment of the invention is set forth, a rocket designated generally by the numeral 200, is propelled aloft by a propellent 201 contained therein and carries aloft three strands of cable 202 packaged in a plurality of coils 203', 203" and 203'". As with the shell projectile 100 of FIGS. 6-8, the rocket projectile 200 includes a submunition 207 which is propelled from the rocket 200 to unwind the strands of cable 202 from the coils 203', 203" and 203'".
In a prefered embodiment, the rocket 200 is shoulder fired although it may be also fired from a vehicle or a stationary position. The rocket 200 is carried in a launching tube 210 which includes an extension 211 at the rear end thereof to lengthen the tube and a removable front and rear covers 212 and 213, respectively. The extension tube 211 locks to the tube 210 via a conventional locking lug 215. The rocket 200 also includes a plurality of folding fins 217 disposed about its aft end.
As with the other embodiments of this invention, the submunition 207 is aligned behind a capture patch 220 that is attached to ends of the coils 203', 203" and 203'". A frangable nose 222 covers the front end of the rocket 200 and is shattered upon launching the submunition 207 so that the cables 202 are pulled from the rocket 200 in strand form by the submunition.
In one embodiment shown in solid lines in FIG. 10, the cable 202 remains attached to the rocket 200 and to the submunition 207, whereby the cable is extended over the helicopter with the relatively large weight of the casing and submunition at each end so as to drop fairly rapidly and drape over the helicopter to snare the rotors.
In another embodiment shown in dotted lines in FIG. 10, the cables 202 are pulled free of the rocket 200 and the submunition 207 is exploded to release the cables so as to in effect drift into the helicopter rotors due to the downward suction of the main rotor.
The same considerations as to the structure and function of capture patches and cable set forth in the description of the embodiment of FIGS. 1-5 apply to the embodiment of FIGS. 9-11.
Other variations, features, and advantages of the present invention are believed to become apparent to those of ordinary skill in the art from a review of this disclosure. This discussion and illustration of prefered embodiments is intended to be examplary of the invention and not all inclusive, the invention being defined by the apended claims.
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A projectile deployed cable weapons system for defeating helicopter rotor systems is disclosed. The deployed cable is intended to settle on the target helicopter from above, and damage is inflicted on the main rotor blade or tail rotor blade of the helicopter by sudden stoppage or castastrophic failure of the contacted rotor system.
A particularly advantageous assemblage for deploying an amount of cable to defeat helicopter rotor systems is also disclosed. The weapons assemblage includes a first cavity for receiving a projectile, a second cavity containing an amount of cable, and a snaring means attached to the first cable and situated with respect to the first cavity so as to intercept the projectile when projected. Most advantageously the assemblage consists of a field container containing both the projectile and cable as a single operating unit to be attached to the muzzle of a mortar cannon of conventional design.
In another embodiment a projectile such as a rocket or shell contains the cable and a submunition. After the projectile is aloft the submunition is fired to carry the cable from submunition in strand form.
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BACKGROUND INFORMATION
There have been advances in the design of changeable, low cost signs and display formats. It is advantageous for businesses to display information which will ultimately serve the interests of the business. To a similar degree, an individual's interests in dissememinating information to others has been served by various modes of expression and display. Individual's have used bumper stickers on cars, lapel pins, T-shirts, personalized license plates, etc. to get their message to others.
This invention incorporates the reduction in cost of magnetic sheeting with the individual's desirement to say their messages.
A similar attempt to design a workable, low cost display format incorporating the arrangement of pieces affixed with alphanumeric characters and secured to some surface of application with magnetics has been attempted by Amanze, U.S. Pat. #5,337,501. The interlocking nature of the zig-zag configuration described by Amanze is `interlocking` only to the extent that there is a stabilizing force between each magnetic character and some functionable surface of application which secures one piece abutted to the border of a contiguous piece.
The present invention improves on this interlocking ability by employing a system of jigsaw puzzle type tabs and endentations. The snug `no escape` configuration of pieces within the present invention's system (without removing some piece from the plane of interlockability) is an improvement over the `contiguous border` character of Amanze's pieces. The construction of the present invention is further stabilized by the interlocking frame construction either surrounding the `character` pieces or integrated within the system of character pieces. Further, Amanze's invention describes a `transparent` background upon which his characters are affixed. The present invention employs an opaque background with normally a rectangular perimeter for the character piece and frame piece constructions. This format is desirable because it has been made familiar to the public as the standard format of `bumper stickers` (typically an opaque rectangle) and it allows for a more practical construction of these character pieces which, along with the frame pieces, can be cut from a single magnetic sheet into functionable pieces which are each employable as some component of the resource grid and frame construction of the present invention.
SUMMARY OF THE INVENTION
A resource grid of alphanumeric characters or other symbols imposed on jigsaw puzzle type pieces is of a design that may be disassembled, and some select reconstruction of the pieces created by the user, is a desired word, phrase, question, or other message which can be completed into a single line or multiple line design which is most desirable with regard to both the spacing between words and letters, and also the achievement of a regular shape at the perimeter of the finished construction, typically a parallelogram. The finished construction may be displayed to convey the word, phrase, etc. contained thereon as a magnetic bumper sticker (sometimes for use in emergencies), a similar grid of refrigerator magnet pieces, or as non-magnetic, jigsaw puzzle board type pieces. The system could also be used for some intelligence exercise for children in that the construction could require correct English, spelling, and a good choice of blank interior grid pieces and frame structure pieces to fill out the grid to a regular geometric form at the perimeter.
The invention makes special accomodation for the spacing of letters within a word to be constructed.
Alphanumeric characters of a specific font style have sufficiently different width dimensions such that imprinting all letters on same sized gridpieces would result in undesirable, excess space between letters.
Consider the word `Mix.` Some fonts which may be desired for use on the display grid have a font version of the letter `i` which has a width dimension which is much smaller than the width dimension of of the capital letter `M.` Connecting three, same width gridpieces imposed with these three letters of this particular font would result in a visually incorrect spacing between the M,. i, and x. A narrow font version of the i, imposed on a gridpiece large enough to accomodate a wide M will appear to be too far away from the M or x or both.
The invention solves this problem. The narrowest gridpiece of the invention will accomodate the dimensions of the narrowest alphanumeric characters of a font (i.e. the letters i and l, and possibly the letters r, t, f, and j, and symbols like a period, comma, etc.).
The largest sized gridpiece, used to accomodate the widest alphanumeric characters of the selected font will have the same height as the narrowest gridpiece, and a width that is a regular multiple of the width of the narrowest piece. If the largest gridpiece has a width that is four times the width of the narrowest gridpiece, it will also have exactly the same perimeter shape as four of the narrowest pieces, interconnected, side by side. Intermediate sized pieces also have a width dimension that is a regular multiple of the width dimension of the narrow gridpiece.
The process of reducing the width dimension of a character piece to exactly one-half, one-third, one-fourth, one-fifth, etc. the width of the widest character piece creates a manageable, regular grid system of pieces whereby a combination of alphanumeric pieces can always be connected and the width of that construction then extended to a desired specific width by attaching similar `blank` gridpieces (no alphanumerics) so as to reach the required dimension to fill and connect with a frame structure of specific dimension. In one form of the invention these gridpieces are designed to be interconnectable with any other interior gridpiece on each of their four sides owing to a design of complimentary tabs and endentations which dovetail, and so, connect one piece snugly to another. In a second form of the invention these alphanumeric character pieces and similar `blank` pieces (`interior grid pieces`) interlock only horizontally employing the system of tabs and endentations on the left and right edges only.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an orthogonal view of a resource grid of interlocking interior grid `character` pieces, framepieces, and connector pieces.
FIG. 2 is a reproduction of FIG. 1 with interior grid character pieces removed.
FIG. 3 is a user constructed grid of pieces from the resource grid shown in FIG. 1.
FIG. 3a is a user constructed grid of pieces of another form of the invention in which interior grid pieces are `interfitted` within the framework structure.
FIG. 3b is a user constructed grid of pieces showing the use of a grid piece imprinted with an entire word.
FIG. 4 is an orthogonal view of a resource grid of interlocking interior grid pieces, end pieces and connector pieces of one form of the invention.
FIG. 5 is a reproduction of FIG. 4 with interior grid character pieces removed.
FIG. 6 is a user constructed grid of pieces from the resource grid shown in FIG. 4.
DETAILED DESCRIPTION
FIG. 1 is one form of the invention where the interlocking grid of alphanumeric characters is shown to be structured to match the interlocking and physically supportive system of framepieces which serve to square the edges of the perimeter of the display format. Shown in FIG. 1 is a construction of two fields of `interior grid` pieces or `character` pieces, each surrounded by an interlocking series of framepieces. The framepieces surrounding the top two lines of interior grid pieces are connected to the second series of framepieces which surround a second two line group of interior grid pieces utilizing two connector pieces (10). The form of the invention in FIG. 1 employs a system of interior grid pieces which make the accomodation for the variation in character width by using a most narrow piece (12) of a specific dimension, and a next sized, interior grid piece (14) which is twice the width of the narrow piece shown and has the same vertical dimension as any other interior grid piece with similar intrerlocking tabs and indentations. A next sized piece (16) has a width equal to three times the width of the narrow pieces (12) and interlocks similarly with other interior grid pieces or frame pieces.
FIG. 2 is a reproduction of FIG. 1 without the two fields of interior grid character pieces. Shown, the remainder, is the framework structure for this example of the invention. It is comprised of connector pieces (10) and frame pieces which include `corner` frame pieces (18) and `single straight edge` framepieces. The corner frame pieces have two adjacent straight edges which form the corner portion of the rectangular shaped perimeter border. In order to increase the number of corner frame pieces supplied to the user so that he might complete more than one regular perimeter frame construction from the single resource grid furnished, a series of rectangular frame constructions are attached one to another (two shown) by the connector pieces (10). The connector pieces (10) have the same dimensions and the same pattern of tabs and endentations for interlocking with character pieces as two similar horizontal frame structure pieces (20) were they aligned and abutted along their straight edges. Frame pieces comprising the upper and lower horizontal framework (20) here employ a system of width dimensions similar to the width dimension system described for the interior grid characters described by FIG. 1, such that any width construction of interior grid pieces can be precisely surrounded by a construction of upper and lower horizontal frame structure pieces (20) and left and right vertical frame structure pieces (22) and/or connector pieces (10).
FIG. 3 is an example of a user constructed grid from the elements of the resource grid shown in FIG. 1. The user has constructed two rectangular framework structures comprised of corner frame pieces (18), left and right vertical frame pieces (22), and upper and lower horizontal frame pieces (20). The two contained fields of interior grid pieces are comprised of alphanumeric and blank pieces of the most narrow width dimension (12), of the next sized width dimension (14) and of the greatest width dimension piece of the example (16). A connnector piece (10) is substituted for a horizontal framepiece in each rectangular framework structure and owing to its design, snugly interlocks one framework construction with the second.
FIG. 3a is an example of a user constructed grid from the elements of a resource grid of a design similar to that of FIG. 1, but of a related form of the invention in which the mathematical relationship between the width dimensions of the alphanumeric interior grid pieces does exist to coordinate with a supporting framework structure; however, the character pieces are `interfitted` snugly within a constructed framework rather than `interlocking` as in the form of the invention described in FIG. 1 which employs a system of tabs and endentations on the interior grid.
FIG. 4 is a second form of the invention which employs endpieces at either end of a construction of the interior grid alphanumeric pieces to either connect one line to another or to simply square the perimeter edge configuration to a rectangle in the case of a single line construction, employing the attachment of one left side endpiece (31) and one right side endpiece (41). Left side endpieces (32) which connect two lines, and left side endpieces (33) which connect three lines, interlock with and square the upper and lower left corners of a construction to a rectangle. The same connecting, interlocking and squaring is achieved from the right side using two line connecting right hand endpieces (42) and three line connecting right hand endpieces (43).
Connector pieces of this form of the invention (52 and 53) physically connect one line or set of lines to another line or set of lines by interlocking within the interior grid pieces of each set of lines. The end pieces and connector pieces comprise the frame structure in this form of the invention. In this example of the invention, the connector pieces would typically be blank and would have vertical dimensions equal to some multiple of the vertical dimension of the character pieces, so as to exist exactly within the dimensions of the lines connected. Two line connector pieces (52) exist precisely within the vertical dimension of two lines of construction. Three line connector pieces (53) exist precisely within the vertical dimension of three lines.
The alphanumeric interior grid character pieces of this form of the invention make the special accomodation for spacing of characters employing the more narrow pieces (60), next sized width pieces (62), or the greatest width pieces (64); but are not interlocking on all four sides with other gridpieces. They interlock with one another only horizontally, employing the system of tabs and endentations on their left and right edges. The top and bottom edges of each of these character pieces is a straight edge. The straight edge at the left side of the left endpieces, the straight edge at the right side of the right endpieces, and the straight lines created at the top and bottom edges of a construction of character pieces comprise the desired rectangular shape at the perimeter of a construction.
FIG. 5 is a reproduction of FIG. 4 with all of the alphanumeric interior grid character pieces removed, leaving only the frame structure pieces of this form of the invention including endpieces (31,32,33 and 41,42,43) and connector pieces (52 and 53) exactly as described for FIG. 4.
FIG. 6 is an example of a user constructed grid from the elements of the resource grid shown in FIG. 4. The user has integrated two rectangular perimeter constructions utilizing a left side end piece (32) which serves to connect and square the interlocked interior grid character pieces of the first line with the interior grid pieces of the second line. A connector piece (52) is utilized both to create a space between words in each line and to further connect and support the two line construction. Two single line right hand endpieces (41) are used to square the right edges of the two integrated constructions. The mathematical relatonship between the width of the connector pieces (52) and the widths of the narrow character pieces (60) and of the next width character pieces (62) and of the greater width character pieces (64) of the example is shown to comprise an exact, working, functionable system for interconnection of pieces maintaining the special accomodation for the difference in widths of characters.
The foregoing description of preferred embodiments of this invention is intended as illustrative. The concept and scope of the invention are limited only by the following claims and obvious variations thereof.
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A changeable magnetic sign kit including; interlocking pieces, upon which are imprinted alphanumeric characters, which can be reconstructed into different messages, and which vary in width to accomodate the variety of widths of characters within a font style, the width dimension of each character piece having a specific mathematical relationship with the width dimension of another; similar interlocking framepieces which connect with the alphanumeric imprinted pieces to connect them with a straight edged perimeter, and connector pieces which interlock with either the framepieces or the character pieces to join one parallelogram comprised of these two type pieces to another parallelogram comprised of these two type pieces.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for producing polyisobutene with a high molecular weight at a higher temperature than the conventional polymerization temperature, using a catalytic system comprising a transition metal compound, a benzene derivative compound, and methylaluminoxane in non-halogenated solvent.
2. Background of the Related Art
Polyisobutene is generally produced by a cationic polymerization method at low temperature. Polyisobutene with a large molecular weight of more than 500,000 is reported to be produced at an extremely low temperature of lower than −80° C. due to the instability of carbocationic active species of polymerization at higher temperature, according to the literature released by Kennedy et al. [(“Polymer”, 6, 579(1965)]. Catalyst used for producing polyisobutene has been selected from strong Lewis acids such as aluminum trichloride, boron trichloride and aluminum tribromide in halogenated solvent system comprising methyl chloride or dichloromethane.
However, such conventional polymerization method has some disadvantages in that (1) special facilities should be established due to the fact that polymerization is performed at an extremely low temperature, (2) heavy production costs are inevitably required for low temperature operation, and (3) chlorine-containing solvent used as a polymerization solvent causes the environmental problems.
In addition to the above mentioned method, another method of polymerizing isobutene using alcohol has been disclosed. Kennedy et al. have suggested a method for producing polyisobutene with molecular weight ranging from thousands to tens of thousands via a living polymerization using a variety of tertiary alcohols and boron trichloride as an initiator for polymerization [“Polymer Bulletin”, 22, 455˜462 (1989)]. Further, Toshiyuki et al. have disclosed a method of polymerizing isobutene using a catalytic system where some aromatic alcohol is combined to titanium tetrachloride (TiCl 4 ) [“Macromolecules”, 29, 6,100˜6,103 (1996)].
Nevertheless, the process for producing polyisobutene in the presence of tertiary alcohol has encountered some problems in that excessive amount of tertiary alcohol should be added to monomer with a mole ratio of 1/100, since it is used as an initiator rather than an additive. Furthermore, boron trichloride which activate the initiator should be added in a high mole ratio of 1/10 to monomer. Another method for producing polyisobutene using aromatic alcohol has also faced disadvantages in its long-term storage and usage due to the instability of the catalytic system comprising transition metal-aromatic alcohol at room temperature.
Meantime, another method for producing polyisobutene using carboxylic acid has been disclosed. For example, M. Marek et al. have reported that isobutene has been very effectively polymerized at −20° C. using hydrofluoric acid as an initiator, together with a co-catalyst such as titanium tetrachloride, titanium tetrabromide, vanadium tetrachloride, and boron trichloride [Makromol. Chem., 174, 1, (1973)]. Further, B. Matyska et al. have suggested a method for polymerizing isoprene in the presence of a catalyst such as trifluoroacetic acid, trichloroacetic acid, titanium trichloride, with a variation in activity according to acidity of catalytic system. [Collect. Czech Chem. Commun., 44, 1262, (1979)].
In the recent years, intensive studies have focused on the method of producing polyisobutene in non-halogenated solvent. For example, a method for producing polyisobutene with ten of thousands of weight average molecular weight has been disclosed using non-coordinated anions such as tris(pentafluorophenyl)boron as a co-catalyst and toluene as a polymerization solvent at a polymerizaiton temperature of −20° C. (U.S. Pat. No. 5,448,001). Shaffer et al. have suggested that a polymer with a number average molecular weight of 140,000 can be obtained with 60% yield at −20° C. in the presence of tris(pentafluorophenyl)boron, [“Journal of Polymer Science: Part A: Polymer Chemistry”, 35, 329-344 (1997)]. The above results suggest that a non-coordination anion generated from a Lewis acid with a large size provides an extra stability of carbocationic active site in the polymerization of isobutene. In this context, research efforts to incorporate a suitable non-coordinating anion has been continuously given to achieve higher reaction temperature in the polymerization of isobutene with high molecular weight.
SUMMARY OF THE INVENTION
Under such circumstances, the inventor et al. have made intensive studies to develop a process for high yield preparation of polyisobutene in non-halogenated solvent at higher polymerization temperature. The inventors have developed a catalytic system in a manner such that the mixture of benzene derivative compound (II) and a variety of transition metal compound (I) supported by methylaluminoxane(I). Methylaluminoxane is a polymeric aluminum compound which is generated from the reaction between alkylaluminium and a small amount of water and proved to be effective in activating the catalytic activity of metallocene in the polymerization various olefins. However, the effect of methylaluminoxane has yet to be established in the cationic polymerization, especially for the polymerization of isobutene.
Therefore, an object of this invention is to provide a process for producing polyisobutene with a large molecular weight at a higher reaction temperature than the conventional polymerization temperature in the absence of a halogenated solvent such as methyl chloride.
To achieve the above objective, the present invention is characterized by a process for producing polyisobutene using isobutene as a monomer and a catalytic system comprising a transition metal compound expressed by the following formula (I), a benzene derivative compound expressed by the following formula (II) and methylaluminoxane expressed by the following formula (III), in the presence of nonhalogen solvent:
MX 4 (I)
where, M is titanium, vanadium or tin;
X is chlorine or bromine.
where, R 1 is hydroxy or carboxy group;
R 2 , R 3 , R 4 , R 5 and R 6 , which are the same or different groups, represent hydrogen, methyl group, methyl group, ethyl group, isopropyl group, isobutyl group, n-butyl group, t-butyl group, octyl group, alkoxy group, fluorine, chlorine, bromine, amino group, nitro group, hydroxy group or acetyl group.
where, n is an integer of 3˜40.
When the above catalytic system is applied to the manufacture of polyisobutene, there are several advantages in that (1) polymer with a large molecular weight can be induced due to the stabilization of cation active species in the growing polymer chain, (2) the loss of yield by unintentional termination can be minimized, and (3) the final polymer can be produced using a general organic solvent such as toluene instead of a halogenated solvent such as dichloromethane, at a higher temperature than the prior arts by about 30˜50° C.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to a process for producing polyisobutene with a very high molecular weight at a higher temperature than the conventional polymerization temperature using a catalytic system comprising a transition metal compound, a benzene derivative compound, and methylaluminoxane. The polyisobutene of the invention can be produced by the following two stepwise preparation methods.
The first method to produce polyisobutene comprises the following processes of:
(1) a process of adding said transition metal compound(I) to the benzene derivative compound (II), followed by the addition of the catalytic system, so activated by the methylaluminoxane (III) for a certain period of time, to isobutene dissolved in a polymerization solvent for polymerization at the temperature of −70˜−20° C. for 30˜360 minutes;
(2) a process of infusing the previously cooled methanol solution into the resulting solution of the above (3) process at the temperature of −70˜−30° C. and of terminating the reaction; and,
(3) a process of washing the polymer, so precipitated, with methanol, followed by filtration and drying to obtain the final polymer.
The second method to produce polyisobutene comprises the following processes of:
(1) a process of adding said methylaluminoxane (III) to isobutene monomer dissolved in a non-halogened solvent;
(2) a process of adding transition metal compound (I) to the benzene derivative compound (II), followed by ageing the mixture at the temperature of −50˜30° C. for 10˜120 minutes to prepare a catalytic system;
(3) a polymerization process of infusing the activated catalytic system, so obtained from the above (2) process into said (1) process and of reacting the mixture at the temperature of−70˜−20° C. for 30˜360 minutes;
(4) a process of infusing the previously cooled methanol solution into the resulting solution of the above (3) process at the temperature of −70˜−20° C. and of terminating the reaction; and,
(5) a process of washing the polymer, so precipitated, with methanol, followed by filtration and drying to obtain the final polymer.
The purity of isobutene used for this invention as a starting material of polymerization is higher than 99% with less than 10 ppm of water content.
The catalyst used for this invention includes a variation of catalytic systems comprising a transition metal compound, benzene derivative compound, and methylaluminoxane. The detailed examples of the transition metal compound expressed by the formula (I) include titanium tetrachloride, vanadium tetrachloride and tin tetrachloride. Also, the detailed examples of the benzene derivative compound expressed by the formula (II) include 2,6-di-t-butyl-p-cresol, 2,4,6-tri-t-butyl-phenol, 2,6-diphenylphenol, 2,4-di-t-butyl-phenol, 2-t-butyl-4-methyl-phenol, benzoic acid and benzoic acid derivatives.
Hence, it is preferred that the transition metal compound (I) is added with a mole ratio of 1/1,000˜1/5,000 to isobutene monomer; the benzene derivative compound (II) is added with a mole ratio of 1/500˜1/10,000 to isobutene monomer; and, methylaluminoxane (III) is added with a mole ratio of 1/100˜1/5,000 to isobutene monomer. More specifically, it is preferred that the transition metal compound(I) is added with a mole ration of 0.5˜2 to the 15 benzene derivative compound (II), while methylaluminoxane (III), is added with a mole ratio of 1˜10 to the transition metal compound (I).
The polymerization solvent of the present invention is one or more non-halogenated solvents selected from the group consisting of toluene, cyclohexane and hexane. It is preferred that 100˜1,000 weight parts of the polymerization solvent is used to 100 weight parts of isobutene monomer. It is more preferred that 200˜400 weight parts of the polymerization solvent is used to 100 weight parts of isobutene monomer.
It is preferred that the polymerization according to the present invention is performed at the temperature of −70 to −20° C. for 30 to 360 minutes. If the polymerization temperature deviates from the above range, the yield and molecular weight of the polymer product are reduced. Also, if the polymerization time deviates from the above range, the molecular weight distribution of polymer product increases due to the generation of polymer product with a low molecular weight.
The polymerization of isobutene is terminated in a manner such that a pre-cooled methanol solution is infused into the reaction solution to inactivates the catalyst. If the temperature of methanol is not maintained at a certain low temperature, the remaining catalyst may initiate an undesirable polymerization that results in polymer products with low molecular weight. The contamination of low molecular weight polymer may leads to a reduction in the physical properties of a final product. Therefore, the polymerization of isobutene should be terminated with methanol with low temperature.
According to the present invention, polyisobutene produced using a catalytic system comprising transition metal compound, benzene derivative compound, and methylaluminoxane, has its number average molecular weight in the range of 100,000˜1,000,000 and the molecular weight distribution of 1.2˜5.0, more preferably in the range of 1.5˜3.0.
This invention is explained in more detail based on the following Examples but is not limited by these Examples.
EXAMPLE 1
All reagents for this experiment were purified and stored under a nitrogen atmosphere before use. The interior of 100 ml reactor was dried under reduced pressure for 2 hours and substituted sufficiently with argon gas. 5.64 g of isobutene (100 mmol), which was purified by passing through activated alumina column and 20 ml of freshly distilled toluene were added to the reactor and then the reactor was cooled to −20° C.
Separately, 0.099 g of BHT(2,6di-t-butyl-p-cresol; 0.45 mmol) was dried under reduced pressure. 10 ml of toluene and 0.055 ml of titanium (IV) chloride (0.6 mmol) were successively added to the dried BHT and reacted for 2 hours. Then 0.85 ml of methylaluminoxane (0.24 mmol) was added to the mixture and the resulted catalyst solution was cooled to −20° C. 1 ml of the catalyst solution was added to the reactor and reacted at −20° C. for 120 minutes. The polymerization was terminated by adding 1 ml of methanol. Precipitated polymeric product was separated from the solution, washed with methanol several times and dried.
EXAMPLES 2˜3
Isobutene was polymerized- in the same manner as Example 1, except for the amounts of BHT used was varied to 0.132 g(0.60 mmol) and 0.165 g (0.75 mmol), respectively.
EXAMPLES 4˜7
Isobutene was polymerized in the same manner as Example 1, except for using 0.118 g of 2,4,6-tri-t-butyl-phenol (0.45 mmol), 0.111 g of 2,6-di-phenyl-phenol (0.45 mmol), 0.093 g of 2,4-di-t-butyl-phenol (0.45 mmol) and 0.074 g of 2-t-butyl-4-methyl-phenol (0.45 mmol), respectively, instead of the BHT.
COMPARATIVE EXAMPLE 1
Isobutene was polymerized in the same manner as Example 1, except the use 0.055 ml of titanium(IV) chloride (0.6 mmol) without BHT and methylaluminoxane in the catalyst solution.
COMPARATIVE EXAMPLE 2
Isobutene was polymerized in the same manner as Example 1, except for using 0.055 ml of titanium (IV) chloride (0.6 mmol) and 0.85 ml of methylaluminoxane (0.24 mmol) in the catalyst solution without BHT.
The following table 1 showed the polymerization results [e.g., yield, number average molecular weight (Mn), weight average molecular weight (Mw) and distribution of molecular weight (Mw/Mn)], when isobutene was polymerized according to each Example and Comparative example.
TABLE 1
Yield (%)
Mn
Mw
Mw/Mn
Example
1
95.3
142,000
336,000
2.36
2
97.0
128,000
379,000
2.96
3
97.7
105,000
447,000
4.26
4
95.8
96,000
319,000
3.32
5
93.0
108,000
347,000
3.21
6
93.2
126,000
377,000
2.99
7
93.1
130,000
400,000
3.10
Comparative
example
1
95.6
33,000
106,000
2.36
2
94.5
71,000
156,000
2.20
From the above table 1, It is clearly shown that the combined catalytic system of titanium tetrachloride, methylaluminoxane, and phenol derivative has a superior activity than either titanium tetrachloride alone or the mixture of titanium tetrachloride and methyl aluminoxane and results in higher molecular weight polymer. Also the successive improvement of catalytic activity by the stepwise addition of methylaluminoxane and phenol derivative to titanium tetrachloride indicates that each component of the catalytic system of the present invention is essential to producing polyisobutene with high molecular weight.
EXAMPLE 8
All reagents were purified and stored under nitrogen atmosphere prior to use. The interior of 100 ml reactor was dried under reduced pressure for 2 hours and filled with argon gas. 5.64 g of isobutene (100 mmol), which was passed through activated alumina column and 20 ml of fresh distilled water were added to the reactor and then the reactor was cooled to −50° C. Separately, the solution of catalyst was prepared by the successive addition of 1 ml of toluene and 0.0055 ml of titanium (IV) chloride (0.6 mmol) to 0.01 g of 2,4,6-trimethylbenzoic acid (0.06 mmol) which was dried under reduced pressure. Then 0.85 ml of methylaluminoxane (0.24 mmol) was added to the mixture. The mixture was stirred for 20 minutes at room temperature and then, further stirred at −50° C. for 10 minutes. The catalyst solution was added to the reactor at −50° C. and stirred for 2 hours. The reaction was terminated by adding 1 ml of methanol. Precipitated polymeric product was separated from the solution, washed with methanol several times and dried.
EXAMPLE 9
Isobutene was polymerized in the same manner as Example 8, except that 0.0093 g of 2,6-dimethylbenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 10
Isobutene was polymerized in the same manner as Example 8, except that 0.0092 g of 2,4-dimethylbenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 11
Isobutene was polymerized in the same manner as Example 8, except that 3,5-dichlorobenzoic acid 0.0117 g(0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 12
Isobutene was polymerized in the same manner as Example 8, except that 0.091 g of 4-ethylbenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 13
Isobutene was polymerized in the same manner as Example 8, except that 0.0107 g of 4t-butylbenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 14
Isobutene was polymerized in the same manner as Example 8, except that 0.0094 g of 3-chlorobenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 15
Isobutene was polymerized in the same manner as Example 8, except that 0.009 g of 3-dimethylbenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 16
Isobutene was polymerized in the same manner as Example 8, except that 0.009 g of 2,5-dimethylbenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 17
Isobutene was polymerized in the same manner as Example 8, except that 0.0087 g of 4-fluorobenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 18
Isobutene was polymerized in the same manner as Example 8, except that 0.0094 g of 4-chlorobenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 19
Isobutene was polymerized in the same manner as Example 8, except that 0.0122 g of 4-bromobenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
Example 20
Isobutene was polymerized in the same manner as Example 8, except that 0.0127 g of 2,4-dinitrobenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 21
Isobutene was polymerized in the same manner as Example 8, except that 0.0127 g of 3,5-dinitrobenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 22
Isobutene was polymerized in the same manner as Example 8, except that 0.0094 g of 2-chlorobenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
EXAMPLE 23
Isobutene was polymerized in the same manner as Example 8, except that 0.0093 g of 2,6dihydroxybenzoic acid (0.06 mmol) was employed instead of 2,4,6-trimethylbenzoic acid.
As for each of the final polymers obtained from Examples 8˜23, its weight ratio of isobutene monomer was calculated and expressed by percentage (weight %) to determine the final yield. Further, the following parameters were determined using gel permeation chromatography(GPC) which was calibrated by polystyrene standard sample: weight average molecular weight(Mw), number average molecular weight(Mn), and distribution of molecular weight(Mw/Mn). The results are shown in the following table 2.
TABLE 2
Example
Yield (%)
Mn
Mw
Mw/Mn
8
50.6
435,000
813,000
1.87
9
86.1
234,000
491,000
2.10
10
71.4
217,000
509,000
2.35
11
95.3
348,000
726,000
2.09
12
66.8
117,000
406,000
3.47
13
73.6
146,000
451,000
3.09
14
97.1
156,000
496,000
3.18
15
79.9
27,000
296,000
11.09
16
84.6
22,000
257,000
11.47
17
89.4
78,000
378,000
4.84
18
85.6
49,000
273,000
5.58
19
86.0
80,000
320,000
3.99
20
55.3
281,000
760,000
2.71
21
75.3
195,000
506,000
2.59
22
71.5
67,000
306,000
4.54
23
81.8
24,000
211,000
8.71
COMPARATIVE EXAMPLES 3˜4
Isobutene was polymerized in the same manner as Example 8, except for the added amount of titanium (IV) chloride as 0.011 ml (0.12 mmol) and 0.022 ml (0.24 mmol), respectively. The results are shown in the following table 3.
TABLE 3
Comparative
TiCl4
Example
(mmol)
Yield (%)
Mn
Mw
Mw/Mn
3
0.12
94.1
221,000
711,000
3.21
4
0.24
96.8
191,000
554,000
2.91
EXAMPLES 24˜26
Isobutene was polymerized in the same manner as Example 8, except for the variation of solvent/monomer ratio(S/M ratio, the weight rate of toluene/isobutene) to 1,6 and 9. The results are shown in the following table 4.
TABLE 4
Example
S/M
Yield (%)
Mn
Mw
Mw/Mn
24
1
78.9
222,000
610,000
2.75
8
3
50.6
435,000
813,000
1.87
25
6
88.3
174,000
478,000
2.74
26
9
76.4
353,000
774,000
2.19
COMPARATIVE EXAMPLE 5
Isobutene was polymerized in the same manner as Example 8, except for using 0.055 ml of titanium (IV) chloride (0.6 mmol) only as a catalyst.
COMPARATIVE EXAMPLE 6
Isobutene was polymerized in the same manner as Example 8, except for using 0.055 ml of titanium (IV) chloride (0.6 mmol) and 0.85 ml of methylaluminoxane (0.24 mmol) as a catalytic system. The results are shown in the following table 5.
TABLE 5
Comparative
example
Yield (%)
Mn
Mw
Mw/Mn
5
82.4
37,000
207,000
5.64
6
61.5
83,000
403,000
4.88
The comparison of the results of Example 8 with Comparative examples 5 and 6 clearly shows that the catalytic system from titanium tetrachloride, methylaluminoxane, and benzoic acid derivative results in higher molecular weight and smaller molecular weight distribution value than either catalytic system from titanium tetrachloride alone or the mixture of titanium tetrachloride and methyl aluiminoxane. Also the successive improvement of catalytic activity by the stepwise addition of methylaluminoxane and benzoic acid derivative to titanium tetrachloride indicates that each component of the catalytic system of the present invention is essential to the preparation of polyisobutene with high molecular weight and narrow molecular weight distribution.
COMPARATIVE EXAMPLES 7˜9
Isobutene was polymerized in the same manner as Comparative example 6, except for using methylaluminoxane as 043 ml(0.12 mmol), 1.28 ml(0.36 mmol ) and 1.7 ml(0.48 mmol), respectively. The results are shown in the following table 6.
TABLE 6
Comparative
MAO
example
(mmol)
Yield (%)
Mn
Mw
Mw/Mn
7
0.12
89.6
47,000
402,000
8.57
6
0.24
61.5
83,000
403,000
4.88
8
0.36
40.0
85,000
588,000
6.94
9
0.48
5.4
123,000
583,000
4.74
As described above, the present invention relates to the process for producing polyisobutene using isobutene as a monomer and a catalytic system comprising transition metal compound expressed by the formula (I), benzene derivative compound expressed by the formula (II), methylaluminoxane expressed by the formula (III), via cationic polymerization. According to the invention, it has several advantages in that (1) the molecular weight of the resulted polyisobutene is higher than that of the prior arts using a transition metal compound as a catalytic system, with high yield, (2) polyisobutene with high molecular weight can be prepared at a higher temperature by 30˜50° C., (3) a general organic solvent such as toluene can be employed instead of halogenated solvent such as methyl chloride.
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This invention relates to a process for polymerizing isobutene using a catalytic system comprising a transition metal compound, a benzene derivative compound, and methylaluminoxane, and the catalytic system applied to the polymerization of isobutene, (1) the added benzene derivative compound and methyl aluminoxane to the transition metal species provides higher stability of cation active site so that polyisobutene with a high molecular weight can be produced even at a higher reaction temperature than the conventional cationic polymerization temperature; (2) nonhalogen solvent such as toluene can be employed as a polymerization solvent instead of halogenated solvents such as methyl chloride; and (3) under the stable catalytic system, a final product with a high yield can be ensured for its long-term use.
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CROSS REFERENCE TO RELATED PATENTS AND APPLICATIONS
[0001] The following patents/applications, the disclosures of each being totally incorporated herein by reference are mentioned:
[0002] U.S. Publication No. US-2006-0067756-A1 (Attorney Docket No. 20031867Q-US-NP), filed Sep. 27, 2005, entitled “PRINTING SYSTEM,” by David G. Anderson, et al., and claiming priority to U.S. Provisional Patent Application Ser. No. 60/631,918 (Attorney Docket No. 20031867-US-PSP), filed Nov. 30, 2004, entitled “PRINTING SYSTEM WITH MULTIPLE OPERATIONS FOR FINAL APPEARANCE AND PERMANENCE,” and U.S. Provisional Patent Application Ser. No. 60/631,921, filed Nov. 30, 2004, entitled “PRINTING SYSTEM WITH MULTIPLE OPERATIONS FOR FINAL APPEARANCE AND PERMANENCE”;
[0003] U.S. Publication No. US-2006-0067757-A1 (Attorney Docket No. 20031867Q-US-NP), filed Sep. 27, 2005, entitled “PRINTING SYSTEM,” by David G. Anderson, et al., and claiming priority to U.S. Provisional Patent Application Ser. No. 60/631,918, Filed Nov. 30, 2004, entitled “PRINTING SYSTEM WITH MULTIPLE OPERATIONS FOR FINAL APPEARANCE AND PERMANENCE,” and U.S. Provisional Patent Application Ser. No. 60/631,921, filed Nov. 30, 2004, entitled “PRINTING SYSTEM WITH MULTIPLE OPERATIONS FOR FINAL APPEARANCE AND PERMANENCE”;
[0004] U.S. Publication No. US-2006-0115287-A1 (Attorney Docket No. 20040503-US-NP), Published Jun. 1, 2006, entitled “Glossing System For Use In A TIPP Architecture,” by Bryan J. Roof;
[0005] U.S. application Ser. No. 11/000,168 (Attorney Docket No. 20021985-US-NP), filed Nov. 30, 2004, entitled “Addressable Fusing and Heating Methods and Apparatus,” by David K. Biegelsen, et al.;
[0006] U.S. Publication No. US-2006-0115288-A1 (Attorney Docket No. 200405030-US-NP), Published Jun. 1, 2006, entitled “Glossing System For Use In A TIPP Architecture,” by Bryan J. Roof;
[0007] U.S. Publication No. US-2006-0132815-A1 (Attorney Docket 20040744-US-NP), Published Jun. 22, 2006, entitled “PRINTING SYSTEMS,” by Robert M. Lofthus, et al.;
[0008] U.S. Publication No. US-2006-0114313-A1 (Attorney Docket 20040448-US-NP), Published Jun. 1, 2006, entitled “PRINTING SYSTEM,” by Steven R. Moore;
[0009] U.S. Publication No. US-2006-0221362-A1 (Attorney Docket 20040676-US-NP), Published Oct. 5, 2006, entitled “PRINTING SYSTEM,” by Paul C. Julien;
[0010] U.S. Publication No. US-2006-0222393-A1 (Attorney Docket 20040971-US-NP), Published Oct. 5, 2006, entitled “PRINTING SYSTEM,” by Jeremy C. deJong, et al.;
[0011] U.S. Publication No. US-2006-0238778-A1 (Attorney Docket 20040704-US-NP), Published Oct. 26, 2006, entitled “PRINTING SYSTEMS,” by Michael C. Mongeon, et al.;
[0012] U.S. Publication No. US-2006-0269310-A1 (Attorney Docket 20040649-US-NP), Published Nov. 30, 2006, entitled “PRINTING SYSTEMS,” by Kristine A. German, et al.;
[0013] U.S. Publication No. US-2006-0268318-A1 (Attorney Docket 20050281-US-NP), Published Nov. 30, 2006, entitled “PRINTING SYSTEM,” by Robert M. Lofthus, et al.;
[0014] U.S. Publication No. US-2006-0268317-A1 (Attorney Docket 20050382-US-NP), Published Nov. 30, 2006, entitled “SCHEDULING SYSTEM,” by Robert M. Lofthus, et al.;
[0015] U.S. Publication No. US-2006-0066885-A1 (Attorney Docket A3546-US-CIP), filed May 25, 2005, entitled “PRINTING SYSTEM,” by David G. Anderson, et al.;
[0016] U.S. application Ser. No. 11/166,299 (Attorney Docket 20041110-US-NP), filed Jun. 24, 2005, entitled “PRINTING SYSTEM,” by Steven R. Moore;
[0017] U.S. Publication No. US-2007-0024894-A1 (Attorney Docket 20041111-US-NP), Published Feb. 1, 2007, entitled “PRINTING SYSTEM,” by Steven R. Moore, et al.;
[0018] U.S. application Ser. No. 11/215,791 (Attorney Docket 2005077-US-NP), filed Aug. 30, 2005, entitled “CONSUMABLE SELECTION IN A PRINTING SYSTEM,” by Eric Hamby, et al.;
[0019] U.S. application Ser. No. 11/234,468 (Attorney Docket 20050262-US-NP), filed Sep. 23, 2005, entitled “PRINTING SYSTEM,” by Eric Hamby, et al.;
[0020] U.S. Publication No. US-2007-0081828-A1 (Attorney Docket 20031549-US-NP), Published Apr. 12, 2007, entitled “PRINTING SYSTEM WITH BALANCED CONSUMABLE USAGE,” by Charles Radulski, et al.;
[0021] U.S. Publication No. 20051103-US-NP (Attorney Docket 20051103-US-NP), Published May 31, 2007, entitled “PRINTING SYSTEM,” by David A. Mueller; and,
[0022] U.S. application Ser. No. 11/317,167 (Attorney Docket 20050823-US-NP), filed Dec. 23, 2005, entitled “PRINTING SYSTEM,” by Robert M. Lofthus, et al.
BACKGROUND
[0023] The present disclosure relates to a technique or process of printing documents on print media and particularly digital printing on print media in sheet form in which some of the marking on the print media is transient or changes over an interval of time. Heretofore, many marking compositions have been employed which faded or disappeared over time and have spawned the expression “disappearing ink.” Also, it is known that certain chemical compositions for the marking will darken upon exposure to radiation in a limited frequency band such as, for example, radiation in the ultraviolet spectrum. Furthermore, it has been known to provide a coating on the surface of the print media which darkened or changed upon exposure to ultraviolet radiation and coatings which responded to heat or infrared radiation to darken. The primary purpose of such transient printing was either to eliminate the content of the document over time for security or privacy reasons or to enable the print media to be reused for printing.
[0024] The aforesaid techniques for transient printing have been treated substantially as novelties in the commercial marketplace and have found primary applicability in the arena of document security applications.
BRIEF DESCRIPTION
[0025] The present disclosure describes a method or technique of printing on sheet print media in which some of the marking is transient over time. A portion of the image on a side of the print media sheet is printed with marking of transient nature over time; and, other portions of the image on the same side of the print media sheet are printed with permanent marking. Thus, the appearance or meaning, depending upon whether the transient portion is graphic or textual, changes over time. This is commercially significant where the change is in the nature of the meaning of text; or, in the case of graphic images, the very nature of the image presented. In one version of the disclosed method, the transient marking may be applied along with permanent marking on a label to be affixed to an article of commerce. The transient marking may thus change the meaning of the label over time, such as instructions for use of the product to which the label is affixed or warnings as to changes in the condition over time of the article to which the label is affixed.
[0026] In another version of the disclosed method, the transient marking and the permanent marking are mutually overprinted, such that, upon change of the transient marking, different aspects of the permanent marking are exposed to view. The method of the present disclosure has applicability for the intended purpose of changing the appearance or meaning of the marking on the print media.
[0027] In another version of the method, coated paper sensitive to color change upon exposure to ultraviolet radiation (U.V.) may be employed in which the desired transient portion is marked by exposure to U.V.; and, the permanent marking performed by another print engine such as an ink jet printer or electrostatic printer.
[0028] In another version of the method, the portion of the image marked in the transient printing may include segments of transient printing with different time intervals for sequential disappearance. The version of the method employing transient marking segments with different time intervals may also be applied for printing labels for use on articles of manufacture.
[0029] In another version of the method, the transient portion of the image may comprise meta tags. In still another version of the method, the transient portion may comprise half tone marking; and, the permanent portion may also comprise half tone marking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a block flow diagram of the method as practiced with plain paper print media;
[0031] FIG. 2 is a block flow diagram of the method as practiced with coated print media; and,
[0032] FIG. 3 is a block flow diagram of the user inputs of the versions of FIGS. 1 and 2 .
DETAILED DESCRIPTION
[0033] Referring to FIG. 1 , the method is exemplified for printing on plain paper, where the user input to the print engine system is indicated at 10 where the user inputs information relating to the image composition, including transient interval(s) and which may include over printing. The user then proceeds to step 11 and selects plain paper as the print media. The method then proceeds at step 12 to inquire as to whether the image to be printed is to be permanent marking only. If the determination at step 12 is negative, the method proceeds to step 14 where the inquiry is made as to whether a transient image is to be printed first. If the inquiry in step 14 is answered in the affirmative, the transient image is printed at step 16 on the plain paper.
[0034] However, if the determination at step 12 was affirmative, the method proceeds to step 18 and the image is permanently marked. If the determination in step 14 is negative, the system proceeds to print the permanent image at step 20 and then proceeds to print the transient image at step 22 .
[0035] Alternatively, following the printing of the transient image at step 16 , the system proceeds to print the permanent image at step 24 . The transient marking of steps 16 and 22 may include marking the material that changes color over time by virtue of the composition of the marking.
[0036] Subsequently, the printed images from either steps 24 or 22 have their exposed transient marking irradiated with ultraviolet radiation at step 26 to effect the desired changes in the transient image. The printed images from steps 26 , 18 may then be assembled to form a document at step 28 and distributed to the end user at step 30 . Upon lapse of the predetermined time interval the transient image disappears as indicated at step 32 .
[0037] The present disclosure also includes the arrangement in which the transient marking is performed in segments wherein each segment is marked with material which disappears in a different interval, thus giving the printed image a sequentially changing appearance over time. If this latter version is employed, the transient marking would be accomplished by printing the individual segments on different e.g. plural print engines. The transient marking may also include meta-tags. The transient marking may include half tone marking; and, the permanent marking may individually or in combination therewith include half tone marking.
[0038] Referring to FIG. 2 , another version of the method of the present disclosure is illustrated wherein a user input at step 40 determines the composition, including transient interval(s), over printing, if any, and proceeds to step 41 and selects printing from coated paper. For example, paper coated with transparent dye which is operative to turn opaque upon exposure to ultraviolet radiation may be employed. Upon completion of the user inputs at step 40 , 41 , the method proceeds to step 42 and inquires as to whether the image is to be permanently marked only. If the query at step 42 is answered in the affirmative, the method proceeds to step 44 and optionally prints the permanent image on plain paper.
[0039] If, however, the query at step 42 is answered in the negative, the method proceeds to step 46 and prints the permanent image on the coated paper. The method then proceeds to step 48 and prints the transient image by localizing ultraviolet radiation on a transient image area at step 48 .
[0040] The method then proceeds from either step 48 or step 44 to step 50 where the document is assembled; and, at step 52 the assembled document is distributed to the end user. The transient image then disappears within the predetermined time interval as indicated at step 54 to provide the desired effect on the printed image.
[0041] Referring to FIG. 3 , block flow diagram of the user composition steps 10 , 40 of the method of FIGS. 1 and 2 is presented wherein at step 60 the method which may be software driven enables the user to generate an editable page layout view of the image to be permanently marked. The method then proceeds to step 62 and enables the user to add editable transient image(s) features to a page layout view of the image to be permanently marked. The method then proceeds to step 64 and inquires as to whether the layout of the combined transient and permanent images is acceptable. The combined image may include over printing of one of the transient and permanent marking with respect to the other. If the query in step 64 is answered in the affirmative, the method proceeds to step 66 and creates a print job ticket or order and sends the job to the digital front end (DFE) of one or more print engines. For example, the transient marking may be accomplished on one print engine; and, the permanent marking on another print engine.
[0042] If the version of the presently disclosed method utilizing segments of the transient image changing over different intervals is employed, these different segments of the transient image may also be marked on different print engines. The print engine may also be of the electrostatic or ink jet type. If the query in step 64 is answered in the negative the program proceeds concurrently to steps 68 , 70 and 72 where respectively the permanent image features, the combined permanent and transient image features and the transient image(s) features are viewed and edited. Upon completion of the user editing at steps 68 , 70 , 72 the program returns to step 64 .
[0043] The result of the disappearing transient image may produce either a change in color, a change in the writing or meaning of textural information, or may change the visual appearance of an image, either by elimination of portions thereof or by eliminating a characteristic such as color from overprinting. The permanent marking may be a first color and the transient marking changing to a different color over a predetermined time interval.
[0044] The second portion of transient marking may also contain codes such as, for example, scrambling, bar codes and graph codes which are transient over a predetermined time interval. The second portion of transient marking may also be effective to disappear and reappear after a predetermined time.
[0045] In plain paper media the transient coating may be made by the ultraviolet sensitive marking followed by ultraviolet radiation exposure. The predetermined time intervals for the transient images can be varied by changing the ultraviolet sensitive marking such as materials and quantity and/or by changing the level of the ultraviolet radiation exposure such as time and intensity. On coated media, the transient marking may be by ultraviolet laser from one print engine; and, the permanent marking applied from another print engine.
[0046] The version of the presently disclosed method employing segments of the transient image changing over different time intervals may be employed with coated papers by providing different coating in selected regions or areas of the coated print media. However, this latter version results in a significant increase in the cost of the coated print media and is thus viewed as more limited to images having a standardized format thereby enabling the specially segmented coated print media to be manufactured in sufficient quantity to result in less costly media.
[0047] The method of the present disclosure thus enables the change in communication of information or the meaning or appearance of images over time by the process of the printing on the print media. This presently disclosed method may be practiced on one side of the print media sheet; or, the transient marking may be performed on the side of the sheet opposite the permanent marking; or, combinations of either may be performed with respect to the front and back sides of the print media sheet. Combinations of transient and permanent marking may also be applied to labels for articles of manufacture where the information thereon is desired to change over time.
[0048] Both permanent and transient images can be digitized into half tone. The arrangement of both half tone images includes juxtaposing the permanent and the transient portions.
[0049] The present disclosure thus describes a method of transient printing and which alters the conveyance or communication of information or images on sheet print media including labels over a predetermined time for serving the purpose of changing the information conveyed by the print media.
[0050] It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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Sheet print media are printed/marked with both transient and permanent marking which may be juxtaposed or the transient marking overprinted to change the meaning or message of text on the appearance of an image over time. Applications include advertising and labels for articles of commerce. The method applies to plain paper or coated print media for subsequent ultraviolet radiation.
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